8FBN15 30vol2

FOREWORD
This Manual (Volume 2) contains diagnosis, service procedures of electrical

controller and display of the TOYOTA ELECTRICAL POWERED FORKLIFT
8FBN15 to 30 series.
For maintenance, specifications and repair procedure for the chassis, body
and material handling system, refer to Volume 1 (Pub. No. CE212).
Please use these manuals for providing quick, correct servicing of the corre-
sponding forklift models.
This manual deals with the above models as of January, 2018. Please under-
stand that disagreement can take place between the descriptions in the man-
ual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
i
Table of Contents
0 DIAGNOSIS CODE LIST .......................................................................... 2
1 CONTROLLER ....................................................................................... 15
2 DISPLAY FUNCTION ............................................................................. 55
3 ELECTRICAL SYSTEM TROUBLESHOOTING .................................. 274
0-2 0 DIAGNOSIS CODE LIST
0 DIAGNOSIS CODE LIST

Indication: Diagnosis code will be indicated on the display when vehicle trouble occurs.
Memory: Diagnosis code will be recorded on the main controller when vehicle trouble occurs. Use this
indicated diagnosis code that can be checked on the display when using the service function
DIAG MEMORY.
Indicator:
Spanner
Overheat warning (O/H)
Battery overheat warning (BT O/H)

UP LED on the charger operation panel (UP LED) ○
Indica- Memo Detection

Indicator Failure mode Phenomenon on vehicle Page
tion ry ECU
STD
Display:
- Drive motor driver main
O/H light- Drive motor
Multi- A0-1 circuit temperature ab- Traveling stop page 291
ing driver
function normal rise
display:
DCR
STD
Display:
- Pump motor driver main
O/H light- Pump mo- Load handling stop. Steering
Multi- A0-2 circuit temperature ab- page 298
ing tor driver become stiff.
display:
PCR
Spanner Main con- Main controller high Traveling and load handling
A1-1 A1-1 page 300
blinking troller voltage stop Steering becomes stiff.
Spanner Drive motor Drive motor driver high
A1-2 A1-2 Traveling stop page 302
blinking driver voltage
Spanner Pump mo- Pump motor driver high Load handling stop. Steering
A1-4 A1-4 page 304
blinking tor driver voltage become stiff.
STD
Display:
- Main controller board
O/H light- Main con-
Multi- A2-1 temperature abnormal Traveling speed become slow page 306
ing troller
function rise
display:
C/R
STD
Display:
- Drive motor driver board
Multi- A2-2 temperature abnormal Traveling stop page 308
ing driver
function rise
display:
DCR
0 DIAGNOSIS CODE LIST 0-3

tion ry
Indicator
ECU
Failure mode Phenomenon on vehicle Page 0
STD
Display:
- Pump motor driver
Multi- A2-3 board temperature ab- page 315
display:
PCR
Spanner Main con- Battery connection in- Traveling and load handling
A3-1 A3-1 page 317
blinking troller correct stop Steering becomes stiff.
Battery connection in-
Spanner Main con- Traveling and load handling
A3-2 A3-2 correct (Different page 319
blinking troller stop Steering becomes stiff.
voltage)
OPS function invalidity
Auto power-off function in-
Spanner Main con- Seat switch GND short
A5-1 A5-1 validity page 320
blinking troller abnormality
Parking brake off warning dis-
able.
Spanner Main con- F1 fuse open circuit ab- Traveling and load handling
A8-1 A8-1 page 322
blinking troller normality stop Steering becomes stiff.
A8-2 A8-2 page 325
F7 fuse / solenoid power
Spanner Main con-
A9-2 A9-2 line open circuit abnor- Load handling stop. page 329
blinking troller
mality
Main controller temper-
Spanner Main con- ature sensor open circuit
AA-1 AA-1 Traveling speed become slow page 333
blinking troller abnormality/ VCC short
circuit abnormality
Drive motor driver board
temperature sensor Depression of maximum
Spanner Drive motor
AA-2 AA-2 open circuit abnormality/ speed page 334
blinking driver
VCC short circuit abnor- Speed-up become slow.
mality
Pump motor driver
board temperature
Spanner Pump mo- Load handling speed is lim-
AA-4 AA-4 sensor open circuit ab- page 335
blinking tor driver ited.
normality/VCC short cir-
cuit abnormality
Spanner Main con- Cooling fan stops working.
AB-1 AB-1 Cooling fan overcurrent page 336
blinking troller Traveling speed become slow.
Cooling fan open/short
AB-2 AB-2 circuit abnormality (80 V page 340
vehicle)
Spanner Main con- Motor driver power sup- Traveling and load handling
AC-1 AC-1 page 343
blinking troller ply abnormality stop Steering becomes stiff.
Drive motor driver to
Spanner Main con- Traveling speed become slow
AD-1 AD-1 main controller commu- page 346
blinking troller Knob position correcting stop
nication abnormality
Pump motor driver to
Spanner Main con- Load handling stop. Steering
blinking troller become stiff.

tion ry ECU
Spanner Main con- Main controller CPU ab- Traveling and load handling
AF-1 AF-1 page 358
AF-2 AF-2 page 358
AF-3 AF-3 page 358
AF-4 AF-4 page 358
Spanner Main con- Main controller CPU ab- Various control operations not
AF-5 AF-5 page 358
blinking troller normality stable
AF-6 AF-6 page 358
AF-7 AF-7 page 358
AF-8 AF-8 page 358
Spanner Drive motor Drive motor driver main
C0-2 C0-2 Traveling stop page 359
blinking driver circuit abnormality
Drive motor driver cur-
Spanner Drive motor
C1-1 C1-1 rent sensor neutral ab- Traveling stop page 362
blinking driver
normality
Spanner Drive motor
C1-2 C1-2 rent sensor overcurrent Traveling stop page 363
blinking driver
abnormality
STD
Display:
- Depression of maximum
O/H light- Main con- Drive motor temperature
Multi- C2-1 speed page 366
ing troller abnormal rise
function Speed-up become slow.
display:
DM
Drive motor temperature Depression of maximum
Spanner Drive motor
C2-2 C2-2 sensor open/short circuit speed page 368
blinking driver
abnormality Speed-up become slow.
Drive motor driver main
Depression of maximum
Spanner Drive motor circuit temperature
C3-1 C3-1 speed page 370
blinking driver sensor open/short circuit
Speed-up become slow.
abnormality
Accelerator poten-
Spanner Main con- Display error code but able to
C4-1 C4-1 tiometer POT1 open ab- page 371
blinking troller operate correctly.
normality
Accelerator poten-
normality
Accelerator poten-
C4-3 C4-3 tiometer POT1 VCC page 375
short circuit abnormality
Accelerator poten-

tion ry
Indicator
ECU
Accelerator poten-
Spanner Main con-
C4-5 C4-5 tiometer offset abnor- Traveling stop page 379
blinking troller
mality
Accelerator poten- Accelerator play increases
Spanner Main con-
C4-6 C4-6 tiometer matching value and maximum speed is lim- page 382
blinking troller
abnormality ited.
Brake potentiometer
C5-1 C5-1 POT1 open circuit ab- page 384
normality
Brake potentiometer
normality
Brake potentiometer
C5-3 C5-3 POT1 VCC short circuit page 388
abnormality
Brake potentiometer
abnormality
Spanner Main con- Brake potentiometer off-
blinking troller set abnormality
Brake potentiometer
Spanner Main con-
C5-6 C5-6 matching value abnor- Traveling stop page 396
blinking troller
mality
Drive motor speed
Spanner Drive motor
C8-1 C8-1 sensor open circuit ab- Traveling stop page 398
blinking driver
normality
Drive motor speed
Spanner Drive motor
C8-2 C8-2 sensor short circuit ab- Traveling stop page 402
blinking driver
normality
Spanner Main con- Inclination angle sensor
C9-1 C9-1 Slope assist function disable page 406
blinking troller open circuit abnormality
blinking troller short circuit abnormality
Inclination angle sensor
Spanner Main con-
C9-3 C9-3 matching value abnor- Slope assist function disable page 410
blinking troller
mality
Spanner Main con- MB contactor open cir- Traveling and load handling
CB-1 CB-1 page 412
blinking troller cuit abnormality stop Steering becomes stiff.
Spanner Main con- MB contactor short cir- Display error code but able to
CB-2 CB-2 page 417
blinking troller cuit abnormality operate correctly.
Spanner Main con- MB contactor coil open Traveling and load handling
CB-3 CB-3 page 420
blinking troller circuit abnormality stop Steering becomes stiff.
Spanner Main con- MB contactor drive cir- Traveling and load handling
CB-4 CB-4 page 423
Spanner Main con- MB contactor coil short Traveling and load handling
CB-5 CB-5 page 426
Spanner Drive motor Drive motor driver CPU
CC-1 CC-1 Traveling stop page 429
blinking driver abnormality

tion ry ECU
Spanner Drive motorDrive motor driver CPU Display error code but able to
CC-6 CC-6 page 429
blinking driver abnormality operate correctly.
Spanner Pump mo- Pump motor driver main Load handling stop. Steering
E0-2 E0-2 page 430
blinking tor driver circuit abnormality become stiff.
Pump motor driver cur-
Spanner Pump mo- Load handling stop. Steering
E1-1 E1-1 rent sensor neutral ab- page 433
blinking tor driver become stiff.
normality
E1-2 E1-2 rent sensor overcurrent page 434
abnormality
STD
Display:
-
O/H light- Main con- Pump motor temperat- Load handling speed is lim-
Multi- E2-1 page 437
ing troller ure abnormal rise ited.
function
display:
PM
Pump motor temperat-
E2-2 E2-2 ure sensor open/short page 439
circuit abnormality
Pump motor driver main
Spanner Pump mo- circuit temperature Load handling speed is lim-
E3-1 E3-1 page 441
blinking tor driver sensor open/short circuit ited.
abnormality
Pump motor speed
E8-1 E8-1 sensor open circuit ab- page 442
normality
Pump motor speed
E8-2 E8-2 sensor short circuit ab- page 445
normality
Spanner Pump mo- Pump motor driver CPU Load handling stop. Steering
EC-1 EC-1 page 448
blinking tor driver abnormality become stiff.
EC-2 EC-2 page 448
EC-3 EC-3 page 448
EC-4 EC-4 page 448
Spanner Pump mo- Pump motor driver CPU Display error code but able to
EC-6 EC-6 page 448
blinking tor driver abnormality operate correctly.
Spanner Main con- CAN bridge communica-
ED-1 ED-1 Recognition unable page 449
blinking troller tion disruption
CAN bridge controller /
Spanner CAN bridge Data Handling Unit
blinking controller (DHU2) communication
disruption
Display to main control-
Spanner Main con- Display function partially dis-
EE-1 EE-1 ler communication ab- page 457
blinking troller able.
normality
normality
Main controller to dis-
Spanner Display function partially dis-
F1-1 F1-1 Display play communication ab- page 458
blinking able.
normality

tion ry
Indicator
ECU
blinking able.
normality
Traveling and load handling
cannot be performed simul-
Spanner Display CPU abnormal-
F4-1 F4-1 Display taneously. page 461
blinking ity
Recognition unable in case of
PIN code entry spec.
blinking ity
blinking ity
F4-4 F4-4 Display Display only page 461
blinking ity
F4-5 F4-5 Display Display function not stable page 461
blinking ity
Spanner Display CPU abnormal- Various control operations not
F4-6 F4-6 Display page 461
blinking ity stable
blinking ity stable
blinking ity stable
Battery fluid-level / Bat-
Battery protective function dis-
tery fluid temperature
Spanner abled
F5-1 F5-1 Display sensor vehicle connec- page 462
blinking Battery data log function par-
tion harness open circuit
tially disable
abnormality
Battery fluid-level / Bat-
Spanner abled
tion harness short circuit
tially disable
abnormality
Battery fluid temperature
Spanner abled
F5-3 F5-3 Display sensor open circuit ab- page 469
normality
tially disable
Spanner abled
F5-4 F5-4 Display sensor temperature ab- page 471
normality
tially disable
UP LED
blinking On-vehicle charger char-
F6-1 F6-1 Display ging abnormality (safety Charging stop page 473
Spanner timer activated)
blinking
UP LED On-vehicle charger
blinking transformer overheating
F6-2 F6-2 Display Charging stop page 478
Spanner abnormality (charge can
blinking not start)
Spanner On-vehicle charger start Unable to charge (charge can
blinking abnormality not start)

tion ry ECU
UP LED
blinking On-vehicle charging Not finish charging (charge
Spanner completion abnormality can not complete)
blinking
Spanner CAN bridge CAN bridge controller
FA-1 FA-1 Recognition unable page 494
blinking controller CPU abnormality
Electrical power quantity sur-
vey function disable
Battery current sensor
Spanner Main con- Battery data log function partly
FB-1 FB-1 neutral voltage abnor- page 495
blinking troller disable
mality
Accident error of battery capa-
city display increases
Watt-hour meter disable
Battery data log function partly
Spanner Main con- Battery current sensor
FB-2 FB-2 disable page 498
blinking troller over current abnormality
Depression of traveling per-
BT O/H Main con- Battery fluid temperature
- FC-1 formance page 501
lighting troller overheat
Spanner Main con- Display power supply
FF-1 FF-1 Display lights off page 503
blinking troller circuit overcurrent
Steering sensor power
Spanner Main con- Steering become stiff
FF-2 FF-2 supply circuit overcur- page 504
rent
Spanner Drive motor Drive motor driver ID ab- Display error code but able to
32-1 32-1 page 506
blinking driver normality operate correctly.
Spanner Pump mo- Pump motor driver ID Display error code but able to
32-3 32-3 page 507
Main controller to Drive
Spanner Drive motor
33-1 33-1 motor driver CAN com- Traveling stop page 508
blinking driver
munication abnormality
Main controller to Pump
33-3 33-3 motor driver CAN com- page 510
Partial limitation of mast con-
trol function.
Partial limitation of auto speed
Spanner Main con- Load sensor open circuit
61-1 61-1 control function. page 512
Partial limitation of height and
load sensing turn speed con-
trol function.
trol function.
Spanner Main con- Load sensor short circuit
trol function.
Spanner Main con- Tilt angle sensor open Partial limitation of mast con-
62-1 62-1 page 516
blinking troller circuit abnormality trol function

tion ry
Indicator
ECU
Spanner Main con- Tilt angle sensor short Partial limitation of mast con-
62-2 62-2 page 518
Spanner Main con- Lift lock solenoid open
64-1 64-1 Lift lowering stop page 520
blinking troller circuit abnormality
Spanner Main con- Lift lock solenoid short
Spanner Main con- Lift lock solenoid drive
64-3 64-3 Lift may not lower. page 524
Spanner Main con- Lift lock solenoid short/
Spanner Main con- Tilt control solenoid
65-1 65-1 Forward tilt stop page 528
65-3 65-3 Mast may not tilt forward. page 532
blinking troller drive circuit abnormality
Tilt control solenoid
Spanner Main con-
65-4 65-4 open/short circuit abnor- Mast may not tilt forward. page 534
blinking troller
mality
Abnormal matching
Spanner Main con- Partial limitation of mast con-
66-1 66-1 value of tilt and load page 536
blinking troller trol function
sensor
trol function.
Lifting height switch Partial limitation of auto speed
Spanner Main con-
67-1 67-1 short/open circuit abnor- control function. page 537
blinking troller
mality Partial limitation of height and
trol function.
Lift height 800 mm
Spanner Main con-
67-5 67-5 switch short circuit ab- Traveling speed become slow page 541
blinking troller
normality
Lift speed is limited when
maximum height limiter is in
active setting.
Lifting height regulation/lifting
height stop, Operating when it
is effective will stop rising
Spanner Main con- Height reel sensor open (For V mast only)
68-1 68-1 page 543
blinking troller circuit abnormality Partial limitation of mast con-
trol function.
Partial limitation of traveling
control function.
trol function.

tion ry ECU
active setting.
Spanner Main con- Height reel sensor short (For V mast only)
68-2 68-2 page 545
trol function.
control function.
trol function.
active setting.
Spanner Main con- Height reel sensor (For V mast only)
68-3 68-3 page 547
blinking troller timeout abnormality Partial limitation of mast con-
trol function.
control function.
trol function.
Misalignment of height se-
lector stop position.
(For V mast only)
Height reel sensor
Spanner Main control function.
68-4 68-4 lowermost position ab- page 549
blinking troller Partial limitation of traveling
normality
control function.
trol function.
(For V mast only)
Spanner Main con- Height reel sensor trol function.
68-5 68-5 page 552
blinking troller matching abnormality Partial limitation of traveling
control function.
trol function.
Knob position correcting func-
Spanner Main con- Tire angle sensor open tion stops working.
71-1 71-1 page 553
blinking troller circuit abnormality Partial limitation of turn speed
control function.
Spanner Main con- Tire angle sensor short tion stops working.
71-2 71-2 page 555
control function.

tion ry
Indicator
ECU
Spanner Main con- Tire angle sensor an- tion stops working.
71-3 71-3 page 557
blinking troller choring abnormality Partial limitation of turn speed
control function.
Steering angle sensor Knob position correcting func-
Spanner Main con-
72-1 72-1 SS1 open circuit abnor- tion stops working. page 560
blinking troller
mality Steering becomes stiff.
Spanner Main con-
blinking troller
Steering angle sensor
Spanner Main con- Knob position correcting func-
72-3 72-3 SSC open circuit abnor- page 568
blinking troller tion stops working.
mality
Spanner Main con-
72-4 72-4 power circuit open circuit tion stops working. page 572
blinking troller
abnormality Steering becomes stiff.
Knob position correcting
73-1 73-1 solenoid open circuit ab- page 574
normality
73-2 73-2 solenoid short circuit ab- page 577
normality
73-3 73-3 solenoid power circuit page 580
abnormality
73-4 73-4 solenoid open/short cir- page 582
cuit abnormality
Spanner Main con- Abnormal matching tion stops working.
74-1 74-1 page 584
blinking troller value for tire angle Partial limitation of turn speed
control function.
Spanner Main con- Shock sensor 1 open
G5-1 G5-1 Shock sensor disabled. page 586
Spanner Main con- Shock sensor 1 short
Spanner Main con- Shock sensor 1 neutral
blinking troller voltage abnormality
Spanner Main con- Lift lever potentiometer
H1-1 H1-1 Lift lowering and upward stop page 598
Lift lever potentiometer
Spanner Main con-
H1-3 H1-3 output deviation abnor- Lift lowering and upward stop page 602
blinking troller
mality
H1-4 H1-4 Load handling stop. page 604
blinking troller neutral abnormality

tion ry ECU
Abnormal matching
Spanner Main con-
H1-5 H1-5 value for lift lever poten- Lift lowering and upward stop page 606
blinking troller
tiometer
Spanner Main con- Tilt lever potentiometer Forward and backward tilt
H2-1 H2-1 page 607
blinking troller open circuit abnormality stop
H2-2 H2-2 page 609
blinking troller short circuit abnormality stop
Tilt lever potentiometer
Spanner Main con- Forward and backward tilt
H2-3 H2-3 output deviation abnor- page 611
blinking troller stop
mality
Spanner Main con- Tilt lever potentiometer
Abnormal matching
H2-5 H2-5 value for tilt lever poten- page 615
tiometer
Attachment 1 lever po-
Spanner Main con- Attachment 1 function stops
H3-1 H3-1 tentiometer open circuit page 616
blinking troller working.
abnormality
H3-2 H3-2 tentiometer short circuit page 618
abnormality
H3-3 H3-3 tentiometer output devi- page 620
ation abnormality
Spanner Main con-
H3-4 H3-4 tentiometer neutral ab- Load handling stop. page 623
blinking troller
normality
Abnormal matching
H3-5 H3-5 value for attachment 1 page 625
lever potentiometer
abnormality
abnormality
ation abnormality
Spanner Main con-
blinking troller
normality
Abnormal matching
lever potentiometer
Lift proportional solenoid
Spanner Main con-
H5-1 H5-1 open circuit abnormality Lift upward stop page 636
blinking troller
(lever pull side)
Spanner Main con-
H5-2 H5-2 short circuit abnormality Lift upward stop page 639
blinking troller
(lever pull side)
Spanner Main con-
H5-3 H5-3 open circuit abnormality Lift lowering stop page 642
blinking troller
(lever push side)

tion ry
Indicator
ECU
Spanner Main con-
H5-4 H5-4 short circuit abnormality Lift lowering stop page 645
blinking troller
(lever push side)
Spanner Main con-
H5-5 H5-5 power circuit abnormal- Load handling stop. page 648
blinking troller
ity
Spanner Main con- open/short circuit abnor-
blinking troller mality (lever pull side/
lever push side)
Tilt proportional solenoid
Spanner Main con-
H6-1 H6-1 open circuit abnormality Backward tilt stop page 653
blinking troller
(lever pull side)
Spanner Main con-
H6-2 H6-2 short circuit abnormality Backward tilt stop page 656
blinking troller
(lever pull side)
Spanner Main con-
H6-3 H6-3 open circuit abnormality Forward tilt stop page 659
blinking troller
(lever push side)
Spanner Main con-
H6-4 H6-4 short circuit abnormality Forward tilt stop page 662
blinking troller
(lever push side)
Spanner Main con-
blinking troller
ity
lever push side)
Attachment 1 propor-
Spanner Main con- tional solenoid open cir- Attachment 1 function stops
H7-1 H7-1 page 670
blinking troller cuit abnormality (lever working.
pull side)
Spanner Main con- tional solenoid short cir- Attachment 1 function stops
H7-2 H7-2 page 673
pull side)
H7-3 H7-3 page 676
push side)
H7-4 H7-4 page 679
push side)
Spanner Main con-
H7-5 H7-5 tional solenoid power Load handling stop. page 682
blinking troller
circuit abnormality
tional solenoid open/
Spanner Main con-
H7-6 H7-6 short circuit abnormality Load handling stop. page 684
blinking troller
(lever pull side/lever
push side)
H8-1 H8-1 page 687
pull side)

tion ry ECU
H8-2 H8-2 page 690
pull side)
H8-3 H8-3 page 693
push side)
H8-4 H8-4 page 696
push side)
Spanner Main con-
blinking troller
circuit abnormality
Spanner Main con-
blinking troller
push side)
Proportional solenoid
Spanner Main con- power supply RY1 con-
HB-1 HB-1 Load handling stop. page 705
blinking troller tact open circuit abnor-
mality
Spanner Main con-
HB-2 HB-2 power supply load short Load handling stop. page 707
blinking troller
circuit abnormality
Spanner Main con-
HB-3 HB-3 power supply RY1 over- Load handling stop. page 709
blinking troller
current abnormality
STD
Display:
-
Multi- O/H light- Drive motor Drive motor driver tem-
- speed page 711
function ing * driver perature low
display:
COLD
DCR
STD
Display:
-
Multi- O/H light- Pump mo- Pump motor driver tem-
- speed page 711
function ing * tor driver perature low
display:
COLD
PCR
*: Multi-function display shows only the each portion and doesn't indicate O/H light.
1 CONTROLLER 1-15
1 CONTROLLER
1
1.1 GENERAL................................................................................................ 16
1.2 COMPONENTS ....................................................................................... 23
1.3 BEFORE REPAIR.................................................................................... 25
1.4 CONNECTOR INSPECTION................................................................... 26
1.5 MAIN CONTROLLER .............................................................................. 45
1.6 PUMP MOTOR DRIVER ......................................................................... 48
1.7 DRIVE MOTOR DRIVER......................................................................... 50
1.8 OCL VALUE MEASUREMENT................................................................ 51
1-16 1 CONTROLLER
1.1 GENERAL
MAIN CONTROLLER
G85703001_
NOTICE
When replacing the main controller, always check the part No.
1 CONTROLLER 1-17
CONNECTOR-PIN ASSIGNMENT
1
CN101 CN102 CN103 CN104
G85703002_
CN101
CIRCUIT
No. TERMINAL NAME REMARKS
CODE
102 SOLLU+ SOLLU+ UNLOAD, LIFT+
103 SLTFB+ SLTFB+ TILTF, R+
104 RYT+ FAN+ RYR, FAN+
105 VBBT VBBT VBBT
106 SLLA2+ SOL1, 4+ SOL1, 4+
107 SLTA1+ SOL2, 3+ SOL2, 3+
108 --- SOL5+ SOL5+
109 --- SOL5B SOL5B
110 --- SOL5A SOL5A
111 SA1PL- SOL3B SOL3B
112 SA1PS- SOL3A SOL3A
113 STPL- SOL2B SOL2B
114 STPS- SOL2A SOL2A
115 SA2PL- SOL4B SOL4B
116 SA2PS- SOL4A SOL4A
117 SLPS- SOL1A SOL1A
118 SLPL- SOL1B SOL1B
--- (1-2 ton series only) VBBA VBBA
119
VBBA (3 ton model only) VBBA VBBA
120 VFAN VFAN VFAN
121 VRTA+ VRTA+ TILT ANGLE SENSOR POWER SUPPLY
122 --- VRS+ SWING ANGLE SENSOR POWER SUPPLY
123 VRA- VRA- ACCELERATOR SENSOR GND
124 VRTRA+ VRTRA+ TIRE ANGLE SENSOR POWER SUPPLY
125 VRH+ VRH+ HEIGHT SENSOR POWER SUPLLY
126 VRL+ VRL+ LIFT LEVER SENSOR POWER SUPPLY
127 VRA2+ VRA2+ ACCELERATOR SENSOR 2 POWER SUPPLY
128 VRA1+ VRA1+ ACCELERATOR SENSOR 1 POWER SUPPLY
129 VRT+ VRT+ TILT LEVER SENSOR POWER SUPPLY
130 VRAT1+ VRAT1+ ATTACHMENT 1 LEVER SENSOR POWER SUPPLY
131 VRAT2+ VRAT2+ ATTACHMENT 2 LEVER SENSOR POWER SUPPLY
132 --- VRAT3+ ATTACHMENT 3 LEVER SENSOR POWER SUPPLY
133 POT- POT- GND3
134 VRB2+ VRB2+ BRAKE SENSOR 2 POWER SUPPLY
135 VRB1+ VRB1+ BRAKE SENSOR 1 POWER SUPPLY
1-18 1 CONTROLLER
CN102
CIRCUIT
CODE
67 --- FNDC1 FAN1
68 --- FNDC2 FAN2
69 VBMBSL VBMBSL VBMBSOL
70 VBMBSL VBMBSL VBMBSOL
71 SOLCOM SOLCOM SOLCOM
72 SOLCOM SOLCOM SOLCOM
73 SLS+ SLS+ KNOB, MPS+
74 OACC3 OACC3 ACCESSORY 3 (for FORWARD)
75 --- OACC2 ACCESSORY 2 (for REVERSE)
76 LS- LS- GND2
77 --- OACC1 ACCESSORY 1 (for BRAKE)
78 --- RY2- RYR2
79 RY1- RY1- RYR1
80 SLS- SLS- KNOB-
81 --- MPS- SLDM-(MPS-)
82 SLLL- SLLL- LIFT-
83 --- SLUL- UNLOAD-
84 --- SLTBL- TILTR-
85 SLTFL- SLTFL- TILTF-
86 VRA12 VRA12 ATTACHMENT 1 LEVER SENSOR 2
88 VRT2 VRT2 TILT LEVER SENSOR 2
89 VRT1 VRT1 TILT LEVER SENSOR 1
90 CSBAT CSBAT BATTERY CURRENT SENSOR
91 VRB2 VRB2 BRAKE SENSOR 2 (combined with SW)
92 POT- POT- GND4
93 --- CHK5V 5V POWER SUPPLY for CHECK
96 VRA1 VRA1 ACCELERATOR SENSOR 1
97 VRTRA VRTRA TIRE ANGLE SENSOR
98 VRA2 VRA2 ACCELERATOR SENSOR 2
99 VRB1 VRB1 BRAKE SENSOR 1 (combined with SW)
100 SSLP VRS SWING ANGLE SENSOR
101 CSBAT- CSBAT- BATTERY CURRENT SENSOR GND
1 CONTROLLER 1-19
CN103
CIRCUIT
No. TERMINAL NAME
CODE
REMARKS 1
32 --- SLSW+ SWING+
33 --- SLSW- SWING-
34 DGND DGND DISPLAY GND
35 KYSAT KYSAT KEYSTART
36 N2 N2 N2
37 LS- LS- GND4
38 --- SMTSA SMTSA
39 IPL+ IPL+ SHOCK SENSOR POWER SUPPLY
40 --- CAN2H CAN2H
41 --- CAN2L CAN2L
42 CAN1H CAN1H CAN1H
43 CAN1L CAN1L CAN1L
STEERING WHEEL ANGLE SENSOR AND ULTRA
44 SSTR+ SSTR+
SONIC SENSOR POWER SUPPLY (combined use)
45 D7V D7V DISPLAY POWER SUPPLY
46 --- CHK15V 15V POWER SUPPLY for CHECK
47 --- CHK33V 3.3V POWER SUPPLY for CHECK
48 VRTA VRTA TILT ANGLE SENSOR
49 VRL2 VRL2 LIFT LEVER SENSOR 2
50 IPL2 IPL2 SHOCK SENSOR 2
51 --- SSTMA SSTMA
52 --- SMTSK SMTSK
53 --- SSTMK SSTMK
54 --- OPTSS2 OPTSS2
55 SH2-1 SH2-1 LIFTING HEIGHT SWITCH 2-1
56 SHL SHL HEIGHT LIMIT SWITCH
57 VRL1 VRL1 LIFT LEVER SENSOR 1
58 --- SYR YAW RATE SENSOR
59 VRH VRH HEIGHT SENSOR
60 SPLF SPLF PRESSURE SENSOR
61 IPL1 IPL1 SHOCK SENSOR 1
62 --- SH2-2 LIFTING HEIGHT SWITCH 2-2
63 STK STK AUTOMATIC FORK LEVELING SWITCH
64 --- OLM+ LASER POINTER POWER SUPPLY
65 SWHO81 VRA32 ATTACHMENT 3 LEVER SENSOR 2
ATTACHMENT 3 LEVER SENSOR 1 (SWITCH for 4/5-
66 SSB VRA31
way)
1-20 1 CONTROLLER
CN104
CIRCUIT
CODE
B48V (1-2 ton series
B48V B80V(B48V)
1 only)
B80V (3 ton model only) B48V B80V(B48V)
2 VBMB VBMB VBMB
3 CBAT+ CBAT+ MB, P+
4 N2 N2 N2
5 N2 N2 N2
6 N2 N2 N2
7 --- N2 N2
8 FNDC MP- MP-
9 CBAT- CBAT- MB-
10 CSBAT+ CSBAT+ BATTERY CURRENT SENSOR POWER SUPPLY
11 --- SYR- YAW RATE SENSOR GND
12 SPLF+ SPLF+ PRESSURE SENSOR POWER SUPPLY
13 --- SYR+ YAW RATE SENSOR POWER SUPPLY
14 PSACC+ PSACC+ ACCESSORY POWER SUPPLY
POWER SUPPLY for MINI LEVER SWITCH (LOAD
15 PSSW+ PSSW+ METER, AUTOMATIC FORK LEVERING and SWITCH
for 4/5-WAY SW)
16 --- CHKG CHKG
17 --- OPT2 OPT2
18 SDM SDM SEAT SWITCH
19 DSR DSR DIRECTION SWITCH REVERSE
20 SPB SPB PARKING BRAKE SWITCH
21 --- OPTSSC OPTSSC
22 SH1 SH1 LIFTING HEIGHT SWITCH 1
23 --- SWA SWA
STEERING WHEEL ANGLE SENSOR 3 (only SSC
24 SSTRC SSTRC
combined with SW)
25 --- OPTSS1 OPTSS1
26 DSF DSF DIRECTION SWITCH FORWARD
27 --- LSOPT1 LSOPT1
28 SHS SLM LOAD DISPLAY
29 --- BMP BMP
30 SSTR1 SSTR1
combined with SW)
31 SSTR2 SSTR2
combined with SW)
1 CONTROLLER 1-21
1.1.1 CONTROLLER CABLES

1
1 ton series
Pump motor driver

Pump motor cable ACS cable
PW PV PU P4
45°
60°
15° 15° 30° 30°
N1 90°
Conecter cable
15°
W
Drive motor cable
30°
V
30°
U
15°
15°
N2 P41 Drive motor driver

ACS cable ACS cable
Terminals tightening torque:

T=11.2 - 16.8 N·m (114 - 171 kgf·cm) [8.27 - 12.3 ft·lbf]
1-22 1 CONTROLLER
2, 3 ton series
Pump motor driver

Pump motor cable ACS cable
PW PV PU P4
30°
75°
15° 30° 30° 30°

N1
Conecter cable
90°
30° W
Drive motor cable
30°
V
15°
U
90°
90°
N2 P41 Drive motor driver

ACS cable ACS cable
Terminals tightening torque:

T=11.2 - 16.8 N·m (114 - 171 kgf·cm) [8.27 - 12.3 ft·lbf]
1 CONTROLLER 1-23
1.2 COMPONENTS
CONTROL PANEL [2401] 1
CONTACTOR PANEL [15,16,18,20,25] [2402]

1-24 1 CONTROLLER
CONTACTOR PANEL [30] [2402]
CONTACTOR ASSY [2403]

1 CONTROLLER 1-25
1.3 BEFORE REPAIR

1
1.3.1 INSPECTION
1. Insulation resistance measurement
NOTICE!
Always measure before inspecting the drive/ma-
terial handling controller and the main controller.
(1) Disconnect the battery plug and measure the resist-
ance between battery plug and body.
G85703014_
Measurement terminals Controller side of battery plug-body

Resistance value depends greatly on the vehicle operating state, place and
Standard weather.
(Approx. 1MΩ or more)
Some components can be inspected after they are removed from the vehicle, some components can be in-
spected as installed on the vehicle.
Main controller must be inspected as installed on the vehicle since the battery voltage must be applied.
Disassembly Procedure
▪ Overhauling the contactor panel is rarely necessary. In most cases, failed parts is replaced after
finding out the cause of the failure from inspection. Therefore, make sure to repair correctly by
referring to the figures of configuration and ASSY.
▪ Do not disassemble drive·material handling AC driver and the main controller, as they should be
replaced in a form of ASSY.
Caution for part replacement

▪ Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking
of tightening may cause other failure.
▪ When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connec-
tion. Incorrect connection may cause other failure.
▪ After installation, check that there is no interference of the bar and harness connection with other
portion.
Discharge of the power condenser
WARNING
The power condenser in the driver may have electrical charge.
So, before Inspection / repairing / troubleshooting, discharge the power condenser in the driver and
check the voltage (less than 3V). [Terminal between P4 and N2]
1-26 1 CONTROLLER
1.4 CONNECTOR INSPECTION
1.4.1 How to use SST

An SST is used to make fast and accurate measurements. Inspection cannot be made if you have an incor-
rect connection method. Take extra caution, as the boards could be damaged if the connection is incorrect.
CAUTION
Always disconnect the battery plug before connecting and disconnecting the SST. Various types of boards
may be damaged if the battery plug is connected.
Parts No. Purpose Remarks

Measures the voltage or the resistance of the
09230-13240-71 Used in CN101 to CN104
main controller.
09240-13241-71 Measure the voltage for AC driver. Used in CN110 , CN111
1.4.2 Inspection
Even if you decide that some boards may be causing an error after inspecting them, you should check the
following items before replacing those boards immediately.
▪ Errors of related harnesses
▪ Looseness of related connectors
▪ Bending or damages of connector pins, and contact failure of related connector pins
If the above items are the cause of the error, a new replaced board will be also damaged.
Be careful of board replacement.
Measuring Method and Standards List

How to read the list
Tester Probe +
Tester Probe -
Connecror No. Connector No. Conditions Standard Remarks

CN101-1 CN101-26
Key switch OFF, DSF ON. Approx. 0V
(45, DSF) (51, LS-)
Terminal name Conditions for measurement
Electric Level No.
Connector pin No.
G85703013_
1 CONTROLLER 1-27
1.4.2.1 Main Controller

1
CN101 CN102 CN103 CN104
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
OFF operation on active test (LIFT
Approx. 0V
CN101-1 CN102-16 LWR SOL)
(3, SOLLU+) (4, SLLL-) ON operation on active test (LIFT
Approx. 11V
LWR SOL)
OFF operation on active test (TILT
Approx. 0V
CN101-2 CN102-19 SOL)
(6, SLTFB+) (7, SLTFL-) ON operation on active test (TILT
Approx. 11V
SOL)
CN101-3 CN102-13 Key switch OFF Approx. 0V
(97, RY1+) (335, RY-) Key switch ON Approx. 12V
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
CN101-5 CN101-16
Approx. 0 to 10V
(9, SLLA2+) (11, SLPS-)
CN101-6 CN101-12
Approx. 0 to 10V
(32, SLTA1+) (33, STPL-)
CN101-7 - - -
CN101-8 - - -
CN101-9 - - -
CN101-10 CN101-6 Resistance measurement with bat-
Approx. 7Ω
(36, SA1PL) (32, SLTA1+) tery plug disconnected
Approx. 7Ω
(37, SA1PS) (32, SLTA1+) tery plug disconnected
Approx. 7Ω
(33, STPL-) (32, SLTA1+) tery plug disconnected
Approx. 7Ω
(34, STPS-) (32, SLTA1+) tery plug disconnected
Approx. 7Ω
(39, SA2PL-) (9, SLLA2+) tery plug disconnected
Approx. 7Ω
(40, SA2PS-) (9, SLLA2+) tery plug disconnected
Approx. 7Ω
(11, SLPS-) (9, SLLA2+) tery plug disconnected
1-28 1 CONTROLLER

Approx. 7Ω
(10, SLPL-) (9, SLLA2+) tery plug disconnected
(1,2 ton)
CN101-18 - - -
48V
CN101-18 CN104-4 (3 ton)
Fan ON Approx. 30V
(99, VFAN) (N2, N2) 80V
(43, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN101-32
- Approx. 4.8V
(57, VRTA+) (51, POT-)
CN101-21 - - -
CN101-22
- - -
(50, VRA-)
CN101-23 CN102-26
- Approx. 4.8V
(316, VRTRA+) (51, POT-)
CN101-24 CN101-32
- Approx. 4.6V
(219, VRH+) (51, POT-)
CN101-25 CN102-26
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN101-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)
CN101-27 CN101-22
- Approx. 4.8V
(53, VRA1+) (50, VRA-)
CN101-28 CN102-26
- Approx. 4.6V
(29, VRT1+) (51, POT-)
CN101-29 CN102-26
- Approx. 4.6V
(30, VRAT1+) (51, POT-)
CN101-30 CN102-26
- Approx. 4.6V
(31, VRAT2+) (51, POT-)
CN101-31 - - -
CN101-32
- - -
(51, POT-)
CN101-33 CN101-32
- Approx. 4.8V
(74, VRB2+) (51, POT-)
CN101-34 CN101-22
- Approx. 4.8V
(72, VRB1+) (50, VRA-)
CN102-1 - - -
CN102-2 - - -
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
(17, SOLCOM) N2, N2 Key switch ON Battery voltage
(17, SOLCOM) N2, N2 Key switch ON Battery voltage
1 CONTROLLER 1-29

OFF operation on active test
CN102-7 CN102-14 (STEERING SOL)
Approx. 0V 1
(329, SLS+) (330, SLS-) ON operation on active test (STEER-
Approx. 11V
ING SOL)
(333, OACC3) (N2, N2) Key switch ON Approx. 0V
CN102-9 - - -
CN102-10
- - -
(51, LS-)
CN102-11 - - -
CN102-12 - - -
Key switch OFF Battery voltage
CN102-13 CN104-4
(335, RY1-) (N2, N2) Battery voltage:
Key switch ON
Approx. 12V
Approx. 10Ω
(330, SLS-) (329, SLS+) tery plug disconnected
CN102-15 - - -
Approx. 10Ω
(4, SLLL-) (3, SOLLU+) tery plug disconnected
CN102-17 - - -
CN102-18 - - -
Approx. 10Ω
(7, SLTFL-) (6, SLTFB+) tery plug disconnected
Attachment 1 lever at neutral Approx. 2.3V
CN102-20 CN102-26
(25, VRA12) (51, POT-) Amount of change when the attach-
Approx. 0.5 to 4V
ment 1 lever is front to rear tilted
CN102-21 CN102-26
Approx. 0.5 to 4V
Tilt lever at neutral Approx. 2.3V
CN102-22 CN102-26
(23, VRT2) (51, POT-) Amount of change when the tilt lever
Approx. 0.5 to 4V
is front to rear tilted
Tilt lever at neutral Approx. 2.3V
CN102-23 CN102-26
(22, VRT1) (51, POT-) Amount of change when the tilt lever
Approx. 0.5 to 4V
CN102-24 CN102-35
- Approx. 2.5V
(304, CSBAT) (305, CSBAT-)
Key switch OFF,
CN102-25 CN101-32 Approx. 0.8 to
Change of amount when the brake
(73, VRB2) (51, POT-) 4.7V
pedal is depressed
CN102-26
- - -
(51, POT-)
CN102-27 - - -
CN102-28 CN102-26
Approx. 0.5 to 4V
CN102-29 CN102-26
Approx. 0.5 to 4V
Key switch OFF,
CN102-30 CN101-22 Approx. 0.4 to
Change of amount when the acceler-
(52, VRA1) (50, VRA-) 4.7V
ator pedal is depressed
1-30 1 CONTROLLER

CN102-31 CN102-26
Tires at neutral Approx. 2.5V
(317, VRTRA) (51, POT-)
Key switch OFF,
CN102-32 CN101-32 Approx. 0.7 to
Change of amount when the acceler-
(54, VRA2) (51, POT-) 4.7V
ator pedal is depressed
Key switch OFF,
CN102-33 CN101-22 Approx. 0.5 to
Change of amount when the brake
(71, VRB1) (50, VRA-) 4.7V
pedal is depressed
CN102-34 CN101-32 Measurement with machine table at
Approx. 2.5V
(310, SSLP) (51, POT-) level condition
CN102-35
- - -
(305, CSBAT-)
CN103-1 - - -
CN103-2 - - -
CN103-3
- - -
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 - - -
CN103-8 CN101-32
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9 - - -
CN103-10 - - -
CN103-11
- Immeasurable -
(145, CAN1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - - -
CN103-16 - - -
CN103-17 CN101-32 Change of amount when tilted for-
Approx. 1 to 4V
(56, VRTA) (51, POT-) ward and backward
Lift lever at neutral Approx. 2.3V
CN103-18 CN102-26
(21, VRL2) (51, POT-) Amount of change when the lift lever
Approx. 0.5 to 4V
CN103-19 CN101-32
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20 - - -
CN103-21 - - -
CN103-22 - - -
CN103-23 - - -
1 CONTROLLER 1-31

Key switch OFF,
CN103-24 CN103-6 Lift at the lower most position
Approx. 5V 1
(91, SH2-1) (51, LS-) Key switch OFF,
Approx. 0V
Lift at the upper most position
Key switch OFF,
Approx. 0V
(221, SHL) (51, LS- Key switch OFF,
Approx. 5V
Lift lever at neutral Approx. 2.3V
CN103-26 CN102-26
(20, VRL1) (51, POT-) Amount of change when the lift lever
Approx. 0.5 to 4V
CN103-27 - - -
CN103-28 CN101-32 Change of amount when height ups Approx. 0.5 to
(220, VRH) (51, POT-) and lowers 4.5V
When the fork is grounded Approx. 1V or less
CN103-29 CN101-32
(59, SPLF) (51, POT-) Change of amount when the loaded Approx. 0.5 to
lift is raised and lowered 4.5V
CN103-30 CN101-32
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - - -
CN103-32 CN102-10 Key switch OFF, Tilt nob switch OFF Approx. 5V
(70, STK) (51, LS-) Key switch OFF, Tilt nob switch ON Approx. 0V
CN103-33 - - -
Key switch OFF,
Approx. 0V
(420, SWH081) (51, LS-) Key switch OFF,
Approx. 5V
Key switch OFF,
Approx. 5V
CN103-35 CN102-10 Seat belt unattached
(450, SSB) (51, LS-) Key switch OFF,
Approx. 0V
Seat belt attached
CN104-1 CN104-4 (1,2 ton)
- Battery voltage
(41, B48V) (N2, N2) 48V
CN104-1 CN104-4 (3 ton)
- Battery voltage
(18, B80V) (N2, N2) 80V
CN104-2 CN104-4 Key switch OFF Approx. 0V (1,2 ton)
(44, VBMB) (N2, N2) Key switch ON Battery voltage 48V
CN104-2 CN104-4 Key switch OFF Approx. 0V (3 ton)
(19, VBMB) (N2, N2) Key switch ON Battery voltage 80V
Key switch OFF Approx. 0V
CN104-3 CN104-9
(1, CBAT+) (2, CBAT-) Approx. 11V to
Key switch ON
12V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)
CN104-7 - - -
1-32 1 CONTROLLER

CN104-8 CN104-4 OFF operation on active test (FAN1) Battery voltage (1,2 ton)
(98, FANDC) (N2, N2) ON operation on active test (FAN1) Approx. 0V 48V
CN104-8 (3 ton)
- - -
(98, FNDC) 80V
Approx. 20Ω
(2, CBAT-) (1, CBAT+) tery plug disconnected
CN104-10 CN102-35
- Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN104-11 - - -
CN104-12 CN102-32
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 - - -
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 CN104-4
- Approx. 14V
(60, PSSW+) (N2, N2)
CN104-16 - - -
CN104-17 - - -
CN104-18 CN102-10 Key switch OFF, Seat switch OFF Approx. 5V
(67, SDM) (51, LS-) Key switch OFF, Seat switch ON Approx. 0V
Key switch OFF,
Approx. 5V
CN104-19 CN102-10 Direction lever in neutral
(46, DSR) (51, LS-) Key switch OFF,
Approx. 0V
Direction lever in reverse
Key switch OFF,
Approx. 5V
CN104-20 CN103-6 Parking brake locked
(66, SPB) (51, LS-) Key switch OFF,
Approx. 0V
Parking brake released
CN104-21 - - -
Key switch OFF,
Approx. 0V
(90, SH1) (51, LS-) Key switch OFF,
Approx. 5V
CN104-23 - - -
CN104-24 CN103-6
Steering wheel operation Approx. 0V - 5V
(314, SSTRC) (51, LS-)
CN104-25 - - -
Key switch OFF,
Approx. 5V
CN104-26 CN102-10 Direction lever in neutral
(45, DSF) (51, LS-) Key switch OFF,
Approx. 0V
Direction lever in forward
CN104-27 - - -
CN104-28 CN120-10 Key switch OFF, Lift nob switch OFF Approx. 5V
(68, SHS) (51, LS-) Key switch OFF, Lift nob switch ON Approx. 0V
CN104-29 - - -
CN104-30 CN103-6
Steering wheel operation Approx. 0V to 5V
(312, SSTR1) (51, LS-)
CN104-31 CN103-6
Steering wheel operation Approx. 0V to 5V
(313, SSTR2) (51, LS-)
1 CONTROLLER 1-33
1.4.2.2 Drive motor driver

CN110 1
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
CN110-1 - - -
CN110-2 - - -
CN110-3 - - -
CN110-4 - - -
CN110-5 - - -
CN110-6 - - -
CN110-7 - - -
CN110-8 -
- Battery voltage
(42, KYSAT) (N1, N1)
CN110-9 -
- Approx. 5V
(86, STDM+) (N1, N1)
CN110-10 -
- Approx. 1 to 4V
(87, STDM) (N1, N1)
CN110-11 - - -
CN110-12 - - -
L: Approx. 0.5V
CN110-13 -
- or
(80, SSD2) (N1, N1)
H: Approx. 1.5V
L: Approx. 0.5V
CN110-14 -
- or
(79, SSD1) (N1, N1)
H: Approx. 1.5V
CN110-15 -
- Approx. 15V
(78, SSD+) (N1, N1)
CN110-16
- Immeasurable -
(146, CAN1L)
CN110-17
- Immeasurable -
(145, CAN1H)
CN110-18 - - -
CN110-19 - - -
CN110-20 - - -
CN110-21 - - -
CN110-22 - - -
CN110-23 - - -
1-34 1 CONTROLLER
1.4.2.3 Pump motor driver

CN111
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
CN111-1 - - -
CN111-2 - - -
CN111-3 - - -
CN111-4 - - -
CN111-5 - - -
CN111-6 -
- Approx. 0V
(152, SETP1) (N1, N1)
CN111-7 - - -
CN111-8 -
- Battery voltage
(42, KYSAT) (N1, N1)
CN111-9 -
- Approx. 5V
(88, STPM+) (N1, N1)
CN111-10 -
- Approx. 1 to 4V
(89, STPM) (N1, N1)
CN111-11 - - -
CN111-12 - - -
CN111-13 - - -
L: Approx. 0.5V
CN111-14 -
- or
(82, SSP1) (N1, N1)
H: Approx. 1.5V
CN111-15 -
- Approx. 15V
(81, SSP+) (N1, N1)
CN111-16
- Immeasurable -
(146, CAN1L)
CN111-17
- Immeasurable -
(145, CAN1H)
CN111-18 - - -
CN111-19 - - -
CN111-20 - - -
CN111-21 - - -
CN111-22 - - -
CN111-23 -
- Approx. 0V
(152, SETP-) (N1, N1)
1 CONTROLLER 1-35
1.4.2.4 Contactor Panel ASSY

(1, 2 ton series) (3 ton model) 1
P1 P1
CN128
CN137 CN137
CN136 CN136
P4 P4
CN127 CN127
CN127 CN128 CN136 CN137
3 2 1
8 7 6 5 4 6 5 4 3 2 1 4 3 2 1 2 1
3
12 11 10 9 8 7 8 7 6 5
G85703018_v2
CN127-1 - - -
CN127-2 N1 terminal Apply the negative probe to the N1
Approx. 48V
(97, RY+) (N1, N1) terminal to measure voltage.
CN127-3 - - -
CN127-4
- - -
(335, RY1)
CN127-5 - - -
1, 2 ton series:
CN127-6 N1 terminal Apply the negative probe to the N1 Approx. 48V
(19, VBMBSL) (N1, N1) terminal to measure voltage. 3 ton model:
Approx. 80V
CN127-7 - - -
1, 2 ton series:
CN127-8 N1 terminal Apply the negative probe to the N1 Approx. 48V
(17, SOLCOM) (N1, N1) terminal to measure voltage. 3 ton model:
Approx. 80V
CN128 connector basic conditions (battery plug connected, key switch ON) 3 ton model only (80V)
CN128-1 - - -
CN128-2 - - -
1-36 1 CONTROLLER

CN128-3 N1 Apply the negative probe to the N1
Approx. 80V
(1, CBAT+) (N1, N1) terminal to measure voltage.
Approx. 80V
Approx. 80V
Approx. 80V
CN128-7 - - -
Fan ON,
CN128-8 N1
Apply the negative probe to the N1 Approx. 30V
(99, VFAN) (N1, N1)
terminal to measure voltage.
Fan ON,
CN128-9 N1
(99, VFAN) (N1, N1)
Fan ON
CN128-10 N1
(99, VFAN) (N1, N1)
Fan ON
CN128-11 N1
(99, VFAN) (N1, N1)
CN128-12 - - -
CN136 connector basic conditions (battery plug connected, key switch OFF)
CN136-1 P2 Battery plug disconnected, and the
Approx. 0 Ω
(101, FLP) (P2, P2) CN136 connector disconnected
Approx. 0 Ω
(41, B48V) (P2, P2) CN136 connector disconnected
CN136-3 CN136-4 Apply the negative probe to the
Approx. 11 V
(2, CBAT-) (1, CBAT+) CN136-3 to measure voltage.
CN136-4 CN136-3 Battery plug disconnected, and the
Approx. 20 Ω
(1, CBAT+) (2, CBAT-) CN136 connector disconnected
CN136-5 P3 Battery plug disconnected, and the (1,2 ton)
Approx. 0 Ω
(44, VBMB) (P3, P3) CN136 connector disconnected 48V
CN136-5 P3 Battery plug disconnected, and the (3 ton)
Approx. 0 Ω
(18, VBMB) (P3, P3) CN136 connector disconnected 80V
Approx. 0 Ω
(19, VBMBSL) (P3, P3) CN136 connector disconnected
CN136-7 - - -
CN136-8 - - -
CN137 connector basic conditions (battery plug connected, key switch OFF)
CN137-1 CN137-2 Apply the negative probe to the
Approx. 5V
(303, CSBAT+) (305, CSBAT-) CN137-2 to measure voltage.
CN137-2
- - -
(305, CSBAT-)
Apply the negative probe to the
CN137-3 CN137-2 CN137-2 to measure voltage.
Approx. 2.5V
(304, CSBAT) (305, CSBAT-) Drive motor, pump motor, all auxili-
ary machines OFF
1 CONTROLLER 1-37
1.4.2.5 Multifunction Display
CN70
1
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
CN70-1 CN70-2
- Approx. 6.3V
(128, CHG7V) (130, CHGGND)
CN70-2
- - -
(130, CHGGND)
CN70-3
- - - *2
(169, TGND)
CN70-4
- - -
(14, DGND)
CN70-5 CN70-4
- Approx. 6.3V
(16, D7V) (14, DGND)
CN70-6 CN70-3
- Approx. 5V *1 *2
(162, ITKY3) (169, TGND)
CN70-7 - - -
CN70-8 CN70-3
- Approx. 5V *1 *2
(160, ITKY1) (169, TGND)
CN70-9
- Immeasurable - *2
(166, OTKY3)
CN70-10
- Immeasurable - *2
(165, OTKY2)
CN70-11
- Immeasurable - *2
(164, OTKY1)
CN70-12 CN70-3
- Approx. 0V *1 *2
(167, LEDTKY1) (169, TGND)
CN70-13 - - -
CN70-14 - - -
CN70-15
- Immeasurable -
(146, CAN1L)
CN70-16
- Immeasurable -
(145, CAN1H)
CN70-17 - - -
CN70-18 CN70-36
- Approx. 48V *2 *3
(43, VBKY) (N1, N1)
CN70-19 CN70-3
- Approx. 3V *1 *2
(168, LEDTKY2) (169, TGND)
CN70-20 CN70-3
- Approx. 5V *1 *2
(161, ITKY2) (169, TGND)
CN70-21 CN70-3
- Approx. 5V *1 *2
(163, IPSTKY1) (169, TGND)
CN70-22 CN70-4
- Approx. 5V
(123, SW1) (14, DGND)
CN70-23 CN70-4
- Approx. 5V
(122, SW2) (14, DGND)
CN70-24 CN70-4
- Approx. 5V
(121, SW3) (14, DGND)
1-38 1 CONTROLLER

CN70-25 CN70-4
- Approx. 5V
(129, CHGAC) (14, DGND)
L: Approx. 1.8V
CN70-26 CN70-4
- or
(140, SLLT) (14, DGND)
H: Approx. 2.7V
CN70-27 - - -
CN70-28 CN70-4
- Approx. 0V
(139, SWTT) (14, DGND)
CN70-29 CN70-4
- Approx. 0V
(125, LED3) (14, DGND)
CN70-30 CN70-4
- Approx. 0V
(126, LED2) (14, DGND)
CN70-31 CN70-4
- Approx. 0V
(127, LED1) (14, DGND)
CN70-32 CN70-4
- Approx. 0V
(124, LED4) (14, DGND)
CN70-33 CN70-4
- Approx. 0V
(132, CHGMS) (14, DGND)
CN70-34 - - -
CN70-35 - - -
CN70-36
- - - *2 *3
(N1, N1)
*1: PIN code entry system
*2: Multi-function display/ DX only
*3: Cold storage specification only
1 CONTROLLER 1-39
1.4.2.6 TEN-KEY (W/ PIN code entry system)

CN33 1
5 4 3 2 1
10 9 8 7 6
CN33-1 CN33-7
- Approx. 5V
(160, ITKY1) (169, TGND)
CN33-2 CN33-7
- Approx. 5V
(161, ITKY2) (169, TGND)
CN33-3 CN33-7
- Approx. 5V
(162, ITKY3) (169, TGND)
CN33-4
- Immeasurable -
(165, OTKY2)
CN33-5 CN33-7
- Approx. 0V
(167, LEDTKY1) (169, TGND)
CN33-6 CN33-7
- Approx. 5V
(163, IPSTKY1) (169, TGND)
CN33-7
- - -
(169, TGND)
CN33-8
- Immeasurable -
(164, OTKY1)
CN33-9
- Immeasurable -
(166, OTKY3)
CN33-10 CN33-7
- Approx. 3V
(168, LEDTKY2) (169, TGND)
1-40 1 CONTROLLER
1.4.2.7 Transformer, Charger

CN68 CN69
6 5 4 3 2 1
2 1
12 11 10 9 8 7
CN68-1 CN68-2
- Approx. 0V
(139, SWTT) (14, DGND)
CN68-2
- - -
(14, DGND)
CN69-1 CN69-3
- Approx. 6.3V
(132, CHGMS) (130, CHGGND)
CN69-2 CN69-3
- Approx. 5V
(129, CHGAC) (130, CHGGND)
CN69-3
- - -
(130, CHGGND)
CN69-4 CN69-3
- Approx. 6.3V
(128, CHG7V) (130, CHGGND)
CN69-5 CN69-3
- Approx. 5V
(121, SW3) (130, CHGGND)
CN69-6 CN69-3
- Approx. 5V
(122, SW2) (130, CHGGND)
CN69-7 CN69-3
- Approx. 5V
(123, SW1) (130, CHGGND)
CN69-8 CN69-3
- Approx. 0V
(124, LED4) (130, CHGGND)
CN69-9 CN69-3
- Approx. 0V
(125, LED3) (130, CHGGND)
CN69-10 CN69-3
- Approx. 0V
(126, LED2) (130, CHGGND)
CN69-11 CN69-3
- Approx. 0V
(127, LED1) (130, CHGGND)
CN69-12 - - -
1 CONTROLLER 1-41
1.4.2.8 Battery Fluid Level and Temperature Sensor

CN35 1
L: Approx. 1.8V
CN35 CN70-4
When connecting to the display or
(140, SLLT) (14, DGND)
H: Approx. 2.7V
1.4.2.9 CAN Bridge

CN100
5 4 3 2 1
9 8 7 6
14 13 12 11 10
CN100-1
- Immeasurable -
(443, CAN3L)
CN100-2
- Immeasurable -
(443, CAN3L)
CN100-3
- Immeasurable -
(442, CAN3H)
CN100-4
- - -
(N2, N2)
CN100-5
- Immeasurable -
(146, CAN1L)
CN100-6 - - -
CN100-7 - - -
CN100-8 - - -
CN100-9
- Immeasurable -
(145, CAN1H)
CN100-10 CN100-13
- Approx. 0V
(N2, SELCB) (N2, N2)
CN100-11 - - -
CN100-12 - - -
CN100-13
- - -
(N2, N2)
CN100-14 CN100-13
- Approx. 48V
(440, VBRY) (N2, N2)
1-42 1 CONTROLLER
1.4.2.10 Telematics Unit

Data Handling Unit (DHU2)
CN284
1 2 3 4
5 6 7 8
CN284-1 CN284-8
- Approx. 48V
(440, VBRY) (N2, N2)
CN284-2
- Immeasurable -
(442, CAN3H)
CN284-3
- Immeasurable -
(443, CAN3L)
CN284-4
- - -
(444, OUT1)
CN284-5 - - -
CN284-6 - - -
CN284-7 - - -
CN284-8
- - -
(N2, N2)
Numeric keypad
CN283
5 4 3 2 1
9 8 7 6
CN283-1 - - -
CN283-2 Immeasurable
- -
(442, CAN3H) -
CN283-3
- Immeasurable -
(443, CAN3L)
CN283-4 CN283-8
Approx. 48V
(440, VBRY) (N2, N2)
CN283-5 - - -
CN283-6 - - -
CN283-7 - - -
CN283-8
- - -
(N2, N2)
CN283-9 - - -
1 CONTROLLER 1-43
Shock sensor
CN281 1
2 4
1 3
CN281-1
- - -
(N2, N2)
CN281-2
- Immeasurable -
(443, CAN3L)
CN281-3 CN281-1
- Approx. 48V
(440, VBRY) (N2, N2)
CN281-4
- Immeasurable -
(442, CAN3H)
Service connector
CN285
1 2
4 3
CN285-1
- Immeasurable -
(442, CAN3H)
CN285-2
- Immeasurable -
(443, CAN3L)
CN285-3
- - -
(N2, N2)
CN285-4 CN285-3
- Approx. 48V
(440, VBRY) (N2, N2)
1-44 1 CONTROLLER
Pre-Operation Check device connector (POC)
CN282
2 4
1 3
CN281-1 CN282-3
- Approx. 48V
(440, VBRY) (N2, N2)
CN282-2
- Immeasurable -
(443, CAN3L)
CN282-3
- - -
(N2, N2)
CN282-4
- Immeasurable -
(442, CAN3H)
1 CONTROLLER 1-45
1.5 MAIN CONTROLLER

1
1.5.1 REMOVAL AND INSTALLATION
Removal Procedure
1. Turn the key switch OFF and disconnect the battery plug.
3
2
2. Remove the rear cover. (bolt: 2 pcs)

3. Open the battery hood and remove the controller upper cover. (bolt: 4 pcs)
4. Remove the rear pillar cover LH.
5. Remove the rear pillar cover RH.
6. Remove the battery guard.
7. Remove the bracket for electrical parts.
(1) Disconnect the connector from the relay and DC/DC
converter.
NOTICE!
The number of harness and cable to be discon-
nected varies depending on vehicle models.
Check that all harnesses and cables are discon-
nected before removing the bolts.
1-46 1 CONTROLLER
T 8. Remove the contactor panel ASSY.

NOTICE!
The parts installed on the contactor panel vary
depending on vehicle models.
(1) Disconnect the cable from the contactor panel.
*Tightening torque:
T = 11.2 - 16.8 N·m (114 - 171 kgf·cm)
[8.26 - 12.4 ft·lbf]
(2) Disconnect the connector from the contactor panel.
T
(3) Remove the bolts. (bolt: 3 pcs)
NOTICE!
Use a 25cm long extension.
G85703012_
9. Remove the main controller ASSY.

(1) Disconnect the connector. (4 place)
(2) Remove the bolts. (bolt: 4 pcs)

*Tightening torque:
T = 3.9 - 7.2 N·m (39.8 - 73.4 kgf·cm)
[2.87 - 5.31 ft·lbf]
1 CONTROLLER 1-47
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
1
NOTICE
When replacing the main controller, it requires initial setups as follows.
Before replacing the main controller, refer to TUNING and OPTION SET in section 4 DISPLAY FUNC-
TION and make a note of initial setting values.
After replacing the main controller, configure the setting for each function with initial setting values.
Also, refer to MATCHING in section 4 DISPLAY FUNCTION and perform matching.
1-48 1 CONTROLLER
1.6 PUMP MOTOR DRIVER
1.6.1 REMOVAL AND INSTALLATION

Removal Procedure
2. Remove the rear cover. (bolt: 2 pcs)
(For step 2 to step 6, refer to REMOVAL AND INSTALLATION for the MAIN CONTROLLER.)
3. Open the battery hood and remove the controller upper cover. (bolt: 4 pcs)
4. Remove the rear pillar cover LH.
5. Remove the rear pillar cover RH.
6. Remove the battery guard.
(Example 1 ton model)
8
8
8 8
8
(Illustration of 1 ton model)
7. Disconnect the connector from the terminals of the pump motor drive controller.
8. Disconnect the cables from the terminals of the pump motor drive controller.
Tightening torque: T = 11.2 - 16.8 N·m (114 - 171 kgf·cm) [8.26 - 12.4 ft·lbf]
1 CONTROLLER 1-49
9. Remove the bolts. (4 pieces)

Size: M8 × 1.25
Length: 25mm 1
Tightening torque:
T = 6.3 - 11.7 N·m (64.2 - 119.3 kgf·cm)
[4.6 - 8.6 ft·lbf]
1 ton series 10. Remove the pump motor drive controller from the
rear frame, using service bolt. (adjustment bolt)
NOTICE!
Service bolt can be installed into a hole, which is
indicated in the illustration.
Service bolt specification
Size: M8 × 1.25
Length: more than 40mm
2, 3 ton series
11. Insert a tool between the pump motor drive controller

and the rear frame and remove the pump motor drive
controller.
1-50 1 CONTROLLER
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
NOTICE
Remove silicone grease applied on the top surface of the rear frame and the under surface of the
pump motor drive controller.
NOTICE
• When installing the pump motor drive controller on the rear frame, apply appropriate amount of
silicone grease on the under surface of the pump motor drive controller. Also, apply silicone
grease on the surface of the rear frame.
• Use either one of the following types of silicone grease.
KS-609 (Shin-Etsu Chemical Co.,Ltd.)
FLOIL G-600 (KANTO KASEI Ltd.)
• Apply threadlocker (LOCTITE 243) to the bolts when tightening the pump motor drive controller.
• Remove excess grease after installing the pump motor drive controller.
1.7 DRIVE MOTOR DRIVER

Removal and Installation Procedure
For the removal and installation procedure, see the procedure of the pump motor drive controller.
1 CONTROLLER 1-51
1.8 OCL VALUE MEASUREMENT

1
For drive circuit
1. Preparation before measurement
(1) Load the forklift so that it is within the rated capacity,
and position it so that the fork tip is facing a wall or
steel pole. Be sure to place a piece of wood between
the fork tip and the wall.
G85703032_
(2) Turn on the SST by pressing the "POWER" key on

the unit.
SST 09140-13130-71
G85703033_
(3) Press the "MODE" key twice to switch to the AC+DC

A measurement mode.
G85703034_
1-52 1 CONTROLLER
(4) After pressing the "SHIFT" key, press the "SAMPL"

key to set the display update rate to “SLOW”.
G85703035_
(5) After pressing the SHIFT key, press the CLEAR key
to start zero point adjustment. (Pressing the CLEAR
key makes the “ADJ” indicator flash and switches the
unit to zero point adjustment mode. When the “ADJ”
indicator stays on after flashing, zero point adjust-
ment is completed.)
G85703036_
2. Measurement work
(1) Set the clamp sensor of the SST on the motor cable.
NOTICE!
▪ Set the clamp sensor so that the cable is posi-
tioned in the center of the clamp with the clamp
sensor aligned perpendicular to the cable.
G85703037_
(2) Turn on the key switch and set the direction switch to
“Forward”. Gradually depress the accelerator pedal to
full throttle and hold there. The SST will start meas-
urement automatically.
G85703038_
1 CONTROLLER 1-53
NOTICE!
▪ The SST start measurement automatically as soon
as forward motion starts. Be sure to wait for ap-
1
proximately 20 seconds before reading the meas-
urement value. “O.L.” (Overflow alert) may be dis-
played during the first 10 seconds, or the dis-
played value may not be stable for a while.
▪ If the measurement value is not stable after ap-
proximately 20 seconds, retry measurement by
pressing the "SHIFT" key down then the "PEAK/
Hz" key to enable filter setting as shown in the il-
lustration.
▪ Measurement can be done in this mode (AC+DC A
mode, Display update mode: SLOW) also. How-
ever, when using other modes, motor current fre-
quency in forward motion is only 10 Hz or below
and current measurement cannot be obtained.
G85703039_
Drive motor current limitation values (OCL)

Model Current (A)
8FBN15, 16, 18 320 - 400
8FBN20, 25 405 - 525
8FBN30 290 - 385
CAUTION
• The drive motor current limit value can be measured in the state without tire slip by pushing op-
eration. When using the brake operation to lock the tire, the measured value will be less than the
reference value.
• Even if it is set to accelerator off or direction neutral after measurement, the current does not be-
come 0 A immediately but it is not abnormal.
• The above values are measured when measured by SST (09140-13130-71). In other instruments,
the same value may not be obtained.
1-54 1 CONTROLLER
For pump circuit
NOTICE
[About the pump motor current limitation value]
The pump motor current limitation value cannot be measured due to the following reason:
• The OCL set value of the pump motor is set with a value higher than the current value of the relief
valve set pressure.
The relief valve in the control valve is activated at the stroke end of each cylinder of the load
handling system.
Therefore, the hydraulic circuit performs the relief before the current value of the pump motor
reaches the OCL value.
OCL value > value at the lift relief
Pump motor current limitation values (OCL)

Reference value
Model Current (A)
8FBN15, 16, 18 300 - 395
8FBN20, 25 355 - 565
8FBN30 225 - 305
2 DISPLAY FUNCTION 2-55
2 DISPLAY FUNCTION
2.1
2
STD DISPLAY ......................................................................................... 55
2.2 MULTI-FUNCTION DISPLAY ................................................................ 147
2.1 STD DISPLAY
2.1.1 GENERAL
The display is placed on top of the right instrument panel to improve forward visibility from the operation
seat.
An LCD display that displays basic items, such as a battery capacity indicator, an hour meter and various
warning lights, has been newly developed and provided as standard. As compared with previous LED indic-
ators, the visibility and ease of recognition of various states have been substantially improved.
In addition, a vehicle maintenance function, a feeling adjustment function and a specification setting function
are provided as service functions.
Power select switch Display area

Overheat warning indicator Spanner indicator
OPS indicator
Battery capacity indicator

Hour meter
Power select indicator
Parking brake Battery fluid level warning indicator

indicator
Hour meter ON indicator Battery overheat warning indicator
2-56 2 DISPLAY FUNCTION
2.1.2 SCREEN
1. Initial screen after Key-On
Initial screen is displayed for two seconds after key-switch is turned on.
NOTICE
• The battery fluid level warning indicator is displayed only when a JIS battery is installed.
• The battery overheat warning indicator is displayed only when a JIS battery is installed and the battery
protection function is provided.
2. Status screen
After the initial screen display, status screen is displayed.
3. Diagnostic code display

If the diagnostic function is activated, the spanner indicator blinks and a warning sound is emitted to
warn the operator of the occurrence of a failure in the vehicle.
At that time, the key ON hour meter and error code indicating where the failure has occurred are dis- 2
played alternately in the hour meter area. 6 error codes are displayed at the maximum at intervals of 2
seconds.
“E” is displayed in the meaning of the error.
Error code
4. Alphabetic characters and numbers in display area
Numbers
Alphabet
NOTICE
J, K, Q, X and Z are not displayed.
2.1.3 DETAIL DESCRIPTION

1. Indicator
(1) OPS indicator 2
When the operator leaves the operation seat, this indicator
lights up and the buzzer sounds for 1 second.
When installing the seatbelt interlock, there may be lights
even when a seatbelt is not installed.
(2) Parking brake indicator
This indicator lights while the parking brake is engaged.
(3) Spanner indicator

This indicator blinks and the buzzer sounds if any vehicle’s
error are detected.
At that time, an error code is displayed in the key ON hour
meter area.
(4) Overheat warning indicator
If the temperature of the controller, motor driver or travel-
ing-load handling motor rises to an abnormal level, this in-
dicator lights up, a warning sound is emitted and the output
is limited.
In the event of overheat, the buzzer sounds for 5 seconds.
In the event of a failure due to overheat, the buzzer contin-
ues to sound until recovery from the failure.
Also, when the motor driver is cold, the indicator lights up,
a warning sound is emitted for 5 seconds and the output is
limited in order to protect the devices in the motor driver.
(5) Battery overheat warning indicator
(When a JIS battery is installed and the battery protection
function is provided)
If the battery fluid temperature rises above the specified
level, this indicator lights up, a warning sound is emitted
and the output is limited. This indicator also helps prevent
the reduction in the battery life due to a rise in the battery
fluid temperature. If this function hinders the operation, it
can be disabled using the service function.
(6) Battery fluid level warning indicator
(When a JIS battery is installed)
If it is detected that there is not enough battery fluid left in
the battery, this indicator lights up to warn the operator. If
the key switch is turned on while there is not enough bat-
tery fluid left, the buzzer also sounds for several seconds.
Moreover, even when the key switch is off, this indicator
blinks to prompt the operator to add battery fluid.
(When a JIS battery is installed and the battery protection
function is provided)
If the vehicle has been operated exceeding the specified
hour without enough battery fluid, the vehicle performance
is limited according to the operated hour. When the vehicle
performance is limited, the indicator blinks to warn the op-
erator.
This warning is to prevent the battery from being used for a
long time with not enough battery fluid and to prompt the
operator to add battery fluid.
2. Battery capacity indicator

This indicates amount of charge in the battery in 10 stages.
(1) Low battery level warning

If the remaining amount of battery fluid decreases below
the warning level, the battery capacity indicator blinks.
Also, when the operator turns the key switch from the OFF
to ON position, a warning sound is emitted for 5 seconds.
(2) Battery over-discharge warning

If the traveling or load handling operation is performed
while the remaining amount of battery is below the spe-
cified value, all the segments of the battery capacity indic-
ator blink and a warning sound is emitted to warn the oper-
ator that the battery is over-discharged.
NOTICE!
The chart below shows relations of “Battery over-discharge warning”, “Low battery level warning”
and “Tuning No.1”.
Discharged Normal tuning setting level [No.1]

amount 1 2 3 4 5 6 7 8
[%] Initial value
50
Low battery level warning

60 Battery capacity indicator blinks.
70
80
90
Over-discharge warning
10 segments of battery capacity
100 indicator blink.
No warning
3. Power select indicator

This indicator indicates the selected power mode (S,
P or H).
When “H mode lock” is enabled, H mode cannot be 2
selected. The H mode lock function can be enabled
or disabled using a Option set provided in the service
function.
4. Key switch on hour meter

This meter counts up and displays the key switch ON
time.
The digit “1” at the right end represents one tenth of
an hour (6 minutes).
The hour meter ON indicator continues to blink as
long as the hour meter is in operation.
Hour meter ON indicator
5. Warning buzzer
(1) Parking brake ON warning
If the vehicle is started or the operator tries to drive while the parking brake is not released, the parking
brake indicator lights up and a warning sound is emitted.
(2) Parking brake OFF warning
If the key switch is turned off while the parking brake is released, a warning sound is emitted.
When the key switch is on, if the operator leaves the operation seat for 2 seconds or more with the
parking brake released, a warning sound is emitted. This function does not work before the start of the
hour meter.
(3) Return to neutral warning for travel OPS
A warning sound is emitted to inform that the operator should release the accelerator and return the dir-
ection switch to neutral in order to start the vehicle. (No warning is displayed on the display.)
(4) Return to neutral warning for load handling OPS
A warning sound is emitted to inform that the operator should return the load handling levers to neutral
in order to start the load handling operation. (No warning is displayed on the display.)
(5) Return to neutral warning at key ON
A warning sound is emitted to inform that, the operator should release the accelerator and return the
direction switch to neutral in order to start the vehicle, when the key switch is on.(No warning is dis-
played on the display.)
(6) Traveling and load handling warning during charging (For models with an on-vehicle charger)
If the accelerator is operated or load handling is performed with the AC plug inserted, a warning sound
is emitted to warn the operator, and the traveling or load handling operation is restricted.
(7) When the operator releases the seatbelt, the buzzer sounds for about 1 second. If the seatbelt is re-
moved or if the seating and seatbelt placement order is not legitimate, the OPS indicator has a light and
the operator is notified that driving is impossible.
2.1.4 SETTING FUNCTION
2.1.4.1 Power select function

The power mode (S, P or H) and its indication on the display change each time the power select switch on
the status screen is pressed.
When “H mode lock” is enabled, H mode cannot be selected. The H mode lock function can be enabled or
disabled using a Option set provided in the service function.
Power mode Power select switch
NOTICE
Always use a finger to operate the switch. Pressing a switch with a pointed stick may cause damage
to the switch.
2.1.5 SERVICE FUNCTIONS
2.1.5.1 General 2
In addition to the functions that are described in the Operator’s Manual and available to customers, the dis-
play has the following built-in functions intended to be used by service staff to perform maintenance of the
vehicle or set its specifications. The service functions are password-protected to prevent customers from us-
ing them by mistake, causing important internal data to be corrupted.
2.1.5.2 Service function list

When used
Function Description Vehicle de- Controller
Others
livery replacement
Displays the electrical system
Upon vehicle
Analyzer status and reads the error inform- - -
abnormality
ation detected by controllers.
Makes fine adjustment of travel- ○ As requested
Tuning -
ing and load handling functions. *2 by customer
Specification set- Sets each vehicle option and ○
- -
ting other specifications. *1 *2,*3
Option set
Each control func- Enables or disables each control ○
- -
tion enable/ disable function. *2,*3
Traveling function Updates voltage values of sensor
○ ○
Load handling signals under the standard -
*2 *4,*5,*6,*7
lever vehicle condition.
OCV starting cur- Sets the oil control valve starting ○ ○
-
rent level current level. *2 *7
Matching ○ ○
Tire data Sets the tire constant. -
*2 *8
Auto power-off time ○ As requested
Sets the auto power-off time. -
setting *2 by customer
Maximum speed ○ As requested
Sets the maximum speed limit. -
limit setting *2 by customer
○
Meter start Starts counting the hour meter. ○ -
*3
Others
menu Enables simultaneous operation Before start-
Demo mode of traveling and load handling be- - - ing the hour
fore starting the hour meter. meter
*1: These functions are used to adjust the controller and display setups to the availability of optional or con-
trol functions. They do not enable or disable the actual functioning of the optional or control functions.
*2: Controller: Main controller
*3: Controller: Display
*4: When removing/installing or replacing brake sensor or accelerator sensor, or when adjusting the pedal
height
*5: When removing/installing, replacing, or adjusting load handling lever angle sensor
*6: When removing/installing, replacing, or adjusting tire angle sensor
*7: When replacing oil control valve.
*8: When tire size is changed or tires are replaced.
2.1.5.3 Before starting matching

Before performing matching, you must set the vehicle to “standard vehicle condition”. For “standard vehicle
condition”, refer to MATCHING for Before Starting Matching page 125.
2.1.6 PASSWORD
NOTICE
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be
damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the begin-
ning. If the service menu cannot be displayed after several attempts, the system may be faulty.
2.1.6.1 Password entry procedure

Step Display Operation Vehicle response
Press the switches until 2 beeps
MODE sound.
Press switch (1) and switch
(A beep will sound when a
1. (2) at the same time for
switch is pressed, and another
more than 5 seconds.
beep will sound 2 seconds later.
Switch (1) Switch (2)
However, continue pressing.)
MODE
Press switch (2) within 10

2. Note : No sound is emitted.
seconds.
MODE
Press switch (1) within 10

3. A short beep sounds.
seconds.
MODE Within 10 seconds, press When pressing the switches, a

switch (1) and switch (2) at short beep sounds, and after 2
4.
the same time for more than seconds repeated short beeps
2 seconds. sound.
5. Service function initial screen is displayed for 5 seconds.
6. Analyzer menu screen is automatically displayed.

2.1.6.2 Service function display
Initial Screen 2
1 Analyzer menu 2 Tuning menu Initial Screen 3 Option set menu 4 Matching menu 6 End
MODE MODE MODE MODE MODE
1 DIAG MEMORY 1 GENERAL 1 OPTIONSET 1 DRIVE 1 METER
MODE MODE MODE MODE MODE
2 I01 2 L LIFT END 2 SAS 2 DEMO
MODE MODE MODE MODE
3 I02 3 L TILT 3 LEVER END
MODE MODE MODE
4 I03 4 L ATT1 4 OCV
MODE MODE MODE
5 I04 5 L ATT2 5 TIRE
MODE MODE MODE
6 I05 END 6 PWR OFF
MODE MODE
7 ACT 7 SPEED
MODE MODE
8 VERSION END
MODE
2.1.7 ANALYZER
2.1.7.1 General
Analyzer function supports operations for inspection/investigating faulty section by displaying the condition of
the control system, using communication between each controller and the display.
By switching the display to analyzer mode, operative conditions of the sensors and actuators which are used
for traveling, load handling and OPS functions, or the error information detected by the controller can be
read.
This is very useful for checking operative condition of each function and saving time for repairing when there
is a detect.
The analyzer has the following functions:
1. Diagnostic memory function (DIAG MEMORY)
The controller stores up to 10 error codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these error codes and indicates them on the display.
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 switch ON/OFF state and the analog input values from individual sensors and
switches in the traveling, load handling, and OPS systems. The circuit or sensor quality can be judged by
monitoring the displayed value.
• I/O MONITOR 1
Displays the temperature of each electrical functional part and the input voltage detected by each
controller for each potential.
• I/O MONITOR 2
Displays the ON/OFF status of each traveling control switch and the input voltage from sensors.
• I/O MONITOR 3
Displays the ON/OFF status of each load handling control switch and the input voltage from sensors.
• I/O MONITOR 4
Displays the ON/OFF status of steering synchronizer solenoid and the input voltage from sensors.
• I/O MONITOR 5
Displays the ON/OFF status of other switches and the input voltage from sensors.
3. Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the se-
lected item in order to permit operation check of that function.
4. Program version display (VERSION)
Displays program version of each controller.
2.1.7.2 List of Analyzer menu items

Screen
Display
Analyzer menu Display SPH Description 2
Item No. item
area
1. DIAG MEMORY 1 diAG 1 01 to 10 1. to 10. Indications of errors occurred
01 TDM Drive motor temperature: °C
02 TDMDH Drive motor driver heat sink temperature: °C
03 TDMDB Drive motor driver board temperature: °C
04 TDMDC Drive motor driver condenser temperature: °C
05 TPM Pump motor temperature: °C
06 TPMDH Pump motor driver heat sink temperature: °C
07 TPMDB Pump motor driver board temperature: °C
08 TPMDC Pump motor driver condenser temperature: °C
2. I/O MONITOR 1 2 IO1 2 09 TMCB Main controller board temperature: °C
10 TSLLT Battery temperature: °C
11 TDSP Display board temperature: °C
12 B48V/80V Battery voltage: V
13 VBKY Voltage after key switch: V
14 VBMBSL Solenoid power source voltage: V
15 VBMB Voltage after MB contactor: V
16 VDMD Drive motor driver main circuit voltage: V
17 VPMD Pump motor driver main circuit voltage: V
01 SPEED Traveling speed: km/h
02 Accelerator sensor 1 voltage: V
VRA
03 Accelerator sensor 2 voltage: V
04 Brake sensor 1 voltage: V
VRB
05 Brake sensor 2 voltage: V
06 SWBK (Not used)
SDM Seat switch
SSB Seatbelt switch
07
3. I/O MONITOR 2 DSF Forward switch
3 IO2 3
(Travel Control) DSR Backward switch
08 SPB Parking brake switch
09 SPEED Traveling speed: km/h
10 Drive motor rpm: rpm
SPDDM
11 Target rpm: rpm
12 Drive motor rotation sensor 1 voltage: V
SSD
13 Drive motor rotation sensor 2 voltage: V
14 Drive motor current sensor 1 voltage: V
CSDM
15 Drive motor current sensor 2 voltage: V
Screen
Display
Analyzer menu Display SPH Description
Item No. item
area
SLLL Lift lowering lock solenoid
01
SLTFL Tilt forward lock solenoid
SHS
02 Double action switch, Seat switch
SDM
03 Pump motor rpm: rpm
SPDPM
04 Target rpm: rpm
05 SSP Pump motor rotation sensor voltage: V
06 Pump motor current sensor1 voltage: V
CSPM
07 Pump motor current sensor2 voltage: V
08 SLLL Lift lowering lock solenoid
09 CSL Lift proportional valve solenoid current: A
4. I/O I/O MONITOR
10 Lift lever angle sensor1 voltage: V
3 VRL
4 IO3 4 11 Lift lever angle sensor2 voltage: V
(Load handling Con-
trol) 12 SLTFL Tilt forward lock solenoid
13 CST Tilt proportional valve solenoid current: A
14 Tilt lever angle sensor1 voltage: V
VRT
15 Tilt lever angle sensor2 voltage: V
Attachment (1) proportional valve solenoid cur-
16 CSA1
rent: A
17 Attachment (1) lever angle sensor1 voltage: V
VRA1
19 CSA2
rent: A
VRA2
01 VRTRA Tire angle sensor voltage: V
02 SPEED Traveling speed : km/h
5. I/O I/O MONITOR 03 Steering angle knob position actual value
4 5 IO4 5
(Steering control) 04 K-POS Steering angle knob position target value
05 Steering synchronizer solenoid
06 SSTR Steering angle sensor voltage: V
6. I/O I/O MONITOR 01 CSBAT Battery current sensor voltage: V
5 6 IO5 6
(Others) 02 DOPT (Not used)
STEER- Steering synchronizer solenoid forced opera-
01
ING SOL tion
LIFT LWR
02 Lift lowering lock solenoid forced operation
SOL
7. ACTIVE TEST 03 TILT SOL Tilt forward solenoid forced operation
7 ACt 7
(Active test) 04 FAN Cooling fan for controller forced operation
ACC
05 (Not used)
OUT1
ACC
06 (Not used)
OUT2
Screen
Display
Analyzer menu Display SPH Description
Item No. item
area
d DISPLAY Display program version 2
C MAIN C/R Main controller program version
8. PROGRAM VER-
SION 8 VEr 8 DM
T Drive motor driver program version
(Program version) DRIVER
PM
P Pump motor driver program version
DRIVER
2.1.7.3 Analyzer menu screen
Operation procedure
1. Enter the password on the status screen to display
the service function initial screen.
2. The screen where “1-AnL” is displayed is the Ana-

lyzer menu screen. On this screen, press switch (2)
to display the “1 diAG” Diag memory screen.
MODE
“1 diAG” (1 DIAG MEMORY)

Switch (1): Switching selection to “2 I01”
Switch (2): Switching to “1 diAG” detail screen
“2 I01” (2 I/O monitor1 TEMP/VOLT)

Switch (2): Switching to “2 I01” detail screen
“3 I02” (3 I/O monitor2 TRAVELING)

“4 I03” (4 I/O monitor3 M.HANDLING)

“5 I04” (5 I/O monitor4 STEERING)

“6 I05” (6 I/O monitor5 OTHERS)

Switch (1): Switching selection to “7 ACt”
“7 ACt” (7 ACTIVE TEST)

Switch (1): Switching selection to “8 VEr”
Switch (2): Switching to “7 ACt” detail screen
2
“8 VEr” (8 VERSION)
Switch (1): Switching selection to “E End”
Switch (2): Switching to “8 VEr” detail screen
“E End”
Switch (1): Switching selection to “1 diAG” Diag
memory
Switch (2): Returning to the “1-AnL” Analyzer menu
screen
2.1.7.4 Diagnostic memory function "1 diAG"

The controller stores up to 10 most recent errors. The “1 diAG” Diag memory screen displays these dia-
gnostic codes with their detection time information (in key ON hour meter reading).
The most recent diagnostic code is displayed as 1, followed by 2, 3 and so on to 10.
Operation procedure
2. Press switch (2) once and make sure that “1 diAG”

Diag memory is displayed on the screen. Then, press
switch (2) (to confirm) to display the “1 01” screen.
NOTICE!
A diagnostic code and hour meter information are
displayed alternately.
MODE 3. Press switch (1) to display the next diagnostic code.
4. Press switch (2) on the “1 E” screen to return to the
Analyzer menu screen.
Switch (1) Switch (2) NOTICE!
▪ The newest displayed error is displayed as 1,
and each previous one is counted backwards
as 2, 3... 10.
▪ When no diagnostic code is displayed on the
screen and the hour meter time is 0.0h, it in-
dicates that no errors occurred in the past
after that row.
▪ It is impossible to directly jump from the Diag
memory screen to other function screen. Re-
turn to the Analyzer menu screen.
▪ For details of diagnostic code, refer to repair
manual for ELECTRICAL SYSTEM
TROUBLESHOOTING, DIAGNOSIS CODE
LIST. (page 278)
“1 diAG: 1 01 to 1 10” (DIAG MEMORY 01 - 10)

Displays diagnostic codes 1 to 10.
Switch (1): Next screen
Switch (2): Not used 2
Displayed alternately.
No. Diagnostic Time of occurrence

01 to 10 code (Key-on hour meter)
(Example: H 1-4)
“1 E” (DIAG MEMORY END)

Switch (1): Switching selection to “1 diAG: 1 01”
Switch (2): Returning to the Analyzer menu screen
2.1.7.5 In/Out Monitor function (I/O MONITOR)

This function displays the analog input voltage and the switch state of each of traveling, material handling,
synchronized steering and OPS switches, sensors and actuators.
The circuit or their quality can be judged by monitoring the displayed value.
2.1.7.6 In/Out Monitor 1 "2 I01"

Displays the temperature of each electrical functional part and the analog input voltage detected by each
controller.
Operation procedure
2. Press switch (2) once and switch (1) once, and make
sure that “2 I01” is displayed on the screen. Then,
press switch (2) (to confirm) to display the “2 01”
screen.
3. From here on, the screen changes in sequence each
time switch (1) is pressed. On the “2 E” screen, press
switch (2) to return to the “1-AnL” Analyzer menu
MODE
screen.

NOTICE!
You cannot move directly from “2 I01” screen to the
screen of the other items. Return to Analyzer menu
screen once, then move to screen of each time. 2
“2 01” (I/O MONITOR 1 01)

Drive motor temperature: °C
Temperature of the drive motor is displayed.
Switch (2): Not used
“2 02” (I/O MONITOR 1 02)

Drive motor driver heat sink temperature: °C
Temperature of the drive motor driver heat sink is dis-
played.
“2 03” (I/O MONITOR 1 03)

Drive motor driver board temperature: °C
Temperature of the drive motor driver board is dis-
played.
“2 04” (I/O MONITOR 1 04)

Drive motor driver condenser temperature: °C
Displays the condenser temperature of the drive mo-
tor driver.
“2 05” (I/O MONITOR 1 05)

Pump motor temperature: °C
Temperature of pump motor is displayed.
“2 06” (I/O MONITOR 1 06)

Pump motor driver heat sink temperature: °C
Temperature of the pump motor driver heat sink is
displayed.
“2 07” (I/O MONITOR 1 07)

Pump motor driver board temperature: °C
Temperature of the pump motor driver board is dis-
played.
“2 08” (I/O MONITOR 1 08)

Pump motor driver condenser temperature: °C
Displays the condenser temperature of the pump mo-
tor driver.
“2 09” (I/O MONITOR 1 09)

Main controller board temperature: °C
Displays the board temperature of the main control-
ler.
“2 10” (I/O MONITOR 1 10)

Battery temperature: °C
Displays the temperature of the battery.
2
“2 11” (I/O MONITOR 1 11)

Display board temperature: °C
Displays the board temperature of the display.
“2 12” (I/O MONITOR 1 12)

Battery voltage: V
Battery voltage is displayed.
“2 13” (I/O MONITOR 1 13)

Voltage after key switch: V
Voltage after key switch is displayed.
“2 14” (I/O MONITOR 1 14)

Solenoid power source voltage: V
Voltage of solenoid power source is displayed.
“2 15” (I/O MONITOR 1 15)

Voltage after MB contactor: V
Voltage of after MB contactor is displayed.
“2 16” (I/O MONITOR 1 16)

Drive motor driver main circuit voltage: V
Voltage of drive motor driver main circuit is displayed.
“2 17” (I/O MONITOR 1 17)

Pump motor driver main circuit voltage: V
Voltage of pump motor driver main circuit is dis-
played.
“2 E” (I/O MONITOR 1 END)

Switch (1): Returning to I/O Monitor 1 01 “2 01”
screen
Switch (2): Returning to I/O Monitor 1 “2 IO1” screen

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
2
Operation procedure
2. Press switch (2) once and switch (1) twice, and make
sure that “3 I02” is displayed on the screen. Then,
screen.
MODE
screen.
NOTICE!
screen once, then move to screen of each time.
“3 01” (I/O MONITOR 2 01)

Traveling speed: km/h
Displays the traveling speed.
“3 02” (I/O MONITOR 2 02)

Accelerator sensor 1 voltage: V
Displays input voltage from the accelerator sensor to
the controller.
Standard:
When accelerator is not operated: 0.40 to 1.25 V
When accelerator pedal is fully depressed: 2.00 to
4.80 V
“3 03” (I/O MONITOR 2 03)

Displays input voltage from the accelerator sensor to
the controller.
Standard:
When accelerator is not operated: 0.65 to 2.32 V
When accelerator pedal is fully depressed: 2.42 to
4.80 V
“3 04” (I/O MONITOR 2 04)

Brake sensor 1 voltage: V
Displays input voltage from the brake sensor to the
controller.
(W/ Brake sensor)
Standard:
When brake is not operated: 0.50 to 1.50 V
When brake pedal is fully depressed: 1.05 to 3.10
V
(W/O Brake sensor)
Standard: 0.00V
“3 05” (I/O MONITOR 2 05)
Displays input voltage from the brake sensor to the
controller.
When brake is not operated: 0.79 to 2.58 V
When brake pedal is fully depressed: 1.50 to 3.82
V
“3 06” (I/O MONITOR 2 06)

Not used
“3 07 (1)” (I/O MONITOR 2 07)

Seat switch
Switch ON/OFF quality judgment by sitting on and
leaving the operator’s seat
1 = ON when sitting on the seat
0 = OFF when leaving the seat
“3 07 (2)” (I/O MONITOR 2 07)

Seatbelt switch
Displays the ON/OFF status of the seatbelt switch.
1 = ON seatbelt is worn
0 = OFF seatbelt is not worn
Seat switch Forward switch
“3 07 (3)” (I/O MONITOR 2 07)
Forward switch (DSF)
“3 07 (4)” (I/O MONITOR 2 07)

Reverse switch (DSR)
Switch ON/OFF quality judgment by operating the dir-
ection lever
Seatbelt switch Reverse switch
Display
Direction lever
Forward switch (DSF) Reverse switch (DSR)
Forward 1 (= ON) 0 (= OFF)
Neutral 0 (= OFF) 0 (= OFF)
Reverse 0 (= OFF) 1 (= ON)
“3 08” (I/O MONITOR 2 08)

Parking brake switch
Switch ON/OFF quality judgment by operating the
parking brake lever.
0 = OFF (in a state of parking brake being operated)
1 = ON (in a state of parking brake being released)
“3 09” (I/O MONITOR 2 09)

“3 10” (I/O MONITOR 2 10)

Drive motor revolution: rpm
This screen indicates the measured revolution of the
drive motor. The rotation sensor is checked by actu-
ally running the vehicle. The number of revolution of
the drive motor increases with an increase in the trav-
eling speed.
“3 11” (I/O MONITOR 2 11)

Drive motor target revolution: rpm
This screen indicates the target number revolution of
the drive motor.
“3 12” (I/O MONITOR 2 12)

Drive motor rotation sensor 1 voltage: V
This screen indicates the voltages of the drive motor
rotation sensors.
When motor is stopped: Constant, either 0.30 to
0.70 V or 0.90 to 1.40 V
When motor is rotating: Variable between approx.
0.30 to 1.40 V
“3 13” (I/O MONITOR 2 13)

This screen indicates the voltages of the drive motor
rotation sensors.
0.70 V or 0.90 to 1.40 V
0.30 to 1.40 V
“3 14” (I/O MONITOR 2 14)

Drive motor current sensor 1 voltage: V
Displays the voltage sensor 1 voltage of the drive mo-
tor. 2
Standard value when vehicle is stopped: approx-
imately 2.50 V
Standard value when vehicle is running: approx-
imately 0.50 V to 4.50 V
“3 15” (I/O MONITOR 2 15)

Displays the voltage sensor 2 voltage of the drive mo-
tor.
Standard value when vehicle is stopped: approx-
imately 2.50 V
Standard value when vehicle is running: approx-
imately 0.50 V to 4.50 V

screen

Displays the load handling control switch ON/OFF states and analog input voltages from load handling con-
trol sensors.
Operation procedure
2. Press switch (2) once and switch (1) three times, and
make sure that “4 I03” is displayed on the screen.
Then, press switch (2) (to confirm) to display the “4
01” screen.
MODE
screen.
NOTICE!
▪ You cannot move directly from “4 I03” screen to
the screen of the other items. Return to Analyzer
menu screen once, then move to screen of each
time.
▪ The number of screens displayed varies according
to the number of levers.
“4 01 (1)” (I/O MONITOR 3 01)

Tilt forward lock solenoid
Lift lowering lock solenoid
Displays output signal to the lift lowering lock solen-
oid.
“4 01 (2)” (I/O MONITOR 3 01)

Displays output signal to the tilt control solenoid.

Lever status
Item No opera- Lift lever Tilt lever
tion Up Down Forward Backward
2
7 01(1) Lift lowering lock solenoid 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
7 01(2) Tilt forward lock solenoid 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF)
Double action switch “4 02” (I/O MONITOR 3 02)

Double action switch
Displays the ON/OFF status of the double action
switch.
Seat switch
Switch ON/OFF quality judgment by sitting on and
leaving the operator’s seat
1 = ON when sitting on the seat
0 = OFF when leaving the seat
Seat switch Switch (1): Next screen
“4 03” (I/O MONITOR 3 03)
Pump motor revolution: rpm
This screen indicates the measured revolution of the
pump motor.
The rotation sensor is checked by actually running
the vehicle. The number of revolution of the pump
motor increases with an increase in the load handling
speed.
“4 04” (I/O MONITOR 3 04)

Pump motor target revolution: rpm
This screen indicates the target number revolution of
the pump motor.
“4 05” (I/O MONITOR 3 05)

Pump motor rotation sensor voltage: V
Displays the voltage from the pump motor rotation
sensor.
Standard:
0.70 V or 0.90 to 1.40 V
0.30 to 1.40 V
“4 06” (I/O MONITOR 3 06)

Pump motor current sensor 1 voltage: V
This screen indicates the voltages of the pump motor
current sensors.
When load handling lever, steering wheel, and
forward/backward switch are in neutral: Approx.
2.5 V
Other than the above: 0.5 to 4.5 V
“4 07” (I/O MONITOR 3 07)

Pump motor current sensor 2 voltage: V
This screen indicates the voltages of the pump motor
current sensors.
When load handling lever, steering wheel, and
forward/backward switch are in neutral: Approx.
2.5 V
“4 08” (I/O MONITOR 3 08)

See I/O MONITOR 3 01 “4 01” items
“4 09” (I/O MONITOR 3 09)

Lift proportional valve solenoid current: A
Displays the current from the lift proportional solen-
oid.
Standard:
During uppermost raising operation: 0.25 to 0.95
A
During lowermost lowering operation: 0.25 to 0.95
A
When lever is neutral: 0.00 A
The current increases according to the amount of op-
eration of the lift lever.
“4 10” (I/O MONITOR 3 10)

Lift lever angle sensor 1 voltage: V
Displays input voltage from lift lever angle sensor 1 to
the controller. 2
Standard:
(STD lever)
V
V
When lever is neutral: 1.65 to 2.88 V
(Mini lever/ Joystick)
V
V
The voltage increases during lift-up operation, while it
decreases during lift-down operation.
“4 11” (I/O MONITOR 3 11)
Lift lever angle sensor 2 voltage: V
the controller.
Standard:
(STD lever)
V
V
V
V
The voltage decreases during lift-up operation, while
it increases during lift-down operation.
“4 12” (I/O MONITOR 3 12)
See I/O Monitor 3 01 “4 01” items
“4 13” (I/O MONITOR 3 13)

Tilt proportional valve solenoid current: A
Displays the current from the tilt proportional solen-
oid.
Standard:
During uppermost forward operation: 0.35 to 0.85
A
During lowermost backward operation: 0.35 to
0.85 A
eration of the tilt lever.
“4 14” (I/O MONITOR 3 14)
Tilt lever angle sensor 1 voltage: V
the controller.
Standard:
(STD lever)
V
2.88 V
V
2.76 V
The input voltage increases during backward tilting
operation, while it decreases during forward tilting op-
eration.
“4 15” (I/O MONITOR 3 15)
Tilt lever angle sensor 2 voltage: V
the controller.
Standard:
(STD lever)
V
4.50 V
V
4.50 V
The input voltage decreases during backward tilting
operation, while it increases during forward tilting op-
eration.
“4 16” (I/O MONITOR 3 16)

Attachment 1 proportional valve solenoid current: A
Displays the current from the attachment 1 propor-
tional solenoid. 2
Standard:
A
A
“4 17” (I/O MONITOR 3 17)
Attachment 1 lever angle sensor 1 voltage: V
Displays input voltage from attachment 1 lever angle
sensor 1 to the controller.
Standard:
(STD lever)
V
V
V
V
The voltage increases during backward tilting opera-
tion, while it decreases during forward tilting opera-
tion.
“4 18” (I/O MONITOR 3 18)

Standard:
(STD lever)
V
V
V
V
eration.
“4 19” (I/O MONITOR 3 19)
Attachment 2 proportional valve solenoid current: A
Displays the current from the attachment 2 propor-
tional solenoid.
Standard:
A
A
“4 20” (I/O MONITOR 3 20)
Standard:
(STD lever)
V
V
V
V
The voltage increases during backward tilting opera-
tion, while it decreases during forward tilting opera-
tion.
“4 21” (I/O MONITOR 3 21)

sensor 2 to the controller. 2
Standard:
(STD lever)
V
V
V
V
eration.
screen
(2): Returning to I/O Monitor 3 “4 IO3” screen

Displays the ON/OFF states of knob position and the analog input voltages from respective sensors.
Operation procedure
2. Press switch (2) once and switch (1) four times, and
01” screen.
MODE
screen.
NOTICE!
“5 01” (I/O MONITOR 4 01)

Tire angle sensor voltage: V
Displays the tire angle sensor voltage.
(W/ Tire angle sensor)
Moving straight ahead: 1.8 V to 2.4 V
When steering right or turning right, input voltage
increases
When steering left or turning left, input voltage
decreases
(W/O Tire angle sensor)
0.00 V
“5 02” (I/O MONITOR 4 02)

2
Knob position
This screen indicates the actual (target) position of the
steering knob and the ON/OFF status of the knob position
159 compensation solenoid
0
1 The value when the knob is in the standard position
shown in the image, with a single rotation of the steering
80 wheel (360°) partitioned into 160, is set to “80”.
Value increases during right turn of steering wheel
Value decreases during left turn of steering wheel
Standard position
Display range: 0 to 159
“5 03” (I/O MONITOR 4 03)

Standard position
The knob position calculated and recognized by the
controller from the steering angle sensor signal.
“5 04” (I/O MONITOR 4 04)

Target value
The knob position calculated and recognized by the
controller from the tire angle sensor signal.
(W/ Knob position correcting solenoid)
Standard:
Increases during right turn, and decreases during left
turn
Display range: 0 to 159
(W/O Knob position correcting solenoid)
Not used
“5 05” (I/O MONITOR 4 05)
Knob position correcting solenoid
0 = OFF power off (no position correction) state
1 = ON power on (position correction in progress)
state
---
“5 06” (I/O MONITOR 4 06)

Steering angle sensor pulse
When the steering wheel is rotated once, SS1 and
SS2 repeat ON and OFF. SSC only turns on when
the knob is in the standard position.
1 = ON
0 = OFF
SS1 SS2 SSC

screen
2.1.7.10 In/Out Monitor 5 "6 I05"

Displays the ON/OFF status of other switches and the input voltage from sensors.
2
Operation procedure
2. Press switch (2) once and switch (1) five times, and
01” screen.
MODE
screen.
NOTICE!
“6 01” (I/O MONITOR 5 01)

Battery current sensor voltage: V
Displays input voltage from the battery current sensor
to the controller.
Standard value when vehicle is stopped: Approx.
2.5 V (When load handling lever, steering wheel,
and forward/backward switch are in neutral)
“6 02” (I/O MONITOR 5 02)

Not used
Switch (1): Switching selection to “6 I05: 6 E”

screen
2.1.7.11 Active test "ACt"

In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected
item in order to permit operation check of that function.
2
List of Active test items
Selection Item
Item Description Content of op- Content of op-
Signal Signal
eration eration
7 01 (STEERING Knob position correcting solenoid
OFF By-pass close ON By-pass open
SOL) forced operation
7 02 (LIFT LWR Lift lowering lock solenoid forced Lowering not Lowering pos-
OFF ON
SOL) operation forced operation possible sible
Tilt control solenoid forced opera- Forward tilt not Forward tilt pos-
7 03 (TILT SOL) OFF ON
tion possible sible
Controller/charger cooling fan
7 04 (FAN) OFF Fan stopped ON Fan operating
forced operation
7 05 (ACC OUT1) Not used Not used
7 06 (ACC OUT2) Not used Not used
▪ On the Active test screen, an ON or an OFF is always displayed next to each item.
▪ If the selected item is forcibly turned off or on by pressing the switch (2) and it is switched over to another
item by pressing the switch (1), forced operation is canceled (and switches over to normal operation).
▪ The displayed character string indicates whether or not the selected item is forcibly operated. (Refer to
below)
Display Condition
on, off (lit) No forced operation of the selected item
on, off (blinking) Forced operation of the selected item in progress
Operation procedure
2. Press switch (2) once and switch (1) six times, and
make sure that “7 ACt” Active test is displayed on the
screen. Then, press switch (2) (to confirm) to display
the “7 01” screen.
MODE


screen.
NOTICE! .
You cannot move directly from “7 ACt” Active test
screen to the screen of the other items. Return to
Analyzer menu screen once, then move to screen of
each time
“7 01” (ACTIVE TEST 6 01)

Knob position correcting solenoid
Slowly turn the steering wheel, and check the differ-
ence of the rear tire movement.
---
ON (By-pass open): Tires do not move match
OFF (By-pass close): Tires move (normal operation)
Switch (1): Switching to next item
Switch (2): Switching forced operation of the selected
item between ON/OFF
Check the quality of lowering action by lift lowering
operation.
ON (Solenoid ON): Lowering possible (normal opera-
tion)
OFF (Solenoid OFF): Lowering not possible

Tilt forward solenoid
Check the quality of mast forward tilt operation by for-
ward tilt operation.
ON (Solenoid ON): Forward tilt possible
OFF (Solenoid OFF): Forward tilt not possible

Controller/charger cooling fan forced operation
Used to check operation of controller cooling fan and
charger cooling fan by visual observation and in the 2
display.
ON (fan ON): controller cooling fan rotates
OFF (fan OFF):controller cooling fan is stopped
Switch (2): Switching forced operation of the selected
item between ON/OFF

Not used

Not used
“7 E” (ACTIVE TEST 6 END)

Switch (1): Returning to Active test 01 “7 01” screen
Switch (2): Returning to Active test “7 ACt” screen
2.1.7.12 Program version "VEr"

Displays program version of each controller.
Operation procedure
2. Press switch (2) once and switch (1) seven times,

and make sure that “8 VEr” Version is displayed on
the screen. Then, press switch (2) (to confirm) to dis-
play the “8d” screen.
time switch (1) is pressed. On the “8E” screen, press
MODE
screen.
NOTICE!
You cannot move directly from “8 VEr” Version
Analyzer menu screen once, then move to screen of
each time.
“8 d” (PROGRAM VERSION d)
Program version of the display
“8 C” (PROGRAM VERSION C)
Program version of the main controller
“8 T” (PROGRAM VERSION T)
Program version of the drive motor driver
“8 P” (PROGRAM VERSION P)
Program version of the pump motor driver
“8 E” (PROGRAM VERSION END)

Switch (1): Returning to Program version D “8 d”
screen
Switch (2): Returning to Program version “8 VEr”
screen
2.1.8 TUNING
2.1.8.1 General
This feature performs fine adjustment of traveling and load handling controls.
When receiving requests from users, such as the request to weaken the acceleration off regenerative brak-
ing force, various settings levels can be changed on the tuning screens.
2.1.8.2 List of Tuning items

Multi-func-
STD
tion display/ Level (*: Initial setting value)
Display Item
DX
Menu No. Menu No. 1 2 3 4 5 6 7 8
Operation timing of the bat-
1 01 01 tery level warning and the Fast * Slow Disabled
over-discharge warning
Battery charge indicator cor- Slow de- Fast de-
1 02 02 *
rection 1 crease crease
Battery charge indicator cor- Sensit- Insensit-
1 03 03 *
rection 2 ive ive
Motor torque in case of bat- Power Power
1 04 04 *
tery discharge down keep
1 05 05 Spare *
Insensit- Sensit-
1 06 06 Accelerator pedal sensitivity *
ive ive
Accelerator pedal operation
1 07 07 Weak * Strong
acceleration torque
1 08 08 Soft start (accelerator on) Slow * Quick
Acceleration OFF regenerat-
ive braking torque
GEN Acceleration-off regenerative
1 10 TUNE 10 Slow * Quick
ERA GEN. braking soft start
Acceleration torque (switch
back)
Acceleration soft start (switch
1 12 12 Slow * Quick
back)
Regenerative braking torque
(switch back)
Regenerative soft start
(switch back)
Regenerative soft stop
(switch back)
Accelerator pedal position
torque
Accelerator pedal/Brake sim- Strong
1 17 17 Weak
ultaneous operating torque *
Slope regenerative speed
when the traveling direction Slow
1 18 18 Fast
and the direction of the direc- *
tion are reverse
Multi-func-
STD
Display Item
DX
Menu No. Menu No. 1 2 3 4 5 6 7 8 2
Slope regenerative speed
when the traveling direction Slow
1 19 19 Fast
and the direction of the direc- *
tion are the same
1 20 20 Spare *
Machine stand stop time at Short
1 21 21 * Long
slope regeneration *1 *
Maximum speed control Fast
1 22 22 Slow
when reverse traveling *
Low speed setting when re- Fast
1 23 23 Slow
verse traveling *
1 24 24 Spare *
Regenerative soft stop (brak-
ing)
Pump motor output during lift Fast
1 26 26 Slow
up operation *
Pump motor output during
1 27 27 forward/backward tilting oper- Slow * Fast
ation
Pump motor output during at-
1 28 28 tachment 1 Push and Pull op- Slow * Fast
eration
GEN 1 29 TUNE 29 tachment 2 Push and Pull op- Slow * Fast
ERA GEN. eration
1 30 30 tachment 3 Push and Pull op- Slow * Fast
eration
Inching speed during height
selector operation
1 32 32 Load meter display time None Short * Long
Maximum limit temperature
Low
1 33 33 for battery fluid temperature High
*
protection
Temperature at battery over-
1 34 34 Low * High
heat warning
1 35 35 Spare *
1 36 36 Slope assist activation angle Gentle * Steep
1 37 37 Spare *
1 38 38 Spare *
1 39 39 Spare *
1 40 40 Spare *
1 41 41 Spare *
1 42 42 Spare *
1 43 43 Spare *
1 44 44 Spare *
1 45 45 Spare *
Multi-func-
STD
Display Item
DX
Menu No. Menu No. 1 2 3 4 5 6 7 8
STA Play before the start of lift
2 01 Wide * Narrow
RT lowering operation
Inching speed during lift
2 02 INCH Slow * Fast
lowering operation
LIFT Maximum speed during lift
2 03 MAX Slow * Fast
DOWN lowering operation
Acceleration speed during lift
2 04 ACC Weak * Strong
lowering operation
Deceleration speed during lift
2 05 DEC Weak * Strong
lowering operation
LIFT
STA Play before the start of lift up
2 06 Wide * Narrow
RT operation
Inching speed during lift-up
operation
LIFT Maximum speed during lift up
UP operation
Acceleration speed during lift
up operation
Deceleration speed during lift
up operation
STA Play until forward tilting oper-
3 01 Wide * Narrow
RT ation start
Inching speed during forward
tilting operation
TILT Maximum speed during for-
FWD ward tilting operation
Acceleration speed during
forward tilting operation
Deceleration speed during
forward tilting operation
TILT
STA Play until backward tilting op-
3 06 Wide * Narrow
RT eration start
Inching speed during back-
ward tilting operation
TILT Maximum speed during back-
BWD ward tilting operation
Acceleration speed during
backward tilting operation
Deceleration speed during
backward tilting operation
Multi-func-
STD
Display Item
DX
Menu No. Menu No. 1 2 3 4 5 6 7 8 2
STA Play until attachment 1 Push
4 01 Wide * Narrow
RT operation start
Inching speed during attach-
ment 1 Push operation
ATT1 Maximum speed during at-
PUSH tachment 1 Push operation
Acceleration speed during at-
tachment 1 Push operation
Deceleration speed during at-
ATT1
STA Play until attachment 1 Pull
4 06 Wide * Narrow
RT operation start
ment 1 Pull operation
PULL tachment 1 Pull operation
tachment 1 Pull operation
STA Play until attachment 2 Push
5 01 Wide * Narrow
RT operation start
ment 2 Push operation
PUSH tachment 2 Push operation
ATT2
STA Play until attachment 2 Pull
5 06 Wide * Narrow
RT operation start
ment 2 Pull operation
PULL tachment 2 Pull operation
*1: Setting a higher level extends the time required to stop the vehicle on a slope. Engage the parking brake
when leaving the vehicle.
Amount of Normal turning level [No.1]

discharge
1 2 3 4 5 6 7 8
[%]
50 Initial setting value

Battery warning
60
Battery indicator blinks.
70
80
90
100
Ten segment of the battery indicator blink.
No warning
2.1.8.3 Tuning menu screen "2-Tun"
Operation procedure
2
the service menu screen.
2. “1-AnL” Analyzer menu is initially displayed on the

service menu screen. On this screen, press switch (1)
once to move to the Tuning menu screen where “2-
Tun” is displayed.
Press switch (1) to move to the option menu “3-OPT”
screen, or switch (2) to move to the “1 GEnErA” Gen-
eral menu screen.
MODE
NOTICE!
The number of tuning menu items displayed varies
according to the number of spools of the load hand-
ling lever.
“1 GEnErA” (1 GENERAL)
General Tuning
Switch (2): To Tuning level setting screen
“2 L LIFT” (LEVER LIFT)

Lift Lever Tuning
“3 L TILT” (LEVER TILT)

Tilt Lever Tuning
“4 L ATT1” (LEVER ATT1)

Attachment 1 Lever Tuning
“5 L ATT2” (LEVER ATT2)

“E End”
Switch (1): Switching selection to “1 GEnErA” Gen-
eral menu screen
Switch (2): Returning to the “2 Tun” Tuning menu
screen
2.1.8.4 Tuning General "1 GEnErA"

Used to fine adjust settings related to traveling, load handling, and so on (except for settings related to the
load handling levers).
2
Operation procedure
1. Display the Tuning menu screen.
2. Check that “1. GEnErA” General menu is selected,
and press the switch (2) to display “1 01” setting
screen.
time switch (1) is pressed. On the “1E” screen, press
MODE switch (2) to return to the Tuning menu screen.
NOTICE!
You cannot move directly from “1 GEnErA” General
Switch (1) Switch (2) menu screen to the screen of the other items. Return
to Tuning menu screen once, then move to screen of
each time.
“1 01 to 1 35” (GENERAL01 - 45)

General Tuning
For correspondence between numbers and items,
see the tuning item list.
Switch (1): Switching selection to next screen
Switch (2): Increasing the tuning level (After level 8,
the tuning level returns to level 1.)
No. Tuning level
“1 E” (GENERAL END)
Switch (1): Switching selection to “1 01
Switch (2): Returning to the “1 GEnErA” General
menu screen
2.1.8.5 Tuning Lever Lift (2 L LIFT)

Sets tuning levels for the lift lever.
2
Operation procedure
1. Display the tuning menu screen.
sure that “2 L LIFT” is displayed on the screen. Then,
screen.
MODE time switch (1) is pressed. On the “2 E” screen, press
switch (2) to return to the Tuning menu screen.
NOTICE!
Switch (1) Switch (2) You cannot move directly from “2 L LIFT” screen to
the screen of the other items. Return to Tuning menu
“2 01 to 2 10” (LEVER LIFT 01 - 10)

Lift Lever Tuning
No. Tuning level
“2 E” (LEVER LIFT END)

Switch (1): Switching selection to “2 01”
Switch (2): Returning to the “2 L LIFT” screen
2.1.8.6 Tuning Lever Tilt (3 L TILT)

Sets tuning levels for the tilt lever.
2
Operation procedure
sure that “3 L TILT” is displayed on the screen. Then,
screen.
NOTICE!
Switch (1) Switch (2) You cannot move directly from “3 L TILT” screen to
“3 01 to 3 10” (LEVER TILT 01 - 10)

Tilt Lever Tuning
No. Tuning level
“3 E” (LEVER TILT END)

Switch (2): Returning to the “3 L TILT” screen
2.1.8.7 Tuning Lever ATT1 (4 L ATT1)

Sets tuning levels for the attachment 1 lever.
2
Operation procedure
make sure that “4 L ATT1” is displayed on the screen.
01” screen.
NOTICE!
Switch (1) Switch (2) You cannot move directly from “4 L ATT1” screen to
“4 01 to 4 10” (LEVER ATT1 01 - 10)

No. Tuning level
“4 E” (LEVER ATT1 END)

Switch (2): Returning to the “4 L ATT1” screen
2.1.8.8 Tuning Lever ATT2 (5 L ATT2)

Sets tuning levels for the attachment 2.
2
Operation procedure
make sure that “5 L ATT2” is displayed on the screen.
01” screen.
NOTICE!
Switch (1) Switch (2) You cannot move directly from “5 L ATT2” screen to
“5 01 to 5 10” (LEVER ATT2 01 - 10)

No. Tuning level
“5 E” (LEVER ATT2 END)

Switch (2): Returning to the “5 L ATT2” screen
2.1.9 OPTION SET
2.1.9.1 General 2
1. The option set function is used to fit the specifications of the controller and the multi-function display to
the options actually equipped on the vehicle. The option set items are not functioning on the vehicle that
doesn’t actually mount them even if the OPTION SET enables them.
2. When main controller or multi-function display is replaced, it is necessary to reset them according to the
vehicle specifications.
2.1.9.2 List of Option Set items

Switching settings
Display Description Indica- Setting con- Indica- Setting con-
tion tent tion tent
1 01 Adjust the battery capacity indicator calculation A1 / A2 / B1 (Specified value)/ B2
A: Not provided/B: Previous type (fluid level unit)/
1 02 Battery fluid level and temperature unit *1
C: Fluid and temperature unit
1 03 Fluid level warning *1 YES Enabled NO Disabled
Disabled
1 04 Setting to enable/ disable H mode lock YES Enabled NO (Specified
value)
1 05 Seatbelt Interlock *1 YES Enabled NO Disabled
Accelerator
Setting of priority between accelerator and priority
1 06 A B Brake priority
brake (Specified
value)
Gradual mo-
tor output
Motor output
stop
stop immedi-
1 07 Drive motor output after depress operation stop A after opera- B
ately after op-
tion stop
eration stop
(Specified
value) *2
Regeneration
Regeneration available
1 08 Accelerator-off regeneration setting YES NO
not available (Specified
value) *3
Setting the number of ways for oil control valve 2/3/4/5
1 09
*1 (5th way setting is not available)
Mini lever/
1 10 Setting the load handling lever type *1 A STD lever B
Joystick
1 11 Fishery industry model *1 YES Enabled NO Disabled
1 12 Attachment 1 lever clamp setting *1 A/B/C/D
1 13 Attachment 2 lever clamp setting *1 A/B/C/D
1 14 Not used A *1 / B / C / D
Setting the mode of buzzer sound when OPS
1 15 A *1 / B / C
and return-to-neutral operate
Enabled
1 16 OPS Operation Notification YES (Specified NO Disabled
value)
Enabled
Setting to enable/disable parking brake off
1 17 YES (Specified NO Disabled
warning
value)
Switching settings
Display Description Indica- Setting con- Indica- Setting con-
tion tent tion tent
‐
1 18 Not used YES ‐ NO (Specified
value)
Travel limita-
Travel limitation accord-
tion regard- ing to dis-
Travel limitation mode at over-discharge warn-
1 19 A less of dis- B charge
ing
charge amount
amount (Specified
value)
Lift interrupt Lift interrupt
Load handling limitation mode at over-dis-
1 20 A (Specified B while travel-
charge warning
value) ing
1 21 Battery fluid level protection *1 YES Enabled NO Disabled
1 22 Battery fluid temp protection *1 YES Enabled NO Disabled
Enabled
1 23 Power keep YES (Specified NO Disabled
value)
‐
1 24 Not used YES ‐ NO (Specified
value)
Setting to enable/disable the steering knob syn-
1 25 YES Enabled NO Disabled
chronizer *1
1 26 On-truck charger specifications *1 YES Enabled NO Disabled
1 27 Not used A / B *1 / C / OFF
1 28 Not used A / B / C / D *1
‐
1 29 Not used A (Specified B ‐
value)
*1: These are set to match the vehicle specifications at the time of shipment.
*2: When set to B, the machine stand may slide down momentary at the moment the accelerator pedal is re-
leased in a steep slope.
*3: When YES is set, if the accelerator pedal is released when driving down on a slope, the anti-rollback
function is disabled.
2.1.9.3 Option Set menu screen
Operation procedure
2

twice to move to the Tuning menu screen where the
“3-OPT” is displayed. Press switch (2) once and
make sure that “1 OPT SET” is displayed. Then,
press switch (2) again (to confirm) to display the Op-
tion Set screen.
MODE
time switch (1) is pressed, and it returns to the Option
Set screen.
NOTICE!
You cannot move directly from “1 OPT SET” screen to
“1 OPT SET” (OPTION SET)
Switch (1): Switching to “E END” screen
Switch (2): Switching between each Option Set
screen
“01 to 23 OPT SET” (OPTION SET 01 - 23)

For the supported numbers and items, see the Option
Set Item List.
“1 E ” (OPTION SET END)

Switch (1): Switching to Option set 01 “1 01” screen
Switch (2): Switching to Option Set “1 OPTSET”
screen
“E End”
Switch (1): Switching to Option Set “1 OPTSET”
screen
Switch (2): Switching to “3-OPT” screen
2.1.10 MATCHING
2.1.10.1 General 2
▪ Each function is controlled by using the sensors and each signal voltage at standard vehicle condition
stored in the controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a
sensor at standard vehicle condition) is required when performing maintenance on a section or replacing
parts related to the sensor.
▪ For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accel-
erator fully released, accelerator fully closed, brake fully released and brake operation starting position
are stored, respectively, in the controller to control based on these values. Therefore, a matching (updat-
ing of the signal voltage of a sensor at standard vehicle condition) is required when performing mainten-
ance on a section or replacing parts related to the sensor.
▪ For tire angle sensor used in the vehicle, the signal voltage value at standard vehicle condition is stored,
in the controller to control based on this value. Therefore, a matching (updating of the signal voltage of a
sensor at standard vehicle condition) is required when performing maintenance on a section or replacing
parts related to the sensor.
▪ Each lever angle sensor for load-handling lever function is controlled based on the memory of signal
voltage values in the neutral position stored in the controller at the time of shipment. Therefore, a match-
ing (updating of the signal voltage of a sensor at standard vehicle condition) is required when performing
maintenance on a section or replacing parts related to the sensor.
▪ The oil control valve (OCV) starting current level is set at the factory for all the control valves together,
and the settings are stored in the main controller memory. Therefore, the settings must be matched fol-
lowing maintenance or replacement of related parts.
▪ It is necessary to input the “tire constant” to the controller according to the tire diameter for optimizing the
traveling control. Although the tire constant is set to the value of new tires at the time of shipment, the tire
constant should be set again according to the “tire constant list” if the type or size of tire is changed.
▪ The auto power-off function switches to a key OFF state after a fixed period of time when the operator
has left the vehicle with the key switch set to ON, in order to prevent misoperation and to save power.
▪ The maximum speed limit function is a function that prevents the operator from exceeding the set max-
imum speed when one has been set in advanced. The operator does not need to perform slight acceler-
ator operations in order to observe the speed limit, and the administrator does not need to monitor the
speed limit.
2.1.10.2 Matching Items and Prerequisite for Implementation
DRIVE
Prerequisite for im-
No. Indication Description
plementation
Accelerator sensor output value with fully opened acceler-
1 1 01 *1, *2
ator position to the controller.
Accelerator sensor output value with fully stepped acceler-
2 1 02 *1, *2
ator position to the controller.
Brake sensor output value with fully released brake posi-
3 1 03 *1, *9
tion to the controller.
Brake sensor output value at the operation starting position
4 1 04 *1, *9
of brake to the controller.
SAS
plementation
Tire angle sensor output value while the vehicle is traveling
1 2 01 *1, *3
straight to the controller.
LEVER
plementation
Lift lever angle sensor output value in the lift lever neutral
1 3 01 *1, *4
position is stored in the controller.
Tilt lever angle sensor output value in the tilt lever neutral
2 3 02 *1, *5
condition is stored in the controller.
Attachment (1) lever angle sensor output value in the at-
3 3 03 tachment (1) lever neutral position is stored in the control- *1, *6
ler.
Attachment (2) lever angle sensor output value in the at-
4 3 04 tachment (2) lever neutral position is stored in the control- *1, *7
ler.
OCV
plementation
4 A1 Control valve A01 starting current level *1, *10
1
4 B1 Control valve B01 starting current level *1, *10
2
TIRE DATA
plementation
1 5 01 The tire data according to the tire size is stored. *1, *8
AUTO POWER-OFF SETTING

plementation
1 6 01 Auto power off time. As necessary
MAXIMUM SPEED LIMIT SETTING

plementation
1 7 01 Maximum speed limit setting. As necessary
Prerequisite content for implementation
*1: When main controller replacement
*2: When removing/installing or replacing accelerator sensor
*3: When removing/installing or replacing tire angle sensor or sensor cover
*4: When replacing lift lever angle sensor
*5: When replacing tilt lever angle sensor
*6: When replacing attachment (1) lever angle sensor
*7: When replacing attachment (2) lever angle sensor
*8: When the tire size or type is changed.
*9: When removing/installing or replacing brake sensor, or adjusting the brake pedal height
*10: When replacing oil control valve.
2.1.10.3 Before starting matching

Before performing matching, you must set the vehicle to “standard vehicle condition”, Refer to MATCHING
chapter for repair manual Vo.1.
2
2.1.10.4 Matching menu screen
Operation procedure

three times to move to the Matching menu screen
where “4-SET” is displayed. Press switch (1) once to
move to the Other service function menu screen
where “5-ETC” is displayed. Then, press switch (2) to
move to the Matching menu screen where “1 DRIVE”
MODE is displayed.
“1 driVE” (DRIVE)
Switch (1): Switching selection to “2 SAS”
Switch (2): Switching to “1 driVE” detail setting menu
“2 SAS” (SAS)
Switch (1): Switching selection to “3 LEVER”
Switch (2): Switching to “2 SAS” detail setting menu
“3 LEVEr” (LEVER)
Switch (1): Switching selection to “4 OCV”
Switch (2): Switching to “3 LEVEr” detail setting menu
“4 OCV” (OCV)
Switch (1): Switching selection to “5 TIRE”
Switch (2): Switching to “4 OCV” detail setting menu
“5 TirE” (TIRE DATA)

Switch (1): Switching selection to “6 PWrOFF”
Switch (2): Switching to “5 TirE” detail setting menu
“6 PWrOFF” (AUTO POWER-OFF SETTING)

Switch (1): Switching selection to “7 SPEED”
Switch (2): Switching to “6 PWrOFF” detail setting
menu
“7 SPEEd” (MAXIMUM SPEED LIMIT SETTING)

Switch (1): Switching selection to “E End”
Switch (2): Switching to “7 SPEEd” detail setting
menu
“E End”
Switch (1): Switching selection to “1 DRIVE”
Switch (2): Returning to the “4-SET” screen
2
2.1.10.5 Matching Drive (1 driVE)

Matching is performed for drive function.
Operation procedure
1. Display the Matching menu screen.
2. Press switch (2) once and make sure that “1 driVE” is
displayed on the screen. Then, press switch (2) (to
confirm) to display the “1 01” screen.
MODE switch (2) to return to the Matching menu screen.
NOTICE!
▪ Displays the current vehicle condition value in
Switch (1) Switch (2) Matching set screen.
▪ Confirm that Spanner indicator is blinking in
DRIVE Matching screen.
During drive matching, the Spanner indicator
blinks, informing that the vehicle does not run
even if the accelerator pedal is depressed.
▪ After completion of the matching operation, [O] is
displayed on the display.
▪ You cannot move directly from Matching screen to
the screen of the other items. Return to Matching
item.
Matching completed Matching failed
Item Matching result

“1 01” (DRIVE 01)

Acceleration Sensor OFF Matching
Switch (2): Pressing this for more than 2 seconds will 2
perform matching
*Performing accelerator sensor fully opened position
matching clears the stored value of accelerator
sensor fully opened position matching of each item.
Vehicle condition
▪ All parts related to the accelerator pedal should
be formally mounted.
▪ The accelerator pedal should be fully stepped on.
“1 02” (DRIVE 02)
Acceleration Sensor ON Matching
Switch (2): Pressing this for more than 2 seconds will
perform matching
Vehicle condition
▪ All parts related to the accelerator pedal should
be formally mounted.
“1 03” (DRIVE 03)

Brake Sensor OFF Matching
perform matching
*Performing brake sensor fully opened position
matching clears the stored value of brake sensor
starting position matching of each item.
Vehicle condition
▪ All parts related to the brake pedal should be
formally mounted and be adjusted.
Moreover, the parking brake should be in the re-
leased (not applied) position.
▪ The brake pedal should be fully released.
“1 04” (DRIVE 04)

Brake sensor actuation point matching
perform matching
Vehicle condition
▪ All parts related to the brake pedal should be
formally mounted and be adjusted.
▪ The brake pedal should be stepped on perpendic-
ularly, and depress it from the upper surface of
toe board o the center of the brake pedal until be-
coming 104±5mm.
Start point of
the brake activation
104±5 mm
(4.09±0.20 in)
Toe board
“1 E” (DRIVE END)
Switch (2): Returning to the “1 driVE” screen
2.1.10.6 Matching SAS (2 SAS)

Matching is performed for synchronized steering.
2
Operation procedure
sure that “2 SAS” is displayed on the screen. Then,
screen.
switch (2) to return to the Matching menu screen.
NOTICE!
Switch (1) Switch (2) ▪ The Matching menu screen displays a numeric
value that represents the current state of the
vehicle.
▪ On completion of the matching operation, an “O”
is displayed on the display.
item.

“2 01” (SAS)
Tire Angle Sensor Matching
perform matching
“2 E” (SAS END)
Switch (2): Returning to the “2 SAS” screen
2.1.10.7 Matching Lever (3 LEVEr)

Matching is performed for lever function.
2
Operation procedure
sure that “3 LEVEr” is displayed on the screen. Then,
screen.
NOTICE!
Switch (1) Switch (2) ▪ The number of the displayed lever matching items
varies according to the number of levers.
▪ After completion of the matching operation, fully
tilt each lever to both the push and pull sides in
order to learn the full-stroke voltage automatically.
▪ On completion of the matching operation, an “O”
open each lever to the push and pull sides.
the screen of the other items.
Return to Matching menu screen once, then move
to screen of each item.

“3 01 to 3 04” (LEVER 01 - 04)

perform matching
“3 E” (LEVER END)
Switch (2): Returning to the “3 LEVEr” screen
2.1.10.8 Matching OCV (4 OCV)

Used to set the control valve starting current level.
The starting current level is set according to the type of the mounted oil control valve before shipment from 2
the factory. However, if the oil control valve or the main controller is changed, the starting current should be
set again according to the value specified on or attached to the new oil control valve.
Operation procedure
make sure that “4 OCV” is displayed on the screen.
A1” screen.
Reference: I-Q Plate of current level on oil control valve

Refer to I-Q PLATE for FRONT MODULE chapter in re-
pair manual Vol.1.
NOTICE!
You cannot move directly from Matching screen to
menu screen once, then move to screen of each item.
“4 A1 to 4 A4” (OCV A1 - A4)

Control valve starting current level setting screen
4 A1: Control valve A01 starting current level
Switch (1): Switching to next Matching screen
Switch (2): Increasing the starting current level
(After level “8”, the next level is “1”)
“4 b1 to 4 b4” (OCV B1 - B4)

Control valve starting current level setting screen
4 B1: Control valve B01 starting current level
Switch (1): Switching to next Matching screen
(After level “8”, the next level is “1”)
“4 E” (OCV END)
Switch (1): Switching selection to “4 A1”
Switch (2): Returning to the “4 OCV” screen
2.1.10.9 Matching Tire data (5 TirE)

Used to set the tire data.
If the type or size of tire is changed, the tire constant should be set again according to the tire constant list. 2
Operation procedure
make sure that “5 TirE” is displayed on the screen.
01” screen.
NOTICE!
“5 01” (TIRE DATA 01)

Tire Data Setting
Switch (2): Increasing the tire constant
“5 E” (TIRE DATA END)

Switch (2): Returning to the “5 TirE” screen
Tire data list

1 ton models
Applicable models
Tire size Tire type
1.5 ton 1.6 ton 1.8 ton
STD (J-Lug) tire 271 - -
6.00-9-10PR
Rib-Lug tire 271 - -
STD (J-Lug) tire - 299 299
Rib-Lug tire - 299 299
6.50-10-10PR
J-Lug, Oversize tire 299 - -
Rib-Lug, Oversize tire 299 - -
21×8-9-14PR Side-ring (J-Lug) tire 273 273 273
21×8-9-10PR Rib-Lug, Side-ring tire 267 267 267
J-Lug, Non-Punc tire 276 276 -
6.00-9 U-Lug, Non-Punc tire 276 276 -
Non-marking tire 276 276 -
J-Lug, Non-Punc tire - - 306
U-Lug, Non-Punc tire - - 306
Non-marking tire - - 306
6.50-10
J-Lug, Non-Punc, Oversize tire 306 306 -
U-Lug, Non-Punc, Oversize tire 306 306 -
Non-marking, Oversize tire 306 306 -
J-Lug, Non-Punc, Side-ring tire 272 272 272
21×8-9
U-Lug, Non-Punc, Side-ring tire 272 272 272
2 ton models
Applicable models
Tire size Tire type
2.0 ton 2.5 ton
STD (J-Lug) tire 270 270
21×8-9-14PR
Rib-Lug tire 270 270
J-Lug, Non-Punc tire 272 272
21×8-9 U-Lug, Non-Punc tire 272 272
Non-marking tire 272 272
J-Lug, Non-Punc, Side-ring tire 309 309
23×9-10
U-Lug, Non-Punc, Side-ring tire 309 309
3 ton model
Applicable models
Tire size Tire type
3.0 ton
STD (J-Lug) tire 369
28×9-15-14PR
Rib-Lug tire 369
J-Lug, Non-Punc tire 368
28×9-15 U-Lug, Non-Punc tire 368
Non-marking tire 368
2.1.10.10 Auto power off time (6 PWrOFF)

Used to set the auto power off time.
2
Operation procedure
2. Press switch (2) once and switch (1) five times, and
make sure that “6 PWrOFF” is displayed on the
screen. Then, press switch (2) (to confirm) to display
the “6 01” screen.
NOTICE!
“6 01” (AUTO POWER-OFF SETTING 01)

Auto power off time setting
The auto power off time can be set in a range of 2 to
60 minutes in steps of 1 minute.
It is displayed in the following sequence: 2 → 3 → 4 ·
· · 60 → OFF → 2.
Switch (2): Changing the auto power off time
“6 E” (AUTO POWER-OFF SETTING END)

Switch (2): Returning to the “6 PWrOFF” screen
2.1.10.11 Maximum speed limit (7 SPEEd)

Used to set the maximum speed limit.
Operation procedure
2. Press switch (2) once and switch (1) six times, and
make sure that “7 SPEEd” is displayed on the screen.
01” screen.
NOTICE!
“7 01” (MAXIMUM SPEED LIMIT SETTING 01)

Maximum speed limit setting screen
The maximum speed limit can be set in a range of 2
to 20 km/h in steps of 1 km/h.
It is displayed in the following sequence: 2 → 3 → 4 ·
· · 20 → OFF → 2.
Switch (2): Changing the maximum speed limit
“7 E” (MAXIMUM SPEED LIMIT SETTING END)

Switch (2): Returning to the “7 SPEEd” screen
2.1.11 OTHERS MENU
2.1.11.1 Others menu screen 2
Operation procedure

four times to move to the Others menu screen where
“5-ETC” is displayed.
time switch (1) is pressed, and pressing switch (2) in
“E End” screen returns to “5-ETC” screen.
MODE
NOTICE!
After completion of the hour meter start operation,
Switch (1) Switch (2) Others menu screen is not displayed any more.
“1 nnEtEr” (METER START)

Switch (2): Switching to the meter start operation
screen
“2 dEnno” (DEMO MODE)

Switch (2): Switching to the demo mode operation
screen
“E End”
Switch (1): Switching selection to “1 nnEtEr”
Switch (2): Returning to the “5-ETC” screen
2.1.11.2 Hour meter start

Used to make the hour meter start to count up.
This function also enables the following functions, regardless of whether the demo mode is enabled or dis- 2
abled.
▪ Enables the load handling operation during traveling.
▪ Enables the parking brake OFF warning function.
Operation procedure
1. Display the Others menu screen.
2. Press switch (2) once and make sure that “1 nnEtEr”
is displayed on the screen. Then, press (2) (to con-
firm) to display the “1 01” screen.
3. Free here on, the screen changes in sequence each
MODE Meter start end “1 E” screen returns to Meter start “1
nnEtEr” screen.
“1 01” (METER START 01)

1. While holding down switch (2) for 2 seconds or more,
press (1) (to switch to YES).
2. Press switch (1) to move to the “1 E” screen.
Switch (1): Switching selection to “1 E”
Switch (2): Used only for the start operation
“1 E” (METER START END)

Switch (1): Switching selection to “1 01” Switch
(2): Returning to the “1 nnEtEr” screen
NOTICE
After completion of the hour meter start operation, the hourglass icon on the key ON hour meter
blinks to indicate that the counting has started.
Key ON hour meter before the start Key ON hour meter after the start of
of counting counting
2.1.11.3 Demo mode

This menu item is used to enable or disable the demo mode.
Before starting the hour meter, you can enable the following functions temporarily in the demo mode. 2
Demo mode Yes (enabled) No (disabled)
Load handling during traveling Allowed Not allowed
Parking brake OFF warning Enabled Disabled
NOTICE
Even after the demo mode has been disabled, the data recorded and the settings made during the
demo mode are all retained.
Operation procedure
1. Display the Others menu screen.
sure that “2 dEnno” is displayed on the screen. Then,
press (2) (to confirm) to display the “2 01” screen.
3. Free here on, the screen changes in sequence each
MODE Demo mode end “2 E” screen returns to Demo mode
“2 dEnno” screen.
NOTICE!
After completion of the hour meter start operation, the
other service function menu is not displayed any
more.
“2 01” (DEMO MODE 01)

1. Press switch (2), switch between YES/NO, then se-
lect YES.
2. Press switch (1) to move to Demo mode “2 E” screen.
Switch (1): To Demo mode “2 E” screen
(2): Switches between YES/NO
NOTICE!
While demo mode is selected, “dEnno” is displayed
on the key ON hour meter screen.
“2 E” (DEMO MODE END)

Switch (1): Switching selection to “2 01” Switch
(2): Returning to the “2 dEnno” screen
Hour meter screen in demo mode

2.2 MULTI-FUNCTION DISPLAY
2.2.1 SERVICE FUNCTIONS 2
2.2.1.1 GENERAL
Using the multiple display, service personnel can access not only the functions described in user manuals
and made accessible to general users but also the following service functions used by service personnel to
perform truck maintenance or to set specifications.
To prevent damage of important internal data or incorrect operation of the service features by the customer,
the service features are protected by a password.
Service function list

Associated occasions
Function Content Deliv- Changing
Others
ery controller
Select this menu to display the
operation status of electrical sys-
Upon truck
Analyzer tems onboard or to access in- - -
error
formation on errors detected by
the controller.
Select this menu to make fine ad- As reques-
○
Tuning justment of the traveling and load - ted by cus-
*2
handling control features. tomers
Enables or disables the optional
Specification ○
specifications, etc. of the vehicle. - -
setting *2,*3
*1
Option set Switching to en-
able/disable Enables or disables each control ○
- -
each control function. *2,*3
function
Traveling func- ○
Updates voltage values of sensor
tion *4,*5,*6,*7,*
signals under the standard ○
SAS - 8,*9,
vehicle condition and sets the *2,*3
Load handling *10,*11,*12,*
mast type.
lever 13,*14
OCV startup cur- Sets the control valve startup cur- ○ ○
-
rent level rent level. *2 *15
Matching ○ ○
Load meter Sets the load meter. -
*3 *7,*10,*11
Tire constant Optimizes the speedometer dis- ○ ○
-
setup play. *2 *16
Sets the load determination
Implemented
Telematics unit value, which is used to determine ○
- as neces-
*17 the load operating time of your *3
sary
telematics unit.
Displays data of each battery for
Displayed as
Battery data log a year in value, bar graph, and - -
necessary
QR code.
Associated occasions
Function Content Deliv- Changing
Others
ery controller
Starts the count of each hour
○
Meter start meter, odometer, trip meter, and ○ -
*3
maintenance meter.
Enables load handling operations Prior to hour
Demo mode during traveling prior to the star- - - meter star-
tup of the hour meter. tup
Implemented
Setting value ini- Initializes setting values that have ○
- as neces-
tialization default values. *2,*3
sary
Secondary ser- Implemented
Sets the secondary service pass- ○
vice password - as neces-
word. *3
setting sary
Secondary man- As reques-
Deletes the secondary manager ○
Other menu ager password - ted by cus-
password. *3
deletion tomers
Implemented
Battery charge Resets the battery charge counter ○
- as neces-
counter reset to 0. *3
sary
Implemented
QR code con- Displays a group of each QR
- - as neces-
tinuous display code continuously.
sary
Implemented
Battery data log Clears battery data log for the ○
- as neces-
clearing service functions. *18 *3
sary
As reques-
Adjusts the multi-function display ○
Contrast - ted by cus-
liquid crystal contrast. *3
tomers
*1: These functions are used to adjust the controller and display setups to the availability of optional or
control functions. They do not enable or disable the actual functioning of the optional or control func-
tions.
*2: Main controller
*3: multi-function display
*4: When removing/installing or replacing brake sensor or accelerator sensor, or when adjusting the pedal
height
*5: When removing/installing or replacing tilt angle sensor
*6: When length change or replacing of tilt angle sensor rod
*7: When removing/installing or replacing load sensor
*8: When removing/installing, replacing, or adjusting tire angle sensor or sensor cover
*9: When removing/installing, replacing, or adjusting steering angle sensor
*10: When installing or changing attachment or fork
*11: When removing/installing or replacing mast
*12: When removing/installing, replacing, or adjusting tilt cylinder
*13: When removing/installing, replacing, or adjusting lifting height sensor
*14: When removing/installing, replacing, or adjusting load handling lever angle sensor
*15: When replacing control valve
*16: When tire size is changed or tire is replaced
*17: Vehicle in which telematics (option) is installed
*18: Even if the battery data log of the service functions is cleared, the battery data log of the administrator
functions will not be cleared.
2.2.1.2 PASSWORD
NOTICE 2
• Use your fingers to press switches on the display panel. If you press a switch using a sharp ob-
ject, the switch may break.
• If you made any mistake while entering the password, turn the key switch OFF and ON, and then
repeat from the beginning. If you cannot access the service menu screen even after several at-
tempts, there may be a system error.
• Do not disclose the password to customers.
Service password entry procedure

Pro-
ced- Indication Operation Vehicle operation
ure
When pressing the

Press switch (2), switch (3)
switches, a short beep
and switch (4) at the same
1 sounds, and after two
time for two seconds or
Switch (2) Switch (4) seconds another short beep
more.
sounds.
Switch (3)
Press switch (4).

2 (Within ten seconds after A short beep sounds.
the previous operation)
Switch (4)
Press switch (1).

3 (Within ten seconds after A short beep sounds.
the previous operation)
Switch (1)
Press switches (2) and (3)

When pressing the
at the same time for two
switches, a short beep
seconds or more. (Com-
4 sounds, and after two
plete to enter the password
seconds another short beep
within ten seconds since
Switch (2) Switch (3) sounds.
the previous step)
When a secondary service password is set:

Enter the password.
5
When a secondary service password is not set:
The initial service screen in the lower row is displayed.
Pro-
ced- Indication Operation Vehicle operation
ure
6 The initial service screen is displayed for five seconds.
After the initial service screen is displayed, the "ANA-

7
LYZER" menu screen is automatically displayed.
Operation on service menu screen

Operating procedure
5 seconds after the service function initial screen is displayed,

2
SERVICE INITIAL SCREEN
the DIAG MEMORY items in the ANALYZER menu can be selected.
The following are the 7 types of SERVICE menu,
and selections can be changed using switch (2) and switch (3).
[ANL] ANALYZER menu
[TUN] TUNING menu
[OPT] OPTION SET menu
[MAT] MATCHING menu
[LOG] BATTERY DATA LOG menu
[etc.] Other service function menu
[ ] Screen for moving back to the normal screen
Switch (1): Selects the following items from the selected menu type
Switch (2): Moves selection of the menu type to the left
Switch (3): Moves selection of the menu type to the right
SWITCH (1) SWITCH (3)
SWITCH (4)
Switch (4): Moves to the selected (decided) setting screen
SWITCH (2)
ANALYZER menu TUNING menu OPTION SET menu MATCHING menu

Screen for moving back to the

BATTERY DATA LOG menu Other service function menu
normal screen
Select the "9. DATA LOG/ADMIN",

it will move to "MANAGER FUNCTION
COMMON BATTERY DATA LOG" menu
Select the "END",

it will move to "BATTERY DATA LOG" menu
MANAGER FUNCTION Return to
COMMON BATTERY DATA LOG menu BATTERY DATA LOG menu
About QR code
QR code is a type of two dimensional bar-code and read by a corresponding bar-code reader, cell phone, or
smartphone application. Data is divided and saved into multiple QR codes.
If a reader supports coupling mode, when all QR codes are read, divided data will be automatically coupled. 2
Entering an identification number (such as vehicle number or unit number) before saving read data allows
you to easily manage the data.
You can create a table or graph from read data using spreadsheet software.
Text data
Enter a vehicle number
NOTICE
• For operations and specifications of a reader, contact the manufacturer of the reader.
• QR codes may not be correctly read depending on the reader. QR codes may be hard to read de-
pending on the brightness around the vehicle or the reflection of a light source.
QR code is a registered trademark of DENSO WAVE Incorporated.

2.2.1.3 ANALYZER
Overview
Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of
the control system, using communication between each controller and the multi-function display.
By switching the multi-function display to analyzer mode, operative conditions of the sensor and actuator that
are used for traveling, load handling, SAS and OPS functions, or the error information detected by the con-
troller can be read. This is very useful for checking operative condition of each function and saving time for
repairing when there is a defect.
Using this analyzer function, you can service the vehicle efficiently and easily.
The analyzer has the following functions:

1. Diagnosis memory function
The controller stores ten newest pieces of detected error information as error codes (diagnosis).
The diagnosis memory monitor retrieves these error codes from the memory and displays them.
Each error code is displayed with its detection time (Key ON hour meter time).
(1) DIAG MEMORY
Reads and displays the diagnosis (error code) and time of occurrence (Key ON hour meter) of a
stored error.
(2) DIAG MEMORY QR
Displays the QR code including the diagnosis (error code) and occurrence time (Key ON hour
meter) of a stored error.
2. In/out monitor function
This function displays the analog input values from individual sensors in the traveling, load handling,
SAS, and OPS. Monitoring the displayed values enables the quality of each circuit/sensor to be judged.
(1) I/O TEMP/VOLT
For each functional component in the electrical systems, this function displays the temperature and
input voltage at different points in the circuit as measured by the controller.
(2) I/O TRAVELING
This function displays the ON/OFF status of traveling and SAS control switches and input voltages
from sensors.
(3) I/O M. HANDLING
This function displays the ON/OFF status of load handling control switches and input voltages from
sensors.
(4) I/O STEERING
This function displays the ON/OFF status of knob position correction control solenoid and input
voltages from sensors.
(5) I/O OTHERS
Displays the ON/OFF status of other switches and the input voltages from respective sensors.
3. Active test "ACTIVE TEST"
In the active test, you can send forcible ON/OFF signals to a selected component to test its operation.
4. Program version display "VERSION"
Displays the program version of each controller.
NOTICE
Active error code display
Displays one active error code on the top right corner of the "I/O MONITOR" and "ACTIVE TEST"
screens.
List of analyzer menu items

ANALYZER menu Screen No. Display item Description
1. DIAG MEMORY 1/2 - 2/2 1. - 10. Displays the error memory that occurred 2
2. DIAG MEMORY QR 1/2 - 2/2 - Displays the diagnostic memory QR code
TDM Drive motor temperature: ℃
TDMDH Drive motor driver main circuit temperature: ℃
1/5
TDMDB Drive motor driver board temperature: ℃
TDMDC Drive motor driver capacitor temperature: ℃
TPM Pump motor temperature: ℃
TPMDH Pump motor driver main circuit temperature: ℃
2/5
TPMDB Pump motor driver board temperature: ℃
TPMDC Pump motor driver capacitor temperature: ℃
TMCB Main controller board temperature: ℃
3. I/O TEMP/VOLT
(temperature/voltage) 3/5 TSLLT Battery fluid temperature: ℃
TDSP Display board temperature: ℃
B48/80V Battery voltage: V
VBKY Voltage after key switch: V
4/5
VBMBSL Solenoid power supply voltage: V
VBMB Voltage after MB contactor: V
Drive motor driver main circuit power supply
VDMD
voltage: V
5/5
Pump motor driver main circuit power supply
VPMD
voltage: V
SPEED Traveling speed: km/h or mph
VRA
1/5
VRB
SWBK (Unused)
SDM Seat switch
SSB Seatbelt switch
2/5 DSF Forward switch
DSR Backward switch
4. I/O TRAVELING SPB Parking brake switch
(traveling control) SYR (Unused)
SSLP Incline angle sensor voltage: V
3/5 SH Fork height switch
SPLF Load sensor voltage: V (in MPa)
Drive motor speed: rpm
4/5 SPDDM
[Target speed]: rpm
SSD
5/5
CSDM

SLLL Lift lock solenoid
SLTFL Forward tilt lock solenoid
SHS Height selector switch , clamp release switch
1/8
STK Tilt knob switch
SDM Seat switch
SHL Fork height restriction switch
VRTA Tilt angle sensor voltage: V
Load sensor voltage: V
SPLF
2/8 (In MPa)
SH Fork height switch
VRH Fork height reel sensor voltage: V
Pump motor speed: rpm
3/8 SPDPM
[Target speed]: rpm
SSP Pump motor rotation sensor voltage: V
4/8 Pump motor current sensor 1 voltage: V
CSPM
5. I/O M.HANDLING Pump motor current sensor 2 voltage: V
(load handling control)
SLLL Lift lowering lock solenoid
CSL Lift proportional valve solenoid current: A
5/8
Lift lever angle sensor1 voltage: V
VRL
Lift lever angle sensor2 voltage: V
SLTFL Tilt forward lock solenoid
CST Tilt proportional valve solenoid current: A
6/8
Tilt lever angle sensor1 voltage: V
VRT
Tilt lever angle sensor2 voltage: V
CSA1
rent: A
7/8
Attachment (1) lever angle sensor1 voltage: V
VRA1
CSA2
rent: A
8/8
VRA2
VRTRA Tire angle sensor voltage: V
6. I/O STEERING
1/1 Knob current position (target value) knob correc-
(steering control) K-POS
tion solenoid status
SSTR Steering sensor pulse
CSBAT Battery current sensor voltage: V
7. I/O OTHERS Shock sensor 1 voltage: V
1/1 IPL
(others) Shock sensor 2 voltage: V
DOPT (Unused)

SWING SOL (Unused)
STEERING
SOL
Knob position correction solenoid forced operation 2
1/2
LIFT LWR
Lift lock solenoid forced operation
SOL
8. ACTIVE TEST TILT SOL Forward tilt lock solenoid forced operation
(operation test)
FAN Controller cooling fan forced operation
ACC OUT1 (Unused)
2/2 ACC OUT2 (Unused)
SWG TEST
(Unused)
LMP
DISPLAY Display program version
1/2 MAIN C/R Main controller program version
9. VERSION
CAN BRIDGE CAN bridge program version
(version)
DM DRIVER Drive motor driver program version
2/2
PM DRIVER Pump motor driver program version
ANALYZER menu screen

Operating procedure
1. Enter the password on the normal screen to display
the service initial screen.
2. The state selected by the [ANL] tab is the ANA-

LYZER menu screen. At this time, pressing switch (2)
selects the [RETURN] tab and displays the END
menu screen for returning to the GENERAL function
screen. Pressing switch (3) selects the [TUN] tab and
displays the "TUNING" menu screen.
▪ "1. DIAG MEMORY"

Switch (1): Move the selection to the next item
Switch (2): To the [Return] END menu screen
Switch (3): To the [TUN] TUNING menu screen
Switch (4): To the "DIAG MEMORY" screen
▪ "2. DIAG MEMORY QR"
Switch (4): To the "DIAG MEMORY QR" screen
▪ "3. I/O TEMP/VOLT"
Switch (4): To the "I/O TEMP/VOLT" screen
▪ "4. I/O TRAVELING"

Switch (3): To the [TUN] TUNING menu screen 2
Switch (4): To the "I/O TRAVELING" screen
▪ "5. I/O M.HANDLING"
Switch (4): To the "I/O M.HANDLING" screen
▪ "6. I/O STEERING"
Switch (4): To the "I/O STEERING" screen
▪ "7. I/O OTHERS"
Switch (4): To the "I/O OTHERS" screen
▪ "8. ACTIVE TEST"
Switch (4): To the "ACTIVE TEST" screen
▪ "9. VERSION"
Switch (4): To the "VERSION" screen
Diagnosis memory function

The controller retains up to ten diagnosis codes (error codes) output in the past on account of electrical prob-
lems.
The diagnosis memory monitor retrieves these error codes from the memory and displays them.
Diagnosis memory display "DIAG MEMORY"
Reads and displays the diagnosis (error code) and time of occurrence (Key-ON hour meter) of a stored error.
Operating procedure
1. Display the "ANALYZER" menu screen.
2. Check that "DIAG MEMORY" is selected on the
screen, and press switch (4) (to confirm) to display
the "DIAG MEMORY 1/2" screen.
3. Press switch (4) on the "DIAG MEMORY 2/2" screen

to return to the "ANALYZER" menu screen.
NOTICE!
▪ The most recently displayed error is represen-
ted as 1, and each subsequent error is repres-
ented as 2, 3, and up to 10, respectively.
▪ When no error codes are displayed on the
Switch (4) screen and the hour meter time is "0.0h", it in-
dicates that no errors occurred in the past
after that row.
▪ You cannot move directly from the "DIAG
MEMORY" screen to the screen of the other
items. Return to the "ANALYZER" menu
screen once, then move to the screen of each
item.
▪ For details on diagnostic codes, refer to the
Diagnostic Code List.
▪ "DIAG MEMORY 1/2"
Displays diagnoses 1 - 5.
Switch (4): To the "DIAGMEMORY 2/2" screen
▪ "DIAG MEMORY 2/2"

Displays diagnoses 6 - 10.
Switch (4): To the "ANALYZER" menu screen
Diagnosis memory QR code display "DIAG MEMORY QR"

Displays the QR code including the diagnosis (error code) and occurrence time (Key ON hour meter) of a
stored error.
Operating procedure
2
2. Select "DIAG MEMORY QR" on the screen by using
switch (1) and press switch (4) (to confirm) to display
the "DIAG MEMORY QR" 1/2 screen.
3. Press switch (4) on the "DIAG MEMORY QR 2/2

screen to return to the "ANALYZER" menu screen.
NOTICE!
▪ Be sure to read QR codes in the order of first
and second. If you move to the next page
without reading the first QR code, return to
the "ANALYZER" menu screen to display the
Switch (4) first QR code again.
▪ If you move to the next page before the QR
code is displayed, the next QR code is not
displayed. Wait for the QR code to be dis-
played and go to the next page.
▪ You cannot move directly from the "DIAG
MEMORY QR" screen to the screen of the
other items. Return to the "ANALYZER" menu
item.
▪ "DIAG MEMORY QR 1/2"
Displays the first QR code.
Switch (4): To the "DIAG MEMORY QR 2/2" screen
▪ "DIAG MEMORY QR 2/2"

Displays the second QR code.
In/out monitor function (I/O MONITOR)

This function displays the input values from individual sensors in the traveling, load handling, SAS, and OPS
systems to the controller.
By monitoring these values, you can see whether each circuit or sensor is functioning normally or not. 2
In/out monitor (1) "I/O TEMP/VOLT"

For each functional component in the electrical systems, this function displays the temperature and input
voltage at different points in the circuit as measured by the controller.
Operating procedure
2. Select "I/O TEMP/VOLT" on the screen by using
the "I/O TEMP/VOLT 1/5" screen.
3. After that, each time switch (4) is pressed, the next

screen is displayed. On the "I/O TEMP/VOLT 5/5"
screen, press switch (4) to return to the "ANALYZER"
menu screen.
NOTICE!
▪ You cannot move directly from the "I/O TEMP/
VOLT" screen to the screen of the other items.
Switch (4) Return to the "ANALYZER" menu screen
once, then move to the screen of each item.
▪ "I/O TEMP/VOLT 1/5"

TDM: Drive motor temperature (℃)
Displays the drive motor temperature
TDMDH: Drive motor driver main circuit temperature (℃)
Displays the drive motor driver main circuit temperature
TDMDB: Drive motor driver board temperature (℃)
Displays the drive motor driver control board temperature
TDMDC: Drive motor driver capacitor temperature (℃)
Displays drive motor driver capacitor temperature
Switch (4): To the "I/O TEMP/VOLT 2/5" screen

TPM: Pump motor temperature (℃)
Displays the Pump motor temperature
TPMDH: Pump motor driver main circuit temperature (℃)
Displays the Pump motor driver main circuit temperature
TPMDB: Pump motor driver board temperature (℃)
Displays the Pump motor driver control board temperature
TPMDC: Pump motor driver capacitor temperature (℃)
Displays the Pump motor driver capacitor temperature

TMCB: Main controller board temperature (℃)
Displays the main controller board temperature
TSLLT: Battery fluid temperature (℃)
Displays the battery fluid temperature
TDSP: Display board temperature (℃)
Displays the display board temperature

B48/80V: Battery voltage (V)
Displays the battery voltage
VBKY: Voltage after key switch (V)
Displays the voltage after key switch
VBMBSL: Solenoid power supply voltage (V)
Displays the solenoid power supply voltage
VBMB: Voltage after MB contactor (V)
Displays voltage at a point after MB contactor

VDMD: Drive motor driver main circuit power supply
voltage (V)
Displays the drive motor driver main circuit power supply
voltage
VPMD: Pump motor driver main circuit power supply
voltage (V)
Displays the Pump motor driver main circuit power supply
voltage
In/out monitor (2) "I/O TRAVELING"

This function displays the ON/OFF status of traveling control switches and input voltages from sensors.
Operating procedure 2
2. Select "I/O TRAVELING" on the screen by using
the "I/O TRAVELING 1/5" screen.

screen is displayed. On the "I/O TRAVELING 5/5"
menu screen.
NOTICE!
▪ You cannot move directly from the "I/O TRAV-
ELING" screen to the screen of the other
Switch (4) items. Return to the "ANALYZER" menu
item.
▪ "I/O TRAVELING 1/5"

SPEED: Traveling speed (km/h or mph)
Displays the traveling speed
VRA: Accelerator sensor 1/2 voltage (V)
Displays an input voltage value from the accelerator sensor
to the controller
Accelerator sensor 1 voltage standard value
0.40 - 1.25 V (with the accelerator not operated)
2.00 - 4.80 V (with the accelerator fully stepped on)
Accelerator sensor 2 voltage standard value
0.65 - 2.32 V (with the accelerator not operated)
2.42 - 4.80 V (with the accelerator fully stepped on)
VRB: Brake sensor 1/2 voltage (V)
Displays an input voltage value from the brake sensor to
the controller
Brake sensor 1 voltage standard value
0.50 - 1.50 V (with the brake not operated)
1.05 - 3.10 V (with the brake fully stepped on)
Brake sensor 2 voltage standard value
0.79 - 2.58V (with the brake not operated)
1.50 - 3.82 V (with the brake fully stepped on)
SWBK: (Unused)
Switch (4): To the "I/O TRAVELING 2/5" screen

SDM: Seat switch
Displays the ON/OFF status of the seat switch
SDM: 0=OFF when sitting on the seat
SDM: 1=ON when leaving the seat
SSB: Seatbelt switch
Displays the ON/OFF status of the seatbelt switch
SSB: 0=OFF when the seatbelt is not fastened
SSB: 1=ON when the seatbelt is fastened
DSF: Forward switch
DSR: Backward switch
Displays the ON/OFF status of the direction
Direction lever forward position
DSF: 1=ON
DSR: 0=OFF
Direction lever neutral position
DSF: 0=OFF
DSR: 0=OFF
Direction lever backward position
DSF: 0=OFF
DSR: 1=ON
SPB: Parking brake switch
Displays the ON/OFF status of the parking brake switch
SPB: 0=OFF (with the parking brake activated)
SPB: 1=ON (with the parking brake released)
SYR: (Unused)
SSLP: Incline angle sensor voltage (V) (Slope assist spe-
cification only)
Displays an input voltage value from the incline angle
sensor to the controller
0.30 - 4.70 V (when the vehicle is stopped on a flat
road)
The voltage value decreases when the vehicle goes up a
slope forward
and increases when it goes down a slope forward
SH: Fork height switch
Displays the states of the fork height switches
SH1 SH2-1 SH2-2 SWH08

0=OFF
1=ON
By lifting/lowering the load, you can see whether the
switches are turned ON/OFF normally.
For the combination of the fork height switches, refer to the
table.
(Lifting height switch included)

Except Australian spec
SH1 SH2-1 SH2-2 SWH08 2
Fork height Indication
switch switch switch switch
Low lifting height, lifting height of less than
1000 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
800 mm
Low lifting height, lifting height of 800 mm
1000 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
or more
High lifting height 0100 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
For Australian spec, vehicles with V mast mounted
1001 1 (=ON) 0 (=OFF) 0 (=OFF) 1 (=OFF)
800 mm
1000 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
or more
High lifting height 0100 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
For Australian spec, vehicles with FV mast or FSV mast mounted
1000 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
800 mm
1000 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
or more
High fork height 0100 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
*1: The height at which the fork height switch is switched varies depending on the set fork height of the mast.
(Lifting height switch not included)
Always 0000
▪ SPLF: Load sensor voltage (V (in MPa))
Displays an input voltage value (V) and detection pressure
(MPa) from the load sensor to the controller
(Load sensor included)
0.50 - 4.50 V (without load)
The voltage value increases with increase of the load
(Load sensor not included)
0.00 V
SPDDM: Drive motor speed [target speed] (rpm)
Displays the actual drive motor speed and the target speed
The rotation sensor is checked by actually driving the
vehicle
As the drive speed increases, the drive motor speed also
increases

SSD: Drive motor rotation sensor 1/2 voltage (V)
Displays the rotation sensor voltage of the drive motor
0.30 - 0.70 V or 0.90 - 1.40 V (standard value at stop)
Fluctuates between approx. 0.30 - 1.40 V (when the mo-
tor is rotating)
CSDM: Drive motor current sensor 1/2 voltage (V)
Displays the current sensor voltage of the drive motor
Approx. 2.50 V (standard value when the vehicle is
stopped)
Approx. 0.50 - 4.50 V (standard value when the vehicle
is running)
In/out monitor (3) "I/O M.HANDLING"

This function displays the ON/OFF status of load handling switches and input voltages from sensors.
2. Select "I/O M.HANDLING" on the screen by using
the "I/O M.HANDLING 1/8" screen.

screen is displayed. On the "I/O M.HANDLING 8/8"
menu screen.
NOTICE!
▪ You cannot move directly from "I/O M.HAND-
LING" screen to the screen of the other items.
Return to the "ANALYZER" menu screen
▪ The number of displayed screens is displayed
according to the number of attachment levers.
▪ "I/O M.HANDLING 1/8"
SLLL: Lift lock solenoid
Displays the output signal to the lift lock solenoid
SLTFL: Forward tilt lock solenoid
Displays the output signal to the forward tilt lock solenoid
SHS: Height selector switch, clamp release switch
Displays the ON/OFF status of the switch
(only for specifications including a height selector switch
and vehicles in which ATT clamp release interlock is moun-
ted)
SHS: 0=OFF
SHS: 1=ON
(Others)
0
STK: Tilt knob switch
Displays the ON/OFF status of the tilt knob switch
STK: 0=OFF
STK: 1=ON
SDM: Seat switch
Displays the ON/OFF status of the seat switch
SDM: 0= OFF　when sitting on the seat
SDM: 1= ON　when leaving the seat
SHL: Fork height restriction switch
Displays the status of the fork height restriction switch
With the fork height restriction switch ON: 1
With the fork height restriction switch OFF: 0
Switch (4): To the "I/O M.HANDLING 2/8" screen

VRTA: Tilt angle sensor voltage (V)
Displays an input voltage value from the tilt angle sensor to
the controller
(Tilt angle sensor included)
Mast vertical state standard value: 1.01 - 4.0 V
The voltage decreases during mast forward tilting, while it
increases during mast backward tilting.
(Tilt angle sensor not included)
0.00 V
SPLF: Load sensor voltage: V (in MPa) (V)
Refer to items for "I/O TRAVELING 3/5"
SH: Fork height switch
Refer to items for "I/O TRAVELING 3/5"
VRH: Fork height reel sensor
Displays the input voltage from the height reel sensor to the
controller.
(Only for specification that includes a height selector)
Standard value: 0.20 - 4.80 V
The voltage increases during mast raising, while it de-
creases during mast lowering.
(Specification that does not include height selector)
0.00 V
SPDPM: Pump motor speed [target speed] (rpm)
Displays the actual Pump motor speed and the target
speed
As the load handling speed increases, the Pump motor
speed also increases

SSP: Pump motor rotation sensor voltage (V)
Displays the rotation sensor voltage of the Pump motor
0.30 - 0.70 V or 0.90 - 1.40 V (at stop)
Fluctuates between approx. 0.30 - 1.40 V (when the mo-
tor is rotating)
CSPM: Pump motor current sensor 1/2 voltage (V)
Displays the current sensor 1/2 voltage of the Pump motor
Approx. 2.50 V (without load handling lever operation,
without steering operation, and the direction is neutral)
0.50 - 4.50 V (except for the above)

SLLL: Lift lock solenoid
Refer to items for "I/O M.HANDLING 1/8"
CSL: Lift proportional valve solenoid current: A
2
Displays the current from the lift proportional solenoid.
0.25 - 0.95 A (with lifting to the uppermost position)
0.25 - 0.95 A (with lowering to the lowermost position)
0.00 A (when motor is stopped)
The current increases according to the amount of operation
of the raising/lowering lever.
VRL: Lift lever angle 1/2 sensor voltage (V)
Displays an input voltage value from the lift lever angle
sensor 1/2 to the controller
Lift lever angle sensor 1 voltage standard value
(Standard lever specification)
1.65 - 4.50 V (with lifting to the uppermost position)
0.30 - 2.88 V (with lowering to the lowermost position)
1.65 - 2.88 V (when the lever is in the neutral position)
(Mini lever specification)
The voltage value increases with lifting operation and de-
creases with lowering operation
Lift lever angle sensor 2 voltage standard value
The voltage value decreases with lifting operation and in-
creases with lowering operation

SLTFL: Tilt lock solenoid
Refer to items for "I/O M.HANDLING 1/8"
CST: Tilt proportional valve solenoid current: A
Displays the current from the tilt proportional solenoid.
0.35 - 0.85 A (with tilting to the backward most tilt posi-
tion)
0.35 - 0.85 A (with tilting to the forward most tilt posi-
tion)
of the tilt lever.
VRT: Tilt lever angle 1/2 sensor voltage (V)
Displays an input voltage value from the tilt lever angle
sensor 1/2 to the controller
Tilt lever angle sensor 1 voltage standard value
1.65 - 4.50 V (with tilting to the backward most tilt posi-
tion)
0.30 - 2.88 V (with tilting to the forward most tilt posi-
tion)
tion)
0.30 - 2.76V (with tilting to the forward most tilt posi-
tion)
The voltage value increases with backward tilt operation
and decreases with forward tilt operation
Tilt lever angle sensor 2 voltage standard value
tion)
tion)
tion)
tion)
The voltage value decreases with backward tilt operation
and increases with forward tilt operation

CSA1: Attachment 1 proportional valve solenoid current: A
tion) 2
tion)
of the tilt lever.
VRA1: Attachment 1 lever angle 1/2 sensor voltage (V)
Displays an input voltage value from the attachment 1 lever
angle sensor 1/2 to the controller
Attachment 1 lever angle sensor 1 voltage standard
value
tion)
tion)
tion)
tion)
value
tion)
tion)
tion)
tion)

CSA2: Attachment 2 proportional valve solenoid current: A
tion)
tion)
of the tilt lever.
VRA2: Attachment 2 lever angle 1/2 sensor voltage (V)
Displays an input voltage value from the attachment 2 lever
angle sensor 1/2 to the controller
value
tion)
tion)
tion)
tion)
value
tion)
1.52 - 4.50 V (with tilting to forward most tilt position)
tion)
1.78 - 4.50 V (with tilting to forward most tilt position)
In/out monitor (4) "I/O STEERING"

This function displays the ON/OFF status of knob position correction control switches and input voltages
from sensors.
Operating procedure
2
2. Select "I/O STEERING" on the screen by using
the "I/O STEERING 1/1" screen.
3. Press switch (4) on the "I/O STEERING 1/1" screen

to return to the "ANALYZER" menu screen.
NOTICE!
▪ You cannot move directly from the "I/O
STEERING" screen to the screen of the other
items. Return to the "ANALYZER" menu
item.
▪ "I/O STEERING 1/1"

VRTRA: Tire angle sensor voltage (V)
Displays an input voltage value from the tire angle sensor
to the controller
(W/ Tire angle sensor)
1.80 - 2.40 V (traveling straight ahead)
The input voltage value increases with right steering and
right turn
The input voltage value decreases with left steering and left
turn
(W/O Tire angle sensor)
0.00 V
K-POS: Knob position
Displays the steering knob position actual value (target
value) and the ON/OFF status of the knob position correc-
tion solenoid
Actual value:
Displays the recognized knob position calculated from the
steering sensor signal by the controller
Target value:
Displays the recognized knob position calculated from the
tire angle sensor signal by the controller
Without knob position correction control:
(Unused)
With knob position correction control:
One rotation of the steering wheel is divided into 160 (0 -
159), and the knob position displayed in the figure is 80.
This value increases with rotation to the right and de-
159
0
creases with rotation to the left.
1 The value should increase with rotation to the right and de-
crease with rotation to the left
80 Display range: 0 - 159
Knob position correction solenoid
Without knob position correction control:
Always: -
Standard positon With knob position correction control:
1=ON Energized (with position correction) status
0=OFF Non-energized (without position correction) status
SSTR: Steering sensor pulse
SS1 SS2 SSC
0=OFF
1=ON
When the steering wheel is rotated once, SS1 and SS2
change from ON -> OFF -> ON. SSC is turned ON only in
the standard position.
In/out monitor (5) (I/O OTHERS)

This function displays the ON/OFF status of others switches and input voltages from sensors.
2. Select "I/O OTHERS" on the screen by using switch
(1) and press switch (4) (to confirm) to display the "I/
O OTHERS 1/1" screen.
3. Press switch (4) on the "I/O OTHERS 1/1" screen to

return to the "ANALYZER" menu screen.
NOTICE!
▪ You cannot move directly from "I/O OTHERS"
screen to the screen of the other items. Re-
turn to the "ANALYZER" menu screen once,
then move to the screen of each item.
▪ "I/O OTHERS 1/1"
CSBAT: Battery current sensor voltage (V)
Displays an input voltage value from the battery current
sensor to the controller
Standard value when the vehicle is stopped
Approx. 2.50 V (load handling lever, steering, and for-
ward and backward switches are in their neutral posi-
tions)
2.30 - 2.70 V (when the vehicle is stopped in a status
other than the above)
IPL: Shock sensor 1/2 voltage (V)
Displays an input voltage value from the shock sensor to
the controller
With shock sensor
Approx. 2.00 V (standard value when the vehicle is
stopped)
Without shock sensor
0.00 V
DOPT: (Unused)
Active test "ACTIVE TEST"

In the active test, you can send forcible ON/OFF signals to a selected component to test its operation.
List of Active test items
Status display
Item Description Content of opera- Content of opera-
Signal Signal
tion tion
Swing lock solenoid forced
SWING SOL Unused
operation
STEERING Knob position correction
OFF By-pass close ON By-pass open
SOL solenoid forced operation
Lift lock solenoid forced oper-
LIFT LWR SOL OFF Lowering impossible ON Lowering possible
ation
Tilt lock solenoid forced oper- Forward tilt im-
TILT SOL OFF ON Forward tilt possible
ation possible
Controller cooling fan forced
FAN OFF Fan stopped ON Fan operated
operation
Accessory output 1 (brake
ACC OUT1 accessory output) forced op- Unused
eration
Accessory output 2 (back-
ACC OUT2 ward traveling accessory out- Unused
put) forced operation
SWG TEST Swing lock solenoid operation
Unused
LMP display mode
▪ For the items in the ACTIVE TEST screen, there are some items that display the status and some that do
not.
▪ When you operate switch (2) or (3) to forcibly turn selected item OFF/ON and then operate switch (1) to
send the item, forced operation is canceled (flows to normal operation).
▪ You can distinguish whether or not forced operation is active by the displayed guidance for switch (2)
and/or switch (3). (See the table)
Displayed operation guidance Status
Selected item is not in forced operation
Selected item is forcibly ON
Selected item is forcibly OFF
No applicable functions. Or, the condition is not received yet

Operating procedure
2. Select "ACTIVE TEST" on the screen by using switch
(1) and press switch (4) (to confirm) to display the
2
"ACTIVE TEST 1/2" screen.
3. Press switch (4) on the "ACTIVE TEST 2/2" screen to

return to the "ANALYZER" menu screen.
NOTICE!
▪ You cannot move directly from the "ACTIVE
TEST" screen to the screen of the other items.
Switch (4)
▪ "ACTIVE TEST 1/2"

SWING SOL: (Unused)
STEERING SOL: Knob position correction solenoid forced
operation
Rotate the steering wheel slowly to check the difference in
movement of the rear tires.
"Without knob position correction control"
ON (with the bypass opened) The tires hardly move.
OFF (with the bypass closed) The tires move. (Normal op-
eration)
"Without knob position correction control"
(Unused)
LIFT LWR SOL: Lift lock solenoid forced operation
Perform lift lowering operation to check the possibility of
lowering operation.
ON (solenoid ON) Lowering possible (normal operation)
OFF (solenoid OFF) Lowering impossible
TILT SOL: Forward tilt lock solenoid forced operation
Performs forward tilt operation to check the possibility of
forward tilt operation of the mast.
ON (solenoid ON) Forward tilt possible
OFF (solenoid OFF) Forward tilt impossible
Switch (1): Select the next item on the "ACTIVE TEST 1/2"
screen
Switch (2): Forcibly turn OFF the selected item
Switch (3): Forcibly turn ON the selected item
Switch (4): To the "ACTIVE TEST 2/2" screen
▪ "ACTIVE TEST 2/2"

FAN: Controller cooling fan forced operation
Check the operation of the controller cooling fan visually
and on the display.
ON (fan ON) The controller cooling fan rotates
ACC OUT1: (Unused)
ACC OUT2: (Unused)
SWG TEST LMP: (Unused)
Switch (2): Forcibly turn OFF the selected item.
Switch (3): Forcibly turn ON the selected item.
Program version "VERSION"

The program version of each controller can be used.
2. Select "VERSION" on the screen by using switch (1)
and press switch (4) (to confirm) to display the "VER-
SION 1/2" screen.
3. Press switch (4) to move to the "VERSION 2/2"

screen. On the "VERSION 2/2" screen, press switch
(4) to return to the "ANALYZER" menu screen.
NOTICE!
▪ You cannot move directly from the "VER-
SION" screen to the screen of the other items.
Switch (4) once, then move to the screen of each item.
▪ "VERSION 1/2"
DISPLAY: Display program version
Displays the program version of the multi-function display
MAIN C/R: Main controller program version
Displays the main controller program version
CAN BRIDGE: CAN bridge program version
Displays the CAN bridge program version
Nothing is displayed when the CAN bridge is not connected
Switch (4): To the "VERSION 2/2" screen
▪ "VERSION 2/2"
DM DRIVER: Drive motor driver program version
Displays the drive motor driver program version
PM DRIVER: Pump motor driver program version
Displays the Pump motor driver program version
2.2.1.4 Tuning "TUNING"
Overview
Select this menu to make fine adjustment of the traveling and load handling control features.
When receiving a user request such as "I want you to adjust the regenerative braking force so it will be
weaker at accelerator off", a setting level can be altered from the tuning screen.
List of tuning items

Level (*: initial setting value)
Menu No. Item
1 2 3 4 5 6 7 8
Operation timing of the battery level warning and Sl
01 Fast * Disabled
the over-discharge warning ow
Slow de- Fast de-
02 Battery charge indicator correction 1 *
crease crease
Sensit- Insensit-
03 Battery charge indicator correction 2 *
ive ive
Power Power
04 Motor torque in case of battery discharge *
down keep
05 Spare *
Insensit- Sensit-
06 Accelerator pedal sensitivity *
ive ive
07 Accelerator pedal operation acceleration torque Weak * Strong
08 Soft start (accelerator on) Slow * Quick
09 Acceleration OFF regenerative braking torque Weak * Strong
10 Acceleration-off regenerative braking soft start Slow * Quick
11 Acceleration torque (switch back) Weak * Strong
12 Acceleration soft start (switch back) Slow * Quick
13 Regenerative braking torque (switch back) Weak * Strong
TUNE 14 Regenerative soft start (switch back) Slow * Quick
GEN.
15 Regenerative soft stop (switch back) Slow * Quick
16 Accelerator pedal position torque Weak * Strong
Accelerator pedal/Brake simultaneous operating Strong
17 Weak
torque *
Slope regenerative speed when the traveling dir-
Slow
18 ection and the direction of the direction are re- Fast
*
verse
Slope regenerative speed when the traveling dir-
Slow
19 ection and the direction of the direction are the Fast
*
same
20 Spare *
Short
21 Machine stand stop time at slope regeneration *1 Long
*
Fast
22 Maximum speed control when reverse traveling Slow
*
Fast
23 Low speed setting when reverse traveling Slow
*
24 Spare *
25 Regenerative soft stop (braking) Slow * Quick

Menu No. Item
1 2 3 4 5 6 7 8
Fast
26 Pump motor output during lift up operation Slow
* 2
Pump motor output during forward/backward tilt-
27 Slow * Fast
ing operation
Pump motor output during attachment 1 Push
28 Slow * Fast
and Pull operation
29 Slow * Fast
and Pull operation
30 Slow * Fast
and Pull operation
31 Inching speed during height selector operation Slow * Quick
Sh
32 Load meter display time None * Long
ort
TUNE Maximum limit temperature for battery fluid tem- Low
33 High
GEN. perature protection *
34 Temperature at battery overheat warning Low * High
35 Spare *
36 Slope assist activation angle Gentle * Steep
37 Spare *
38 Spare *
39 Spare *
40 Spare *
41 Spare *
42 Spare *
43 Spare *
44 Spare *
45 Spare *
*1: Setting a higher level extends the time required to stop the vehicle on a slope. Engage the parking
brake when leaving the vehicle.
Battery Level and Overdischarge Warnings for Battery Charge Indicator
Amount of Normal turning level [No.1]

discharge
1 2 3 4 5 6 7 8
[%]
50 Initial setting value

Battery warning
60
Battery indicator blinks.
70
80
90
100
Ten segment of the battery indicator blink.
No warning

Menu No. Item
1 2 3 4 5 6 7 8
Play before the start of lift lowering opera-
START Wide * Narrow
tion
INCH Inching speed during lift lowering operation Slow * Fast
Maximum speed during lift lowering opera-
LIFT MAX Slow * Fast
tion
DOWN
Acceleration speed during lift lowering oper-
ACC Weak * Strong
ation
Deceleration speed during lift lowering op-
DEC Weak * Strong
eration
START Play before the start of lift up operation Wide * Narrow
INCH Inching speed during lift-up operation Slow * Fast
LIFT
MAX Maximum speed during lift up operation Slow * Fast
UP
ACC Acceleration speed during lift up operation Weak * Strong
DEC Deceleration speed during lift up operation Weak * Strong
START Play until forward tilting operation start Wide * Narrow
Inching speed during forward tilting opera-
INCH Slow * Fast
tion
Maximum speed during forward tilting oper-
TILT MAX Slow * Fast
ation
FWD
Acceleration speed during forward tilting
ACC Weak * Strong
operation
Deceleration speed during forward tilting
DEC Weak * Strong
operation
START Play until backward tilting operation start Wide * Narrow
Inching speed during backward tilting oper-
INCH Slow * Fast
ation
Maximum speed during backward tilting op-
TILT MAX Slow * Fast
eration
BWD
Acceleration speed during backward tilting
ACC Weak * Strong
operation
Deceleration speed during backward tilting
DEC Weak * Strong
operation
START Play until attachment 1 Push operation start Wide * Narrow
Inching speed during attachment 1 Push
INCH Slow * Fast
operation
Maximum speed during attachment 1 Push
ATT1 MAX Slow * Fast
operation
PUSH
Acceleration speed during attachment 1
ACC Weak * Strong
Push operation
Deceleration speed during attachment 1
DEC Weak * Strong
Push operation
START Play until attachment 1 Pull operation start Wide * Narrow
Inching speed during attachment 1 Pull op-
INCH Slow * Fast
eration
Maximum speed during attachment 1 Pull
operation
PULL
ACC Weak * Strong
Pull operation
DEC Weak * Strong
Pull operation

Menu No. Item
1 2 3 4 5 6 7 8
START Play until attachment 2 Push operation start Wide * Narrow
2
Inching speed during attachment 2 Push
INCH Slow * Fast
operation
Maximum speed during attachment 2 Push
operation
PUSH
ACC Weak * Strong
Push operation
DEC Weak * Strong
Push operation
START Play until attachment 2 Pull operation start Wide * Narrow
Inching speed during attachment 2 Pull op-
INCH Slow * Fast
eration
Maximum speed during attachment 2 Pull
operation
PULL
ACC Weak * Strong
Pull operation
DEC Weak * Strong
Pull operation
Tuning menu screen "TUNING"

Operating procedure
1. Enter the password on the normal screen to display the
service initial screen.
2. In the initial "SERVICE" menu screen, the [ANL] tab is
displayed to indicate the "ANALYZER" menu screen.
Press switch (3) once. The [TUN] tab is selected. This is
the "TUNING" menu screen.
Press switch (2) to select the [ANL] tab and move to the
"ANALYZER" menu screen. Press switch (3) to select
the [OPT] tab and move to "OPTION SET" menu screen.
▪ "1. GENERAL"
Switch (1): Move the selection to the next item.
Switch (2): To the [ANL] ANALYZER menu screen
Switch (3): To the [OPT] OPTION SET menu screen
Switch (4): To the tuning setting screen
▪ "2. LIFT LEVER"
▪ "3. TILT LEVER"
▪ "4. ATT1 LEVER"
▪ "5. ATT2 LEVER"
Tuning "GENERAL"
Makes fine adjustment of traveling and load handling functions.
1. Display the "TUNING" menu screen.
2. Check that "GENERAL" is selected on the screen,
and press switch (4) (to confirm) to display the "TUNE
GEN. (01 - 05)" screen.
3. Each time switch (4) is pressed, the next screen is

displayed. With the "TUNE GEN. (41 - 45)" screen
displayed, press switch (4) to return to the "TUNING"
menu screen.
NOTICE!
▪ You cannot move directly from "GENERAL"
Switch (4) turn to the "TUNING" menu screen once, then
move to the screen of each item.
▪ "TUNE GEN." screen 1 (01 - 05)

Switch (1): Switch selection to next item on the screen
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Display the next five items
NOTICE!
▪ With the "TUNE GEN. (41 - 45)" screen displayed, the
"TUNING" menu screen returns.



Switch (4): Returning to "TUNING" menu screen
Tuning "LIFT LEVER"

Makes fine adjustment of lift lever functions.
Operating procedure
2. Use switch (1) to select "LIFT LEVER" on the screen,
and press switch (4) (to confirm) to display the "LIFT
DOWN" (lift lever lowering operation tuning) screen.
3. When switch (4) is pressed on the "LIFT DOWN"

screen, the "LIFT UP" (lift lever lifting operation tun-
ing) screen is displayed. Press switch (4) again to re-
turn to the "TUNING" menu screen.
NOTICE!
▪ You cannot move directly from "LIFT LEVER
TUNING" screen to the screen of the other
Switch (4) items. Return to the "TUNING" menu screen
▪ "LIFT DOWN"
Switch (4): To "LIFT UP" (lift lever lifting operation tuning)
screen
▪ "LIFT UP"
Switch (4): Return to "TUNING" menu screen
Tuning "TILT LEVER"

Makes fine adjustment of tilt lever functions.
2. Use switch (1) to select "TILT LEVER" on the screen,
and press switch (4) (to confirm) to display the "TILT
FWD" (tilt lever front tilt operation tuning) screen.
3. When switch (4) is pressed on the "TILT FWD"

screen, the "TILT BWD" (tilt lever rear tilt operation
tuning) screen is displayed. Press switch (4) again to
return to the "TUNING" menu screen.
NOTICE!
▪ You cannot move directly from "TILT LEVER
▪ "TILT FWD"
Switch (4): To "TILT BWD" (tilt lever rear tilt operation tun-
ing) screen
▪ "TILT BWD"
Tuning "ATT1 LEVER"

Makes fine adjustment of attachment 1 lever functions.
Operating procedure
2. Use switch (1) to select "ATT1 LEVER" on the
the "ATT1 PUSH" (attachment 1 lever front tilt opera-
tion tuning) screen.
3. When switch (4) is pressed on the "ATT1 PUSH"

screen, the "ATT1 PULL" (attachment 1 lever rear tilt
operation tuning) screen is displayed. Press switch
(4) again to return to the "TUNING" menu screen.
NOTICE!
▪ You cannot move directly from "ATT1 LEVER
▪ "ATT1 PUSH"
Switch (4): To "ATT1 PULL" (attachment 1 lever rear tilt op-
eration tuning) screen
▪ "ATT1 PULL"
Tuning "ATT2 LEVER"

Makes fine adjustment of attachment 2 lever functions.
2. Use switch (1) to select "ATT2 LEVER" on the
the "ATT2 PUSH" (attachment 2 lever front tilt opera-
tion tuning) screen.
3. When switch (4) is pressed on the "ATT2 PUSH"

screen, the "ATT2 PULL" (attachment 2 lever rear tilt
operation tuning) screen is displayed. Press switch
(4) again to return to the "TUNING" menu screen.
NOTICE!
▪ You cannot move directly from "ATT2 LEVER
▪ "ATT2 PUSH"
Switch (4): To "ATT2 PULL" (attachment 2 lever rear tilt op-
eration tuning) screen
▪ "ATT2 PULL"
2.2.1.5 Option Set "OPTIONSET"
NOTICE
• The option set function is used to set control of the controller and display control according to
the options equipped on the vehicle. It does not enable or disable the function itself.
• If main controller or Multi-function Display is replaced, it is necessary to reset it according to the
vehicle specifications.
List of option set items

Switching settings
Indication Content Indica- Indica-
Setting content Setting content
tion tion
Setting Japanese language English
DISP.MODE J Japanese I
display (Specified value)
Set to km/h
MPH Traveling speed display unit YES Set to mph NO
(Specified value)
D/M/Y (Europe : Specified value) / Y/M/D (Japan)
DATE TYPE Calendar display
/ M/D/Y (U.S.)
B-TYPE Battery type A1 / A2 / B1 (Specified value) / B2
Battery fluid-level/fluid temper- A: None / B: Previous type (fluid level unit)
B UNIT *1
ature unit C: Fluid-level/fluid temperature unit
B LEVEL ALM *1 Fluid-level warning YES Enabled NO Disabled
Disabled
H MODE LOCK H mode lock YES Enabled NO
(Specified value)
Unlocked until Unlocked until
MENULOCK
Menu unlock specifications A the key is turned B set to YES
SPEC
OFF (Specified value)
S-BELT WARN
Seatbelt Interlock YES Enabled NO Disabled
*1
D-REC *1 Telematics unit YES Enabled NO Disabled
Accelerator prior-
Accelerator pedal/Brake sim-
ACCEL & BRK A ity B Brake priority
ultaneous operation
(Specified value)
Gradual motor
output stop Motor output stop
HOLD TRQ Traveling motor output after
A after operation B immediately after
MODE *2 depress operation stop
stop operation stop
(Specified value)
regeneration
COASTING RUN Accelerator-off regeneration Regeneration not
YES NO available
*3 setting available
(Specified value)
SLOPE ASSIST
Slope assist YES Enabled NO Disabled
*1
OIL CONTROL VALVE 2/3/4/5
OCV WAY *1
SERIAL NUMBER (5th way setting is not available)
Setting the load handling lever Mini lever/Joy-
LEVER SPEC *1 A STD lever B
type stick specification
CLOSED MO- Setting for fishery industry
YES Enabled NO Disabled
TOR *1 models
Attachment 1 lever clamp set- A: Disabled / B: PUSH enabled / C: PULL enabled /
D ACT ATT1 *1
ting D: Both enabled
Attachment 2 lever clamp set- A: Disabled / B: PUSH enabled / C: PULL enabled /
D ACT ATT2 *1
ting D: Both enabled
D ACT ATT3 (Unused) A (Specified value) / B / C / D
Switching settings
tion tion
Setting the mode of buzzer 2
BUZZER SPEC sound when OPS and return- A (Specified value) / B / C
to-neutral operate
Enabled
SEAT BUZZER OPS Operation Notification YES NO Disabled
(Specified value)
Parking brake non-pulling Enabled
PKB BUZZER YES NO Disabled
warning (Specified value)
A: None / B: Displayed when speed is 0 km/h /
WHEEL IND *1 Wheel indicator display mode
C: Always displayed
Setting to enable/disable over- Disabled
SPD ALM2 YES Enabled NO
speed alarm 2 (Specified value)
(Unused)
TILT IND (Unused) YES (Unused) NO
(Specified value)
(Unused)
DIR IND (Unused) YES (Unused) NO
(Specified value)
NO: Disabled / t: Enabled, unit of ton /
LOAD METER *1 Load meter display
kg: Enabled, unit of kg
Setting to enable/disable lift-
ASC W/LOAD *1 ing height and load weight YES Enabled NO Disabled
sensing traveling control
Setting to enable/disable the
vehicle speed limitation by lift-
MODE *1 S Enabled A Disabled
ing height and load weight
sensing traveling control
vehicle speed limitation by lift-
CURVE CONT *1 YES Enabled NO Disabled
ing height and load weight
sensing turning control
Travel limitation
Travel limitation
Travel limitation mode at over- according to dis-
D-LIM MODE A regardless of dis- B
discharge warning charge amount
charge amount
(Specified value)
Load handling Traveling and
Load handling limitation mode operation prohibi- load handling op-
P-LIM MODE A B
at over-discharge warning tion eration prohibi-
(Specified value) tion
Setting to enable/disable act-
T FWD LIMIT *1 YES Enabled NO Disabled
ive mast front tilt angle control
Setting to enable/disable
T BWD LEVEL *1 backward tilt automatic level- YES Enabled NO Disabled
ing control
Setting to enable/disable for-
T F-SPD LIM *1 YES Enabled NO Disabled
ward tilt speed limit control
B LEVEL LIMT *1 Battery fluid-level protection YES Enabled NO Disabled
Maximum limit temperature for
B TEMP LIMIT *1 battery fluid temperature pro- YES Enabled NO Disabled
tection
Enabled
POWER KEEP Power Keep YES NO Disabled
(Specified value)
SHOCK Setting to enable/disable
SENSOR *1 shock-sensor
Setting to enable/disable
H-SELECTOR *1 YES Enabled NO Disabled
height selector
Switching settings
tion tion
(Unused)
SHOU-TOKU (Unused) YES (Unused) NO
(Specified value)
KNOB CONT *1 YES Enabled NO Disabled
steering knob synchronizer
CHARGER UNIT On-truck charger specifica-
*1 tions
CHARGE REC
Watt-hour meter display YES Enabled NO Disabled
*1
Enabled
B DATA LOG Battery data log function YES NO Disabled
(Specified value)
MOTION ALM (Unused) F / R (Specified value) / F&R / OFF
DIR-SW/MVT (Unused) D / MVT / D&MVT / D/MVT (Specified value)
(Unused)
STOP LAMP (Unused) A B (Unused)
(Specified value)
Setting the Australia specifica-
AUS. SPEC *1 YES Enabled NO Disabled
tion (AS2359-2015-compliant)
*1: These are set to match the vehicle specifications at the time of shipment.
*2: When set to B, the machine stand may slide down momentary at the moment the accelerator pedal is re-
leased in a steep slope.
*3: When YES is set, if the accelerator pedal is released when driving down on a slope, the anti-rollback
function is disabled.
Option Set menu screen "OPTIONSET"

Enables or disables the optional specifications, etc. of the vehicle.
Operating procedure
2. In the initial "SERVICE" menu screen, the [ANL] tab
is displayed to indicate the "ANALYZER" menu
screen. Press switch (3) twice. The [OPT] tab is se-
lected. This is the "OPTION SET" menu screen.
Press switch (2) to select the [TUN] tab and move to
the "TUNING" menu screen.
Press switch (3) to select the [MAT] tab and move to
the "MATCHING" menu screen.
3. Check that "OPTIONSET" is selected on the screen,

and press switch (4) (to confirm) to display the "OP-
TIONSET" screen.
4. Each time switch (4) is pressed, the next screen is

displayed. With the "B DATA LOG" screen displayed,
press switch (4) to return to the "OPTION SET" menu
screen. 2
NOTICE!
▪ You cannot move directly from "OPTIONSET"
turn to the "OPTION SET" menu screen once,
then move to the screen of each item.
▪ After changing "D-REC", turn the key switch
OFF. The enabled/disabled state is changed
from the next key switch ON.
▪ If an error related to the telematics unit (ED-1,
ED-4) occurs and prevents logging in, D-REC
can be disabled using the manager function
to use the vehicle temporarily before conduct-
ing an inspection. It allows the operator to
start or stop the vehicle with the key switch
only.
▪ "OPTIONSET" screen 1
Switch (2): In the selected option set item, move the focus
one value to the left
Switch (3): In the selected option set item, move the focus
one value to the right
Switch (4): Display the next five items
When a screen displaying “B DATA LOG” is displayed, it
returns to the "OPTION SET" menu screen.
2.2.1.6 MATCHING
Overview
▪ Each function is controlled by the signal voltage of the sensors memorized on the controllers in the
standard vehicle condition. If servicing or a replacement that affects any of these sensors has been per-
formed, a "matching" operation is required to update the measurement of the sensor signal voltage val-
ues under the standard Vehicle condition.
▪ The traveling function uses an accelerator sensor and a brake sensor, which memorize voltages of these
sensors at full close, at full open, and at the operating point, and controls the functions based on the
memorized values. Also, the slope assist models are controlled based on the values from their incline
angle sensors. If servicing or a replacement that affects any of these sensors has been performed, a
"matching" operation is required to update the measurement of the sensor signal voltage values under
the standard Vehicle condition.
▪ For the tilt angle sensor, load sensor, and tire angle sensor used for the SAS function, the signal voltage
values under the mast vertical, no load, and tire straight condition, are stored, respectively, in the control-
ler for control based on these values together with the set mast type. Also, in vehicles with the height se-
lector specification and vehicles having a V mast, control is performed based on the value of the lifting
height sensor. If servicing or a replacement that affects any of these sensors has been performed, a
"matching" operation is required to update the measurement of the sensor signal voltage values under
the standard Vehicle condition. Also, matching is needed for the tilt angle sensor when the vehicle pos-
ture has changed excessively, and for the load sensor when the load under no load condition is changed
because of addition or removal of any attachment or a fork, mast replacement, fork length change and so
on.
▪ Each lever angle sensor used for the load handling lever has memorized signal voltage values in the
controller with each lever in the neutral position before shipment for control based on these memorized
values. If servicing or a replacement that affects any of these sensors has been performed, a "matching"
operation is required to update the measurement of the sensor signal voltage values under the standard
Vehicle condition.
▪ The load meter stores mast specification information and signal voltage values during no-load of the load
sensor in the multi-function display for indication based on them. Therefore, if servicing or part replace-
ment that affects mast or load sensors has been performed, a matching operation is required to update
the mast specification information and the measurement of the sensor signal level under the standard
vehicle condition.
▪ For a correct speedometer reading, the controller has to be supplied with a "tire constant", a value that
corresponds to the outside diameter of the tire. Whenever the tire size or type is changed, reset the tire
constant according to "Tire constant list".
▪ Load determination value, which is used to determine the load operating time of your telematics unit, is
stored on the display. When replacing the display or adjustment is required due to customer's load, set
the value.
Matching Items and Prerequisite for Implementation

1. DRIVE
Prerequisite for im- 2
plementation
Output value for the accelerator sensor when the accel-
1 ACCEL OFF *1, *2
erator pedal is at full close.
Output value for the accelerator sensor when the accel-
2 ACCEL ON *1, *2
erator pedal is at full open.
Output value for the brake sensor when the brake pedal
3 BRAKE OFF *1, *16
is at full close.
Output value for the brake sensor at the brake operating
4 BRAKE ACT *1, *16
point
Incline angle sensor output value in the vehicle hori-
5 SLOPE SENSOR *1, *20
zontal state
2. SAS
plementation
Tilt angle sensor output value at the fork horizontal posi-
1 TILT LEVEL *1, *3, *4, *7, *8, *9
tion
Tilt angle sensor output value in the mast vertical stand- *1, *3, *4, *5, *7, *8,
2 TILT FWD LIMIT
ard state, and load sensor output value at no load *9
Tire angle sensor output value at vehicle straight travel-
3 TIRE POSITION *1, *6
ing
4 MAST TYPE Installed mast type *8, *14
Output value for the fork height sensor when the fork is
5 HEIGHT SENSOR *1, *8, *18
fully lowered
3. LEVER
plementation
Lift lever angle sensor output value at the lift lever neut-
1 LEVER 1 *1, *10
ral position
Tilt lever angle sensor output value at the tilt lever neut-
2 LEVER 2 *1, *11
ral position
Attachment 1 lever angle sensor output value at the at-
3 LEVER 3 *1, *12
tachment 1 lever neutral position
Attachment 2 lever angle sensor output value at the at-
4 LEVER 4 *1, *13
tachment 2 lever neutral position
4. OCV
plementation
A01 Control valve A01 starting current level *1, *17
1
B01 Control valve B01 starting current level *1, *17
2
5. LOAD METER (for models with the multi-function display DX (OPT) only)
plementation
Installed mast type
1 MAST TYPE V → SV → FSV → FV → FSW → FW → QFV → - *8, *14
(Not set)
2 CYL. SIZE 1 Cylinder bore *8, *14
3 CYL. SIZE 2 Cylinder bore *8, *14
4 ZERO SET 1 Zero point of load meter *5, *7, *8, *14
5 ZERO SET 2 Zero point of load meter *5, *7, *8, *14
For precision adjust-
6 COMPENSATION Load meter accuracy
ment
6. TIRE DATA
plementation
1 TIRE DATA Tire constant data *1, *15
7. D-REC(Vehicles with telematics unit (OPT) mounted only)
plementation
1 LOAD DETECT Load determination value *14, *19
Prerequisite content for implementation

*1: When changing the main controller
*2: When removing or installing, or replacing the accelerator sensor
*3: When removing or installing, or replacing the tilt angle sensor
*4: When changing the length of the tilt angle sensor rod or replacing the tilt angle sensor rod
*5: When removing or installing, or replacing the load sensor
*6: When removing or installing, or replacing the tire angle sensor or the sensor cover.
*7: When installing or changing the fork or any attachment
*8: When removing or installing, or replacing the mast
*9: When removing or installing, or replacing the tilt cylinder
*10: When replacing the lift lever angle sensor
*11: When replacing the tilt lever angle sensor
*12: When replacing the attachment 1 lever angle sensor
*13: When replacing the attachment 2 lever angle sensor
*14: When replacing the multi-function display
*15: When changing the tire type or size
*16: When removing or installing, or replacing the brake sensor
*17: When replacing the oil control valve
*18: When removing or installing, or replacing the fork height sensor
*19: When adjustment is required due to customer's load
*20: When removing or installing, or replacing the incline angle sensor
Matching menu screen

Operating procedure
1. Enter the password on the normal screen to display the 2
service initial screen.
2. In the initial "SERVICE" menu screen, the [ANL] tab is
displayed to indicate the "ANALYZER" menu screen.
Press switch (3) three times. The [MAT] tab is selected.
This is the "MATCHING" menu screen.
Press switch (2) to select the [OPT] tab and move to the
"OPTION SET" menu screen.
Press switch (3) to select the [LOG] tab and move to the
"BATTERY DATA LOG" menu screen.
NOTICE!
▪ The “LOAD METER” items are displayed only in
vehicles in which the multi-function DX (OPT) is
mounted.
▪ "D-REC" is displayed only for the models with
the telematics unit (OPT).
▪ "1. DRIVE"
Switch (3): To the [LOG] Other service function menu screen
Switch (4): To traveling matching screen
▪ "2. SAS"
Switch (4): To SAS matching screen
▪ "3. LEVER"
Switch (4): To lever matching screen
▪ "4. OCV"
Switch (4): To MATCHING OIL CONTROL VALVE screen
▪ "5. LOAD METER"
Switch (4): To load meter setting screen
▪ "6. TIRE DATA"

Switch (4): To tire constant setting screen
▪ "7. D-REC"
Switch (4): To load determination value setting screen
Matching "DRIVE"
Performs matching on traveling functions.
Operating procedure
1. Display the "MATCHING" menu screen.
2. Check that "DRIVE" is selected on the screen, and press
switch (4) (to confirm) to display the "ACCEL OFF"
screen.
3. Each time switch (4) is pressed, the next screen is dis-

played. With the "BRAKE ACT" or "SLOPE SENSOR"
screen displayed, press switch (4) to return to the
"MATCHING" menu screen.
NOTICE!
▪ In the MATCHING SET screen, values in bracket
( ) display currently stored value, and the values
Switch (4) outside bracket ( ) display current vehicle condi-
tion value.
▪ In the traveling matching screen, check that the
wrench light is blinking.
The blinking wrench light indicates that the
vehicle will not run during traveling matching
even if the accelerator lever is operated.
▪ When a matching operation is completed, "OK"
is shown on the display.
▪ You cannot move directly from each matching
screen to the screen of the other items.
Return to the "MATCHING" menu screen once,
then move to screen of each item.
▪ "ACCEL OFF"
Accelerator sensor full-close position matching
Switch (1): Press for two seconds or more to perform match-
ing
2
Switch (4): To the next matching screen
Performing accelerator sensor fully opened position match-
ing clears the stored value of accelerator sensor fully
opened position matching of each item.
Vehicle condition
▪ All parts related to the accelerator pedal should be
formally mounted.
▪ "ACCEL ON"
Accelerator sensor full-open position matching
ing
Vehicle condition
▪ All parts related to the accelerator pedal should be
formally mounted.
NOTICE!
For safety, make sure that the wrench indicator on
DISPLAY is flashing (twice blinks per a second) be-
fore the accelerator pedal is stepped on.
The flashing of the wrench indicator informs that the
mode of main controller is being shifted to the driv-
ing inhibition mode.
So this procedure can be done in condition that the
vehicle cannot be driven even with the accelerator
pedal fully stepped on.
▪ "BRAKE OFF"
Brake sensor full-close position matching
ing
Performing brake sensor fully opened position matching
clears the stored value of brake sensor starting position
matching of each item.
Vehicle condition
▪ All parts related to the brake pedal should be form-
ally mounted and be adjusted.
▪ The brake pedal should be fully released.
▪ "BRAKE ACT"
Brake sensor operating point matching
ing
Switch (4): To the next matching screen or "MATCHING"
menu screen
Vehicle condition
▪ All parts related to the brake pedal should be form-
ally mounted and be adjusted.
▪ The brake pedal should be stepped on perpendicu-
larly, and depress it from the upper surface of toe
board o the center of the brake pedal until becoming
104±5mm.
Start point of
the brake activation
104±5 mm
(4.09±0.20 in)
Toe board
▪ "SLOPE SENSOR"(Only when slope assist OPT selec-

ted)
Incline angle sensor horizontal matching
ing
Switch (4): To "MATCHING" menu screen
Vehicle condition
▪ This procedure should be done in condition that all
equipments including forks or attachment are moun-
ted as specified.
However, it is acceptable to do this procedure in con-
dition of no forks for the fork-less specification.
▪ Vehicle should be with no load on the level ground.
▪ Forks or attachments should be lowered less than
500 mm (20 in.), but should not be on the ground.
▪ The vehicle should be in stationary state.
Matching "SAS"
Performs matching on SAS functions.
2. Use switch (1) to select "SAS" on the screen, and press
switch (4) (to confirm) to display the TILT LEVEL (tilt ho-
rizontal angle matching) screen.

played. With the "MAST TYPE" or "HEIGHT SENSOR"
screen displayed, press switch (4) to return to the
NOTICE!
▪ In the MATCHING set screen, values in bracket ( )
display currently stored value, and the values
outside bracket ( ) display current vehicle condi-
tion value.
▪ When a matching operation is completed, "OK"
is shown on the display.
the "MATCHING" menu screen once, then move
▪ "TILT LEVEL""TILT FWD LIMIT"

ing
Vehicle condition
V mast FV · FSV mast
ted as specified.
dition of no forks only for the fork-less specification.
100 mm ▪ Vehicle should be with no load on the level ground.
(3.94 in)
500 mm ▪ V: The inner mast should be raised to a height of ap-
(19.7 in) proximately 250 mm (9.84 in) for the V mast.
G85714102_ FV, FSV: The rear lift cylinders should be raised to a
height of approximately 100 mm (3.94 in).
▪ The mast should be adjusted to the base position by

tilting only forward.
Tilt the mast backward enough and adjust again,
when the mast is tilted beyond the desired position.
▪ In special case that the execution of "the other pro-
cedure" is specified, the mast should be lifted to the
top and the hydraulic oil control valve should be re-
lieved.
Refer to MATCHING chapter for repair manual Vol.1.
G85714103_
▪ "TIRE POSITION"
ing
Vehicle condition
▪ The matching must be performed on a vehicle
equipped with a fork or attachment.
Only with the forkless specification, the matching can
be performed without a fork.
▪ The vehicle must be put in a no-load state on a hori-
zontal road.
▪ The fork (or attachment) must be lowered as much
as possible to check tire straight travel position
easier.
▪ The mast must be set in a roughly vertical position
(check visually).
▪ The tire must be set in the straight travel position.
Refer to MATCHING chapter for repair manual Vol.1.
50 mm
(2.0 in)
50 mm
(2.0 in)
5 m (16 ft)
G85714104_
▪ "MAST TYPE"
Mast type setting screen
Selects the type of installed masts.
Switch (2): Types change in the following order: V ← SV ←
FSV ← FV ← FSW ← FW ← QFV ← "-" (Not set)
Switch (3): Types change in the following order: V → SV →
FSV → FV → FSW → FW → QFV → "-" (Not set)
Switch (4): When V mast height selection specification,
moves to the next "MATCHING" screen When other mast
type, returns to the "MATCHING" menu screen
▪ "HEIGHT SENSOR"
ing
Switch (4): To the next matching screen 2
Vehicle condition
ted as specified.
▪ Truck should be with no load on the level ground.
▪ Set the mast approximately vertical, and forks or at-
tachments at height of the ground. (The visual obser-
vation is acceptable.)
▪ The truck should be in stationary state.
Matching "LEVER"
Performs matching on the load handling lever.
Operating procedure
2. Use switch (1) to select "LEVER" on the screen, and
press switch (4) (to confirm) to display the LEVER1 (lift
lever matching) screen.

played, and the displayed screen returns to the
NOTICE!
Switch (1) Switch (4) ▪ The displayed number of lever matching items
corresponds to the number of ways of the lever.
▪ In the MATCHING set screen, values in bracket ( )
display currently stored value, and the values
outside bracket ( ) display current vehicle condi-
tion value.
▪ After completion of the matching operation, [OK]
open each lever to the push and pull sides.
the "MATCHING" menu screen once, then move
Vehicle condition
▪ All the material handling levers should be at the
neutral positions.
▪ In case of models with Mini-lever or Joy-stick lever
spec., the battery hood should be closed, and the
armrest should be horizontal. (The visual observation
is acceptable.)
▪ "LEVER1"
ing
In the last LEVER matching screen, returns to the "MATCH-
ING" menu
▪ "LEVER2"
ing
ING" menu
▪ "LEVER3"
ing
ING" menu
▪ "LEVER4"
ing
ING" menu
Procedure of memorizing material handling lever potentiometer signals at the end position
1. Vehicle condition
Turn on the key switch after the memorizing material handling lever potentiometer signals at the neutral
position, Confirm the condition OPS is working (OPS indicator of the display turns on), or all the loading 2
piping is connected.
2. Memorizing method
Hold for 2 seconds or more each maximum operation of the forward / backward tilting in all levers, and
the main controller memorizes the maximum operation voltage.
Matching "OCV"
Used to set the oil control valve starting current level.
The starting current level is set according to the type of the mounted oil control valve before shipment from
the factory. However, if the oil control valve or the main controller is changed, the starting current should be
set again according to the value specified on or attached to the new oil control valve.
Operating procedure
2. After pressing switch (1) 3 times, checking that “4.
OCV” is displayed in the screen, and then pressing
switch (4) (deciding), the “MAT.OCV” screen is dis-
played.

time switch (4) is pressed, and it returns to the
Reference: I-Q Plate of current level on oil control valve

Refer to I-Q PLATE for FRONT MODULE chapter in re-
pair manual Vol.1.
“OCV A01 to OCV A04” Screen

Control valve starting current setting screen
OCV A01: Control valve A01 starting current level
Switch (1): Switching selection to next item
Switch (2): Reducing the starting current level
Switch (4): To “MAT.OCV B01” screen
“OCV B01 to OCV B04” Screen

Control valve starting current setting screen
OCV B01: Control valve B01 starting current level
Switch (2): Reducing the starting current level
Switch (4): To “MATCHING" menu screen
Matching "LOAD METER"

Sets the load meter.
Operating procedure
2. Use switch (1) to select "LOAD METER" on the screen,
and press switch (4) (to confirm) to display the "MAST
TYPE" screen.

played. With the "COMPENSATION" screen displayed,
press switch (4) to return to the "MATCHING" menu
screen.
▪ "MAST TYPE"
Selects the type of installed masts.
Switch (2): Types change in the following order: V ← SV ←
FSV ← FV ← FSW ← FW ← QFV ← "-" (Not set)
Switch (3): Types change in the following order: V → SV →
FSV → FV → FSW → FW → QFV → "-" (Not set)
Switch (4): To the next screen
When QFV, “-” (unspecified) is selected, returns to the

Switch (3)
▪ "CYL. SIZE", "CYL. SIZE 1"

Cylinder diameter No. 1 setting screen (low fork height)
Switch (2): Decrease the cylinder diameter No. 1 value
Switch (3): Increase the cylinder diameter No. 1 value
2
FSV, FV
▪ "CYL. SIZE 2"

FSV, FV Cylinder diameter No. 2 setting screen (high fork height)
Switch (2): Decrease the cylinder diameter No. 2 value
Switch (3): Increase the cylinder diameter No. 2 value
Cylinder Diameter List

Mast type Models Cylinder diameter No.1 Cylinder diameter No.2
1.5, 1.6 , 1.8 ton 45 -
V 2.0, 2.5 ton 50 -
3.0 ton 55 -
1.5, 1.6, 1.8 ton 70 45
FSV 2.0, 2.5 ton 75 50
3.0 ton 85 55
1.5, 1.6, 1.8 ton 70 32
FV 2.0, 2.5 ton 75 35
3.0 ton 85 40
▪ Lift cylinder bore (V), Front lift cylinder bore (FSV, FV)
▪ Rear lift cylinder bore (FSV), Piston rod outside diameter of rear lift cylinder (FV)
▪ "ZERO SET", "ZERO SET1"

Load meter zero point matching screen (low fork height)
Performing matching operation (pressing switch (1) for two
seconds or more) displays the result.
OK: Matching completed
NG: When signal voltage is outside the matching range, or
when the mast is at high fork height
When NG is indicated, check the vehicle and mast condi-
tions, load sensor errors, and disconnection and short circuit
of the harness.
ing
FSV, FV Switch (4): To the next screen
Vehicle condition
ted as specified.
▪ Set the mast approximately vertical, and lift up forks
or attachments at height of approximately 500 mm
(19.69 in) from the ground. (The visual observation is
acceptable.)
NOTICE!
Set the above height for all type of the mast (V,
FV, FSV).
▪ "ZERO SET2"
FSV, FV, FSW, FW Load meter zero point matching screen (high fork height)
Performing matching operation (pressing switch (1) for two
seconds or more) displays the result.
OK: Matching completed
NG: When signal voltage is outside the matching range, or
when the mast is at low fork height
When NG is indicated, check the vehicle and mast condi-
tions, load sensor errors, and disconnection and short circuit
of the harness.
ing
Vehicle condition
ted as specified.
▪ Set the mast approximately vertical, and raise the
rear lift cylinders to a height of approximately 100mm
(3.94 in). (The visual observation is acceptable.)
NOTICE!
Set the above height only for FV and FSV mast.
▪ "COMPENSATION"
V, SV
FSV, FV, FSW, FW Load meter correction setting screen
This function corrects values indicated on the display ac-
cording to actual live load. When performing correction, take
2
on loading object (object with its accurate weight is known),
then while lifting the fork for approx. 1 m, adjust the value in-
dicated on the top right hand corner of the screen to the
laden weight by operating the switch.
Switch (2): Minus correction
Switch (3): Plus correction

Switch (3)
Matching "TIRE DATA"

Sets the tire constant.
Whenever the tire size or type is changed, reset the tire constant according to "Tire constant list".
Operating procedure
2. Use switch (1) to select "TIRE DATA" on the screen,
and press switch (4) (to confirm) to display the "TIRE
DATA" screen.
3. Press switch (4) again to return to the "MATCHING"

menu screen.
▪ "TIRE DATA"
Tire constant setting screen
Switch (2): Decrease the tire constant
Switch (3): Increase the tire constant
Tire constant list

1 ton models
Applicable models
Tire size Tire type
1.5 ton 1.6 ton 1.8 ton
STD (J-Lug) tire 271 - -
6.00-9-10PR
Rib-Lug tire 271 - -
STD (J-Lug) tire - 299 299
Rib-Lug tire - 299 299
6.50-10-10PR
J-Lug, Oversize tire 299 - -
Rib-Lug, Oversize tire 299 - -
21×8-9-14PR Side-ring (J-Lug) tire 273 273 273
21×8-9-10PR Rib-Lug, Side-ring tire 267 267 267
J-Lug, Non-Punc tire 276 276 -
6.00-9 U-Lug, Non-Punc tire 276 276 -
Non-marking tire 276 276 -
J-Lug, Non-Punc tire - - 306
U-Lug, Non-Punc tire - - 306
Non-marking tire - - 306
6.50-10
J-Lug, Non-Punc, Oversize tire 306 306 -
U-Lug, Non-Punc, Oversize tire 306 306 -
Non-marking, Oversize tire 306 306 -
J-Lug, Non-Punc, Side-ring tire 272 272 272
21×8-9 U-Lug, Non-Punc, Side-ring tire 272 272 272
Non-marking, Side-ring tire 272 272 272
2 ton models
Applicable models
Tire size Tire type
2.0 ton 2.5 ton
STD (J-Lug) tire 270 270
21×8-9-14PR
Rib-Lug tire 270 270
J-Lug, Non-Punc tire 272 272
21×8-9 U-Lug, Non-Punc tire 272 272
Non-marking tire 272 272
J-Lug, Non-Punc, Side-ring tire 309 309
23×9-10
U-Lug, Non-Punc, Side-ring tire 309 309
3 ton model
Applicable models
Tire size Tire type
3.0 ton
STD (J-Lug) tire 369
28×9-15-14PR
Rib-Lug tire 369
J-Lug, Non-Punc tire 368
28×9-15 U-Lug, Non-Punc tire 368
Non-marking tire 368
Matching "D-REC"
Only for telematics ready type (with the telematics unit) (OPT) and telematics installed model (OPT)
Sets the load determination value used for the load operating time of the telematics unit. 2
It has been set to 0.3 t as an initial value. Perform setting when adjustment is required for customer's load.
Operating procedure
2. Use switch (1) to select "D-REC" on the screen, and
press switch (4) (to confirm) to display the "LOAD
DETECT" screen.
3. Press switch (4) again to return to the "MATCHING"

menu screen.
▪ "LOAD DETECT"
Load determination value setting screen
Switch (2): Decrease the load determination value
Switch (3): Increases the load determination value
2.2.1.7 BATTERY DATA LOG
Overview
The battery data log function records battery operation and charge information.
Such information allows you to grasp the customer's usage status of the vehicle. Recorded information can
be read in the manager function or the service function of the multi-function display.
NOTICE
• Battery data log information in the manager functions can also be checked in the service functions.
• Records the following data for the entire month, up to one year. In addition, data can be displayed in a
value, graph, and QR code.
Screen Data Content

Average battery fluid temperature
Displays the average battery temperat-
and maximum battery fluid temper-
ure and maximum battery temperature
ature
for the entire month.
(JIS battery (OPT))
Integrated time of exceeding a fixed
Displays the integrated time in which
value of battery temperature
the battery is overheated for the entire
Service function (JIS battery (OPT) and battery pro-
month.
tection function (OPT))
Displays the battery discharge amount
Battery discharge amount
Displays the number of charges by the
Number of charges (on-vehicle
on-vehicle charger for the entire
charger (OPT))
month.
Displays the number of days when
Number of operating days traveling or load handling with Key ON
Displays the Key ON time for the en-
Key ON time
tire month.
Manager function Displays the integrated time from
(can also be checked with the Battery fluid-level warning time
when the battery is out of fluid to when
service function) (JIS battery (OPT))
the issue is fixed for the entire month.
Displays the battery level when start-
ing charging by the on-vehicle charger
Battery level when starting charging
for the entire month in frequency distri-
and minimum battery level *1
bution and the minimum battery level
recorded for the entire month.
*1: In vehicles in which an on-vehicle charger (OPT) is not mounted, only the lowest battery capacity is dis-
played
Battery data log menu screen

Operating procedure
1. Enter the password on the normal screen to display 2
screen.
On this screen, press switch (3) for four times. A
screen with the [LOG] tab selected is the "BATTERY
DATA LOG" menu screen.
Press switch (2) to select the [MAT] tab and move to
the "MATCHING" menu screen. Press switch (3) to
Switch (2) Switch (3) select the [etc] tab and move to the Other service
function menu screen.
NOTICE!
▪ The “BATT TEMP” and “BATT OVERHEAT”
items are displayed only when JIS battery
(OPT) is selected.
▪ Only when the on-vehicle charger(OPT) is se-
lected, "CHARGE TIMES" is displayed.
▪ "1. BATT TEMP"
Switch (2): To the [MAT] MATCHING menu screen
Switch (3): To the [etc] Other service function menu screen
Switch (4): To the average battery fluid temperature and
maximum battery fluid temperature screen
▪ "2. BATT TEMP QR"
Switch (4): To the average battery fluid temperature and
maximum battery fluid temperature QR code display screen
▪ "3. BATT OVRHEAT"
Switch (4): To the integrated time of exceeding a fixed
value of battery temperature screen
▪ "4. BATT OVRHEAT QR"
Switch (4): To the integrated time of exceeding a fixed
value of battery temperature QR code display screen
▪ "5. DISCHARGE"
Switch (4): To the battery discharge amount screen
▪ "6. DISCHARGE QR"
Switch (4): To the battery discharge amount QR code dis-
play screen
▪ "7. CHARGE TIMES"

Switch (4): To the number of charges screen
▪ "8. CHARGE TIMES QR"
Switch (4): To the number of charges QR code display
screen
▪ "9. DATA LOG /ADMIN"
Switch (4): To the battery data log screen of the manager
setting menu
Average battery fluid temperature and maximum battery fluid temperature "BATT
TEMP"
(JIS battery (OPT))
2
Average battery fluid temperature
Displays the average battery fluid temperature for the entire month.
If the battery temperature is constantly high, check the customer's usage status of the battery. The temperat-
ure can be affected by seasonal factors, but there is still a chance that the battery charging method or cool-
ing time is not appropriate.
Maximum battery fluid temperature
Displays the highest battery fluid temperature for the entire month.
Operating procedure
1. Display the "BATTERY DATA LOG" menu screen.
2. Check that "BATT TEMP" is selected on the screen

and press switch (4) (to confirm) to display the "BATT
TEMP" screen.
Switch (4)
▪ "BATT TEMP 1/4"

Displays the average and maximum battery fluid temperat-
ures from this month to five months ago in values.
Switch (4): To the "BATT TEMP 2/4" screen
▪ "BATT TEMP 2/4"

ures from six months ago to 11 months ago in values.
▪ "BATT TEMP 3/4"

ures from this month to five months ago in bar graphs.
▪ "BATT TEMP 4/4"

ures from six months ago to 11 months ago in bar graphs.
Switch (4): To the "BATTERY DATA LOG" menu screen
NOTICE!
▪ The data for the past 12 months at the maximum are
displayed, handling the duration from 0:00 on the first
of the current month to 24:00 on the last day of the
month as one month.
▪ If the temperature is below zero, a bar graph is not dis-
played.
Average battery fluid temperature and maximum battery fluid temperature QR code
display "BATT TEMP QR"
(JIS battery (OPT))
2
Displays the average battery fluid temperature and the maximum battery fluid temperature in QR code.
If data is displayed in two QR codes and a reader supports coupling mode, when all QR codes are read, di-
vided data will be automatically coupled.
Operating procedure
2. Use switch (1) to select "BATT TEMP QR" on the
screen and press switch (4) (to confirm) to display the
"BATT TEMP QR" screen.
▪ "BATT TEMP QR 1/2"

Displays the first QR code of the average and maximum
battery fluid temperatures.
Switch (4): To the "BATT TEMP QR 2/2" screen
▪ "BATT TEMP QR 2/2"

Displays the second QR code of the average and max-
imum battery fluid temperatures.
NOTICE!
displayed in QR code, handling the duration from 0:00
on the first of the current month to 24:00 on the last
day of the month as one month.
▪ Be sure to read QR codes in the order of first and
second. If you move to the next page without reading
the codes, return to the "BATTERY DATA LOG" menu
screen and read them in the correct order.
▪ If you move to the next page before the QR code is dis-
played, the next QR code is not displayed. Wait for the
QR code to be displayed and go to the next page.
Integrated time of exceeding a fixed value of battery temperature "BATT OVRHEAT"

(JIS battery (OPT) and battery protection function (OPT))
Displays the total integrated time in which the battery is overheated for the entire month. 2
It is the integrated time in which vehicle performance is limited due to fluid temperature overheat when the
battery protecting function (OPT) is installed.
To adjust the battery overheat temperature, you can use the tuning No.34.
The tuning No. 34 temperature has been set to approx. 60 ℃ by default.
If the battery temperature is constantly high, check the customer's usage status of the battery. The temperat-
ure can be affected by seasonal factors, but there is still a chance that the battery charging method or cool-
ing time is not appropriate.
Operating procedure
2. Use switch (1) to select "BATT OVRHEAT" on the
"BATT OVRHEAT" screen.
▪ "BATT OVRHEAT 1/3"

Displays the integrated time of exceeding a fixed value of
battery temperature from this month to five months ago in
values.
Switch (4): To the "BATT OVRHEAT 2/3" screen

battery temperature from six months ago to 11 months ago
in values.
Switch (4): To the "BATT OVRHEAT 3/3" screen

battery temperature from this month to 11 months ago in
bar graphs.
NOTICE!
month as one month.
Integrated time of exceeding a fixed value of battery temperature QR code display

"BATT OVRHEAT QR"
(JIS battery (OPT) and battery protection function (OPT))
2
Displays the integrated time of exceeding a fixed value of battery temperature in QR code.
Operating procedure
2. Use switch (1) to select "BATT OVRHEAT QR" on
the screen and press switch (4) (to confirm) to display
the "BATT OVRHEAT QR" screen.
▪ "BATT OVRHEAT QR 1/2"

Displays the first QR code of the integrated time of exceed-
ing a fixed value of battery temperature.
Switch (4): To the "BATT OVRHEAT QR 2/2" screen
▪ "BATT OVRHEAT QR 2/2"

Displays the second QR code of the integrated time of ex-
ceeding a fixed value of battery temperature.
NOTICE!
Battery discharge amount "DISCHARGE"

Displays the total battery discharge amount for the entire month.
You can calculate an "average discharge amount per day" from the battery discharge amount and the num-
ber of operating days.
By comparing the average discharge amount per day with the battery capacity, you can check if the appro-
priate battery capacity is configured for the customer's operation.
Operating procedure
2. Use switch (1) to select "DISCHARGE" on the screen
and press switch (4) (to confirm) to display the "DIS-
CHARGE" screen.

▪ "DISCHARGE 1/3"
Displays the battery discharge amount from this month to
five months ago in values.
2
Switch (4): To the "DISCHARGE 2/3" screen
▪ "DISCHARGE 2/3"
Displays the battery discharge amount from six months ago
to 11 months ago in values.
Switch (4): To the "DISCHARGE 3/3" screen
▪ "DISCHARGE 3/3"
Displays the battery discharge amount from this month to
11 months ago in bar graphs.
NOTICE!
month as one month.
Battery discharge amount QR code display "DISCHARGE QR"

Displays the battery discharge amount in QR code.
Operating procedure
2. Use switch (1) to select "DISCHARGE QR" on the
"DISCHARGE QR" screen.
▪ "DISCHARGE QR 1/2"
Displays the first QR code of the battery discharge amount.
Switch (4): To the "DISCHARGE QR 2/2" screen
▪ "DISCHARGE QR 2/2"
Displays the second QR code of the battery discharge
amount.
2
NOTICE!
Number of charges "CHARGE TIMES"

(On-vehicle charger (OPT))
Displays the number of charges by the on-vehicle charger for the entire month.
You can calculate an "average number of charges per day" from the number of charges and the number of
operating days.
If the number of charges per day is high, check the battery level when starting charging as well.
Operating procedure
2. Use switch (1) to select "CHARGE TIMES" on the
"CHARGE TIMES" screen.

▪ "CHARGE TIMES 1/3"

Displays the number of charges from this month to five
months ago in values.
Switch (4): To the "CHARGE TIMES 2/3" screen

Displays the number of charges from six months ago to 11
Switch (4): To the "CHARGE TIMES 3/3" screen

Displays the number of charges from this month to 11
months ago in bar graphs.
NOTICE!
month as one month.
Number of charges QR code display "CHARGE TIMES QR"

Displays the number of charges in QR code. 2
Operating procedure
2. Use switch (1) to select "CHARGE TIMES QR" on the
"CHARGE TIMES QR" screen.
▪ "CHARGE TIMES QR 1/2"

Displays the first QR code of the number of charges.
Switch (4): To the "CHARGE TIMES QR 2/2" screen
▪ "CHARGE TIMES QR 2/2"

Displays the second QR code of the number of charges.
NOTICE!
Manager function common battery data log menu "DATA LOG/ADMIN"

Battery data log information in the manager functions can also be checked in the service functions.
Operating procedure
2. Use switch (1) to select "DATA LOG/ADMIN" and
press switch (4) (to confirm) to display the battery
data log menu common to the manager function
menu.
Press switch (2) or (3) to select the [Return] tab and
move to a screen to return to "BATTERY DATA LOG"
menu of the service function.

▪ "OPERATION"
Switch (2): To the [Return] End menu screen
Switch (3): To the [Return] End menu screen 2
Switch (4): To the number of operating days screen
▪ "OPERATION QR"
Switch (4): To the number of operating days QR code dis-
play screen
▪ "KEY ON"
Switch (4): To the Key ON time screen
▪ "KEY ON QR"
Switch (4): To the Key ON time QR code display screen
▪ "BATT LVL ALM"
Switch (4): To the battery fluid-level warning time screen
▪ "BATT LVL ALM QR"
Switch (4): To the battery fluid-level warning time QR code
display screen
▪ "CHG STRT CAP"
Switch (4): To the battery level when starting charging and
minimum battery level screen
▪ "CHG STRT CAP QR"
Switch (4): To the battery level when starting charging and
minimum battery level QR code display screen
Number of operating days "DATA LOG/ADMIN" "OPERATION"

Displays the number of days when traveling or load handling with Key ON for the entire month.
Operating procedure
data log menu of the manager function menu.
3. Use switch (1) to select "OPERATION" and press

switch (4) (to confirm) to display the number of oper-
ating days of the manager function.
NOTICE!
▪ The same data as "OPERATION" in the battery
data log of the manager function is displayed.
▪ "OPERATION 1/3"
Displays the number of operating days from this month to
five months ago in values.
Switch (4): To the "OPERATION 2/3" screen
▪ "OPERATION 2/3"
Displays the number of operating days from six months ago
to 11 months ago in values.
2
Switch (4): To the "OPERATION 3/3" screen
▪ "OPERATION 3/3"
Displays the number of operating days from this month to
11 months ago in bar graphs.
NOTICE!
month as one month.
Number of operating days QR code display "DATA LOG/ADMIN" "OPERATION QR"

Displays the number of operating days in QR code.
Operating procedure
3. Use switch (1) to select "OPERATION QR" and press

switch (4) (to confirm) to display the number of oper-
ating days QR of the manager function.
NOTICE!
▪ The same data as "OPERATION QR" in the
battery data log of the manager function is
Switch (1) Switch (4) displayed.
▪ "OPERATION QR 1/2"
Displays the first QR code of the number of operating days.
Switch (4): To the "OPERATION QR 2/2" screen
▪ "OPERATION QR 2/2"
Displays the second QR code of the number of operating
days.
2
NOTICE!
month as one month.
Key ON time "DATA LOG/ADMIN" "KEY ON"

Displays the Key ON time for the entire month. You can grasp the trends throughout the year.
You can calculate an "average Key ON time per day" from the number of operating days and Key ON time.
In addition, you can calculate a "rate of operations" from the average Key ON time per day and the operating
hours.
Operating procedure
3. Use switch (1) to select "KEY ON" and press switch

(4) (to confirm) to display the Key ON time of the
manager function.
NOTICE!
▪ The same data as "KEY ON" in the battery
▪ "KEY ON 1/3"
Displays the Key ON time from this month to five months
ago in values.
Switch (4): To the "KEY ON 2/3" screen
▪ "KEY ON 2/3"
Displays the Key ON time from six months ago to 11
2
Switch (4): To the "KEY ON 3/3" screen
▪ "KEY ON 3/3"
Displays the Key ON time from this month to 11 months
ago in bar graphs.
NOTICE!
month as one month.
Key ON time QR code display "DATA LOG/ADMIN" "KEY ON QR"

Displays the Key ON time in QR code.
Operating procedure
3. Use switch (1) to select "KEY ON QR" and press

switch (4) (to confirm) to display the Key ON time QR
of the manager function.
NOTICE!
▪ The same data as "KEY QR" in the battery
▪ "KEY ON QR 1/2"
Displays the first QR code of the Key ON time.
Switch (4): To the "KEY ON QR 2/2" screen
▪ "KEY ON QR 2/2"
Displays the second QR code of the Key ON time.
2
NOTICE!
Fluid-level warning time "DATA LOG/ADMIN" "BATT LVL ALM"

(JIS battery (OPT))
Displays the total integrated time from detecting that the battery is out of fluid to fixing the issue for the entire
month.
The time in which battery is out of fluid is integrated even during Key OFF.
Operating procedure
3. Use switch (1) to select "BATT LVL ALM" and press

switch (4) (to confirm) to display the fluid-level warn-
ing time of the manager function.
NOTICE!
▪ The same data as "BATT LVL ALM" in the bat-
tery data log of the manager function is dis-
Switch (1) Switch (4) played.
▪ "BATT LVL ALM 1/3"

Displays the fluid-level warning time from this month to five
Switch (4): To the "BATT LVL ALM 2/3" screen

Displays the fluid-level warning time from six months ago to
11 months ago in values.
2
Switch (4): To the "BATT LVL ALM 3/3" screen

Displays the fluid-level warning time from this month to 11
months ago in bar graphs.
NOTICE!
month as one month.
Fluid-level warning time QR code display "DATA LOG/ADMIN" "BATT LVL ALM QR"
(JIS battery (OPT))
Displays the fluid-level warning time in QR code.
Operating procedure
3. Use switch (1) to select "BATT LVL ALM QR" and

press switch (4) (to confirm) to display the fluid-level
warning time QR of the manager function.
NOTICE!
▪ The same data as "BATT LVL ALM QR" in the
battery data log of the manager function is
Switch (1) Switch (4) displayed.
▪ "BATT LVL ALM QR 1/2"

Displays the first QR code of the fluid-level warning time.
Switch (4): To the "BATT LVL ALM QR 2/2" screen
▪ "BATT LVL ALM QR 2/2"

Displays the second QR code of the fluid-level warning
time.
2
NOTICE!
Battery level when starting charging and minimum battery level "DATA LOG/ADMIN"
"CHG STRT CAP"
Battery level when starting charging
Displays the battery level when starting charging by the on-vehicle charger for the entire month in frequency
distribution.
You can grasp the charge trends, like charge is frequent during deep discharge or auxiliary charge is fre-
quent.
Minimum battery level
Displays the minimum battery level recorded for the entire month.
Operating procedure
3. Use switch (1) to select "CHG STRT CAP" and press

switch (4) (to confirm) to display the battery level
when starting charging and minimum battery level of
the manager function.
NOTICE!
▪ The same data as "CHG STRT CAP" in the
Switch (1) Switch (4) battery data log of the manager function is
displayed.
▪ An off-vehicle charger does not record the
data.
▪ "CHG STRT CAP"

Displays the battery level when starting charging from this
month to 11 months ago in bar graphs in the order.
The minimum battery level is displayed at the right of the 2
screen.
Switch (4): To the screen of previous month
Pressing switch (4) on the screen of 11 months ago returns
to the "BATTERY DATA LOG" menu screen.
NOTICE!
month as one month.
Vertical axis: Battery level Minimum

when starting charging battery level
Horizontal axis: Number of charges

Battery level when starting charging and minimum battery level QR code display
"DATA LOG/ADMIN" "CHG STRT CAP QR"
Displays the battery level when starting charging and minimum battery level in QR code.
If data is displayed in five QR codes and a reader supports coupling mode, when all QR codes are read, di-
Operating procedure
3. Use switch (1) to select "CHG STRT CAP QR" and

level when starting charging QR of the manager func-
tion.
NOTICE!
▪ The same data as "CHG STRT CAP QR" in the
Switch (1) Switch (4) battery data log of the manager function is
displayed.
▪ "CHG STRT CAP QR 1/5"

Displays the first QR code of the battery level when starting
charging and minimum battery level.
Switch (4): To the "CHG STRT CAP QR 2/5" screen

Displays the second QR code of the battery level when
starting charging and minimum battery level.
2

Displays the third QR code of the battery level when start-
ing charging and minimum battery level.
Switch (4): To the CHG STRT CAP QR 4/5 screen

Displays the fourth QR code of the battery level when start-
ing charging and minimum battery level.

Displays the fifth QR code of the battery level when starting
charging and minimum battery level.
NOTICE!
▪ Be sure to read QR codes in the order of first, second,
and so forth. If you move to the next page without
reading the codes, return to the "BATTERY DATA
LOG" menu screen and read them in the correct order.
2.2.1.8 OTHERS MENU
NOTICE
After the hour meter start operation is completed, "METER START" and "DEMO MODE" are not dis-
played on the Other service function menu screen.
Other service function menu screen

Operating procedure
screen.
On this screen, press switch (3) for five times. A
screen with the [etc.] tab selected is the Other service
Press switch (2) to select the [LOG] tab and move to
the "BATTERY DATA LOG" menu screen.
Switch (2) Switch (3) Press switch (3) to select the [Return] tab and move
to the normal screen.
▪ "1. METER START"

Switch (2): To the [LOG] BATTERY DATA LOG menu
screen
Switch (4): To the meter start operation screen
▪ "2. DEMO MODE"
screen
Switch (4): To the demo mode setting screen
▪ "3. TO DEFAULT SET"
screen
Switch (4): To the default set screen
▪ "4. MASK PASSWORD"

screen 2
Switch (4): To the secondary service password setting
screen
▪ "5. MANAGER PASS CLR"
screen
Switch (4): To the secondary manager password deletion
screen
▪ "6. CHARGER CNT CLR"
screen
Switch (4): To the charger counter clear screen
▪ "7. QR-GROUP A"
screen
Switch (4): To the QR code continuous display screen A
▪ "8. QR-GROUP B"
screen
Switch (4): To the QR code continuous display screen B
▪ "9. BATT LOG CLR"
screen
Switch (4): To the battery data log clear screen
▪ "10. CONTRAST"
screen
Switch (4): To the contrast adjustment screen
Hour meter start "METER START"

Starts integrating the hour meters, odometer, trip meter, and maintenance hour meter.
In addition, it enables the following functions whether or not the demo mode is enabled or disabled.
▪ Enables load handling operation during traveling.
▪ Enables the parking brake off warning function.
▪ Enables to retrieve battery data log.
▪ Enables to retrieve watt-hour meter (OPT) data.
▪ Clears the detection record of the shock detection device (OPT) and enables the detection/alarm/record
functions.
▪ Enable all functions of the PIN code entry system (OPT).
NOTICE
• Battery data log and watt-hour meter data retrieved when the demo mode is enabled are not
cleared.
• Shock detection level and PIN code authentication data set when the demo mode is enabled are
not cleared.
Since all data start to be recorded when the hour meter is started, set the date and time of Multi-function Dis-
play before starting the hour meter.
Operating procedure
1. Display the Other service function menu screen.
2. Select "METER START" on the screen and press
switch (4) (to confirm) to display the "METER
START" screen.
NOTICE!
▪ The "METER START" and "DEMO MODE"
items in the Other service function menu
screen are not displayed after the hour meter
start operation.
▪ The H mode condition can be checked in the
hour meter start screen. The H mode lock
shows "NO".
Switch (4)
▪ "METER START"
3. Press switch (2) for two seconds or more to display
an additional right arrow on the screen.
2
4. While pressing switch (2), if you press switch (3), in-

verted "NO" on the screen turns to inverted "YES",
and the setting is completed.
5. Press switch (4) to return to Other service function

menu screen.
Hour meter NOTICE!

Key ON hour meter before the start ▪ When the hour meter start operation is com-
pleted, the hourglass on the Key ON hour
meter display flashes, showing that integra-
tion has started.
Key ON hour meter after the start

Prior to hour meter startup After hour meter startup

Demo mode "DEMO MODE"

Enables or disables the demo mode.
Before the hour meter start operation, the following functions can be enabled temporarily as "demo mode":
2
Demo mode YES (enabled) NO (disabled)
Load handling operation during traveling Allowed Not allowed
Parking brake off warning Enabled Disabled
Battery data log Enabled Disabled
Watt-hour meter (OPT) Enabled Disabled
Shock sensor (OPT) Detection/warning/record Enabled Disabled
Only registered au- Authentication is pos-
Authentication function thentication numbers sible by just pressing
PIN code entry system (OPT) can be authenticated the log-in switch
Register/change/reset au-
Enabled Disabled
thentication number
NOTICE
• Note that all settings and records during the demo mode remain even after the demo mode is dis-
abled.
• Since all data start to be recorded when the demo mode is enabled, set the date and time of the
multi-function display before enabling the demo mode.
Operating procedure
2. Use switch (1) to select "DEMO MODE" and press
switch (4) (to confirm) to display the "DEMO MODE"
screen.
NOTICE!
▪ The "METER START" and "DEMO MODE"
items in the Other service function menu
screen are not displayed after the hour meter
start operation.
▪ The H mode condition can be checked in the
hour meter start screen. The H mode lock
shows "NO".

▪ "DEMO MODE"
Switch (2): Change the demo mode setting to YES (en-
abled)
Switch (3): Change the demo mode setting to NO (dis-
abled)
Switch (4): To Other service function menu screen
NOTICE!
Display in the key ON hour meter
▪ While the demo mode is set, "DEMO" is dis-
screen during demo mode played on the Key ON hour meter screen.
Default set "TO DEFAULT SET"

Initializes setting items that have default values, such as tuning values.
Applicable setting items 2
▪ Menu lock
▪ Power select mode (ESPH)
▪ Traveling power control value, load handling power control value
▪ Traveling speed setting for low speed
▪ Maximum speed control setting
▪ Over speed alarm setting value
▪ Tuning value
▪ Auto Power Off Time
CAUTION
Data that depend on each vehicle, such as option set data, matching data, and tire fixed data, are not
applicable.
Operating procedure
2. Use switch (1) to select "TO DEFAULT SET" on the
"TO DEFAULT SET" screen.
Before hour meter start
After hour meter start

▪ "TO DEFAULT SET"

3. Press switch (2) to select YES.
4. Keep pressing switch (1) for two seconds or more to

execute the default set.
When the default set is executed, the progress status
is displayed in a bar. When the default set is com-
pleted, "OK" is displayed.
NOTICE!
▪ During the default set execution, do not per-
form Key OFF operation or remove the battery
plug.
▪ Except for during the default set execution,
press switch (4) to return to the Other service
Secondary service password "MASK PASSWORD"

Sets and deletes the secondary service password.
Using the four switches on the multi-function display, you can set any four-digit number as a secondary ser-
vice password. 2
When this is set, after entering a normal service password required to display the service function screen,
you are promoted for a secondary service password. Only when an input password matches, you can move
to the service function password.
A secondary service password is not set at the time of shipment.
NOTICE
• Set a secondary password only when necessary.
• If a secondary password is lost, the display must be replaced.
• To prevent loss of secondary password, which causes the service functions to be inaccessible,
manage the password at organization level (such as distributor or dealer).
• When the truck leaves your management, such as being sold, clear the secondary password.
Operating procedure
2. Use switch (1) to select "MASK PASSWORD" on the
"MASK PASSWORD" screen.

▪ "MASK PASSWORD" Delete secondary service password

When not even a single digit is entered on the secondary
service password setting screen, press switch (1) for two
seconds or more to delete the password. When it is com-
pleted, "OK" is displayed.
NOTICE!
▪ The secondary service password deletion op-
eration can be accepted only when not even a
single digit of the password is entered (all di-
gits are ■).
▪ "MASK PASSWORD" Set secondary service password

When all four digits are entered, "SET" is displayed at the
lower-left of the screen, allowing you to set the password.
On this screen, press switch (1) for two seconds or more to
set the password. When it is completed, "OK" is displayed.
NOTICE!
▪ The password is not set until all four digits
are typed.
▪ Press switch (4) for two seconds or more to
discard the ongoing input and return to Other
service function menu screen.
Secondary manager password deletion "MANAGER PASS CLR"

Deletes the secondary manager password.
When the customer requests, the secondary manager password can be deleted using the service function.
Operating procedure
2
2. Use switch (1) to select "MANAGER PASS CLR" on
the "MANAGER PASS CLR" screen.
▪ "MANAGER PASS CLR"

On this screen, press switch (1) for two seconds or more to
delete the password. When it is completed, "OK" is dis-
played.
Switch (1): Press for two seconds or more to perform pass-
word deletion
Switch (4): To the Other service function menu screen
Charger counter clear "CHARGER CNT CLR"

Clears the charger counter.
When the customer requests, the charger counter can be cleared using the service function.
Operating procedure
2. Use switch (1) to select "CHARGER CNT CLR" on
the "CHARGER CNT CLR" screen.

▪ "CHARGER CNT CLR"

Switch (1): Press for two seconds or more to clear the char-
ger counter
QR code continuous display group A "QR-GROUP A"

Continuously displays data, such as vehicle operation, charging status, and error detection information, in
QR code.
In Group A, the items are displayed in the following order:
▪ Diagnosis memory (service function)
▪ Number of operating days (manager function)
▪ Key ON time (manager function)
▪ Watt-hour meter (multi-meter)
▪ Battery discharge amount (service function)
Displaying QR codes continuously has minimized the movement between menus to the smallest possible ex-
tent.
NOTICE
• Be sure to read QR codes in the order of first, second, and so forth. If you move to the next page without
reading the codes, return to the Other service function menu screen and read them in the correct order.
• If you move to the next page before the QR code is displayed, the next QR code is not displayed.
Wait for the QR code to be displayed and go to the next page.
Operating procedure
2. Use switch (1) to select "QR-GROUP A" on the
"DIAG MEMORY QR 1/2" screen.

▪ "DIAG MEMORY QR" Diagnostic memory QR code

Displays the diagnosis (error code) and occurrence time
(key ON hour meter) of a stored error in QR code.
The same screen as "DIAG MEMORY QR" in the analyzer
function is displayed.
Switch (4): Display the next QR code.
When pressed on the "DIAG MEMORY QR 2/2" screen,
the "OPERATION QR 1/2" screen is displayed.
NOTICE!
▪ "OPERATION QR" Number of operating days QR code
Displays the number of days when traveling or load hand-
ling with Key ON for the entire month for one year in QR
code.
The same screen as "OPERATION QR" in the battery data
log is displayed.
When pressed on the "OPERATION QR 2/2" screen, the
"KEY ON QR 1/2" screen is displayed.
▪ "KEY ON QR" Key ON time QR code

Displays the Key ON time for the entire month for one year
in QR code.
The same screen as "KEY ON QR" in the battery data log 2
is displayed.
When pressed on the "KEY ON QR 2/2" screen, the "CHG,
CO2 QR 1/5" screen is displayed.
▪ "CHG, CO2" Watt-hour meter (battery protecting function

(OPT)) QR code
Displays the integral power consumption for the entire
month/CO2 emission for the past three months and the
daily power consumption/CO2 emission for the past 30
days in QR code. In addition, displays the CO2 emission
coefficient in QR code.
The same screen as "CHG, CO2" in the watt-hour meter
QR screen displayed after the hour meters screen is dis-
played.
When pressed on the "CHG, CO2 5/5" screen, the "DIS-
CHARGE QR 1/2" screen is displayed.
▪ "DISCHARGE QR" Battery discharge amount QR code

Displays the total battery discharge amount for the entire
month for one year in QR code.
The same screen as "DISCHARGE QR" in the battery data
log is displayed.
When pressed on the "DISCHARGE QR 2/2" screen, the
Other service function menu screen returns.
QR code continuous display group B "QR-GROUP B"

Continuously displays data about the battery usage condition in QR code.
In Group B, the items are displayed in the following order:
▪ Battery fluid-level warning time (manager function)
▪ Integrated time of exceeding a fixed value of battery temperature (service function)
▪ Average battery fluid temperature and maximum battery fluid temperature (service function)
▪ Number of charges (service function)
▪ Battery level when starting charging and minimum battery level (manager function)
Displaying QR codes continuously has minimized the movement between menus to the smallest possible ex-
tent.
NOTICE
• Be sure to read QR codes in the order of first, second, and so forth. If you move to the next page without
reading the codes, return to the Other service function menu screen and read them in the correct order.
• If you move to the next page before the QR code is displayed, the next QR code is not displayed.
Wait for the QR code to be displayed and go to the next page.
Operating procedure
2. Use switch (1) to select "QR-GROUP B" on the
"BATT LVL ALM 1/2" screen.

▪ "BATT LVL ALM QR" Battery fluid-level warning time (JIS

battery (OPT)) QR code
Displays the integrated time from when the battery is out of
fluid to when the issue is fixed for the entire month for one 2
year in QR code.
The same screen as "BATT LVL ALM QR" in the battery
data log is displayed.
When pressed on the "BATT LVL ALM QR 2/2" screen, the
"OVERHEAT QR QR 1/2" screen is displayed.
▪ "OVRHEAT QR" Integrated time of exceeding a fixed
value of battery fluid temperature (JIS battery (OPT) and
battery protection function (OPT)) QR code
Displays the total integrated time in which the battery is
overheated for the entire month for one year in QR code.
The same screen as "BATT OVERHEAT QR" in the battery
When pressed on the "OVERHEAT QR 2/2" screen, the
"BATT TEMP QR 1/2" screen is displayed.
▪ "BATT TEMP QR" Average battery fluid temperature and
maximum battery fluid temperature (JIS battery (OPT)) QR
code
Displays the average battery fluid temperature and the
maximum battery fluid temperature for one year in QR
code.
The same screen as "BATT TEMP QR" in the battery data
log is displayed.
When pressed on the "BATT TEMP QR 2/2" screen, the
"CHARGE TIMES QR 1/2" screen is displayed.
▪ "CHARGE TIMES QR" Number of charges (on-vehicle
charger of 200 V, 3-phase (OPT)) QR code
Displays the number of charges by the on-vehicle charger
for the entire month for one year in QR code.
The same screen as "CHARGE TIMES QR" in the battery
When pressed on the "CHARGE TIMES QR 2/2" screen,
the "CHARGE STRT CAP QR 1/5" screen is displayed.
▪ "CHG STRT CAP QR" Battery level when starting charging

and minimum battery level QR code
Displays the battery level when starting charging by the on-
vehicle charger for the entire month in frequency distribu-
tion and the minimum battery level recorded for the entire
month for one year in QR code.
The same screen as "CHG STRT CAP QR" in the battery
When pressed on the "CHG STRT CAP QR 5/5" screen,
the Other service function menu screen returns.
Battery data log clear "BATT LOG CLR"

Clears battery data log for the service functions.
Recorded data can be reset (cleared) using the manager function to provide for possible change of owners 2
who use the forklift on a rental basis or on other occasions.
Operating procedure
2. Use switch (1) to select "BATT LOG CLR" on the
"BATT LOG CLR" screen.

▪ "BATT LOG CLR" Clear charger counter

Press switch (1) for two seconds or more to clear the bat-
tery data log.
Switch (1): Press for two seconds or more to clear the bat-
tery data log.
NOTICE!
The following battery data log items are cleared:
▪ Average battery fluid temperature and maximum
battery fluid temperature
▪ Integrated time of exceeding a fixed value of bat-
▪ Battery discharge amount
▪ Number of charges
The following data displayed on the manager function
are not cleared:
▪ Number of operating days
▪ Key ON time
▪ Battery fluid-level warning time
▪ Battery level when starting charging and min-
imum battery level
Be careful that data, once reset, cannot be restored.
Liquid crystal contrast adjustment "CONTRAST"

Adjusts the multi-function display liquid crystal contrast.
2. Use switch (1) to select "CONTRAST" on the screen
and press switch (4) (to confirm) to display the "CON-
TRAST" screen.
▪ "CONTRAST"
Switch (2): Decrease the contrast
Switch (3): Increase the contrast
Switch (4): To Other service function menu screen
3-274 3 ELECTRICAL SYSTEM TROUBLESHOOTING
3 ELECTRICAL SYSTEM TROUBLESHOOTING

3.1 BEFORE TROUBLESHOOTING........................................................... 274
3.2 TO USE SST ......................................................................................... 277
3.3 DIAGNOSIS CODE LIST....................................................................... 278
3.4 WHEN ERROR CODE IS DISPLAYED................................................. 291
3.5 NO ERROR CODE IS DISPLAYED ...................................................... 712
3.1 BEFORE TROUBLESHOOTING
3.1.1 Handling the Connectors

1. Before connecting or removing each connector or ter-
minal, always disconnect the battery plug.
2. To disconnect a connector, always release the con-
nector lock first and then hold the connector itself to
pull it out without pulling the harness.
To connect a connector, securely push it in until
locked in position.
3. To bring a tester probe into contact with a connector,

do so from the connector back side (harness side).
4. For connectors where a tester probe cannot be inser-
ted from the back side, such as waterproof connect-
ors, carefully bring the tester probe into contact with
them so as not to deform the connector terminals.
5. Do not directly touch the connector terminals with
your hands.
6. When you touch terminals where voltage is applied
with tester probes, extreme care must be taken so
that two tester probes do not contact each other.
3 ELECTRICAL SYSTEM TROUBLESHOOTING 3-275
3.1.2 Inspection Procedure of the Wire Harness and Connectors

If a trouble occurs, firstly inspect the connectors and wire harness of a related electric circuit according to the
following procedure.
3
Continuity inspection
1. Disconnect the connectors at both ends of a corres-
ponding harness.
2. Measure the resistance between the corresponding
terminals of the connectors at both ends.
Standard: 10 Ω or less
NOTICE!
▪ Make the measurement while lightly shaking
the wire harness up and down, and right and
left.
▪ Disconnection rarely occurs at the center part
of the vehicle wiring. Disconnection occurs in
most cases at connector parts. In particular,
inspect the connectors of the sensor parts
with sufficient care.
Short-circuit inspection
ponding harness.
2. Measure the resistance between a corresponding ter-
minal of each connector and the frame. Always in-
spect the connectors on both sides.
Standard: 1 MΩ or more
NOTICE!
▪ Make the measurement while lightly shaking
the wire harness up and down, and right and
left.
3. Measure the resistance between the terminals in

each connector where each corresponding terminal is
provided. Always inspect the connectors on both
sides.
Standard: 1 MΩ or more
NOTICE!
▪ The wiring may be pinched by the body or
short-circuited due to a clamp failure.
Visual contact-pressure inspection

ponding harness.
2. Visually inspect each connector terminal for rust,
trapped foreign matter, etc.
3. Inspect each caulking for looseness or damage. Also,
lightly pull the wire harness out from each connector
to inspect that the harness cannot be removed.
4. Inspect the drawing force by inserting a male terminal

of the connector terminal prepared for inspection into
each female terminal. If the drawing force is smaller
than the other terminals, the contact may be defect-
ive.
NOTICE!
▪ If rust occurs, foreign matter is trapped, or the
contact pressure of the male and female ter-
minals decreases at a terminal part, removing
and then installing the connection connector
again may change the contact state to normal.
In the case, disconnect and connect the con-
nector several times. If any defect is ob-
served, a terminal contact failure may be the
cause.
3.2 TO USE SST

Use SSTs for quick, accurate electrical troubleshooting on the 8FBN series.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect con-
nection, careful operation is necessary. 3
No. SST name Remarks
-
09230-13240-71 Main controller check harness
(for power source check)
09230-13700-71 CN76 short harness 61-1, 2
C2-2
C4-1 to 6
C5-1 to 6
C8-1, 2
E2-2
CN7 IC check pin
SST2: E8-1, 2
Check harness
09232-13130-71 FB-1, 2
Each short harness
62-1, 2
67-5
71-1, 3
72-1 to 4
G5-1 to 6
SST8: CN97 harness
68-1 to 3
09238-13130-71 CN90 check harness
Harness for Motor Driver (for voltage
09240-13241-71 E8-1, 2
measurement)
To perform troubleshooting of models with Telematics (OPT), use TruckCom.

The following SSTs are used for TruckCom.
For details on how to use TruckCom, refer to the TruckCom instruction manual.
No. Name
09250-82110-71 Castor USB
09561-12640-71 PC-CAN cable
CAUTION
Always disconnect the battery plug before SST connection and disconnection.
If the battery plug is kept connected, various boards may be damaged.
3.3 DIAGNOSIS CODE LIST

Indication: Diagnosis code will be indicated on the display when vehicle trouble occurs.
Memory: Diagnosis code will be recorded on the main controller when vehicle trouble occurs. Use this
indicated diagnosis code that can be checked on the display when using the service function
DIAG MEMORY.
Indicator:
Spanner
Overheat warning (O/H)
Battery overheat warning (BT O/H)

UP LED on the charger operation panel (UP LED) ○

tion ry ECU
STD
Display:
- Drive motor driver main
Multi- A0-1 circuit temperature ab- Traveling stop page 291
ing driver
display:
DCR
STD
Display:
- Pump motor driver main
Multi- A0-2 circuit temperature ab- page 298
display:
PCR
Spanner Main con- Main controller high Traveling and load handling
A1-1 A1-1 page 300
blinking troller voltage stop Steering becomes stiff.
Spanner Drive motor Drive motor driver high
A1-2 A1-2 Traveling stop page 302
blinking driver voltage
Spanner Pump mo- Pump motor driver high Load handling stop. Steering
A1-4 A1-4 page 304
blinking tor driver voltage become stiff.
STD
Display:
- Main controller board
O/H light- Main con-
Multi- A2-1 temperature abnormal Traveling speed become slow page 306
ing troller
function rise
display:
C/R
STD
Display:
- Drive motor driver board
Multi- A2-2 temperature abnormal Traveling stop page 308
ing driver
function rise
display:
DCR

tion ry ECU
STD
Display:
- Pump motor driver 3
Multi- A2-3 board temperature ab- page 315
display:
PCR
Spanner Main con- Battery connection in- Traveling and load handling
A3-1 A3-1 page 317
blinking troller correct stop Steering becomes stiff.
Battery connection in-
Spanner Main con- Traveling and load handling
A3-2 A3-2 correct (Different page 319
blinking troller stop Steering becomes stiff.
voltage)
OPS function invalidity
Auto power-off function in-
Spanner Main con- Seat switch GND short
A5-1 A5-1 validity page 320
Parking brake off warning dis-
able.
A8-1 A8-1 page 322
A8-2 A8-2 page 325
F7 fuse/solenoid power
Spanner Main con-
A9-2 A9-2 line open circuit abnor- Load handling stop. page 329
blinking troller
mality
Main controller temper-
Spanner Main con- ature sensor open circuit
AA-1 AA-1 Traveling speed become slow page 333
blinking troller abnormality/VCC short
circuit abnormality
Drive motor driver board
temperature sensor Depression of maximum
Spanner Drive motor
AA-2 AA-2 open circuit abnormality/ speed page 334
blinking driver
VCC short circuit abnor- Speed-up become slow.
mality
Pump motor driver
board temperature
AA-4 AA-4 sensor open circuit ab- page 335
normality/VCC short cir-
cuit abnormality
AB-1 AB-1 Cooling fan overcurrent page 336
Cooling fan open/short
AB-2 AB-2 circuit abnormality (80 V page 340
vehicle)
Spanner Main con- Motor driver power sup- Traveling and load handling
AC-1 AC-1 page 343
blinking troller ply abnormality stop Steering becomes stiff.

tion ry ECU
AF-1 AF-1 page 358
AF-2 AF-2 page 358
AF-3 AF-3 page 358
AF-4 AF-4 page 358
AF-5 AF-5 page 358
AF-6 AF-6 page 358
AF-7 AF-7 page 358
AF-8 AF-8 page 358
Spanner Drive motor Drive motor driver main
C0-2 C0-2 Traveling stop page 359
blinking driver circuit abnormality
Spanner Drive motor
C1-1 C1-1 rent sensor neutral ab- Traveling stop page 362
blinking driver
normality
Spanner Drive motor
C1-2 C1-2 rent sensor overcurrent Traveling stop page 363
blinking driver
abnormality
STD
Display:
- Depression of maximum
O/H light- Main con- Drive motor temperature
Multi- C2-1 speed page 366
ing troller abnormal rise
function Speed-up become slow.
display:
DM
Drive motor temperature Depression of maximum
Spanner Drive motor
C2-2 C2-2 sensor open/short circuit speed page 368
blinking driver
abnormality Speed-up become slow.
Drive motor driver main
Spanner Drive motor circuit temperature
blinking driver sensor open/short circuit
abnormality
Accelerator poten-
normality
Accelerator poten-
normality
Accelerator poten-
Accelerator poten-

tion ry ECU
Accelerator poten-
Spanner Main con-
C4-5 C4-5 tiometer offset abnor- Traveling stop page 379
blinking troller
mality 3
Accelerator poten- Accelerator play increases
Spanner Main con-
C4-6 C4-6 tiometer matching value and maximum speed is lim- page 382
blinking troller
abnormality ited.
Brake potentiometer
normality
Brake potentiometer
normality
Brake potentiometer
abnormality
Brake potentiometer
abnormality
Spanner Main con- Brake potentiometer off-
blinking troller set abnormality
Brake potentiometer
Spanner Main con-
C5-6 C5-6 matching value abnor- Traveling stop page 396
blinking troller
mality
Drive motor speed
Spanner Drive motor
C8-1 C8-1 sensor open circuit ab- Traveling stop page 398
blinking driver
normality
Drive motor speed
Spanner Drive motor
C8-2 C8-2 sensor short circuit ab- Traveling stop page 402
blinking driver
normality
Inclination angle sensor
Spanner Main con-
C9-3 C9-3 matching value abnor- Slope assist function disable page 410
blinking troller
mality
Spanner Main con- MB contactor open cir- Traveling and load handling
CB-1 CB-1 page 412
Spanner Main con- MB contactor short cir- Display error code but able to
CB-2 CB-2 page 417
blinking troller cuit abnormality operate correctly.
Spanner Main con- MB contactor coil open Traveling and load handling
CB-3 CB-3 page 420
Spanner Main con- MB contactor drive cir- Traveling and load handling
CB-4 CB-4 page 423
Spanner Main con- MB contactor coil short Traveling and load handling
CB-5 CB-5 page 426

tion ry ECU
Spanner Drive motorDrive motor driver CPU Display error code but able to
CC-6 CC-6 page 429
blinking driver abnormality operate correctly.
Spanner Pump mo- Pump motor driver main Load handling stop. Steering
E0-2 E0-2 page 430
blinking tor driver circuit abnormality become stiff.
E1-1 E1-1 rent sensor neutral ab- page 433
normality
E1-2 E1-2 rent sensor overcurrent page 434
abnormality
STD
Display:
-
O/H light- Main con- Pump motor temperat- Load handling speed is lim-
Multi- E2-1 page 437
ing troller ure abnormal rise ited.
function
display:
PM
Pump motor temperat-
E2-2 E2-2 ure sensor open/short page 439
circuit abnormality
Pump motor driver main
Spanner Pump mo- circuit temperature Load handling speed is lim-
E3-1 E3-1 page 441
blinking tor driver sensor open/short circuit ited.
abnormality
Pump motor speed
E8-1 E8-1 sensor open circuit ab- page 442
normality
Pump motor speed
E8-2 E8-2 sensor short circuit ab- page 445
normality
EC-1 EC-1 page 448
EC-2 EC-2 page 448
EC-3 EC-3 page 448
EC-4 EC-4 page 448
Spanner Pump mo- Pump motor driver CPU Display error code but able to
EC-6 EC-6 page 448
Spanner Main con- CAN bridge communica-
blinking troller tion disruption
CAN bridge controller/
Spanner CAN bridge Data Handling Unit
blinking controller (DHU2) communication
disruption
normality
normality
blinking able.
normality

tion ry ECU
blinking able.
normality 3
blinking ity
blinking ity
blinking ity
F4-4 F4-4 Display Display only page 461
blinking ity
F4-5 F4-5 Display Display function not stable page 461
blinking ity
blinking ity stable
blinking ity stable
blinking ity stable
Battery fluid-level/Bat-
Spanner abled
tion harness open circuit
tially disable
abnormality
Battery fluid-level/Bat-
Spanner abled
tion harness short circuit
tially disable
abnormality
Spanner abled
F5-3 F5-3 Display sensor open circuit ab- page 469
normality
tially disable
Spanner abled
F5-4 F5-4 Display sensor temperature ab- page 471
normality
tially disable
UP LED
blinking On-vehicle charger char-
F6-1 F6-1 Display ging abnormality (safety Charging stop page 473
Spanner timer activated)
blinking
UP LED On-vehicle charger
blinking transformer overheating
F6-2 F6-2 Display Charging stop page 478
Spanner abnormality (charge can
blinking not start)
Spanner On-vehicle charger start Unable to charge (charge can
blinking abnormality not start)

tion ry ECU
UP LED
blinking On-vehicle charging Not finish charging (charge
Spanner completion abnormality can not complete)
blinking
Electrical power quantity sur-
vey function disable
Battery current sensor
Spanner Main con- Battery data log function partly
FB-1 FB-1 neutral voltage abnor- page 495
blinking troller disable
mality
Watt-hour meter disable
Battery data log function partly
Spanner Main con- Battery current sensor
FB-2 FB-2 disable page 498
blinking troller over current abnormality
Depression of traveling per-
BT O/H Main con- Battery fluid temperature
- FC-1 formance page 501
lighting troller overheat
Spanner Main con- Display power supply
FF-1 FF-1 Display lights off page 503
blinking troller circuit overcurrent
Steering sensor power
Spanner Main con- Steering become stiff
FF-2 FF-2 supply circuit overcur- page 504
rent
Spanner Drive motor Drive motor driver ID ab- Display error code but able to
32-1 32-1 page 506
blinking driver normality operate correctly.
Spanner Pump mo- Pump motor driver ID Display error code but able to
32-3 32-3 page 507
Main controller to Drive
Spanner Drive motor
33-1 33-1 motor driver CAN com- Traveling stop page 508
blinking driver
Main controller to Pump
33-3 33-3 motor driver CAN com- page 510
trol function.
Spanner Main con- Load sensor open circuit
trol function.
trol function.
Spanner Main con- Load sensor short circuit
trol function.
Spanner Main con- Tilt angle sensor open Partial limitation of mast con-
62-1 62-1 page 516

tion ry ECU
Spanner Main con- Tilt angle sensor short Partial limitation of mast con-
62-2 62-2 page 518
Spanner Main con- Lift lock solenoid open 3
Spanner Main con- Lift lock solenoid short
Spanner Main con- Lift lock solenoid drive
Spanner Main con- Lift lock solenoid short/
65-3 65-3 Mast may not tilt forward. page 532
blinking troller drive circuit abnormality
Tilt control solenoid
Spanner Main con-
65-4 65-4 open/short circuit abnor- Mast may not tilt forward. page 534
blinking troller
mality
Abnormal matching
Spanner Main con- Partial limitation of mast con-
66-1 66-1 value of tilt and load page 536
blinking troller trol function
sensor
trol function.
Lifting height switch Partial limitation of auto speed
Spanner Main con-
67-1 67-1 short/open circuit abnor- control function. page 537
blinking troller
mality Partial limitation of height and
trol function.
Lift height 800 mm
Spanner Main con-
67-5 67-5 switch short circuit ab- Traveling speed become slow page 541
blinking troller
normality
active setting.
Spanner Main con- Height reel sensor open (For V mast only)
68-1 68-1 page 543
trol function.
control function.
trol function.

tion ry ECU
active setting.
Spanner Main con- Height reel sensor short (For V mast only)
68-2 68-2 page 545
trol function.
control function.
trol function.
active setting.
Spanner Main con- Height reel sensor (For V mast only)
68-3 68-3 page 547
blinking troller timeout abnormality Partial limitation of mast con-
trol function.
control function.
trol function.
(For V mast only)
Height reel sensor
Spanner Main control function.
68-4 68-4 lowermost position ab- page 549
blinking troller Partial limitation of traveling
normality
control function.
trol function.
(For V mast only)
Spanner Main con- Height reel sensor trol function.
68-5 68-5 page 552
blinking troller matching abnormality Partial limitation of traveling
control function.
trol function.
Spanner Main con- Tire angle sensor open tion stops working.
71-1 71-1 page 553
control function.
Spanner Main con- Tire angle sensor short tion stops working.
71-2 71-2 page 555
control function.

tion ry ECU
Spanner Main con- Tire angle sensor an- tion stops working.
71-3 71-3 page 557
blinking troller choring abnormality Partial limitation of turn speed 3
control function.
Spanner Main con-
blinking troller
Spanner Main con-
blinking troller
Steering angle sensor
72-3 72-3 SSC open circuit abnor- page 568
mality
Spanner Main con-
72-4 72-4 power circuit open circuit tion stops working. page 572
blinking troller
abnormality Steering becomes stiff.
73-1 73-1 solenoid open circuit ab- page 574
normality
73-2 73-2 solenoid short circuit ab- page 577
normality
73-3 73-3 solenoid power circuit page 580
abnormality
73-4 73-4 solenoid open/short cir- page 582
cuit abnormality
Spanner Main con- Abnormal matching tion stops working.
74-1 74-1 page 584
blinking troller value for tire angle Partial limitation of turn speed
control function.
Lift lever potentiometer
Spanner Main con-
H1-3 H1-3 output deviation abnor- Lift lowering and upward stop page 602
blinking troller
mality

tion ry ECU
Abnormal matching
Spanner Main con-
H1-5 H1-5 value for lift lever poten- Lift lowering and upward stop page 606
blinking troller
tiometer
H2-1 H2-1 page 607
blinking troller open circuit abnormality stop
H2-2 H2-2 page 609
blinking troller short circuit abnormality stop
Tilt lever potentiometer
H2-3 H2-3 output deviation abnor- page 611
mality
Spanner Main con- Tilt lever potentiometer
Abnormal matching
H2-5 H2-5 value for tilt lever poten- page 615
tiometer
abnormality
abnormality
ation abnormality
Spanner Main con-
blinking troller
normality
Abnormal matching
lever potentiometer
abnormality
abnormality
ation abnormality
Spanner Main con-
blinking troller
normality
Abnormal matching
lever potentiometer
Spanner Main con-
H5-1 H5-1 open circuit abnormality Lift upward stop page 636
blinking troller
(lever pull side)
Spanner Main con-
H5-2 H5-2 short circuit abnormality Lift upward stop page 639
blinking troller
(lever pull side)
Spanner Main con-
H5-3 H5-3 open circuit abnormality Lift lowering stop page 642
blinking troller
(lever push side)

tion ry ECU
Spanner Main con-
H5-4 H5-4 short circuit abnormality Lift lowering stop page 645
blinking troller
(lever push side) 3
Spanner Main con-
blinking troller
ity
lever push side)
Spanner Main con-
H6-1 H6-1 open circuit abnormality Backward tilt stop page 653
blinking troller
(lever pull side)
Spanner Main con-
H6-2 H6-2 short circuit abnormality Backward tilt stop page 656
blinking troller
(lever pull side)
Spanner Main con-
H6-3 H6-3 open circuit abnormality Forward tilt stop page 659
blinking troller
(lever push side)
Spanner Main con-
H6-4 H6-4 short circuit abnormality Forward tilt stop page 662
blinking troller
(lever push side)
Spanner Main con-
blinking troller
ity
lever push side)
H7-1 H7-1 page 670
pull side)
H7-2 H7-2 page 673
pull side)
H7-3 H7-3 page 676
push side)
H7-4 H7-4 page 679
push side)
Spanner Main con-
blinking troller
circuit abnormality
Spanner Main con-
blinking troller
push side)
H8-1 H8-1 page 687
pull side)

tion ry ECU
H8-2 H8-2 page 690
pull side)
H8-3 H8-3 page 693
push side)
H8-4 H8-4 page 696
push side)
Spanner Main con-
blinking troller
circuit abnormality
Spanner Main con-
blinking troller
push side)
Spanner Main con- power supply RY1 con-
HB-1 HB-1 Load handling stop. page 705
blinking troller tact open circuit abnor-
mality
Spanner Main con-
HB-2 HB-2 power supply load short Load handling stop. page 707
blinking troller
circuit abnormality
Spanner Main con-
HB-3 HB-3 power supply RY1 over- Load handling stop. page 709
blinking troller
current abnormality
STD
Display:
-
Multi- O/H light- Drive motor Drive motor driver tem-
- speed page 711
function ing * driver perature low
display:
COLD
DCR
STD
Display:
-
Multi- O/H light- Pump mo- Pump motor driver tem-
- speed page 711
function ing * tor driver perature low
display:
COLD
PCR
*: Multi-function display shows only the each portion and doesn't indicate O/H light.
3.4 WHEN ERROR CODE IS DISPLAYED
Error Code: A0-1

3
Failure mode: Drive motor driver main circuit temperature abnormal
rise
CAUTION
• If AB-1, AB-2 is displayed at the same time, give a higher priority to troubleshooting AB-1, AB-2.
• Disconnect the battery plug and check that the power cable/motor cable connection is not loose.
• Do not leave the truck in places where it gets hot.
Probable cause
▪ Power cable/motor cable connection defect
▪ Connector connection defect
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
▪ Overheating (overload continuous use)
▪ Drive motor driver defect
▪ Main controller defect
▪ Fan power supply defect
Related part
48V
CN104-8 (98,FNDC) CN113-2
Main
Main Cooling
Cooling fan
fan 11
controller
CN104-3 (1,CBAT+) CN113-1
controller
Drive motor driver
Temperature-sensor
Temperature-sensor
80V
CN104-8 (98,FNDC) CN128-2
CN128-10
Main
Main CN104-3 (1,CBAT+) CN128-5 Cooling
Cooling fan
fan
controller
controller power
power CN128-3
CN101-18 (99,VFAN) CN128-9
Drive motor
Drive motor driver
driver
CN113-2
Temperature-sensor
Temperature-sensor
Cooling fan 1
CN113-1
Step 1
Cooling fan inspection
1. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
STD Display:
[ANL] 7 ACT 7-04 (FAN)
Multi-function/DX:
[ANL] ACTIVE TEST 2/2 FAN
FAN OFF→ON
Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
Step 2
Error recheck
1. Turn the key switch ON and check the error display on the
display. 3
Judgment
Result Procedure
"DCR" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the drive motor driver falls, the "DCR"
"DCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.
Step 3
Temperature check and error recheck
1. Record the drive motor driver main circuit temperature.
STD Display:
[ANL] 2 IO1 2-02 (TDMDH)
Multi-function/DX:
[ANL] I/O TEMP/VOLT 1/5
TDMDH
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 15 minutes), and then turn the key switch ON to
check the error display on the display.
Judgment
Result Procedure
Step 4
Temperature recheck
1. Check the drive motor driver main circuit temperature and
compare it with the recorded value.
STD Display:
[ANL] 2 IO1 2-02 (TDMDH)
Multi-function/DX:
TDMDH
Judgment
Result Procedure
It decreased 5℃ or more. Go to Step 3
It did not decrease 5℃ or more. Drive motor driver defect
Step 5
2. Visually inspect whether there is no problem with the inside
of the CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.")
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check the rotation condition of the
fan.
STD Display:
Multi-function/DX:
FAN OFF→ON
Judgment
Result Procedure
Turning Connector connection defect
Go to Step7 (48V vehicle)
Not turning
Step 6
Fan power supply inspection
2. Disconnect the CN128 connector and measure the fan 3
power source resistance.
Portion to be inspected Standard
CN128-2 - CN128-5 Approx.4.7 kΩ
CN128-5 - CN128-9 Approx.4.7 kΩ
CN128 CN128-5 - CN128-3 0Ω
CN128-3 - CN128-10 Approx.4.7 kΩ
6 5 4 3 2 1
12 11 10 9 8 7
Judgment
Result Procedure
NG Fan power supply defect
OK Go to Step 7
Step 7
Harness inspection
2. Disconnect the CN102, CN104, CN113 connectors.
CN101 3. Inspect for continuity and short circuiting of the harness.
CN113 NOTICE!
1 2 3 4 5 6 7
1 2 Turn the key switch OFF, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17
connect the CN102, CN104, CN113, and CN128 connectors,
18 19 20 21 22 23 24 25 26 27
visually inspect whether there is no problem with the inside
28 29 30 31 32 33 34
of the connector and the wire caulking, and then inspect
CN104 CN128
the harness.
Refer to "BEFORE TROUBLESHOOTING."
1 2 3 4 5 6
1 2 3 4 5 6 7
7 8 9 10 11 12
48 V vehicles
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-3 - CN113-1 Continuity
CN104-8 - CN113-2 Continuity
CN104-3 - CN104-8 No Continuity
80 V vehicles
Judgment
Result Procedure
NG Harness defect
OK Go to Step 8
Step 8
1. Disconnect the battery plug, and then connect the CN102,
CN104 and CN113 connectors. Connect the battery plug 3
and turn the key switch ON.
STD Display:
Multi-function/DX:
FAN OFF→ON
Judgment
Result Procedure
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after repla-
cing the cooling fan, replace the main controller, as there
could be other types of defect.
Error Code: A0-2

Failure mode: Pump motor driver main circuit temperature abnormal
rise
CAUTION
Probable cause
▪ Pump motor driver defect
Related part
Pump
Pump motor
motor driver
driver
Temperature sensor
Temperature-sensor
Step 1
Error recheck
display.
Judgment
Result Procedure
"PCR" display Go to Step 2
If the temperature of the pump motor driver falls, the "PCR"
"PCR" not display display disappears, and you can use the truck as usual. Be-
Step 2
1. Record the pump motor driver main circuit temperature.
STD Display: 3
[ANL] 2 IO1 2-06 (TPMDH)
Multi-function/DX:
TPMDH
Judgment
Result Procedure
Step 3
Temperature recheck
1. Check the pump motor driver main circuit temperature and
compare it with the recorded value.
STD Display:
[ANL] 2 IO1 2-06 (TPMDH)
Multi-function/DX:
TPMDH
Judgment
Result Procedure
It decreased by 5℃ or more. Go to Step 3
It did not decrease by 5℃ or more. Pump motor driver defect
Error Code: A1-1

Failure mode: Main controller high voltage
CAUTION
• If CB-1, CB-3, or CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3, or CB-5.
Probable cause
▪ Battery defect
▪ Battery fluid-level low
▪ Battery plug defect
▪ Battery voltage overvoltage
Related part
MB
P2 P3
CN102-3 (19,VBMBSL)
F7
CN102-4 (19,VBMBSL)
Main
Main
controller
controller
N1
Step 1
Error recheck
1. Turn the key switch OFF, disconnect the battery plug and
then leave it for 2 minutes or more.
2. Reconnect the battery plug and turn the key switch ON to
check the error.
Judgment
Result Procedure
Error at A1-1 Go to Step 2
Error at A3-1 Perform A3-1 troubleshooting
No error at A1-1 and A3-1 Perform battery inspection
Step 2
Battery voltage inspection
2. Use the tester to measure the voltage at both ends of the 3
battery plug.
Judgment
Result Procedure
64V or more (48V vehicles), 109V or more
Perform battery inspection
(80V vehicles)
Less than 64V (48V vehicles), less than
Main controller defect
109V (80V vehicles)
Error Code: A1-2

Failure mode: Drive motor driver high voltage
CAUTION
• If CB-1, CB-3, or CB-5 is displayed with A1-2 at the same time, give a higher priority to troubleshoot-
ing CB-1, CB-3, or CB-5.
Probable cause
▪ Battery defect
▪ The battery plug was disconnected during traveling / load handling
Related part
MB
F1
P1 P4
Drive motor driver
Step 1
Error recheck
check the error.
Judgment
Result Procedure
No error at A1-2 and A3-1 Go to Step 2
Step 2
1. Check if disconnect the battery plug during traveling or load
handling.
3
Judgment
Result Procedure
Do not disconnect the battery plug during traveling or load
YES
handling.
NO Perform battery inspection
Step 3
2. Use the tester to measure the voltage at both ends of the
battery plug.
Judgment
Result Procedure
(80V vehicles)
Drive motor driver defect
107V (80V vehicles)
Error Code: A1-4

Failure mode: Pump motor driver high voltage
CAUTION
• CB-1, CB-3, or CB-5 is displayed with A1-4 at the same time, give a higher priority to troubleshooting
CB-1, CB-3, or CB-5.
Probable cause
▪ Battery defect
▪ The battery plug was disconnected during traveling / load handling
Related part
MB
F1
P1 P4
Pump
Pump motor
motor driver
driver
Step 1
Error recheck
check the error.
Judgment
Result Procedure
No error at A1-4 and A3-1 Go to Step 2
Step 2
1. Check if disconnect the battery plug during traveling or load
handling.
3
Judgment
Result Procedure
Do not disconnect the battery plug during traveling or load
YES
handling.
NO Perform battery inspection
Step 3
battery plug.
Judgment
Result Procedure
(80V vehicles)
Pump motor driver defect
107V (80V vehicles)
Error Code: A2-1

Failure mode: Main controller board temperature abnormal rise
CAUTION
Probable cause
▪ Temperature sensor defect (main controller defect)
Related part
Main
Main controller
controller
Temperature-sensor
Temperature sensor
Step 1
Error recheck
display.
Judgment
Result Procedure
"C/R" display Go to Step 2
If the temperature of the main controller falls, the "C/R" dis-
"C/R" not display play disappears, and you can use the truck as usual. Because
an error occurred due to a continuous use in an overloaded
condition, check the truck usage and avoid an overloaded
continuous use.
Step 2
Main controller board temperature check and error recheck
1. Record the main controller board temperature.
STD Display: 3
[ANL] IO1 2-09 (TMCB)
Multi-function/DX:
TMCB
Judgment
Result Procedure
"C/R" display Go to Step 3
If the temperature of the main controller falls, the "C/R" dis-
"C/R" not display play disappears, and you can use the truck as usual. Because
condition, check the truck usage and avoid an overloaded
continuous use.
Step 3
Main controller board temperature recheck
1. Check the main controller board temperature and compare
it with the recorded value.
STD Display:
[ANL] IO1 2-09 (TMCB)
Multi-function/DX:
TMCB
Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 2
It did not rise by 5℃ or more. Temperature sensor defect (main controller defect)
Error Code: A2-2

Failure mode: Drive motor driver board temperature abnormal rise
CAUTION
• If AB-1, AB-2 is displayed at the same time, give a higher priority to troubleshooting AB-1, AB-2.
Probable cause
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
Related part
48V
CN104-8 (98,FNDC) CN113-2
3
Main
Main Cooling
controller
controller CN104-3 (1,CBAT+) CN113-1 Cooling fan
fan 11
Drive motor driver
Temperature-sensor
Temperature-sensor
80V
CN104-8 (98,FNDC) CN128-2
CN128-10
Main
Main CN104-3 (1,CBAT+) CN128-5 Cooling fan
controller power
power CN128-3
CN101-18 (99,VFAN) CN128-9
Drive motor driver

CN113-2
Temperature-sensor
Temperature-sensor
Cooling
Coolingfan
fan11
CN113-1
Step 1
STD Display:
[ANL] ACt 7-04 (FAN)
Multi-function/DX:
[ANL] ACTIVE TEST 2/2
FAN: OFF → ON
Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
Step 2
Error recheck
display.
Judgment
Result Procedure
Step 3
1. Record the values of the drive motor driver board temperat-
ure and drive motor driver capacitor temperature.
STD Display:
[ANL] IO1 2-03 (TDMDB)
[ANL] IO1 2-04 (TDMDC)
Multi-function/DX:
TDMDB, TDMDC
Judgment
Result Procedure
Step 4
Temperature recheck
1. Check the values of the drive motor driver board temperat-
ure and drive motor driver capacitor temperature and com- 3
pare them with the recorded values.
STD Display:
[ANL] IO1 2-03 (TDMDB)
[ANL] IO1 2-04 (TDMDC)
Multi-function/DX:
TDMDB, TDMDC
Judgment
Result Procedure
It did not decrease 5℃ or more. Drive motor driver defect
Step 5
of the CN113 connector, and the wire caulking.
by “ACTIVE TEST” and check the rotation condition of the
fan.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
Not turning
Step 6
2. Disconnect the CN128 connector and measure the fan
CN128-2 - CN128-5 approx.4.7ｋΩ
CN128-5 - CN128-9 approx.4.7ｋΩ
CN128 CN128-5 - CN128-3 0Ω
CN128-3 - CN128-10 approx.4.7ｋΩ
6 5 4 3 2 1
12 11 10 9 8 7
Judgment
Result Procedure
OK Go to Step 7
Step 7
Harness inspection
2. Disconnect the CN102, CN104, CN113 connectors. 3
CN113 NOTICE!
1 2 3 4 5 6 7
1 2 Turn the key switch OFF, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
of the connector and the wire caulking, and then inspect
CN104 CN128
the harness.
1 2 3 4 5 6
1 2 3 4 5 6 7
7 8 9 10 11 12
48 V vehicles
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-3 - CN113-1 Continuity
80 V vehicles
Judgment
Result Procedure
NG Harness defect
OK Go to Step 8
Step 8
1. Disconnect the battery plug, and then connect the CN102,
CN104, and CN113 connectors. Connect the battery plug
STD Display:
Multi-function/DX:
FAN OFF→ON
Judgment
Result Procedure
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after repla-
cing the cooling fan, replace the main controller, as there
could be other types of defect.
Error Code: A2-3

Failure mode: Pump motor driver board temperature abnormal rise
3
CAUTION
Probable cause
Related part
Pump
Pump motor
motor driver
driver
Temperature-sensor
Temperature sensor Temperature-sensor
Temperature sensor
(circuit board) (capacitor)
Step 1
Error recheck
display.
Judgment
Result Procedure
Step 2
1. Record the values of the pump motor driver board temperat-
ure and pump motor driver capacitor temperature.
STD Display:
[ANL] IO1 2-07 (TPMDB)
[ANL] IO1 2-08 (TPMDC)
Multi-function/DX:
TPMDB, TPMDC
Judgment
Result Procedure
Step 3
Temperature recheck
1. Check the values of the pump motor driver board temperat-
ure and pump motor driver capacitor temperature and com-
pare them with the recorded values.
STD Display:
[ANL] IO1 2-07 (TPMDB)
[ANL] IO1 2-08 (TPMDC)
Multi-function/DX:
TPMDB, TPMDC
Judgment
Result Procedure
It did not decrease 5℃ or more. Pump motor driver defect
Error Code: A3-1

Failure mode: Battery connection incorrect
Probable cause 3
▪ Charger contact defect.
▪ Set voltage defect.
▪ The voltage in the B48V line after the F5 fuse is above the set voltage.(48V)
The voltage in the B80V line after the F6 fuse is above the set voltage.(80V)
Related part
48V
P1 F5
CN136-1 (41) CN104-1 (41,B48V)
Main
Main
controller
controller
Battery
Battery
N1
80V
P1 F6
CN136-5 (18) CN104-1 (18,B80V)
Main
Main
controller
Battery
N1
Step 1
Error recheck
2. Reconnect the battery plug correctly and turn the key switch
ON.
Judgment
Result Procedure
Battery plug connection defect or battery improper connec-
No error at A3-1
tion
Step 2
battery plug.
STD Display:
[ANL] IO1 2-12 (B48/80V)
Multi-function/DX:
B48/80V
Judgment
Result Procedure
Go to Step 3
(80V vehicles)
110V (80V vehicles)
Step 3
1. Check of battery voltage
P1[+] to N1[-]
Judgment
Result Procedure
64V or more (48V vehicles), 110V or more Check the battery, and replace it with a regular battery if ne-
(80V vehicles) cessary.
110V (80V vehicles)
Error Code: A3-2

Failure mode: Battery connection incorrect (Different voltage)
Probable cause 3
▪ Main controller incorrectly installed.
▪ Main controller defect.
Related part
48V
P1 F5
CN136-1 (41) CN104-1 (41,B48V)
CN101-4 (41,VBBT) Main

Main
controller
controller
Battery
Battery
N1
80V
P1 F6
CN136-5 (18) CN104-1 (18,B80V)
Main
Main
F5 controller
P0 CN136-2 (41) CN101-4 (41,VBBT)
Battery
Battery
N1
Step 1
Main controller inspection
2. Check the part number of the main controller.
Judgment
Result Procedure
Wrong part No. Wrong main controller installed.
Correct part No. or The controller has not
been replaced.
Error Code: A5-1

Failure mode: Seat switch GND short abnormality
Probable cause
▪ Connector contact defect
▪ Seat switch defect
▪ Harness defect
Related part
CN102-10 (51,LS-) CN44-1
Main
Main controller
controller Seat switch
CN104-18 (67,SDM) CN44-2
Step 1
Seat switch condition inspection
visually inspect the inside of the CN44 connector and the
wire caulking for errors.
and turn the key switch ON while the operator is off the
vehicle.
STD Display:
[ANL] 3 IO2 3-07 (SDM)
Multi-function/DX:
[ANL] I/O TRAVELING 2/5
SDM
Judgment
Result Procedure
Displays “0” Connector connection defect
Displays “1” Go to Step 2
Step 2
Seat switch condition inspection
2. After disconnecting the CN44 connector, connect the bat- 3
tery plug and turn the key switch ON.
STD Display:
[ANL] 3 IO2 3-07 (SDM)
Multi-function/DX:
SDM
Judgment
Result Procedure
Displays “0” Seat switch defect
Displays “1” Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN102, CN104, and CN44 connectors.
3. Inspect for continuity and short circuiting of the harness.
CN102
NOTICE!
1 2 3 4 5 6 7
Turn the key switch OFF, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17 18 19
connect the CN102, CN104, and CN44 connectors, visually
20 21 22 23 24 25 26 27
inspect whether there is no problem with the inside of the
28 29 30 31 32 33 34 35
CN44 connector and the wire caulking, and then inspect the har-
CN104 ness.
1 2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 CN102-10 - CN44-1 Continuity
26 27 28 29 30 31 CN104-18 - CN44-2 Continuity
CN44-1 - CN44-2 No continuity
Judgment
Result Procedure
NG Harness defect
OK Main controller defect
Error Code: A8-1

Failure mode: F1 fuse open circuit abnormality
CAUTION
• If CB-1, CB-3, CB-5, A8-2 (48V vehicle) or A9-2 (80V vehicle) is occurring, give a higher priority to
troubleshooting CB-1, CB-3, CB-5, A8-2 or A9-2.
Probable cause
▪ Terminal tightening defect
▪ Motor driver defect
▪ F1 fuse installation defect
▪ F1 fuse defect
▪ Cable defect
Related part
F6
48V CN136-5 (44)
MB F1 P4
P3 Main
CN104-2 (44,VBMB) Main
controller
controller
Battery
Battery
N1
− ＋
Drive
Drive motor driver
− ＋
Pump
Pump motor driver
driver
80V F7
CN136-6 (19)
MB F1 P4
P3
Main
controller
controller
Battery
Battery
N1 CN102-2 (19,VBMBSL)
− ＋
Drivemotor
Drive motor driver
driver CN102-4 (19,VBMBSL)
− ＋
Pumpmotor
Pump motordriver
driver
Step 1
Terminal tightening inspection
2. Visually inspect whether there is no loosening at the bolt 3
tightening section of each motor driver’s [+] terminal, [-] ter-
minal, P4 terminal, and N1 terminal.
3. Connect the battery plug and turn the key switch ON to
check for errors.
Judgment
Result Procedure
No error at A8-1 Terminal tightening defect
Step 2
Motor driver supply voltage check
measure the voltage between [+] terminal and [-] terminal of
the drive motor driver.
NOTICE!
Turn the key switch OFF, disconnect the battery plug, and
then visually inspect whether there is no problem with the
copper bar for connecting the motor driver [+] terminal and
[-] terminal, such as raptures or cracks, and then perform
the inspection.
Judgment
Result Procedure
0V Go to Step 3
Approx. 48V (48V vehicles)
All motor drivers defect
Approx. 80V (80V vehicles)
Step 3
F1 fuse installation check
2. Visually inspect whether there is no problem with F1 fuse in-
stallation.
check for errors.
Judgment
Result Procedure
No error at A8-1 F1 fuse installation defect
Step 4
F1 fuse inspection
2. Remove the F1 fuse and measure the resistance at both
ends of the F1 fuse.
Motor driver defect inspection *1
remove the copper bar for connecting the motor driver [+]
terminal.
2. Measure the resistance between [+] terminal and [-] ter-
minal of the motor driver.
3. For an analog type tester, use the black tester probe for [+]
terminal, and the red tester probe for [-] terminal.
4. Motor driver defect if the measured value is 10 [Ω] or less
Judgment
Result Procedure
0Ω Motor driver defect (*1)
F1 fuse defect
∞Ω Or motor driver defect (*1) or short circuit between P4 and N1
terminal.
Error Code: A8-2

Failure mode: F6 fuse open circuit abnormality
3
CAUTION
• If CB-1, CB-3 and CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3 and CB-5.
Probable cause
▪ F6 fuse defect
▪ F6 fuse box defect
▪ Harness defect
Related part
48V F6
CN136-5 (44)
MB F1 P4
Battery P3
Main
controller
controller
F7
CN136-6 (19) CN102-3 (19,VBMBSL)
N1
CN102-4 (19,VBMBSL)
80V F7
CN136-6 (19)
MB F1 P4
P2
Battery P3
Main
controller
controller
F6
CN136-5 (18) CN104-1 (18,B80V)
N1
Step 1
Connector connection inspection
2. Disconnect the CN104, CN136 connector and visually in-
spect whether there is no problem with the inside of the
connector and the wire caulking.
3. Connect the CN104, CN136 connector and connect the bat-
tery plug.
4. Turn the key switch ON and check for any errors.
Judgment
Result Procedure
Go to Step 2 (48V vehicles)
Error at A8-2
No error at A8-2 Connector connection defect
Step 2
VBMBSL voltage value inspection
1. Connect the battery plug and turn the key switch ON.
STD Display:
[ANL] 2 IO1 2-14 (VBMBSL)
Multi-function/DX:
VBMBSL
Judgment
Result Procedure
25 [V] or more Go to Step 3
Less than 25 [V] Perform CB-1 troubleshooting
Step 3
Fuse installation inspection
stallation.
Judgment
Result Procedure
Step 4
Fuse inspection
2. Remove the F6 fuse and measure the resistance at both 3
Judgment
Result Procedure
0 [Ω]
F6 fuse defect
∞ [Ω]
Replace the F6 fuse and Go to Step 6.
Step 5
Fuse box inspection
1. Install the F6 fuse and disconnect the connector of the F6
fuse box.
2. Measure the resistance at both ends on the connector side
of the F6 fuse box.
Judgment
Result Procedure
0 [Ω] Go to Step 6
∞ [Ω] F6 fuse box defect
Step 6
Harness inspection
2. If the connector of the F6 fuse box was disconnected in the
previous step, connect the connector.
3. Disconnect the CN104 and CN136 connectors.
NOTICE!
CN104 CN136 Turn the key switch OFF, disconnect the battery plug, dis-
connect the CN104 and CN136 connectors, visually inspect
1 2 3 4
whether there is no problem with the inside of the con-
1 2 3 4 5 6 7
5 6 7 8 nector and the wire caulking, and then inspect the harness.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 48V vehicles
CN104-2 (44) - CN136-5 (44) Continuity
CN136-5 (44, fuse side) - P3 Continuity
CN104-2 (44) - N1 No continuity
CN136-5 (44,fuse side) - N1 No continuity
80V vehicles
CN104-1 (18) - CN136-5 (18) Continuity
CN136-5 (18, fuse side) - P2 Continuity
CN136-5 (18, fuse side) - N1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: A9-2

Failure mode: F7 fuse/solenoid power line open circuit abnormality
3
CAUTION
• If CB-1, CB-3 and CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3 and CB-5.
Probable cause
▪ F7 fuse defect
▪ F7 fuse box defect
▪ Harness defect
Related part
48V
P3 F7
CN136-6 (19) CN102-3 (19,VBMBSL)
Main
Main
controller
controller
CN102-4 (19,VBMBSL)
80V
P3 F7
CN136-6 (19) CN102-3 (19,VBMBSL)
Main
Main
CN102-4 (19,VBMBSL) controller
controller
CN104-2 (19,VBMB)
Step 1
2. Disconnect the CN104, CN136 connector and visually in-
spect whether there is no problem with the inside of the
connector and the wire caulking.
3. Connect the CN104, CN136 connector and connect the bat-
tery plug.
Judgment
Result Procedure
No error at A9-2 Connector connection defect
Error at A9-2
Step 2
VBMB voltage value inspection
STD Display:
[ANL] 2 IO1 2-15 (VBMB)
Multi-function/DX:
VBMB
Judgment
Result Procedure
Less than 25V Perform CB-1 troubleshooting
25V or more Go to Step 3
Step 3
Fuse installation condition inspection
stallation.
Judgment
Result Procedure
Error at A9-2
Step 4
VDMD, VPMD voltage inspection
STD Display: 3
[ANL] 2 IO1 2-16(VDMD)
[ANL] 2 IO1 2-17(VPMD)
Multi-function/DX:
VDMD, VPMD
Judgment
Result Procedure
Less than 25V (for both) Perform CB-1 troubleshooting
25V or more (either one) Go to Step 5
Step 5
F7 fuse inspection
2. Remove the F7 fuse and measure the resistance at both
Judgment
Result Procedure
F7 fuse defect
∞Ω
Replace the F7 fuse and Go to Step 7.
0Ω
Step 6
F7 fuse box inspection
1. Install the F7 fuse and disconnect the connector of the F7
fuse box.
2. Measure the resistance at both ends on the connector side
of the F7 fuse box.
Judgment
Result Procedure
∞Ω F7 fuse box defect
0Ω Go to Step 7
Step 7
Harness inspection
2. If the connector of the F7 fuse box was disconnected in the
previous step, connect the connector.
CN102
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 CN136
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8
CN104 Refer to "BEFORE TROUBLESHOOTING."
48V and 80V vehicles
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 Portion to be inspected Standard
18 19 20 21 22 23 24 25 CN102-3 (19) - CN136-6 (19) Continuity
26 27 28 29 30 31
CN102-4 (19) - CN136-6 (19) Continuity
CN136-6 - P3 Continuity
80V vehicles
CN104-2 (19) - CN136-6 Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: AA-1

Failure mode: Main controller temperature sensor open circuit
abnormality/VCC short circuit abnormality
3
CAUTION
• If AA-1 is displayed, the Main controller is defective, so replace it.
Probable cause
Related part
Main controller
Temperature sensor
Temperature-sensor
TH101
Error Code: AA-2

Failure mode: Drive motor driver board temperature sensor open
circuit abnormality/VCC short circuit abnormality
CAUTION
• If AA-2 is displayed, it indicates drive motor driver defect. Replace it.
Probable cause
Related part
Drive
Drive motor
motor driver
driver
Temperature sensor
Temperature-sensor
Error Code: AA-4

Failure mode: Pump motor driver board temperature sensor open
circuit abnormality/VCC short circuit abnormality
3
CAUTION
• If AA-4 is displayed, it indicates pump motor driver abnormality. Replace it.
Probable cause
Related part
Pump
Pump motor
motor driver
driver
Temperature sensor
Temperature-sensor
Error Code: AB-1

Failure mode: Cooling fan overcurrent
CAUTION
• When checking for AB-1 errors on 48V vehicles, turn the FAN ON by “ACTIVE TEST” and wait for
100 seconds
(Since it takes 100 seconds to confirm an AB-1 error)
Probable cause
▪ Cooling fan 1 defect
▪ Cooling fan 2 defect
▪ Harness defect
▪ Fan power defect
Related part
48V
CN104-8 (98,FNDC) CN113-2
CN104-3 (1,CBAT+) CN113-1 Cooling
Cooling fan
fan 11
Main
Main CN104-1 (41,B48V)
controller
controller CN114-2
＋
CN114-1 Cooling
Cooling fan
fan 22
80V
CN104-8 (98,FNDC) CN128-2 CN128-10
CN104-3 (1,CBAT+) CN128-5 fan CN128-3
Coolingfan
Cooling
power supply
power supply CN128-8
CN101-18 (99,VFAN) CN128-9
CN104-1 (18,B80V) CN128-4
CN104-4 (N2,N2) ＋
Main
Main
controller
controller CN104-5 (N2,N2)
CN104-6 (N2,N2) CN113-2
CN103-5 (N2,N2) CN113-1 Cooling

Coolingfan
fan11
CN114-2
CN114-1 Cooling
Coolingfan
fan22
Step 1
2. Visually inspect whether there is no problem with the inside 3
of the CN113 and CN114 connector, and the wire caulking.
by “ACTIVE TEST” and check for errors.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
No error at AB-1 Connector connection failure
Error at AB-1 Go to Step 2
Step 2
Cooling fan circuit inspection
2. After disconnecting the CN113 and CN114 connectors, con-
nect the battery plug and turn the key switch ON, forcibly
turn ON the cooling fan by “ACTIVE TEST” and check for
errors.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
No error at AB-1 Go to Step 3
Go to Step 6 (48 V vehicles)
Error at AB-1
Go to Step 5 (80 V vehicles)
Step 3
Motor driver cooling fan 1 inspection
2. Connect the CN113 connector, disconnecting the CN114
connector, connect the battery plug and turn the key switch
ON, forcibly turn ON the cooling fan by “ACTIVE TEST” and
check for errors.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
No error at AB-1 Go to Step 4
Error at AB-1 Motor driver cooling fan 1 failure
Step 4
Motor driver cooling fan 2 inspection
2. Connect the CN114 connector, disconnecting the CN113
connector, connect the battery plug and turn the key switch
ON, forcibly turn ON the cooling fan by “ACTIVE TEST” and
check for errors.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
No error at AB-1 Motor driver cooling fan 1 and 2 failure
Error at AB-1 Motor driver cooling fan 2 failure
Step 5
Fan power supply inspection (80 V vehicles only)
tery plug and turn the key switch ON, forcibly turn ON the
cooling fan by “ACTIVE TEST” and check for errors.
STD Display:
Multi-function/DX:
FAN: OFF → ON
Judgment
Result Procedure
No error at AB-1 Fan power failure
Step 6
Harness inspection
2. Disconnect the CN104, CN113 and CN114 connectors.
NOTICE!
1 2 3 4 5 6 7 CN113
8 9 10 11 12 13 14 15 16 17
1 2
connect the CN104, CN113, CN114, CN101 (80 V vehicles)
18 19 20 21 22 23 24 25 26 27
and CN128 (80 V vehicles) connectors, visually inspect
28 29 30 31 32 33 34
CN104 nector and the wire caulking, and then inspect the harness.
CN114
1 2 3 4 5 6 7 1 2 48 V vehicles
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-3 - CN104-8 No continuity
80 V vehicles
Judgment
Result Procedure
NG Harness defect
OK Main controller failure
Error Code: AB-2

Failure mode: Cooling fan open/short circuit abnormality (80 V
vehicle)
Probable cause
▪ Connector connection failure
▪ Fan power failure
▪ Harness defect
Related part
80V
CN104-8 (98,FNDC) CN128-2 CN128-10
CN104-3 (1,CBAT+) CN128-5 Cooling CN128-3
Coolingfan
fan
CN101-18 (99,VFAN) CN128-9 power
power supply
supply CN128-8
CN104-1 (18,B80V) CN128-4
＋
CN104-4 (N2,N2)
Main
Main
controller
CN104-6 (N2,N2) CN113-2
CN103-5 (N2,N2) CN113-1 Cooling

Coolingfan
fan11
CN114-2
CN114-1 Cooling
Coolingfan
fan22
Step 1
2. Visually inspect whether there is no problem with the inside 3
of the CN113 and CN114 connector, and the wire caulking.
and turn the key switch ON, forcibly turn OFF the cooling
fan by “ACTIVE TEST” and check for errors.
STD Display:
Multi-function/DX:
FAN: ON → OFF
Judgment
Result Procedure
No error at AB-2 Connector connection defect
Step 2
2. Disconnect the CN128 connector and measure the fan
CN128
CN128-2 - CN128-5 Approx. 4.7 kΩ
CN128-5 - CN128-8 Approx. 4.7 kΩ
6 5 4 3 2 1
12 11 10 9 8 7
Judgment
Result Procedure
NG Fan power defect
OK Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN101, CN104, CN113, CN114 and CN128
connectors.
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
connect the CN101, CN104, CN113, CN114 and CN128 con-
18 19 20 21 22 23 24 25 26 27
CN128 nectors, visually inspect whether there is no problem with
28 29 30 31 32 33 34
the inside of the connector and the wire caulking, and then
1 2 3 4 5 6
CN104 inspect the harness.
7 8 9 10 11 12
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-3 - CN128-5 Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: AC-1

Failure mode: Motor driver power supply abnormality
Probable cause 3
▪ Harness defect
Related part
48V MB F1
P2 P4
＋
Drive motor
CN110-8 driver
driver
＋
Pump motor
CN111-8 driver
driver
CN103-4 (42,KYSAT)
F5
Main
Main
CN104-1 (41,B48V) controller
CN101-4 (41,VBBT)
P2 MB F1 P4
80V
＋
Drive
Drive motor
motor
CN110-8 driver
driver
＋
Pump motor
CN111-8 driver
driver
CN103-4 (42,KYSAT)
F6
Main
Main
CN104-1 (41,B80V) controller
controller
Step 1
Harness inspection
connectors.
CN103
NOTICE!
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
connect the CN101, CN103, CN104, CN110, and CN111 con-
28 29 30 31 32 33 34 35 nectors, visually inspect whether there is no problem with
inspect continuity of the CN103 - CN110 and CN111.
CN110 CN111 Also, inspect for continuity between the harness and N1
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Refer to "BEFORE TROUBLESHOOTING."
9 10 11 12 13 14 15 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23
CN103-4 (42) - CN110-8 (42) Continuity
CN103-4 (42) - CN111-8 (42) Continuity
Judgment
Result Procedure
NG Harness defect
OK Go to Step 2
Step 2
2. Disconnect the CN110 and CN111 connectors and connect
the CN101, CN103 and CN104 connectors.
check for errors.
Judgment
Result Procedure
Error at AC-1 Main controller defect
No error at AC-1 Go to Step 3
Step 3
Drive motor driver inspection
2. Disconnect the CN110 and CN111 connectors and connect
the CN101, CN103 and CN104 connectors.
check for errors.
Judgment
Result Procedure
Error/no error at AC-1 Go to Step 4
Step 4
Pump motor driver inspection
2. Disconnect the CN110 connector and connect the CN101, 3
CN103, CN104 and CN111 connectors.
check for errors.
Judgment
Result Procedure
Error at AC-1 in Step 3 Drive motor driver defect
Error at AC-1 in Step 4 Pump motor driver defect
Error Code: AD-1

Failure mode: Drive motor driver to main controller communication
abnormality
CAUTION
• If AC-1 is displayed at the same time, give a higher priority to troubleshooting AC-1.
• If AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.
Probable cause
Related part
CN103-4 (42,KYSAT) CN110-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN110-17 (145,CAN1H)
Drive
Drive motor
motor driver
driver
CN103-12 (146,CAN1L) CN110-16 (146,CAN1L)
CN103-5 (N2,N2)
Main
Main
controller
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Error recheck
visually inspect the inside of the CN103 and CN110 con-
nectors and the wire caulking for errors.
and turn the key switch ON to check for errors.
Judgment
Result Procedure
Error at AD-1 or AD-2 Perform AD-2 troubleshooting.
No error at AD-1 or AD-2 Connector connection defect
Error Code: AD-2

Failure mode: Drive motor driver to main controller communication
abnormality
3
CAUTION
Probable cause
▪ Motor driver of different class
▪ Harness defect
Related part
CN103-4 (42,KYSAT) CN110-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN110-17 (145,CAN1H)
CN103-12 (146,CAN1L) CN110-16 (146,CAN1L)
Drive motor driver
Main
Main
controller CN103-5 (N2, N2) CN110-6
NC
CN104-4 (N2, N2) CN110-23
NC
CN104-5 (N2, N2)
CN104-6 (N2, N2)
CN111-8 (42,KYSAT)
CN70-16 (145,CAN1H) CN111-17 (145,CAN1H)
Display
Display CN70-15 (146,CAN1L) CN111-16 (146,CAN1L)
CN111-6 (152,SETP2) Pump motor driver
CN111-7
NC
CN111-23 (152,SETP-)
Step 1
check that the part number of the motor driver is correct.
Especially if you have replaced the motor driver, check that
another model of the motor driver is not installed.
Judgment
Result Procedure
Wrong part No. Motor driver of different class
Correct part No. Go to Step 2
Step 2
Error recheck
visually inspect the inside of the CN103, CN104, CN110,
CN111 and CN70 connectors and the wire caulking for er-
rors.
NOTICE!
Especially if you replaced the motor driver immediately be-
fore connecting the connector, check that the connector is
properly corrected.
Judgment
Result Procedure
1. No errors starting from AD Connector connection defect
2. All of the below hold true
▪ Error at AD-1 or AD-2 Go to Step 7
▪ Error at AD-5 or AD-6
In cases except for 1. and 2. Go to Step 3
Step 3
Error recheck
1. Recheck the errors at Step 2.
Judgment
Result Procedure
Go to Step 4
Error at AD-2
Record the displayed error that starts with AD.
No error at AD-2 Troubleshoot the displayed errors.
Step 4
Drive motor driver identification check
2. Disconnect the CN111 connector. 3
3. Connect the battery plug and turn the key switch ON. Re-
cord the displayed errors.
Harness check
2. Connect the CN111 connector and disconnect the CN103
and CN110 connectors.
NOTICE!
CN103 ▪ Disconnect the pump motor driver to check that the
drive motor driver is not operating as a pump motor
1 2 3 4 5 6
CN110 driver.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 ▪ Turn the key switch OFF, disconnect the battery plug,
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 disconnect the CN103 and CN110 connectors, visually
inspect whether there is no problem with the inside of
the connector and the wire caulking, and then inspect
the harness.
CN110-6 - N2 No continuity
Judgment
Result Procedure
Go to Step 5
NG
Harness defect
Go to Step 5
OK
Step 5
Error recheck
1. Check the error recorded at Step 3.
Judgment
Result Procedure
AD-2 error only Replace the defect portion of Step 4.
Error at AD-2 and AD-6 Go to Step 6
Step 6
Pump motor driver identification check
2. Disconnect the CN110 connector.
3. Connect the battery plug and turn the key switch ON. Re-
cord the displayed errors.
Harness inspection
2. Connect the CN110 connector and disconnect CN103 and
CN111 connectors.
NOTICE!
CN103 ▪ Disconnect the drive motor driver to check that the
pump motor driver is not operating as a drive motor
1 2 3 4 5 6
CN111 driver.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 ▪ Turn the key switch OFF, disconnect the battery plug,
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 disconnect the CN103 and CN111 connectors, visually
inspect whether there is no problem with the inside of
the connector and the wire caulking, and then inspect
the harness.
Judgment
Result Procedure
Harness defect
NG In addition to the harness, replace the defect portion of Step
4
OK In addition to the pump motor driver, replace the defect por-
tion of Step 4
Step 7
Harness inspection
2. Disconnect the CN103, CN104, CN110, CN111 and CN70 3
connectors.
NOTICE!
CN110
CN103 Turn the key switch OFF, disconnect the battery plug, dis-
1 2 3 4 5 6 7 8 connect the CN103, CN104, CN110, CN111 and CN70 con-
9 10 11 12 13 14 15
1 2 3 4 5 6 16 17 18 19 20 21 22 23 nectors, visually inspect whether there is no problem with
7 8 9 10 11 12 13 14 15 16
CN111
17 18 19 20 21 22 23 24 25 26 27 inspect the harness.
28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 Refer to "BEFORE TROUBLESHOOTING."
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
OK Go to Step 8
Step 8
Main control supply voltage check
2. Connect the CN103, CN104 and CN70 connectors and dis-
connect CN110 and CN111 connectors.
4. Inspect the motor driver supply voltage.
Voltage measurement between CN110-8 and N2.
CN110
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
Judgment
Result Procedure
Less than 15 V Main controller defect
15 V or more Go to Step 9
Step 9
2. Connect the CN103, CN104 and CN110 connectors and
disconnect the CN111 connector.
3. Connect the battery plug and turn the key switch ON. In-
spect the motor driver supply voltage and errors.
5. Check for errors.
CN111 NOTICE!
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
▪ Disconnect the pump motor driver and connect the
16 17 18 19 20 21 22 23 main controller and drive motor driver to perform in-
spection.
▪ Measure the voltage on the disconnected pump motor
driver harness.
Judgment
Result Procedure
Go to Step 10
Voltage: less than 15 V
Record the results.
Voltage: 15 V or more Go to Step 10
Error at AD-2 Record the results.
No error at AD-2 Record the results.
Step 10
2. Connect the CN103, CN104 and CN111 connectors and 3
disconnect the CN110 connector.
CN110 NOTICE!
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
▪ Disconnect the drive motor driver and connect the main
16 17 18 19 20 21 22 23 controller and pump motor driver to perform inspec-
tion.
▪ Measure the voltage on the disconnected drive motor
driver harness.
Judgment
Result Procedure
Go to Step 11
Voltage: less than 15 V
Record the results.
Error at AD-6 Record the results.
No error at AD-6 Record the results.
Step 11
1. Check the results of Steps 9 and 10.
Judgment
Result Procedure
Failure of inspection targets of less than 15 V (drive motor
Voltage of one of them: less than 15 V
driver or pump motor driver)
Voltage of all: 15 V or more If the problem persists after the main controller is replaced,
Error at all connections replace the drive motor driver and pump motor driver, be-
cause there may be other defects.
Voltage of all: 15 V or more Failure of inspection targets with error display (drive motor
No error for any one of them driver or pump motor driver)
Error Code: AD-5

Failure mode: Pump motor driver to main controller communication
abnormality
CAUTION
• If AD-1 or AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.
• If AD-6 is displayed at the same time, give a higher priority to troubleshooting AD-6.
Probable cause
Related part
CN103-4 (42,KYSAT) CN111-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN111-17 (145,CAN1H)
CN103-12 (146,CAN1L) CN111-16 (146,CAN1L)
Main
Main Pump motor driver
CN111-6 (152,SETP2)
controller CN103-5 (N2, N2)
CN104-4 (N2, N2) CN111-23 (152,SETP-)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Step 1
Error recheck
visually inspect the inside of the CN103 and CN111 con-
nectors and the wire caulking for errors.
Judgment
Result Procedure
Error at AD-5 or AD-6 Perform AD-6 troubleshooting
No error at AD-5 and AD-6 Connector connection defect
Error Code: AD-6

Failure mode: Pump motor driver to main controller communication
abnormality
3
CAUTION
• If AD-1 or AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.
Probable cause
▪ Motor driver of different class
▪ Harness defect
Related part
CN103-4 (42,KYSAT) CN110-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN110-17 (145,CAN1H)
CN103-12 (146,CAN1L) CN110-16 (146,CAN1L)
Drive motor driver
Main
Main
controller CN103-5 (N2, N2) CN110-6
NC
CN104-4 (N2, N2) CN110-23
NC
CN104-5 (N2, N2)
CN104-6 (N2, N2)
CN111-8 (42,KYSAT)
CN70-16 (145,CAN1H) CN111-17 (145,CAN1H)
Display
Display CN70-15 (146,CAN1L) CN111-16 (146,CAN1L)
CN111-7
NC
CN111-23 (152,SETP-)
Step 1
check that the part number of the motor driver is correct.
NOTICE!
Especially if you have replaced the motor driver, check that
another model of the motor driver is not installed.
Judgment
Result Procedure
Wrong part No. Motor driver of different class
Correct part No. Go to Step 2
Step 2
Error recheck
visually inspect the inside of the CN111 connector and the
NOTICE!
Especially if you replaced the motor driver immediately be-
fore connecting the connector, check that the connector is
properly corrected.
Judgment
Result Procedure
No error at AD-5 and AD-6 Connector connection failure
Error at AD-5 or AD-6 Go to Step 3
Step 3
Pump motor driver identification check
Disconnect the CN110 connector.
2. Connect the battery plug and turn the key switch ON. Check
the displayed errors.
NOTICE!
Disconnect the drive motor driver to check that the pump
motor driver is not operating as a drive motor driver.
Judgment
Result Procedure
No error at AD-2 Go to Step 4
Error at AD-2 Go to Step 5
Step 4
Harness inspection
2. Disconnect the CN111 connector and inspect the harness. 3
NOTICE!
CN111 connect the CN111 connector, visually inspect whether
there is no problem with the inside of the connector and
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 the wire caulking, and then inspect the harness.
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
OK Pump motor driver defect
Step 5
Harness inspection
2. Disconnect the CN103 and CN111 connectors and inspect
the harness.
NOTICE!
1 2 3 4 5 6
CN111 whether there is no problem with the inside of the con-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 nector and the wire caulking, and then inspect the harness.
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23 Refer to "BEFORE TROUBLESHOOTING."
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: AF-1, AF-2, AF-3, AF-4, AF-5, AF-6, AF-7, AF-8
Failure mode: Main controller CPU abnormality
CAUTION
• If AF is displayed, the Main controller is defective, so replace it.
Probable cause
Related part
Main controller
Error Code: C0-2

Failure mode: Drive motor driver main circuit abnormality
3
CAUTION
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before performing troubleshooting.
Probable cause
▪ Drive motor cable connection defect
▪ Drive motor defect
▪ Drive motor cable defect
Related part
P7
U
P8
Drive motor driver V Drive
Drive motor
motor
P9
W
Step 1
Error recheck
1. Disconnect the battery plug and visually inspect whether
there is no problem with the drive motor cable tightening
and the wire caulking.
2. After connecting the drive motor cable, connect the battery
plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display by stepping on the
accelerator pedal.
Judgment
Result Procedure
Go to Step 2
Error at C0-2
Record the displayed error codes.
No error at C0-2 Drive motor cable connection defect
Step 2
1. Return the direction lever to the neutral position, turn the
key switch OFF and disconnect the battery plug.
2. Disconnect three drive motor cables on the drive motor
driver side and insulate the terminal of the disconnected
cables.
check whether C0-2 occurs.
Judgment
Result Procedure
Error at C0-2 Drive motor driver defect
No error at C0-2 Go to Step 3
Step 3
Drive motor cable inspection
2. Individually disconnect the motor driver side and motor side
of the drive motor cable.
3. Inspect continuity and short circuit of the drive motor cable.
NOTICE!
connect the drive motor cable, visually inspect whether
there is no problem with the terminal, cable caulking, and
coating, and then inspect the P7, P8, and P9 cables.
Both end of P7 cable Continuity
P7 cable - P8 cable No continuity
Judgment
Result Procedure
OK (no E0-2 display at the same time at
Go to Step 4
Step 1)
OK (E0-2 display at the same time at Step
Go to Step 5
1)
NG Drive motor cable defect
Step 4
1. Exchange the drive motor driver and the pump motor driver.
2. Connect the battery plug and turn the key switch ON. 3
3. Operate the direction lever forward or backward, and check
the error display.
(Ignore 32-1 and 32-3 errors).
Judgment
Result Procedure
Error at C0-2 Drive motor defect
Error at E0-2 The motor driver that the drive motor driver was replaced
with is faulty.
Step 5
Drive motor inspection
2. Inspect the drive motor.
Judgment
Result Procedure
NG Drive motor defect
OK Drive motor driver defect
Error Code: C1-1

Failure mode: Drive motor driver current sensor neutral abnormality
Probable cause
Related part
Drive motor driver
Temperature-sensor
Current sensor
Error Code: C1-2

Failure mode: Drive motor driver current sensor overcurrent
abnormality
3
CAUTION
• C8-1 or C8-2 is displayed with C1-2 at the same time, give a higher priority to troubleshooting C8-1
or C8-2.
Probable cause
▪ Drive motor cable connection defect
▪ Drive motor defect
▪ Drive motor cable defect
▪ Drive motor speed sensor defect
Related part
P7
U
P8
Drive motor
Drive motor driver
driver V Drive motor
P9
W
Step 1
Error recheck
1. Turn the key switch OFF/ON to check that C0-2 error is dis-
played.
Judgment
Result Procedure
No error at C0-2 Go to Step 2
Error at C0-2 Perform C0-2 troubleshooting.
Step 2
Error recheck
visually inspect whether there is no problem with the drive
motor cable tightening and the wire caulking.
2. After connecting the drive motor cable, connect the battery
accelerator pedal.
Judgment
Result Procedure
Go to Step 3
Error at C1-2
No error at C1-2 Drive motor cable connection defect
Step 3
Drive motor cable inspection
2. Disconnect the driver side and the motor side of the drive
motor cable.
3. Inspect continuity and short circuit of the drive motor cable.
NOTICE!
connect the drive motor cable, visually inspect whether
Judgment
Result Procedure
OK (no E1-2 display at the same time at
Go to Step 4
Step 2)
OK (E1-2 display at the same time at Step
Go to Step 5
2)
NG Drive motor cable defect
Step 4
1. Exchange the drive motor driver and the pump motor driver.
2. Connect the battery plug and turn the key switch ON. 3
accelerator pedal. (Ignore 32-1 and 32-3 errors).
Judgment
Result Procedure
Error at C1-2 Drive motor defect
Error at E1-2 The motor driver that the drive motor driver was replaced
with is faulty.
Step 5
Drive motor inspection
inspect the drive motor.
Judgment
Result Procedure
NG Drive motor defect
Error Code: C2-1

Failure mode: Drive motor temperature abnormal rise
CAUTION
• Do not leave the vehicle in places where it gets hot.
Probable cause
Related part
CN110-9 (86,STDM+) CN52-2
Drive motor driver Temperature sensor

(drive motor)
CN110-10 (87,STDM) CN52-1
Step 1
Error recheck
display.
Judgment
Result Procedure
"DM" display Go to Step 2
If the temperature of the drive motor falls, the "DM" display
"DM" not display disappears, and you can use the vehicle as usual. Because
condition, check the vehicle usage and avoid an overloaded
continuous use.
Step 2
Drive motor temperature check and error recheck
1. Record the drive motor temperature values.
STD Display: 3
[ANL] IO1 2-01 (TDM)
Multi-function/DX:
TDM
2. Turn the key switch OFF, leave the vehicle for a while (ap-
Judgment
Result Procedure
"DM" display Go to Step 3
If the temperature of the drive motor falls, the "DM" display
"DM" not display disappears, and you can use the vehicle as usual. Because
condition, check the vehicle usage and avoid an overloaded
continuous use.
Step 3
Drive motor temperature recheck
1. Check the drive motor temperature value and compare it
with the recorded value.
STD Display: (TDM)
[ANL] IO1 2-01
Multi-function/DX:
TDM
Judgment
Result Procedure
All of the temperatures rose by 5℃ or more. Go to Step 2
Drive motor temperature did not rise by 5℃
Perform troubleshooting from C2-2 Step 2.
or more.
Error Code: C2-2

Failure mode: Drive motor temperature sensor open/short circuit
abnormality
Probable cause
▪ Drive motor temperature sensor defect
▪ Drive motor temperature sensor harness defect
Related part
CN110-9 (86,STDM+) CN52-2
Drive motor driver Temperature sensor

(drive motor)
CN110-10 (87,STDM) CN52-1
Step 1
Error recheck
of the CN52 connector and the wire caulking.
and turn the key switch ON to check the error display.
Judgment
Result Procedure
Error at C2-2 Go to Step 2
No error at C2-2 Connector connection defect
Step 2
Temperature sensor individual inspection
3. Carry out a temperature sensor individual inspection.
Measure the resistance of the temperature sensor between
CN52-2 and CN52-1 on the sensor side of the CN52 con-
nector.
CN52
Standard: Approx. 245 Ω to 600 kΩ
2 1 NOTICE!
Resistance values vary at a low or high temperature. Use
the values in the following table as a guideline.
Temperature sensor resist-
Temperature ance value
(between CN52-2 - CN52-1)
20℃ Approx. 13 kΩ
80℃ Approx. 1.75 kΩ
Judgment
Result Procedure
OK Go to Step 3
NG Drive motor temperature sensor defect
Step 3
Harness inspection
NOTICE!
CN110 CN52 whether there is no problem with the inside of the con-
1 2 3 4 5 6 7 8 nector and the wire caulking with SST disconnected, and
9 10 11 12 13 14 15 1 2
16 17 18 19 20 21 22 23 then inspect the harness.
CN110-9 - CN52-2 Continuity *1
*1: Use SST2 to connect CN52-1 and CN52-2 on the harness
side. You can check for continuity between CN110-9 -
CN110-10.
Judgment
Result Procedure
NG Drive motor temperature sensor harness defect
Error Code: C3-1

Failure mode: Drive motor driver main circuit temperature sensor
open/short circuit abnormality
CAUTION
• If C3-1 is displayed, it indicates drive motor driver defect. Replace it.
Probable cause
Related part
Drive motor driver
Temperature-sensor
Temperature sensor
Error Code: C4-1

Failure mode: Accelerator potentiometer POT1 open abnormality
3
CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.
Probable cause
▪ Harness defect
▪ Accelerator sensor defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

Main controller Accelerator sensor
CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
Error recheck
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
3. Connect the CN26 connector and connect the battery plug.
Judgment
Result Procedure
Step 2
Accelerator sensor inspection
3. Measure the resistance value of the accelerator sensor.
NOTICE!
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-4 (52) - CN26-6 (50)
Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3
Step 3
Inspect for continuity of the harness
CN101
3. Inspect for continuity of the harness.
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 connect the CN101, CN102 and CN26 connectors, visually
28 29 30 31 32 33 34
CN26
connector and the wire caulking, and then inspect the har-
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-27 (53) - CN26-5 Continuity *1
28 29 30 31 32 33 34 35
CN102-30 (52) - CN26-4 Continuity *1
CN26-5 (53) - CN26-6 (50) No continuity
CN102-30.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-2

Failure mode: Accelerator potentiometer POT2 open abnormality
3
CAUTION
Probable cause
▪ Harness defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
Error recheck
Judgment
Result Procedure
Step 2
NOTICE!
Turn the key switch OFF, disconnect the battery plug and
CN26
CN26-1 (55) - CN26-2 (50) 1.8 - 3.5 kΩ
CN26-3 (54) - CN26-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-26 (55) - CN26-1 Continuity *1
28 29 30 31 32 33 34 35
CN102-32 (54) - CN26-3 Continuity *1
CN102-32.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-3

Failure mode: Accelerator potentiometer POT1 VCC short circuit
abnormality
3
CAUTION
Probable cause
▪ Harness defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
Error recheck
Judgment
Result Procedure
Step 2
NOTICE!
CN26
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
CN26-4 (52) - CN26-6 (50)
CN26-3 (54) - CN26-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-22 (50) - CN26-6 Continuity *1
28 29 30 31 32 33 34 35
CN102-30.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-4

Failure mode: Accelerator potentiometer POT2 VCC short circuit
abnormality
3
CAUTION
Probable cause
▪ Harness defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
Error recheck
Judgment
Result Procedure
Step 2
NOTICE!
CN26
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
CN26-3 (54) - CN26-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-32 (51) - CN26-2 Continuity *1
28 29 30 31 32 33 34 35
CN102-32.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-5

Failure mode: Accelerator potentiometer offset abnormality
3
CAUTION
Probable cause
▪ Harness defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
Error recheck
Judgment
Result Procedure
Step 2
NOTICE!
CN26
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
CN26-4 (52) - CN26-6 (50)
CN26-3 (54) - CN26-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN101, CN102 and CN26 connectors. 3
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-27 (53) - CN26-5 Continuity *1
28 29 30 31 32 33 34 35
CN101-22 (50) - CN26-6 Continuity *2
CN101-26 (55) - CN26-1 Continuity *3
CN101-32 (51) - CN26-2 Continuity *4
*1: You can use SST2 to connect the following points and
check for continuity between CN101 - CN102.
　　SST2 connection points / continuity check points
*1: CN26-5 - CN26-4 / CN101-27 - CN102-30
*2: CN26-6 - CN26-3 / CN101-22 - CN102-30
*3: CN26-1 - CN26-3 / CN101-26 - CN102-32
*4: CN26-2 - CN26-3 / CN101-32 - CN102-32
Judgment
Result Procedure
NG Harness defect
Error Code: C4-6

Failure mode: Accelerator potentiometer matching value abnormality
CAUTION
• If C4-1, 2, 3, 4 and 5 have occurred, perform troubleshooting for C4-1, 2, 3, 4 and 5 first.
Probable cause
▪ Accelerator potentiometer matching defect
▪ Accelerator potentiometer assembly defect
Related part
CN101-27 (53,VRA1+) CN26-5
CN102-30 (52,VRA1) CN26-4
CN101-22 (50,VRA-) CN26-6

CN101-26 (55,VRA2+) CN26-1
CN102-32 (54,VRA2) CN26-3
CN101-32 (51,POT-) CN26-2
Step 1
1. Perform accelerator potentiometer matching
(Refer to “MATCHING” in DISPLAY chapter.)
Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3
Step 2
Accelerator potentiometer supply voltage check
1. Accelerator sensor 1/2 voltage
STD Display: 3
[ANL] IO2 3-02, 3-03 (VRA)
Multi-function/DX:
VRA
NOTICE!
When the accelerator is not operated, check that the
voltage with the accelerator fully depressed is within the
range shown in the below table.
Accelerator pedal position Sensor 1 Sensor 2
When the accelerator is not
0.40 - 1.24 V 0.65 - 2.31 V
operated
When the accelerator is fully
2.00 - 4.79 V 2.42 - 4.79 V
depressed
Judgment
Result Procedure
Within the standard range Main controller defect
Go to Step 3
Outside the standard range Accelerator potentiometer assembly defect
After reassembling it, perform matching
Step 3
Error recheck
1. After turning the key switch OFF, disconnect the battery
plug. After 30 seconds, connect it again and turn the key
switch ON.
Judgment
Result Procedure
Error at C4-6 Main controller defect
Accelerator potentiometer matching defect
No error at C4-6
The vehicle can be used as is.
Error Code: C5-1

Failure mode: Brake potentiometer POT1 open circuit abnormality
CAUTION
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.
Probable cause
▪ Harness defect
▪ Brake sensor defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

Main controller Brake sensor
CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2
Step 1
Error recheck
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
Judgment
Result Procedure
Step 2
Brake sensor inspection
3. Measure the resistance value of the brake sensor.
NOTICE!
CN6
CN6-5 (72) - CN6-6 (50) 1.8 - 3.5 kΩ
CN6-4 (71) - CN6-6 (50)
Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN6
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-34 (72) - CN6-5 Continuity *1
28 29 30 31 32 33 34 35
CN102-33 (71) - CN6-4 Continuity *1
CN102-30.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-2

Failure mode: Brake potentiometer POT2 open circuit abnormality
CAUTION
after reassembly.
Probable cause
▪ Harness defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2
Step 1
Error recheck
wire caulking.
Judgment
Result Procedure
Step 2
NOTICE!
CN6
CN6-1 (74) - CN6-2 (51) 1.8 - 3.5 kΩ
CN6-3 (74) - CN6-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN6
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-33 (74) - CN6-1 Continuity *1
28 29 30 31 32 33 34 35
CN102-25.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-3

Failure mode: Brake potentiometer POT1 VCC short circuit
abnormality
CAUTION
• If C5-5 has occurred, perform troubleshooting for C5-5 first.
after reassembly.
Probable cause
▪ Harness defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2

Step 1
Error recheck
2. Disconnect the CN6 connector and visually inspect whether 3
wire caulking.
Judgment
Result Procedure
Step 2
NOTICE!
CN6
CN6-5 (72) - CN6-6 (50) 1.8 - 3.5 kΩ
CN6-1 (74) - CN6-2 (51) 1.8 - 3.5 kΩ
CN6-4 (71) - CN6-6 (50)
CN6-3 (73) - CN6-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN6
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-22 (50) - CN6-6 Continuity *1
28 29 30 31 32 33 34 35
CN102-33.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-4

Failure mode: Brake potentiometer POT2 VCC short circuit
abnormality
3
CAUTION
after reassembly.
Probable cause
▪ Harness defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2
Step 1
Error recheck
wire caulking.
Judgment
Result Procedure
Step 2
NOTICE!
CN6
CN6-1 (74) - CN6-2 (51) 1.8 - 3.5 kΩ
CN6-3 (73) - CN6-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN6
CN102 1 2 3 4 5 6 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-32 (51) - CN6-2 Continuity *1
28 29 30 31 32 33 34 35
CN102-25.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-5

Failure mode: Brake potentiometer offset abnormality
3
CAUTION
after reassembly.
Probable cause
▪ Harness defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2
Step 1
Error recheck
wire caulking.
Judgment
Result Procedure
Step 2
NOTICE!
CN6
CN6-5 (72) - CN6-6 (50) 1.8 - 3.5 kΩ
CN6-1 (74) - CN6-2 (51) 1.8 - 3.5 kΩ
CN6-4 (71) - CN6-6 (50)
CN6-3 (73) - CN6-2 (51)
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN101
NOTICE!
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27 1 2 3 4 5 6 inspect whether there is no problem with the inside of the
28 29 30 31 32 33 34
CN102 ness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN101-34 (72) - CN6-5 Continuity *1
28 29 30 31 32 33 34 35 CN101-22 (50) - CN6-6 Continuity *2
*1: You can use SST2 to connect the following points and
check for continuity between CN101 - CN102.
　　SST2 connection points / continuity check points
*1: CN6-5 - CN6-4 / CN101-34 - CN102-33
*2: CN6-6 - CN6-4 / CN101-22 - CN102-33
*3: CN6-1 - CN6-3 / CN101-33 - CN102-25
*4: CN6-2 - CN6-3 / CN101-32 - CN102-25
Judgment
Result Procedure
NG Harness defect
Error Code: C5-6

Failure mode: Brake potentiometer matching value abnormality
CAUTION
• If C5-1, 2, 3, 4 and 5 have occurred, perform troubleshooting for C5-1, 2, 3, 4 and 5 first.
after reassembly.
Probable cause
▪ Brake potentiometer matching defect
▪ Brake potentiometer assembly defect
Related part
CN101-34 (72,VRB1+) CN6-5
CN102-33 (71,VRB1) CN6-4
CN101-22 (50,VRA-) CN6-6

CN101-33 (74,VRB2+) CN6-1
CN102-25 (73,VRB2) CN6-3
CN101-32 (51,POT-) CN6-2
Step 1
1. Perform brake potentiometer matching
Judgment
Result Procedure
Step 2
Brake potentiometer voltage check
1. Brake sensor 1/2 voltage
STD Display: 3
[ANL] IO2 3-04,3-05 (VRB)
Multi-function/DX:
VRB
NOTICE!
At the brake operating point, the difference should be
within the range shown in the following table, and 0.40 V or
more from the matching voltage of the brake when not in
operation.
Brake pedal position Sensor 1 Sensor 2
When the brake is not oper-
0.50 - 1.60 V 0.82 - 2.56 V
ated
At the brake operating point 1.00 - 2.94 V 1.42 - 3.66 V
Judgment
Result Procedure
Within the standard range Main controller defect
Go to Step 3
Outside the standard range Accelerator potentiometer assembly defect
After reassembling it, perform matching
Step 3
Error recheck
1. After turning the key switch OFF, disconnect the battery
plug. After 30 seconds, connect it again and turn the key
switch ON.
Judgment
Result Procedure
Brake potentiometer matching defect
No error at C5-6
The vehicle can be used as is.
Error Code: C8-1

Failure mode: Drive motor speed sensor open circuit abnormality
CAUTION
• Jack up until drive wheels leave the ground and support the vehicle with wooden blocks before per-
forming troubleshooting.
Probable cause
▪ Drive motor speed sensor 1/2 harness defect
▪ Drive motor speed sensor 1 defect
▪ Drive motor speed sensor 1/2 defect
Related part
P4 CN110-15 (78,SSD+) CN53-2

＋ Drive
Drivemotor
motor
speed sensor
rpm sensor 11
CN110-14 (79,SSD1) CN53-1
Drive
Drive motor
motor
driver
driver CN54-2
N1
− Drive
Drivemotor
motor
CN110-13 (80,SSD2) CN54-1 speed sensor2 2
rpm sensor
Step 1
Error recheck
of the CN110, CN53, and CN54 connectors and the wire
caulking.
Judgment
Result Procedure
Step 2
Inspect for continuity and short circuiting of the harness
2. Disconnect the CN110, CN53, and CN54 connectors. 3
NOTICE!
connect the CN110, CN53, and CN54 connectors, visually
CN110 CN53 CN54 inspect whether there is no problem with the inside of the
1 2 3 4 5 6 7 8 connector and the wire caulking, and then inspect the har-
9 10 11 12 13 14 15 1 2 1 2
16 17 18 19 20 21 22 23 ness.
Measurement terminals Standard
*1: Use SST2 to connect CN53-1 and CN53-2 on the CN110
CN110-14.
CN110-13.
Judgment
Result Procedure
OK Go to Step 3
NG Drive motor speed sensor 1/2 harness defect
Step 3
2. Connect the CN110 connector, connect the battery plug
with the CN53, and CN54 connectors disconnected, and
turn the key switch ON.
3. Measure the voltage between CN53-2 and N1 and between
CN54-2 and N1.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
12 - 16 V Go to Step 4
Except 12 - 16 V Drive motor driver defect
Step 4
Error recheck
2. Connect the CN110 connector, and use SST2 to connect
between CN53-1 and CN53-2 and between CN54-1 and
CN54-2 with the CN53 and CN54 connectors disconnected.
check the error display
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Displays C8-2 error Go to Step 5
Displays C8-1 error or no error Drive motor driver defect
Step 5
2. Remove the SST2, connect the CN110 connector, and 3
measure the resistance between CN53-1 (CN110 side) and
N1 and between CN54-1 (CN110 side) and N1, with the
CN53 and CN54 connectors disconnected.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Both are approximately 100 Ω. Go to Step 6
Either is except approximately 100 Ω. Drive motor driver defect
Step 6
Drive motor speed sensor inspection
2. Connect the CN53 and CN54 connectors.
3. Connect the battery plug and turn the key switch ON to dis-
play C8-1 error.
Drive motor speed sensor: Sensor 1/Sensor 2
STD Display:
[ANL] IO2 3-12 (SSD1)
[ANL] IO2 3-13 (SSD2)
Multi-function/DX:
SSD
Judgment
Result Procedure
Drive motor speed sensor 1 voltage:
0.3 or less
Drive motor speed sensor 1 defect
0.4 to 1.9
0.4 to 1.9
0.3 or less
0.3 or less
Drive motor speed sensor 1/2 defect
less than 0.3
Error Code: C8-2

Failure mode: Drive motor speed sensor short circuit abnormality
CAUTION
• Jack up until drive wheels leave the ground and support the vehicle with wooden blocks before per-
forming troubleshooting.
Probable cause
▪ Drive motor speed sensor 1/2 harness defect
▪ Drive motor speed sensor 1/2 defect
Related part
P4 CN110-15 (78,SSD+) CN53-2

＋ Drive
Drivemotor
motor
speed sensor
rpm sensor 11
CN110-14 (79,SSD1) CN53-1
Drive
Drive motor
motor
driver
driver CN54-2
N1
− Drive
Drivemotor
motor
CN110-13 (80,SSD2) CN54-1 speed sensor2 2
rpm sensor
Step 1
Error recheck
of the CN110, CN53 and CN54 connectors and the wire
caulking.
Judgment
Result Procedure
Step 2
2. Disconnect the CN110, CN53 and CN54 connectors and in- 3
spect the harness.
NOTICE!
connect the CN110, CN53 and CN54 connectors, visually
CN110 CN53 CN54 inspect whether there is no problem with the inside of the
1 2 3 4 5 6 7 8 connector and the wire caulking, and then inspect the har-
9 10 11 12 13 14 15 1 2 1 2
16 17 18 19 20 21 22 23 ness.
Measurement terminals Standard
CN110-14.
CN110-13.
Judgment
Result Procedure
OK Go to Step 3
NG Drive motor speed sensor 1 and 2 harness defect
Step 3
with the CN53 and CN54 connectors disconnected, and turn
the key switch ON.
3. Measure the voltage between CN53-2 and N1 and between
CN54-2 and N1.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Except 12 - 16 V Drive motor driver defect
Step 4
Error recheck
with the CN53 and CN54 connectors disconnected, and turn
the key switch ON to check the error display.
Judgment
Result Procedure
Displays C8-1 error Go to Step 5
Displays C8-2 error or no error Drive motor driver defect
Step 5
2. Connect the CN110 connector, measure the resistance 3
between CN53-1 (CN110 side) and N1 and between
CN54-1 (CN110 side) and N1, with the CN53 and CN54
connectors disconnected.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Both are approximately 100 Ω. Go to Step 6
Either is except approximately 100 Ω. Drive motor driver defect
Step 6
Drive motor speed sensor inspection
2. Connect the CN53 and CN54 connectors.
3. Connect the battery plug and turn the key switch ON to dis-
play C8-2 error.
Drive motor speed sensor: Sensor 1/Sensor 2
STD Display:
[ANL] IO2 3-12 (SSD1)
[ANL] IO2 3-13 (SSD2)
Multi-function/DX:
SSD
Judgment
Result Procedure
2.0 or less
0.4 to 1.9
0.4 to 1.9
2.0 V or more
2.0 or more
Drive motor speed sensor 1/2 defect
2.0 V or more
Error Code: C9-1

Failure mode: Inclination angle sensor open circuit abnormality
Probable cause
▪ Inclination angle sensor defect
▪ Harness defect
Related part
CN103-8 (300,IPL+) CN132-1
Main
Main Inclination angle
controller CN102-34 (310,SSLP) CN132-2 Inclination
sensor angle
sensor
CN101-32 (51,POT-) CN132-3
Step 1
Connector inspection
3. After connecting the CN132 connector, connect the battery
plug and turn the key switch ON to check for errors.
Judgment
Result Procedure
No error at C9-1 Connector contact defect
Step 2
Inclination angle sensor inspection
2. Disconnect the CN132 connector and connect CN132-1 and 3
CN132-2 on the harness side with SST2.
3. Connect the battery plug, turn the key switch ON, and check
for error codes.
CN132
1 2 3
Judgment
Result Procedure
Error at C9-2 Inclination angle sensor defect
Step 3
2. Disconnect the CN101, CN102, CN103 and CN132 con-
nectors and inspect the harness with SST2 disconnected.
CN102
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
connect the CN101, CN102, CN103 and CN132 connectors,
28 29 30 31 32 33 34 35 CN132 visually inspect the inside of the connectors and the wire
caulking for any error without connecting SST2, and per-
CN103 1 2 3 form inspection.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN102-34 - CN132-2 Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: C9-2

Failure mode: Inclination angle sensor short circuit abnormality
Probable cause
▪ Inclination angle sensor sensor defect
▪ Harness defect
Related part
CN103-8 (300,IPL+) CN132-1
Main
Main Inclination angle
controller CN102-34 (310,SSLP) CN132-2 Inclination
sensor angle
sensor
CN101-32 (51,POT-) CN132-3
Step 1
plug and turn the key switch ON to check for errors.
Judgment
Result Procedure
No error at C9-2 Connector contact defect
Step 2
2. Disconnect the CN101, CN102, CN103, CN112 and CN132 3
connectors.
NOTICE!
1 2 3 4 5 6 7 visually inspect the inside of the connectors and the wire
CN132
8 9 10 11 12 13 14 15 16 17 caulking for any error, and perform inspection.
18 19 20 21 22 23 24 25 26 27 1 2 3 Refer to "BEFORE TROUBLESHOOTING."
28 29 30 31 32 33 34

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
Inclination angle sensor inspection
2. Disconnect the CN132 connector and connect the CN101
and CN102, CN103 connectors.
3. Connect the battery plug, turn the key switch ON, and check
error codes.
Judgment
Result Procedure
Error at C9-1 Inclination angle sensor defect
Error Code: C9-3

Failure mode: Inclination angle sensor matching value abnormality
CAUTION
• When C9-1 and C9-2 errors are occurring, perform the following only after the troubleshooting has
been completed.
Probable cause
▪ Inclination angle sensor horizontal matching defect
Main controller
Step 1
1. Perform tilt angle sensor matching.
Judgment
Result Procedure
Step 2
Inclination angle sensor voltage inspection
1. Check the voltage of the tilt angle sensor.
SSLP
Incline of road surface Standard
Flat ground 2.25 - 2.75 V
Judgment
Result Procedure
Go to Step 3
Out of the limits of the standard values Inclination angle sensor assembly failure. After reassembling
it, perform matching and then perform Step 3.
Within the limits of the standard values Main controller defect
Step 3
Error recheck
2. After 30 seconds, connect the battery plug again and turn 3
the key switch ON.
Judgment
Result Procedure
No error at C9-3 Inclination angle sensor horizontal matching defect
Error Code: CB-1

Failure mode: MB contactor open circuit abnormality
CAUTION
• If CB-3 or CB-5 is occurring at the same time, give a higher priority to troubleshooting them.
Probable cause
▪ MB contactor defect
▪ Harness defect
▪ F6/F7 fuse defect
▪ F6/F7 fuse box defect
Related part
48V MB
P2 P3 F1 P4
F7
CN139-4 CN139-3 (18) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F6
CN139-2 CN139-1 (44) CN104-2 (44, VBMB) Main
Main
controller
controller
F5
CN138-4 CN138-3 (41) CN104-1 (41, B48V)
N1
CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)
MB MB
Contactor CN134-2
Contactor CN136-4 (1,CBAT+) CN104-3 (1, CBAT+)
80V MB
P2 P3 F1 P4
P0
F7
CN136-6 (19) CN102-3 (19,VBMB)
CN102-4 (19,VBMB)
CN104-2 (19, VBMB) Main
Main
F6
CN136-5 (18) CN104-1 (18, B80V) controller
N1 F5
CN141-1 CN136-2 (41) CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)

MB MB
Contactor CN134-2
Step 1
2. Disconnect the CN139 (48 V vehicles), CN136 (80 V 3
vehicles) connector and visually inspect whether there is no
problem with the inside of the connector and the wire
caulking.
3. Connect the CN139 (48 V vehicles), CN136 (80 V vehicles)
connector and connect the battery plug.
Judgment
Result Procedure
No error at CB-1 Connector connection defect
Error at CB-1 Go to Step 2
Step 2
Check the operation of the MB contactor
1. Check whether the MB contactor will operate when the key
switch is turned ON.
Judgment
Result Procedure
Operates Go to Step 4
Does not operate Go to Step 3
Step 3
Check the connection of the MB contactor
1. Turn the key switch OFF, disconnect the battery plug, and
visually check the MB contactor contact (foreign matter or
freezing).
Judgment
Result Procedure
MB contactor defect
NG
Take measures on the incorrect items, Use the vehicle as is.
OK Perform CB-3 troubleshooting
Step 4
Fuse inspection
2. Remove the F6 (48 V vehicles) / F7 (48 V, 80 V vehicles)
fuses and measure the resistance at both ends of the F6
(48 V vehicles) / F7 (48 V, 80 V vehicles) fuses.
Judgment
Result Procedure
F6/F7 fuse defect
∞Ω
Replace the defective fuse and Go to Step 6.
0Ω Go to Step 5
Step 5
Fuse box inspection
1. Install the F6 (48 V vehicles) / F7 (48 V, 80 V vehicles)
fuses and disconnect the connector of the fuse box.
2. Measure the resistance at both ends of the F6 (48 V
vehicles) / F7 (48 V, 80 V vehicles) fuse box.
Judgment
Result Procedure
∞Ω F6/F7 fuse box defect
0Ω Go to Step 6
Step 6
1. Disconnect the CN102, CN104, CN140 (48 V vehicle) and
CN136 (80 V vehicle) connectors. 3
CN102
NOTICE!
1 2 3 4 5 6 7 CN139
8 9 10 11 12 13 14 15 16 17 18 19 1 2
20 21 22 23 24 25 26 27 3 4
connect the CN102, CN104, CN140 (48 V vehicles), and
28 29 30 31 32 33 34 35 (48V) CN136 (80 V vehicles) connectors, visually inspect whether
there is no problem with the inside of the connector and
CN104 the wire caulking, and then inspect the harness.
CN136 Refer to "BEFORE TROUBLESHOOTING."
1 2 3 4 5 6 7
1 2 3 4 48 V vehicles
8 9 10 11 12 13 14 15 16 17
5 6 7 8
18 19 20 21 22 23 24 25
26 27 28 29 30 31 (80V)
CN139-3 (19) - CN102-3 (19) Continuity
CN139-3 (19) - CN102-4 (19) Continuity
CN139-1 (44) - CN104-2 (44) Continuity
80 V vehicles
CN136-6 (19) - CN102-3 (19) Continuity
CN136-6 (19) - CN102-4 (19) Continuity
CN136-6 (19) - CN104-2 (19) Continuity
Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
Step 7
Voltage inspection
2. Measure the voltage at both ends on the contactor contact
1, 2 ton models (48 V)
side
P1
F4,F5 F6,F7
P4 F1
3 ton models (80 V)
P1
F7
F6
F4
F5
P4 F1
Judgment
Result Procedure
30 V or more MB contactor defect
Error Code: CB-2

Failure mode: MB contactor short circuit abnormality
3
CAUTION
• AD-5, AD-6, 33-3, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1, EC-2, or EC-3 is displayed with CB-2 at the same
time, give a higher priority to troubleshooting AD-5, AD-6, 33-3, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1,
EC-2, or EC-3.
• If CB-2 error occurs, electric charge remains in the drive motor driver/pump motor driver after dis-
connecting the battery plug. Measure the voltage between P4 and N1 and conduct work when the
voltage becomes 3 V or less.
Probable cause
Related part
48V MB
P2 P3 F1 P4
F7
CN139-4 CN139-3 (18) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F6
CN139-2 CN139-1 (44) CN104-2 (44, VBMB) Main
Main
controller
controller
F5
CN138-4 CN138-3 (41) CN104-1 (41, B48V)
N1
CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)
MB MB
Contactor CN134-2
80V MB
P2 P3 F1 P4
P0
F7
CN136-6 (19) CN102-3 (19,VBMB)
CN102-4 (19,VBMB)
Main
F6
CN136-5 (18) CN104-1 (18, B80V) controller
N1 F5
CN141-1 CN136-2 (41) CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)

MB MB
Contactor
Contactor CN134-2 CN136-4 (1,CBAT+) CN104-3 (1, CBAT+)
Step 1
Error recheck
1. Turn the key switch OFF, disconnect the battery plug, con-
nect it again, turn the key switch ON, and wait for five
seconds.
2. Turn the key switch OFF. After five seconds, turn the key
switch ON and check for errors.
Judgment
Result Procedure
No error at CB-2 No problem Use the vehicle as is.
Step 2
MB contactor inspection
1. Check whether the MB contactor is isolated with the key
switch OFF.
Judgment
Result Procedure
Isolation Go to Step 3
No isolation Go to Step 4
Step 3
Voltage inspection
1. Turning the key switch OFF, disconnect the battery plug,
connect it again and turn the key switch ON. 3
2. Turn the key switch OFF. After five seconds, measure the
1, 2 ton models (48 V)
voltage between P4 and N1.
P1
F4,F5 F6,F7
P4 F1
3 ton models (80 V)
P1
F7
F6
F4
F5
P4 F1
Judgment
Result Procedure
15 V or more Pump motor driver defect
Step 4
MB contactor inspection
2. Measure the voltage between P4 and N1 to check that it is
3 V or less.
3. Visually check the condition of the MB contactor contact.
Judgment
Result Procedure
Welding MB contactor defect
Isolation Perform troubleshooting for CB-3 error
Error Code: CB-3

Failure mode: MB contactor coil side open circuit abnormality
Probable cause
▪ Harness defect
Related part
48V MB
P2 P3 F1 P4
F7
CN139-4 CN139-3 (18) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F6
CN139-2 CN139-1 (44) CN104-2 (44, VBMB) Main
Main
controller
controller
F5
CN138-4 CN138-3 (41) CN104-1 (41, B48V)
N1
CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)
MB MB
Contactor
80V MB
P2 P3 F1 P4
P0
F7
CN136-6 (19) CN102-3 (19,VBMB)
CN102-4 (19,VBMB)
Main
F6 controller
CN136-5 (18) CN104-1 (18, B80V)
N1 F5
CN141-1 CN136-2 (41) CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)

MB MB
Contactor CN134-2
Step 1
2. Disconnect the CN136 connector and visually inspect 3
Judgment
Result Procedure
Step 2
MB contactor coil inspection
3. Inspect MB contactor coil resistance.
15 - 30 Ω
CN136-3 - CN136-4
CN136 (Approx. 20 Ω : 20ºC)
1 2 3 4
5 6 7 8
Judgment
Result Procedure
OK Go to Step 3
NG MB contactor defect
Step 3
Harness inspection
2. Disconnect the CN104 and CN136 connector.
NOTICE!
CN104 CN136 whether there is no problem with the inside of the con-
nector and the wire caulking, and then inspect the harness.
1 2 3 4 5 6 7 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
8 9 10 11 12 13 14 15 16 17 8 7 6 5
18 19 20 21 22 23 24 25 Portion to be inspected Standard
26 27 28 29 30 31
CN136-3 (2) - CN104-9 (2) Continuity
CN136-4 (1) - CN104-3 (1) Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: CB-4

Failure mode: MB contactor drive circuit abnormality
Probable cause 3
▪ Harness defect
Related part
48V MB
P2 P3 F1 P4
F7
CN139-4 CN139-3 (18) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F6
CN139-2 CN139-1 (44) CN104-2 (44, VBMB) Main
Main
controller
controller
F5
CN138-4 CN138-3 (41) CN104-1 (41, B48V)
N1
CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)
MB MB
Contactor
80V MB
P2 P3 F1 P4
P0
F7
CN136-6 (19) CN102-3 (19,VBMB)
CN102-4 (19,VBMB)
Main
F6 controller
CN136-5 (18) CN104-1 (18, B80V)
N1 F5
CN141-1 CN136-2 (41) CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)

MB MB
Contactor CN134-2
Step 1
Judgment
Result Procedure
Step 2
15 - 30 Ω
CN136-3 - CN136-4
1 2 3 4
5 6 7 8
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN104 and CN136 connector. 3
NOTICE!
CN136 connect the CN104 and CN136 connectors, visually inspect
8 7 6 5 Refer to "BEFORE TROUBLESHOOTING."
CN136-3 (2) - P1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: CB-5

Failure mode: MB contactor coil side short circuit abnormality
Probable cause
▪ Harness defect
Related part
48V MB
P2 P3 F1 P4
F7
CN139-4 CN139-3 (18) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F6
CN139-2 CN139-1 (44) CN104-2 (44, VBMB) Main
Main
controller
controller
F5
CN138-4 CN138-3 (41) CN104-1 (41, B48V)
N1
CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)
MB MB
Contactor
80V MB
P2 P3 F1 P4
P0
F7
CN136-6 (19) CN102-3 (19,VBMB)
CN102-4 (19,VBMB)
Main
F6 controller
CN136-5 (18) CN104-1 (18, B80V)
N1 F5
CN141-1 CN136-2 (41) CN101-4 (41, VBBT)
CN134-1 CN136-3 (2,CBAT-) CN104-9 (2, CBAT-)

MB MB
Contactor CN134-2
Step 1
2. Disconnect the CN136 connector and visually inspect 3
Judgment
Result Procedure
Step 2
15 - 30 Ω
CN136-3 - CN136-4
1 2 3 4
5 6 7 8
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN104 and CN136 connector.
NOTICE!
CN136
4 3 2 1
8 7 6 5

Judgment
Result Procedure
NG Harness defect
Error Code: CC-1, CC-2, CC-3, CC-4, CC-6

Failure mode: Drive motor driver CPU abnormality
3
CAUTION
• If CC-1, CC-2, CC-3, CC-4 or CC-6 is displayed, it indicates drive motor driver defect. Replace it.
Probable cause
Related part
Drive
Drive motor
motor driver
driver
Error Code: E0-2

Failure mode: Pump motor driver main circuit abnormality
CAUTION
• If E0-2 error occurs, electric charge remains in the pump/drive motor driver after disconnecting the
battery plug. Measure the voltage between P4 and N1 and conduct work when the voltage becomes
3 V or less.
Probable cause
▪ Pump motor cable connection defect
▪ Pump motor defect
▪ Pump motor cable defect
Related part
P14
U
P15
Pump motor driver V Pump motor
Pump motor
P16
W
Step 1
Error recheck
visually inspect whether there is no problem with the pump
2. After connecting the pump motor cable, connect the battery
or backward, and check the error display.
Judgment
Result Action
Go to Step 2
Error at E0-2
No error at E0-2 Pump motor cable connection defect
Step 2
key switch OFF and disconnect the battery plug. 3
2. Disconnect three pump motor cables on the pump motor
driver side and insulate the terminal of the disconnected
cables.
whether E0-2 will occur.
Judgment
Result Action
Error at E0-2 Pump motor driver defect
No error at E0-2 Go to Step 3
Step 3
Pump motor cable inspection
2. Individually disconnect the motor driver side and motor side
of the pump motor cable.
3. Inspect continuity and short circuit of the pump motor cable.
NOTICE!
connect the pump motor cable, visually inspect whether
Judgment
Result Procedure
OK (no C0-2 display at the same time at
Go to Step 4
Step 1)
OK (C0-2 display at the same time at Step
Go to Step 5
1)
NG Pump motor cable defect
Step 4
1. Exchange the pump motor driver and the drive motor driver.
the error display.
Judgment
Result Action
Error at C0-2 The motor driver that the pump motor driver was replaced
with is faulty.
Error at E0-2 Pump motor defect
Step 5
Pump motor inspection
2. Inspect the pump motor.
Judgment
Result Action
NG Pump motor defect
Error Code: E1-1

Failure mode: Pump motor driver current sensor neutral abnormality
Probable cause 3
Related part
Pump motor driver
Current sensor
Error Code: E1-2

Failure mode: Pump motor driver current sensor overcurrent
abnormality
CAUTION
• E8-1 or E8-2 is displayed with E1-2 at the same time, give a higher priority to troubleshooting E8-1 or
E8-2.
• If E1-2 error occurs, electric charge remains in the pump drive motor driver after disconnecting the
3 V or less.
Probable cause
▪ Pump motor cable connection defect
▪ Pump motor defect
▪ Pump motor speed sensor defect
Related part
P14
U
P15
Pump motor
Pump motor driver
driver V Pump motor
P16
W
Step 1
Error recheck
1. Turn the key switch OFF/ON, and operate the direction
lever with forward or backward, and check if occurs E0-2 er-
ror.
Judgment
Result Procedure
No error at E0-2 Go to Step 2
Error at E0-2 Perform E0-2 troubleshooting.
Step 2
Error recheck
visually inspect whether there is no problem with the pump 3
2. After connecting the pump motor, connect the battery plug
or backward, and check the error display.
Judgment
Result Action
Go to Step 3
Error at E1-2
No error at E1-2 Pump motor cable connection defect
Step 3
Pump motor cable inspection
2. Disconnect the driver side and the motor side of the pump
motor cable.
3. Inspect continuity and short circuit of the pump motor cable.
NOTICE!
connect the pump motor cable, visually inspect whether
Judgment
Result Procedure
OK (no C1-2 display at the same time at
Go to Step 4
Step 2)
OK (C1-2 display at the same time at Step
Go to Step 5
2)
NG Pump motor cable defect
Step 4
1. Exchange the pump motor driver and the drive motor driver.
the error display.
Judgment
Result Procedure
Error at C1-2 The motor driver that the pump motor driver was replaced
with is faulty.
Error at E1-2 Pump motor defect
Step 5
Pump motor inspection
2. Inspect the pump motor.
Judgment
Result Action
NG Pump motor defect
Error Code: E2-1

Failure mode: Pump motor temperature abnormal rise
3
CAUTION
• Do not leave the vehicle in places where it gets hot.
Probable cause
Related part
CN111-9 (88,STPM+) CN55-2
Temperature sensor
Pump motor driver (pump motor)
motor)
(pump
CN111-10 (89,STPM) CN55-1
Step 1
Error recheck
display.
Judgment
Result Procedure
"PM" display Go to Step 2
If the temperature of the pump motor falls, the "PM" display
"PM" not display disappears, and you can use the truck as usual. Because an
error occurred due to a continuous use in an overloaded con-
dition, check the truck usage and avoid an overloaded con-
tinuous use.
Step 2
Pump motor temperature check and error recheck
1. STD Display:
[ANL] IO1 2-05 (TPM)
Multi-function/DX:
TPM
2. Record the pump motor temperature values.
Judgment
Result Procedure
"PM" display Go to Step 3
If the temperature of the pump motor falls, the "PM" display
"PM" not display disappears, and you can use the truck as usual. Because an
error occurred due to a continuous use in an overloaded con-
dition, check the truck usage and avoid an overloaded con-
tinuous use.
Step 3
Pump motor temperature recheck
1. STD Display:
[ANL] IO1 2-05 (TPM)
Multi-function/DX:
TPM
2. Check the pump motor temperature value and compare it
with the recorded value.
Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 2
It did not rise by 5℃ or more. Perform troubleshooting from E2-2 Step 2.
Error Code: E2-2

Failure mode: Pump motor temperature sensor open/short circuit
abnormality
3
Probable cause
▪ Pump motor temperature sensor defect
▪ Pump motor temperature sensor harness defect
Related part
CN111-9 (88,STPM+) CN55-2
Temperature sensor
Pump motor driver (pump motor)
motor)
(pump
CN111-10 (89,STPM) CN55-1
Step 1
Error recheck
Judgment
Result Procedure
Error at E2-2 Go to Step 2
No error at E2-2 Connector connection defect
Step 2
Pump motor temperature sensor individual inspection
3. Carry out a temperature sensor individual inspection.
4. Measure the resistance of the temperature sensor between
CN55-2 and CN55-1 on the sensor side of the CN55 con-
nector.
Standard: Approx. 245 Ω to 600 kΩ
CN55
NOTICE!
2 1
Resistance values vary at a low or high temperature. Use
the values in the following table as a guideline.
Temperature sensor resist-
Temperature ance value
(between CN55-2 - CN55-1)
80℃ Approx. 1.75 kΩ
Judgment
Result Procedure
OK Go to Step 3
NG Pump motor temperature sensor defect
Step 3
Harness inspection
NOTICE!
CN111 CN55 connect the CN111 and CN55 connectors, visually inspect
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 nector and the wire caulking with SST disconnected, and
16 17 18 19 20 21 22 23
then inspect the harness.
CN111-10.
Judgment
Result Procedure
NG Pump motor temperature sensor harness defect
Error Code: E3-1

Failure mode: Pump motor driver main circuit temperature sensor
open/short circuit abnormality
3
CAUTION
• If E3-1 is displayed, it indicates pump motor driver abnormality. Replace it.
Probable cause
Related portion
Pump
Pump motor
motor driver
driver
Temperature sensor
Error Code: E8-1

Failure mode: Pump motor speed sensor open circuit abnormality
CAUTION
3 V or less.
Probable cause
▪ Pump motor speed sensor harness defect
Related part
P4 CN111-15 (81,SSP+) CN56-2

＋
Pump motor Pump

Pumpmotor
motor
driver
driver speed sensor
N1 CN111-14 (82,SSP1) CN56-1

−
Step 1
Error recheck
visually inspect the inside of the CN56 and CN111 connect-
ors and the wire caulking for any error.
Judgment
Result Procedure
Step 2
Harness inspection
2. Disconnect the CN111 and CN56 connectors. 3
NOTICE!
CN111 CN56 connect the CN111 and CN56 connectors, visually inspect
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 nector and the wire caulking with SST2 disconnected, and
16 17 18 19 20 21 22 23
CN111-14.
Judgment
Result Procedure
OK Go to Step 3
NG Pump motor speed sensor harness defect
Step 3
with the CN56 connector disconnected, and turn the key
switch ON.
3. Measure the voltage between CN56-2 (CN111 side) and
N2.
CN56
1 2
Judgment
Result Procedure
Except 12 - 16 V Pump motor driver defect
Step 4
Error recheck
2. Use SST2 to connect between CN56-1 and CN56-2 at the
CN111 side, with the CN56 connector disconnected.
check the error display
CN56
1 2
Judgment
Result Procedure
Displays E8-2 error Go to Step 5
Displays E8-1 error or no error Pump motor driver defect
Step 5
2. Remove the SST2, measure the resistance between
CN56-1 (CN111 side) and N2, with the CN56 connector dis-
connected.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor speed sensor defect
Approx. other than 100 Ω Pump motor driver defect
Error Code: E8-2

Failure mode: Pump motor speed sensor short circuit abnormality
3
CAUTION
3 V or less.
Probable cause
▪ Pump motor speed sensor harness defect
Related part
P4 CN111-15 (81,SSP+) CN56-2

＋
Pump motor Pump

Pumpmotor
motor
driver
driver speed sensor
N1 CN111-14 (82,SSP1) CN56-1

−
Step 1
Error recheck
visually inspect the inside of the CN56 and CN111 connect-
ors and the wire caulking for any error.
Judgment
Result Procedure
Step 2
Harness inspection
NOTICE!
CN111 CN56 Turn the key switch OFF, disconnect the battery plug, dis-
1 2 3 4 5 6 7 8 connect the CN111 and CN56 connectors, visually inspect
9 10 11 12 13 14 15 1 2
16 17 18 19 20 21 22 23 whether there is no problem with the inside of the con-
nector and the wire caulking with SST2 disconnected, and
CN111-14.
Judgment
Result Procedure
OK Go to Step 3
NG Pump motor speed sensor harness defect
Step 3
with the CN56 connector disconnected, and turn the key
switch ON.
3. Measure the voltage between CN56-2 (CN111 side) and
N2.
CN56
1 2
Judgment
Result Procedure
Except 12 - 16 V Pump motor driver defect
Step 4
Error recheck
2. Connect the battery plug with the CN56 connector discon- 3
nected, and turn the key switch ON to check the error dis-
play.
Judgment
Result Procedure
Displays E8-1 error Go to Step 5
Displays E8-2 error or no error Pump motor driver defect
Step 5
2. Measure the resistance between CN56-1 (CN111 side) and
N2, with the CN56 connector disconnected.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor speed sensor defect
Approx. other than 100 Ω Pump motor driver defect
Error Code: EC-1, EC-2, EC-3, EC-4, EC-6

Failure mode: Pump motor driver CPU abnormality
CAUTION
• If EC-1, EC-2, EC-3, EC-4 or EC-6 is displayed, it indicates pump motor driver defect. Replace it.
Probable cause
Related part
Pump motor driver

Error Code: ED-1

Failure mode: CAN bridge communication disruption
Probable cause 3
▪ Harness defect
▪ Telematics power source semiconductor relay defect
▪ CAN bridge controller defect
Related part
48V
P2 MB P3
F5
CN138-4
CN209-6 (41,B48V)
CN209-1 (334,PSACC+) CN104-14 CN103-11 (145,CAN1H)
CN209-2 (333,OACC3) CN102-8 Main Main CN103-12
controller
CN104-5 (N2,N2) controller (146,CAN1L)
▲ ▲
▲ ▲
CN100-5 Numeric
CN100-14 (IG) CAN keypad
keypad
CAN CN100-9
CN209-4 (440,VBRY) bridge
bridge
N1 CN100-13 (N2,E1) controller
Telematics power
Telematics power source
source CN100-4 (N2,E2)
semiconductor relay
semiconductor relay SSR3
SSR3
80V
P2 MB P3
P0
F5 CN209-6 (41,B48V)
CN136-2
CN209-2 (333,OACC3) CN102-8 Main
Main CN103-12
controller
▲ ▲
▲ ▲
CN100-5 Numeric
keypad
CAN CN100-9
bridge
Telematics power source CN100-4 (N2,E2)
Step 1
Telematics power source check
1. With the battery plug connected, sit on the seat and turn the
key switch ON.
2. Press the logoff button (red [○] button) on the numeric
keypad, and check whether the red lamp on the numeric
keypad will turn on every time you press it.
Judgment
Result Procedure
Not lit Go to Step 2
Lit Go to Step 6
Step 2
of the CN100, CN102, CN104 and CN209 connectors and
the wire caulking.
3. After connecting the CN100, CN102, CN104 and CN209
connectors, connect the battery plug and turn the key switch
ON. Wait for 10 seconds or more and then check for errors.
Judgment
Result Procedure
No ED-1 Connector connection defect
ED-1 exists Go to Step 3
Step 3
Harness inspection
(80V vehicles) connectors.
CN102
CN100 NOTICE!
1 2 3 4 5 6 7
1 2 3 4 5
6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
10 11 12 13 14 connect the CN100, CN102, CN104, CN209, and CN136 (80V
28 29 30 31 32 33 34 35 vehicles) connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
CN104 CN209 caulking, and then inspect the harness.
48V and 80V vehicles
1 2 3 4 5 6 7 1 2 3
8 9 10 11 12 13 14 15 16 17
4 5 6 Portion to be inspected Standard
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN209-1 (334) - CN104-14 Continuity
CN209-6 (41) - P2 Continuity
CN104-5 (N2) - CN100-13 Continuity
CN104-14 (334) - N1 (N1) No continuity
80V vehicles
Portion to be inspected (80V vehicles) Standard
CN209 CN136
3
1 2 3 4 3 2 1
8 7 6 5
4 5 6
Judgment
Result Procedure
NG Harness defect
OK Go to Step 4
Step 4
Semiconductor relay inspection
2. Disconnect the CN209 connector, and check the resistance
at the relay side.
NOTICE!
CN209
The following CN209(333)(+) - CN209-1(334)(+) are the
measurement methods of an analog tester
3 2 1
6 5 4
▪ Since diodes are connected inside the relay, the meas-
urement method could differ depending on the tester
used.
(For details, refer to INSPECTION OF ELECTRIC
PARTS)
CN209-2 (333) - CN209-1 (334) Approx. 750 Ω
(Tester range: Ω x 10)
Judgment
Result Procedure
NG Telematics power source semiconductor relay defect
OK Go to Step 5
Step 5
1. Turn the key switch ON, and turn the seat switch ON.
2. Measure the voltage at both ends of the relay
CN209-1 (334) - CN209-2 (333) Approx. 15 V
CN209
3 2 1
6 5 4
Judgment
Result Procedure
NG Telematics power source semiconductor relay defect
Step 6
of the CN100, CN103 and CN104 connectors and the wire
caulking.
3. After connecting the CN100, CN103 and CN104 connect-
ors, connect the battery plug and turn the key switch ON.
Wait for 10 seconds or more and then check for errors.
Judgment
Result Procedure
Step 7
Harness inspection
CN103
CN100 NOTICE!
1 2 3 4 5 6
1 2 3 4 5
6 7 8 9
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
10 11 12 13 14 connect the CN100, CN103, and CN104 connectors, visually
28 29 30 31 32 33 34 35 inspect the inside of the connectors and the wire caulking
for any error, and perform inspection.
CN104 CN209
1 2 3 4 5 6 7 1 2 3 CN103-11 (145) - CN100-9 Continuity
8 9 10 11 12 13 14 15 16 17
4 5 6 CN103-12 (146) - CN100-5 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-5 (N2) - CN100-13 Continuity
Judgment
Result Procedure
NG Harness defect
OK CAN bridge controller defect
Error Code: ED-4

Failure mode: CAN bridge controller/Data Handling Unit (DHU2)
communication disruption
CAUTION
• If ED-1 is occurring, give a higher priority to troubleshooting ED-1.
Probable cause
▪ Harness defect
▪ Data Handling Unit (DHU2) defect
Related part
48V
P2 MB P3
F5
CN138-4
CN209-6 (41,B48V)
CN209-2 (333,OACC3) CN102-8 Main Main CN103-12
controller
▲ ▲
▲ ▲
CN100-5 Numeric
keypad
CAN CN100-9
bridge
Telematics power
Telematics power source
source CN100-4 (N2,E2)
semiconductor relay
SSR3
80V
P2 MB P3
P0
F5 CN209-6 (41,B48V)
CN136-2
CN209-2 (333,OACC3) CN102-8 Main
Main CN103-12
controller
▲ ▲
▲ ▲
CN100-5 Numeric
keypad
CAN CN100-9
bridge
Telematics power source CN100-4 (N2,E2)
Step 1
Telematics power source check
1. With the battery plug connected, sit on the seat and turn the
key switch ON. 3
2. Check the lighting of green LED on the operation manage-
ment system.
Judgment
Result Procedure
Not lit Go to Step 2
Lit Go to Step 4
Step 2
of the CN100 and CN209 connectors and the wire caulking.
3. After connecting the CN100 and CN209 connectors, con-
nect the battery plug and turn the key switch ON. Wait for
10 seconds or more and then check for errors.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN209 CN284
the inside of the connectors and the wire caulking for any
3 2 1
1 2 3 4 error, and perform inspection.
6 5 4 5 6 7 8
CN284-8 - N1 (N1) Continuity
Judgment
Result Procedure
NG Harness defect
OK Operation management system defect
Step 4
of the CN100 and CN284 connectors and the wire caulking.
3. After connecting the CN100 and CN284 connectors, con-
nect the battery plug and turn the key switch ON. Wait for
10 seconds or more and then check for errors.
Judgment
Result Procedure
Step 5
Harness inspection
CN209 NOTICE!
CN100
1 2 3 4 5 1 2 3
6 7 8 9 connect the CN110 and CN284 connectors, visually inspect
10 11 12 13 14 4 5 6 whether there is no problem with the inside of the con-
CN284
1 2 3 4
5 6 7 8 CN100-3 (442) - CN284-2 Continuity
CN100-13 - N1 (N1) Continuity
CN100-2 (443) - CN100-13 (N1) No continuity
CN100-3 (442) - CN100-13 (N1) No continuity
Judgment
Result Procedure
NG Harness defect
OK Operation management system defect
Error Code: EE-1, EE-2

Failure mode: Display to main controller communication abnormality
3
CAUTION
• If the EE-1 or EE-2 memories were confirmed on the display, the communication with the display has
already recovered. Use the vehicle as is.
Probable cause
▪ Display defect
Related part
CN103-11 (145,CAN1H) CN70-16
Main controller Display

Display
CN103-12 (146,CAN1L) CN70-15
Step 1
Error recheck
1. Check whether F1-1 or F1-2 error is occurring on the dis-
play screen.
Judgment
Result Procedure
Occurring Go to F1-1 or F1-2 troubleshooting
Not occurring Display defect, or main controller defect
Error Code: F1-1

Failure mode: Main controller to display communication abnormality
Probable cause
Related part
CN103-3 (14,DGND) CN70-4
CN103-14 (16,D7V) CN70-5

Display
CN103-11 (145,CAN1H) CN70-16
CN103-12 (146,CAN1L) CN70-15
Step 1
Error recheck
there is no problem with the inside of the CN103 and CN70
connectors and the wire caulking.
Judgment
Result Procedure
Displays F1-1 or F1-2 Perform F1-2 troubleshooting
Connector connection defect
Does not display F1-1 or F1-2
Use the vehicle as is
Error Code: F1-2

Failure mode: Main controller to display communication abnormality
Probable cause 3
▪ Harness defect
▪ Display defect
Related part
CN103-4 (42,KYSAT) CN110-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN110-17 (145,CAN1H)
Main
Main CN103-12 (146,CAN1L) CN110-16 (146,CAN1L)
controller CN103-3 (14,DGND) Drive motor driver
CN103-14 (16,D7V) CN110-6
NC
CN103-5 (N2, N2) CN110-23
NC
CN70-5 (16,D7V)
CN70-4 (14,DGND) CN111-8 (42,KYSAT)
Display CN70-16 (145,CAN1H) CN111-17 (145,CAN1H)
CN70-15 (146,CAN1L) CN111-16 (146,CAN1L)
Pump motor
driver
CN111-7
NC
CN111-23 (152,SETP-)
Step 1
Error recheck
there is no problem with the inside of the CN103 and CN70
connectors and the wire caulking.
Judgment
Result Procedure
Error at F1-2 Go to Step 2
No error at F1-2 Connector connection defect
Step 2
Harness inspection
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN103-11 - CN70-16 Continuity (Approx. 0 Ω)
CN103-12 - CN70-15 Continuity (Approx. 0 Ω)
CN103
CN70-15 - CN70-16 No continuity (other than 0 Ω)
1 2 3 4 5 6 CN70-15 - CN70-4 No continuity (other than 0 Ω)
7 8 9 10 11 12 13 14 15 16 CN70-15 - CN70-5 No continuity (other than 0 Ω)
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN70-16 - CN70-4 No continuity (other than 0 Ω)
Judgment
Result Procedure
NG Harness defect
OK Go to Step 3
Step 3
Traveling and load handling inspection
2. After connecting the CN70 and CN103 connectors, connect
the battery plug and turn the key switch ON to check the op-
eration of traveling and load handling.
Judgment
Result Procedure
Display defect
Traveling and load handling can operate If the problem persists after the display is replaced, replace
the main controller, because there may be other failures.
Traveling and load handling cannot operate If the problem persists after the main controller is replaced,
replace the display, because there may be other failures.
Error Code: F4-1, F4-2, F4-3, F4-4, F4-5, F4-6, F4-7, F4-8
Failure mode: Display CPU abnormality
3
CAUTION
• If F4 is displayed, the display is defective, so replace it.
Probable cause
▪ Display defect
Related portion
Multi-display
Error Code: F5-1

Failure mode: Battery fluid-level/Battery fluid temperature sensor
vehicle connection harness open circuit abnormality
CAUTION
• Connect the battery plug after connecting the CN35 connector, because connecting the battery plug
before connecting the CN35 connector may cause an error.
If an error is caused by connecting the battery plug before connecting the CN35 connector, a normal
error disappears after about one minute.
Probable cause
▪ Battery fluid level sensor and temperature improper connection
▪ Truck connection harness defect
▪ Battery fluid level sensor and temperature defect
▪ Display defect
▪ Battery fluid temperature sensor defect
Related part
P1
Battery fluid level connector
Sensor
Sensor
Battery fluid
Battery fluid level
level detection
detection G
G output
output CN70-26
signal Y (140,SLLT)
Display
Sensor
Sensor power
power supply
supply R
R
CN35
Battery
Sensorfluid
for
temperature
battery fluid
sensor
level and
temperature
temperature
Battery
Battery fluid
fluid temperature
temperature B
B
Battery
Sensorfluid
for
temperature
battery fluid Battery fluid temperature W
temperature
sensor
Battery
Batteryfluid
fluidtemperature
temperatureconnector
connector
Battery
Battery
N1
Step 1
1. Check that the sensor installed on the battery is the battery
fluid level sensor and fluid temperature sensor.
3
Judgment
Result Procedure
OK Go to Step 2
With the display service function, change the battery unit set-
NG tings (Option set → STD: 1 OPTSET 1 02, Multi-function dis-
play DX: B UNIT).
Step 2
Error recheck
1. Disconnect the battery plug and visually inspect the CN35
connector on the truck side is connected to the battery fluid
level sensor and fluid temperature sensor.
2. After connecting the connector, connect the battery plug,
Judgment
Result Procedure
F5-1 displayed Go to Step 3
F5-1 not displayed Connector connection defect
Step 3
Harness inspection
3. Inspect conduction and short circuit of the harness.
CN35 NOTICE!
1 Turn the key switch OFF, disconnect the battery plug, dis-
connect the CN35 and CN70 connectors, and conduct after
visually inspecting there are no problems inside the con-
nector, and on the wire caulking.
CN70
Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN35 connector - CN70-26 Conduction
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Judgment
Result Procedure
OK Go to Step 4
NG Truck connection harness defect
Step 4
Inspect the sensor for battery fluid level sensor and fluid tem-
perature output current
2. Connect the battery plug, and while the key switch is OFF,
check the output current of the battery fluid level sensor and
fluid temperature sensor.
NOTICE!
CN35
Disconnect the CN35 connector, and connect the battery
plug, and while the key switch is OFF, check the output
1
current on the battery fluid level between CN35 connector
and N1 terminal on the sensor side, and the fluid temperat-
ure sensor.
For an analog type tester, use the red tester probe for the
CN35 connector, and the black tester probe for the N1 ter-
minal.
Inspected point Standard
CN35 connector - N1 terminal Approx. 2 mA to 15 mA
Judgment
Result Procedure
OK Go to Step 5
NG Battery fluid level sensor and fluid temperature sensor defect
Step 5
Single unit inspect the battery fluid temperature sensor
2. Disconnect the battery fluid temperature sensor connector.
3. Individually inspect the sensor for battery fluid temperature.
4. Measure the resistance of the sensor for battery fluid tem-
perature between the fluid temperature B terminal and the
fluid temperature W terminal on the battery fluid temperat-
ure sensor side.
Standard value: Approx. 330 kΩ to Approx. 35 kΩ
(Battery fluid temperature 0 to 50 ℃)
NOTICE!
Resistance values vary at a low or high temperature; there-
fore, use the values in the following table as guideline.
Resistance of battery fluid
temperature sensor
20 ℃ Approx. 124 kΩ
Judgment
Result Procedure
OK Display defect
NG Battery fluid temperature sensor defect
Error Code: F5-2

Failure mode: Battery fluid-level/Battery fluid temperature sensor
vehicle connection harness short circuit abnormality
3
Probable cause
▪ Truck connection harness defect
▪ Battery fluid level and fluid temperature sensors defect
▪ Display defect
Related part
P1
Battery fluid
Battery fluid level
level connector
connector
Sensor
Battery
Battery fluid
fluid level
level detection
detection G
G Sensor CN35 CN70-26
output
output YY
signal (140,SLLT)
Sensor power supply R Display
CN70-1 (128,CHG7V)
Battery CN70-5 (16,D7V)
Batteryfluid
fluid
temperature
level sensor CN70-6 (162,ITKY3)
and fluid
sensor and CN70-8 (160,ITKY1)
temperature
temperature CN70-15 (146,CAN1L)
Battery fluid temperature B sensors CN70-16 (145,CAN1H)
Battery fluid temperature B
CN70-18 (43,VBKY)
Battery
Batteryfluid
fluid CN70-20 (161,ITKY2)
temperature
temperature Battery fluid temperature W CN70-21 (163,IPSTKY1)
sensor
sensor CN70-22 (123,SW1)
CN70-23 (122,SW2)
Battery
Batteryfluid
fluidtemperature
connector CN70-24 (121,SW3)
CN70-25 (129,CHGAC)
Battery
Battery CN70-28 (139,SWTT)
N1
CN70-33 (132,CHGMS)
Step 1
Error recheck
visually inspect there are no problems inside the CN35 and
CN70 connectors, and on the wire caulking.
Judgment
Result Procedure
Step 2
Display voltage inspection
3. Connect the battery plug and inspect the display voltage
with the key switch ON.
NOTICE!
CN35
plug, and while the key switch is ON, check the voltage
between the CN35 connector to N1 terminal.
1
CN35 connector (Main harness side) - N1
0V
terminal
Judgment
Result Procedure
NG (except 0 V) Go to Step 3
OK (0 V) Go to Step 5
Step 3
Harness inspection
3. Connect the battery plug and inspect the harness voltage
with the key switch ON.
NOTICE!
Disconnect the CN35 and CN70 connectors, and connect
CN35
the battery plug, and while the key switch ON, inspect the
voltage between the CN35 connector and N1 terminal.
1
CN35 connector (Main harness side) - N1
0V
terminal
Judgment
Result Procedure
OK (0 V) Go to Step 4
NG (except 0 V) Truck connection harness defect
Step 4
Harness inspection
2. Disconnect the CN35 and CN70 connectors. 3
NOTICE!
connect the CN35 and CN70 connectors, and conduct after
CN70 visually inspecting there are no problems inside the con-
nector, and on the wire caulking.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN70-26 - CN70-1 No conduction
Judgment
Result Procedure
OK Display defect
NG Truck connection harness defect
Step 5
3. Inspect the battery fluid temperature sensor as a single unit.
Measure the resistance of the battery fluid temperature
sensor between the fluid temperature B terminal and the
fluid temperature W terminal on the battery fluid sensor
side.
NOTICE!
Resistance value of battery
fluid temperature sensor
Judgment
Result Procedure
OK Go to Step 6
Step 6
Inspect the sensor for battery fluid level sensor and fluid tem-
perature output current
2. Connect the battery plug and while the key switch is OFF,
check the output current of the battery fluid level sensor and
fluid temperature sensor.
NOTICE!
CN35
plug, and while the key switch is OFF, check the output
1
current on the battery fluid level between CN35 connector
and N1 terminal on the sensor side, and the fluid temperat-
ure sensor.
For an analog type tester, use the red tester probe for the
CN35 connector, and the black tester probe for the N1 ter-
minal.
CN35 connector - N1 terminal Approx. 2 mA to 15 mA
Judgment
Result Procedure
OK Display defect
NG Battery fluid level sensor and fluid temperature sensor defect
Error Code: F5-3

Failure mode: Battery fluid temperature open circuit abnormality
3
CAUTION
• Park the truck in room temperature, because leaving it in a low-temperature environment (-20 ℃ or
less) may cause an error.
If an error is displayed by leaving the truck in a low-temperature environment for a long time, there
is no problem using it with the error displayed.
If the sensor is normal, the error disappears if the battery fluid temperature becomes higher than -20
℃.
(The battery temperature can be checked in the multi-function display DX: [ANL] I/O TEMP/VOLT 3/5
TSLLT, STD: 2 IO1 2-10; however, it is displayed as -20 ℃ for the temperature -20 ℃ or less)
If the user's work environment is always at a low temperature, and the error often occurs, set the op-
tion set “B UNIT” (STD: 1 OPTSET 1 02) to “A” to prevent the error from displayed; however, the bat-
tery fluid level and fluid temperature detection functions are also disabled.
Probable cause
▪ Usage at low battery fluid temperature (-20 ℃ or less)
▪ Sensor for Battery Fluid Temperature defect
▪ Sensor for Battery Fluid Level and Temperature defect
Related part
P1
Battery
Battery fluid
fluid level
level connector
connector
Sensor
Sensor
Battery fluid
Battery fluid level
level detection
detection G
G output
output CN70-26
signal Y (140,SLLT)
Sensor power supply R Display
CN35
Sensor
Sensorfor for
battery
battery fluid
fluid
level and
level and
temperature
temperature
Battery
Battery fluid
fluid temperature
temperature B
B
Battery
Sensorfluid
for
temperature
temperature
sensor
Battery
Batteryfluid
fluidtemperature
connector
Battery
N1
Step 1
Error recheck
1. Disconnect the battery plug, and visually inspect there are
no problems inside the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING".)
Judgment
Result Procedure
Step 2
Single unit inspect of the battery fluid temperature sensor
3. Single unit inspect the battery fluid temperature sensor.
sensor between the fluid temperature B terminal to the fluid
temperature W terminal on the battery fluid temperature
sensor side.
NOTICE!
Resistance value of battery
fluid temperature sensor
Judgment
Result Procedure
OK Battery fluid level sensor and fluid temperature sensor defect
Error Code: F5-4

Failure mode: Battery fluid temperature sensor temperature
abnormality
3
CAUTION
• If F5-1 is displayed at the same time, give a higher priority to troubleshooting of F5-1.
When the battery plug is connected before connecting the CN35 connector, it may cause error;
therefore, connect the battery plug after connecting the CN35 connector.
If an error occurs by connecting the battery plug before connecting the CN35 connector, the error
disappears after about one minute if everything is normal.
Probable cause
▪ Battery fluid level sensor and fluid temperature sensor improper connection
▪ Battery fluid level sensor and fluid temperature sensor defect
Related part
P1
Battery
Battery fluid
fluid level
level connector
connector
Sensor
Sensor
Battery fluid
Battery fluid level
level detection
detection G
G output
output CN70-26
signal Y (140,SLLT)
Display
Sensor power supply R
CN35
Sensor
Sensorfor for
battery
battery fluid
fluid
level and
level and
temperature
temperature
Battery
Battery fluid
fluid temperature
temperature B
B
Battery
Sensorfluid
for
temperature
temperature
sensor
Battery
Batteryfluid
fluidtemperature
connector
Battery
N1
Step 1
Sensor inspection
1. Check that the sensor installed on the battery is the battery
fluid level sensor and fluid temperature sensor.
Judgment
Result Procedure
OK Go to Step 2
With the display service function, change the battery unit set-
NG tings (Option set “B UNIT”).
STD: 1 OPTSET 1 02
Step 2
Error recheck
1. Disconnect the battery plug and visually inspect there are
no problems inside the connector, and on the wire caulking.
Judgment
Result Procedure
F5-4 not displayed Connector connection failure
Step 3
3. Single unit inspect the battery fluid temperature sensor.
sensor failure between the fluid temperature B terminal to
the fluid temperature W terminal on the battery fluid temper-
ature sensor side.
Standard: Abnormal with approximately 6 kΩ or less
Judgment
Result Procedure
OK Battery fluid level sensor and fluid temperature sensor failure
NG Battery fluid temperature sensor failure
Error Code: F6-1

Failure mode: On-vehicle charger charging abnormality (safety timer
activated)
3
CAUTION
• For causes other than listed following, refer to “Charging completes normally but the charge is in-
sufficient” or “Charging does not start when the [START] button is pushed (The charging screen is
shown on the display)”.
• F6-1 error indication will disappear after disconnecting the AC power plug. Error code can be
checked on DIAG MEMORY of the mask function. Before conducting troubleshooting, inspect the
magnet switch, and check the thermal relay is not operating. When it is operating, check the charger
component parts (magnet switch and transformer ASSY) first.
• Before performing troubleshooting of F6-1 error, turn on the key switch and check if any other error
code will be indicated. If displayed, perform troubleshooting with priority given to that error.
Probable cause
▪ AC power supply voltage defect
▪ Power cable defect
▪ Magnet switch defect
▪ FCH fuse blown
▪ Harness defect
▪ Operation panel defect
▪ Display defect
Related part
33 ton
tonseries
series CN104-1 (18,B80V)
Main
Main
controller
controller
F6
1・2
1, ton
2 ton series
Main
Main
CN101-4 (41,VBBT) controller
controller
F5
CN68-2 CN70-4 (14,DGND)

P2 Transformer
Transformer CN68-1 CN70-28 (139,SWTT)
FCH CN70-3 (169,TGND)
Transformer
Transformer CN70-5 (16,D7V)
Thermoswitch
Thermo switch
CN70-15 (146,CAN1L)
CN70-16 (145,CAN1H)
CN70-18 (43,VBKY)
CN70-36 (N2,GND)
CN69-1 CN70-33 (132,CHMS)
DISPLAY
DISPLAY
CN69-2 CN70-25 (129,CHAC)
CN61
CN69-3 CN70-2 (130,CHGND)

N2
CN69-4 CN70-1 (128,CH7V)
CHG
Operation CN69-5 CN70-24 (121,SW3)
Panel
panel
CN69-6 CN70-23 (122,SW2)
CN69-7 CN70-22 (123,SW1)
ACAC ACAC CN69-8 CN70-32 (124,LED4)
Power Power Magnet
Magnet
Power Power switch CN69-9 CN70-29 (125,LED3)
supply plug switch
supply plug
CN69-10 CN70-30 (126,LED2)
Power
Power
cable
cable (95,MSCH)
Step 1
Inspect the voltage check on the AC power supply side
1. Turn off the key switch and disconnect the AC power plug.
2. Check voltage of each AC power supply terminal.
Each AC power supply terminal AC 191 to 220 V
Judgment
Result Action
OK (AC191 to 220V) Go to Step 2
NG (0V or abnormal voltage reduction,
AC power supply defect
phase interruption)
Step 2
Inspect the AC power plug terminal voltage check
1. Turn the key switch OFF and disconnect the AC power
plug. 3
2. Check voltage of each AC power plug terminal.
Each power plug terminal AC 191 to 220 V
Judgment
Result Action
OK (AC191 to 220V) Go to Step 3
NG (0V or abnormal voltage reduction,
Power cable defect
phase interruption)
Step 3
Inspect the charger timer test
1. Refer to REPAIR MANUAL.
NOTICE!
If it is impossible to perform timer test, perform Step7 first,
and then try timer test of charger again.
Judgment
Result Action
F7-1 error Go to Step 4
To “ Charging completes normally but the charge is insuffi-
Test complete
cient”
Not all 10 charging progress indicator come
Display defect
on in 10 seconds after starting the test
Step 4
Magnet switch inspection
1. Turn the key switch OFF and connect the AC power plug.
2. Press “START” button.
3. Check if the magnet switch is closed and held in that posi-
tion.
Judgment
Result Action
OK (Closed and held) Go to Step 5
To “ Charging does not start when the [START] button is
NG
pushed (The charging screen is shown on the display)”
Step 5
Magnet switch inspection
1. Press “STOP” button.
2. Check magnet switch for its continuity.
Judgment
Result Action
OK (Open) Go to Step 6
NG( Not open) Magnet switch defect
Step 6
FCH fuse inspection
1. Turn the key switch OFF and disconnect the AC power plug
and the battery plug.
2. Remove the FCH fuse and check for its continuity.
NOTICE!
Remove the FCH fuse and check for its continuity.
Both end of the FCH fuse Continuity
Judgment
Result Action
To “ Charging completes normally but the charge is insuffi-
OK (Continuity)
cient”
NG (No continuity) FCH fuse blown
Step 7
Inspect the operation button check
1. Disconnect the AC power plug and the battery plug.
2. Disconnect the CN69 connector and check for its continuity. 3
NOTICE!
Disconnect the CN69 connector, and visually check inside
the connector and the caulked portion of each wire for de-
fects.
CN69 (Refer to "BEFORE TROUBLESHOOTING.")
1 2 3 4 5 6
Operation Portions to be checked Standard
7 8 9 10 11 12 Hold down the CN69-5 - CN69-3 (oper-
Continuity
“STOP” button ation panel side)
Hold down the CN69-7 - CN69-3 (oper-
Continuity
“START” button ation panel side)
Release the “ CN69-5 - CN69-3 (oper-
No continuity
STOP” button ation panel side)
Release the “ CN69-7 - CN69-3 (oper-
No continuity
START” button ation panel side)
Judgment
Result Action
OK Go to Step 8
NG Operation panel defect
Step 8
Harness inspection
1. Disconnect the CN69 and 70 connectors and check for their
continuities.
NOTICE!
Disconnect the CN69 and CN70 connectors, and visually
CN69
check inside the connector and the caulked portion of each
wire for defects.
1 2 3 4 5 6
7 8 9 10 11 12
CN70 CN69-7 - CN70-22 Continuity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Judgment
Result Action
OK Display defect
NG Harness defect
Error Code: F6-2

Failure mode: On-vehicle charger transformer overheating
abnormality (charge can not start)
CAUTION
• If AB-1, AB-2 errors are also displayed, perform troubleshooting with priority given to AB-1, AB-2.
Probable cause
▪ Transformer defect
▪ Tap adjustment defect
▪ Transformer thermo switch defect
▪ Harness defect
▪ Fan defect
▪ Display defect
Related part
Transformer thermo switch
CN68-1 CN70-28 (139,SWTT)

CN68-2 CN70-4 (14,DGND) Display
Transformer
1・2
1, 2 ton
tonseries
series
CN104-8 (98,FNDC1) CN113-2
Cooling fan 1
CN104-3 (1,CBAT+) CN113-1 (controller)
(controller)
Main
Main
controller CN114-2
Cooling fan 2
CN114-1 (transformer)
(transformer)
3 ton series
CN104-8 (98,FNDC1) CN128-2 CN128-10
CN128-3
Main
Main Fan power
CN104-3 (1,CBAT+) CN128-5 CN128-8
controller supply
supply
CN101-18 (99,VFAN) CN128-9 CN128-4
CN113-2
Cooling
Cooling fan
fan 11
CN113-1 (controller)
(controller)
CN114-2
Cooling
Cooling fan
fan 22
CN114-1 (transformer)
(transformer)
Step 1
Inspect the transformer check as a single unit
1. Refer to REPAIR MANUAL
3
Judgment
Result Action
OK Go to Step 2
Transformer defect
NG If there is defect in the transformer, it may be caused by other
factors, so follow the check procedure below after replacing
the transformer.
Step 2
Inspect the tap voltage check
Judgment
Result Action
OK Go to Step 3
NG Tap adjustment defect
Step 3
Error recheck
1. Check of Connect the AC power plug.
Judgment
Result Action
OK Go to Step 6
NG (F6-2 error occurs immediately) Go to Step 4
Step 4
Inspect the overheating detect function check
1. Turn the key switch OFF and disconnect the battery plug
and the AC power plug.
2. Disconnect the CN68 connector and check if any error oc-
curs.
NOTICE!
Perform this check with the CN68 connector disconnected
and short-circuit the CN68-1 and CN68-2 connectors on the
main harness side. Connect the battery plug and the AC
power plug, and check if the F6-2 does not occur.
Judgment
Result Action
OK (F6-2 error is not detected) Transformer thermo switch defect
NG (F6-2 error is detected) Go to Step 5
Step 5
Harness inspection
1. Disconnect the CN68 and CN70 connectors and check har-
ness.
NOTICE!
CN68 Check each harness for its continuity. Perform this check
with the battery plug and the CN68 and CN70 connectors
1 2
disconnected.
CN68-1 - CN70-28 (main harness side) Continuity*1
CN70
CN68-2 - CN70-4 (main harness side) Continuity*1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN68-1 - CN68-2 (main harness side) No continuity
*1: Short-circuit the CN68-1 to CN68-2 connectors (harness
side), and check for the continuities between the CN70-28 and
CN70-4.
Judgment
Result Action
OK Display defect
NG Harness defect
Step 6
Check the fan operation
1. Disconnect the AC power plug.
2. Forcibly turn on the power to the cooling fans, using Active
Test in the Analyzer menu, and check the rotation of the
cooling fan 2.
STD Display: [ANL] 7 ACT 7-04
Multi-function Display: [ANL] ACTIVE TEST 2/2
FAN OFF → ON
Judgment
Result Action
OK (Cooling fan 2 rotates) Normal Use the devise as it is
NG (Cooling fan 2 does not rotate) Go to Step 7
Step 7
Check the fan operation
1. Disconnect the battery plug, and visually check inside the
CN114 connector and the caulked portion of each wire for
defects. (Refer to "BEFORE TROUBLESHOOTING.")
2. Connect the connector and the battery plug, and then turn
the key switch ON. Forcibly turn on the cooling fans, using
Active Test in the Analyzer menu, and check the rotation of
the cooling fan 2.
STD Display: [ANL] 7 ACT 7-04
Multi-function Display: [ANL] ACTIVE TEST 2/2
FAN OFF → ON
Judgment
Result Action
OK (Cooling fan 2 rotates) Connector contact defect
NG (Cooling fan 2 does not rotate) Go to Step 8 3
Step 8
Fan power supply inspection (3 ton model only)
2. Disconnect the CN128 connector and check the resistance
of the fan power supply.
NOTICE!
Check the resistance of the fan power supply. Perform this
check with the battery plug and the CN128 connector dis-
connected.
CN128
1 2 3 4 5 6 CN128-2 - CN128-5 Approx. 4.7 kΩ
7 8 9 10 11 12
CN128-5 - CN128-9 Approx. 4.7 kΩ
CN128-5 - CN128-4 0Ω
CN128-4 - CN128-8 Approx. 4.7 kΩ
Judgment
Result Action
OK Go to Step 9
Step 9
Harness inspection
connectors and check the harnesses for their continuities.
(The CN101 and CN128 connectors are only for 3 ton
model)
CN101 NOTICE!
Check the resistance of the fan power supply. Disconnect
1 2 3 4 5 6 7 CN114 the battery plug and the CN101, CN104, CN114 and CN128
8 9 10 11 12 13 14 15 16 17
1 2
connectors, visually check the caulked portion of each wire
18 19 20 21 22 23 24 25 26 27 for defects and perform the check.
28 29 30 31 32 33 34 (Refer to "BEFORE TROUBLESHOOTING.")
CN104 1, 2 ton series
CN128
1 2 3 4 5 6 7
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17
7 8 9 10 11 12
18 19 20 21 22 23 24 25 CN104-8 - CN114-2 Continuity
26 27 28 29 30 31
3 ton series
Judgment
Result Action
OK Go to Step 10
NG Harness defect
Step 10
Cooling fan 2 inspection
1. Disconnect the battery plug and connect the CN101,
CN104, CN114 and CN128 connectors (the CN101 and
CN128 connectors are only for 3 ton model), connect the
battery plug and turn the key switch ON.
2. Forcibly turn on the power to the cooling fans, using Active
Test in the Analyzer menu, and check the rotation of the
Cooling fan 2.
STD Display:
[ANL] 7 ACT 7-04
Multi-function Display:
FAN OFF → ON
NOTICE!
If the replaced fan does not rotate in the ACTIVE TEST
mode, there might be other defected part, so replace the
main controller.
Judgment
Result Action
OK (Cooling fan 2 rotates) Connector contact defetct
NG (Cooling fan 2 does not rotate) Cooling fan 2 defect
Error Code: F7-1

Failure mode: On-vehicle charger start abnormality
3
CAUTION
• If F6-1errors are also displayed, perform troubleshooting with priority given to F6-1.
• Before conducting troubleshooting, inspect the magnet switch, and check the thermal relay is not
operating. When it is operating, check the charger component parts (magnet switch and transformer
ASSY) first.
Probable cause
▪ Wire connection defect
▪ Capacity unsuitable
▪ Tap adjustment defect
▪ FCH fuse blown
▪ Transformer defect
▪ Harness defect
▪ Display defect
Related part
ton series
3 ton series CN104-1 (18,B80V)
Main
Main
controller
controller
F6
1・2
1, tonseries
2 ton series CN104-1 (41,B48V)
Main
Main
controller
F5
CN68-2 CN70-4 (14,DGND)

P2 Transformer
Transformer
Thermo switch
Thermo switch
CN70-15 (146,CAN1L)
CN70-16 (145,CAN1H)
CN70-18 (43,VBKY)
CN70-36 (N1,N1)
CN69-1 CN70-33 (132,CHMS)
DISPLAY
DISPLAY
CN69-2 CN70-25 (129,CHAC)
CN61
CN69-3 CN70-2 (130,CHGND)

N2
CN69-4 CN70-1 (128,CH7V)
CHG
panel
Panel
CN69-7 CN70-22 (123,SW1)
CN69-8 CN70-32 (124,LED4)
Power Power Magnet
Magnet
supply plug switch
supply plug
Power
Power
cable (95,MSCH)
cable
Step 1
Inspect the voltage check of the battery power supply
1. Compare the indicated value on the display and the actual
measured value (P2 ←→ N2).
STD Display:
[ANL]2 IO1 2-12 (B48/80V)
B48/80V
Judgment
Result Action
OK (Displayed value is in the range of ±
Go to Step 2
10% of actual measured value)
NG (Displayed value is outside the range of
± 10% of actual measured value)
Step 2
Inspect the wire connection check
and the battery plug. 3
2. Check the wire connection.
NOTICE!
Check if the P2 and N2 terminals of the transformer and the
main controller are correctly connected and there is no
looseness.
Check if the CN61, CN69 and CN70 connectors are cor-
rectly connected.
Check if there is no loose connection at the battery plug
and the AC power plug. (Also check if terminal is in good
condition and there is no heat generation at the time of
power distribution)
Check if there is no damage on the power cable.
Judgment
Result Action
OK Go to Step 3
NG Wire connection defect
Step 3
Inspect the check the power distribution of the transformer
1. Connect the battery plug and the AC power plug.
2. Press “START” button of the charger.
3. Check the transformer operating sound.
* After checking, press the STOP button to stop charging.
Judgment
Result Action
OK (Heard) Go to Step 4
NG (Not heard) Go to Step 6
Step 4
Inspect the check the compatibility of the capacity of the battery
and the transformer.
Judgment
Result Action
OK Go to Step 5
NG Capacity unsuitable
Step 5
Inspect the tap adjustment check
1. Refer to the REPAIR MANUAL
Judgment
Result Action
OK Transformer defect
NG Tap adjustment defect
Step 6
Inspect the transformer fuse check
1. Refer to the REPAIR MANUAL
Judgment
Result Action
OK(0 Ω) Go to Step 7
NG( ∞ Ω) FCH fuse defect
Step 7
Inspect the primary voltage of transformer check
2. Connect the AC power plug and press “START” button of
the charger.
NOTICE!
CN61
Disconnect the CN61 connector, connect the AC power
plug and press “START” button.
1 2
3 4
CN61-1 (U) - CN61-2 (V) (REC side) 191 to 220 V
CN61-2 (V) - CN61-4 (W) (REC side) 191 to 220 V
CN61-4 (W) - CN61-1 (U) (REC side) 191 to 220 V
Judgment
Result Action
OK Transformer defect
NG Go to Step 8
Step 8
Inspect the magnet switch voltage check
1. Disconnect the CN61 connector and perform the check.
A1 NOTICE! 3
Disconnect the CN61 connector, connect the AC power
plug and press “START” button.
A1 to 96 191 to 220 V
Press “STOP” button.
A1 to 96 0V
FW-1S CLK-50JT
96
Judgment
Result Action
NG Go to Step 9
OK Magnet switch defect
Step 9
Harness inspection
NOTICE!
Disconnect the CN69 and CN70 connectors and visually
CN69
wire for defects.
1 2 3 4 5 6
7 8 9 10 11 12
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN69-3 - CN70-2 Continuity
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Judgment
Result Action
OK Operation panel defect (*1)
NG Harness defect
*1If there is no improvement in symptom after replacing the op-
eration panel, there might be other defected part, so replace the
display.
Error Code: F8-1

Failure mode: On-vehicle charging completion abnormality
3
CAUTION
• Turn off the breaker of the power distribution panel and stop power supply of AC200V to the AC
power plug, and then perform the check
• Before conducting troubleshooting, inspect the magnet switch, and check the thermal relay is not
operating. When it is operating, check the charger component parts (magnet switch and transformer
ASSY) first.
Probable cause
▪ Harness defect
▪ Display defect
Related part
33 ton
tonseries
Main
Main
controller
controller
F6
1・2
1, ton
2 ton series
Main
Main
controller
F5
CN68-2 CN70-4 (14,DGND)

P2 Transformer
Transformer
Thermoswitch
Thermo switch
CN70-15 (146,CAN1L)
CN70-16 (145,CAN1H)
CN70-18 (43,VBKY)
CN70-36 (N2,GND)
CN69-1 CN70-33 (132,CHMS)
DISPLAY
DISPLAY
CN69-2 CN70-25 (129,CHAC)
CN61
CN69-3 CN70-2 (130,CHGND)

N2
CN69-4 CN70-1 (128,CH7V)
CHG
Panel
panel
CN69-6 CN70-23 (122,SW2)
CN69-7 CN70-22 (123,SW1)
Power Power Magnet
Magnet
supply plug switch
supply plug
CN69-10 CN70-30 (126,LED2)
Power
Power
cable
cable (95,MSCH)
Step 1
Inspect the voltage check of the battery power supply
1. Compare the indicated value on the display and the actual
measured value (between P2 ←→ N2).
STD Display
[ANL]2 IO1 2-12 (B48/80V)
Multi-function Display
B48/80V
Judgment
Result Action
OK (Displayed value is in the range of ±
Go to Step 2
10% of actual measured value)
NG (Displayed value is outside the range of
± 10% of actual measured value)
Step 2
Inspect the magnet switch check
2. Disconnect the CN61 connector and check for its continuity.
NOTICE!
FW-1S CLK-50JT
Main input
terminal (S) Main input Disconnect the CN61 connector and make sure that the
Main input Main input terminal (S) Main input
terminal (R) terminal (T)
Main input
terminal (R)
terminal (T) magnet switch is turned off.
Main input terminal (R) to main output ter-
No continuity
minal (R)
Main output Main input terminal (S) to main output ter-
terminal (R) No continuity
Main output
Main output
terminal (T)
Main output Main output
terminal (R) Main output terminal (T)
minal (S)
terminal (S)
terminal (S)
Main input terminal (T) to main output ter-
No continuity
minal (T)
Judgment
Result Action
OK (No continuity) Go to Step 3
NG (Continuity) Magnet switch defect
Step 3
Inspect the operation panel check
2. Connect the CN61 connector, and disconnect the CN69 3
connector.
NOTICE!
Disconnect the CN69 connector and visually check inside
the connector and the caulked portion of each wire for de-
fects.
6 5 4 3 2 1 Inspected place Standard
12 11 10 9 8 7 CN69-1 - CN69-3 (Operation panel side) No continuity
Judgment
Result Action
OK Go to Step 4
NG Operation panel defect
Step 4
Harness inspection
1. Disconnect the CN69 and CN70 connectors and perform
the check.
NOTICE!
Disconnect the CN69 and the CN70 connectors and visually
wire for defects.
6 5 4 3 2 1 Inspected place Standard
12 11 10 9 8 7 CN69-1 - CN69-3 (Main harness side) No continuity
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Judgment
Result Action
OK Go to Step 5
NG Harness defect
Step 5
Inspect the magnet switch signal check
NOTICE! 3
Disconnect the CN70 connector and perform the check
CN70 CN70-33 - CN70-2 (Display side) No continuity
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
Judgment
Result Action
OK (No continuity) Operation panel defect
NG (Continuity) Display defect
Error Code: FA-1, FA-2, FA-3

Failure mode: CAN bridge controller CPU abnormality
CAUTION
• If FA-2, FA-2, and FA-3 are displayed, it indicates the CAN bridge controller defect; therefore, replace
it.
Probable cause
▪ CAN bridge controller defect
Related part
CAN bridge
CAN bridge controller
controller
Error Code: FB-1

Failure mode: Battery current sensor neutral voltage error
3
CAUTION
• If the error is still displayed after replacing the battery current sensor, other causes can be con-
sidered; therefore, replace the main controller.
Probable cause
▪ Harness defect
▪ Battery current sensor defect
Related part
CN104-10 (303,CSBAT+) CN137-1 ―――CN137-1

CN135-3
CN102-24 (304,CSBAT) CN137-3 ―――CN137-3

CN135-2 Battery current
Main controller
sensor
sensor
CN102-35 (305,CSBAT-) CN137-2 ―――CN137-2
CN135-1
Step 1
Error recheck
2. Disconnect the CN137 connector and visually inspect inside
the connector, and on the wire caulking.
Judgment
Result Procedure
FB-1 error displayed Go to Step 2
FB-1 error not displayed Connector connection defect
Step 2
Harness inspection
CN102
3. Inspect the harness.
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
connect the CN102, CN104, and CN137 connectors, and
28 29 30 31 32 33 34 35
CN137
visually inspect inside each connector, and on the wire
caulking part. (Note: Perform inspection in the state that
CN104 1 2 SST is not connected)
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 CN104-10 (303) - CN137-1 (303) Conduction *1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-24 (304) - CN137-3 (304) Conduction *1
CN102-35 (305) - CN137-2 (305) Conduction *2
CN137-1 (303) - CN137-2 (305) No conduction
*1: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
CN102-35.
Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
Battery current sensor inspection
2. After disconnecting the CN137 connector, connect the bat-
3. Check the battery current sensor value on the analyzer
screen.
STD Display:
[ANL] 6 IO5 6-01 (CSBAT)
[ANL] I/O OTHERS 1/1
CSBAT
Judgment
Result Procedure
Approx. 0.00 Go to Step 4
Other than 0.00 Main controller defect
Step 4
2. Disconnect the CN137 connector and connect CN137-1 and 3
CN137-3 with SST2.
3. Connect the battery plug, and turn the key switch ON.
CN137
screen.
1 2
3
STD Display:
[ANL] 6 IO5 6-01(CSBAT)
CSBAT
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FB-2

Failure mode: Battery current sensor over current abnormality
Probable cause
▪ Harness defect
▪ Battery current sensor defect
Related part
CN104-10 (303,CSBAT+) CN137-1 ―――CN137-1

CN135-3
CN102-24 (304,CSBAT) CN137-3 ―――CN137-3

CN135-2 Battery current
Main controller
sensor
sensor
CN102-35 (305,CSBAT-) CN137-2 ―――CN137-2
CN135-1
Step 1
Error recheck
2. Disconnect the CN137 connector and visually inspect inside
the connector and on the wire caulking.
Judgment
Result Procedure
FB-2 error display Go to Step 2
FB-2 no error display Connector connection defect
Step 2
Harness inspection
CN102
3. Inspect the harness.
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
connect the CN102, CN104, and CN137 connectors, and
28 29 30 31 32 33 34 35
CN137
visually inspect there are no problems inside each con-
nector, and on the wire caulking. (Note: Perform inspection
CN104 1 2 in the state that SST is not connected)
3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 CN104-10 (303) - CN137-1 (303) Conduction *1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-24 (304) - CN137-3 (304) Conduction *1
CN102-35 (305) - CN137-2 (305) Conduction *2
CN102-24.
CN102-35.
Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
screen.
STD Display:
CSBAT
Judgment
Result Procedure
Approx. 0.00 Go to Step 4
Step 4
2. Disconnect the CN139 connector and connect CN137-1 and
CN137-3 with SST2.
CN137
screen.
1 2
3
STD Display:
CSBAT
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FC-1

Failure mode: Battery fluid temperature overheat
3
CAUTION
• Do not leave the truck in the environment the temperature is high.
Probable cause
▪ The temperature around the battery is high
▪ Battery fluid level and fluid temperature sensor defect
Related part
CN70-26 (140,SLLT) CN35 Battery fluid level

Battery fluid and
level
Display fluid temperature
and fluid sensor
temperature sensor
Step 1
Error recheck
1. Turn the key switch ON, and check the battery overheat in-
dicator on the display.
Judgment
Result Procedure
When the battery fluid temperature drops, the battery over-
heat indicator turns OFF, and the truck can be used; how-
ever, it is considered that continuous operation under over-
Indicator turns OFF
loaded condition caused the error; therefore, check the oper-
ating condition, and do not conduct continuous operation in
overloaded state.
Indicator ON Go to Step 2
Step 2
Check the battery fluid temperature and recheck the error
1. Check the battery fluid temperature on the analyzer screen
and record the value.
STD Display:
[ANL] 2 IO1 2-10 (TSLLT)
TSLLT
2. Turn the key switch OFF, and after leaving the truck for 12
hours or longer, turn the key switch ON, and check the bat-
tery overheat indicator on the display.
Judgment
Result Procedure
When the battery fluid temperature drops, the battery over-
heat indicator turns OFF, and the truck can be used; how-
ever, it is considered that continuous operation under over-
Indicator OFF
loaded condition caused the error; therefore, check the oper-
ating condition, and do not conduct continuous operation in
overloaded state.
Indicator ON Go to Step 3
Step 3
Recheck the battery fluid temperature
1. Check the battery fluid temperature on the analyzer screen
and compare it with the value recorded last time.
STD Display:
[ANL] 2 IO1 2-10 (TSLLT)
TSLLT
Judgment
Result Procedure
It did not decrease for 5 ℃ or more Perform troubleshooting for F5-3 and F5-4 errors
It decreased for 5 ℃ or more Go to Step 2
Error Code: FF-1

Failure mode: Display power supply circuit overcurrent
3
CAUTION
• FF-1 error during occurrence cannot be checked on the display; therefore, follow the troubleshoot-
ing when the error is not displayed to conduct inspection and repair.
Probable cause
▪ Display defect
▪ Harness defect
Related part
CN103-14 (16,D7V) CN70-5
CN103-3 (14,DGND) CN70-4
Step 1
Error recheck
Visually inspect there are no problems inside the CN103
and CN70 connectors, and on the wire caulking.
turn the key switch ON and check the screen display.
Judgment
Result Procedure
Displayed and no FF-1 error Connector connection defect
Not displayed Go to Step 2
Step 2
1. Follow troubleshooting when the error is not displayed to
conduct inspection and repair.
Troubleshooting when no error is displayed:
[Control type] Power supply related [Phenomenon gener-
ated in machine] Display is not displayed (the truck moves)
Error Code: FF-2

Failure mode: Steering sensor power supply circuit overcurrent
Probable cause
▪ Steering sensor defect
▪ Harness defect
Related part
CN103-13 (311,SSTR+) CN19-1
Main controller Steering sensor
CN103-6 (51,LS-) CN19-2
Step 1
Error recheck
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN19 connector, and on the wire
caulking
turn the key switch ON and check the screen display.
Judgment
Result Procedure
FF-2 error Go to Step 2
No FF-2 error Connector connection defect
Step 2
Inspect the steering sensor power
3. Measure the voltage between CN19-1 and CN19-2 of the
CN19 connectors on the harness side.
4. Inspect the steering sensor power.
CN19 NOTICE!
1 2 Turn the key switch OFF, disconnect the battery plug, and
3 4 5 6 visually inspect there are no problems inside the CN19
connector, and on the wire caulking
CN19-1 (311) - CN19-2 (51) Approx. 15 V
Judgment
Result Procedure
NG Go to Step 3
OK Steering sensor defect
Step 3
Harness inspection
NOTICE!
CN19
connect the CN19 and CN103 connectors, and conduct
1 2 3 4 5 6 after visually inspecting there are no problems inside the
1 2
7 8 9 10 11 12 13 14 15 16
3 4 5 6
connector, and on the wire caulking.
17 18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING".)
28 29 30 31 32 33 34 35

CN103-13 (311) - CN19-1 (311) Conduction
CN103-6 (51) - CN19-2 (51) Conduction
Judgment
Result Procedure
NG Harness defect
Error Code: 32-1

Failure mode: Drive motor driver ID abnormality
CAUTION
• When a driver as using a pump motor driver is installed as a drive motor driver on the vehicle, the
32-1 error always occurs. But it is not abnormality.
• If AD-5, AD-6 occurs, perform troubleshooting for that first.
Probable cause
▪ Drive motor driver failure
Related part
Drive motor CN110

driver
driver
Pump motor CN111

driver
driver
Step 1
Connector contact inspection
2. After disconnecting the CN110, CN111 connector, check
the inside of connector and the caulked portion of wire
whether it has defect or not by visual confirm.
3. Connect the CN110, CN111 connector, connect the battery
plug.
4. Turn the key switch ON to see if an error occurs.
Judgment
Result Procedure
32-1error occurs. Drive motor driver failure
32-1error does not occur. Connector contact defect
Error Code: 32-3

Failure mode: Pump motor driver ID abnormality
3
CAUTION
• When a new motor driver or a driver as using drive motor driver is installed as a pump motor driver
on the vehicle, the 32-3 error always occurs. But it is not abnormality.
• If AD-1 or AD-2 occurs, perform troubleshooting for that first.
Probable cause
▪ Pump motor driver failure
Related part
Drive motor CN110

driver
driver
Pump motor CN111

driver
driver
Step 1
2. After disconnecting the CN110, CN111 connector, check
the inside of connector and the caulked portion of wire
3. Connect the CN110, CN111 connector, connect the battery
plug.
Judgment
Result Procedure
32-3error occurs. Pump motor driver failure
Error Code: 33-1

Failure mode: Main controller to Drive motor driver CAN
communication abnormality
CAUTION
• If AD-1 or AD-2 occurs, perform troubleshooting for AD-1 or AD-2 first.
Probable cause
▪ Harness defect
Related part
CN103-4 (42,KYSAT) CN110-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN110-17 (145,CAN1H) Drive motor
CN103-12 (146,CAN1L) CN110-16 (146,CAN1L) driver
driver
Main controller CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Step 1
2. After disconnection the CN103, CN104 and CN110 con-
nector, check the inside of connector and the caulked por-
tion of wire whether it has defect or not by visual confirm.
3. Connect the CN103, CN104 and CN110 connector, connect
the battery plug.
Especially if the drive motor driver has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
33-1error occurs. Go to Step 2
Step 2
Harness inspection
NOTICE!
CN103 Perform this check with the battery plug and the CN103,
CN104, CN110 connectors disconnected, and visually
1 2 3 4 5 6
CN110 check inside the connector and the caulked portion of its
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 wire for defects.
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23 (Refer to "BEFORE TROUBLESHOOTING".)
28 29 30 31 32 33 34 35

CN103-4(42) - CN110-8(42) Continuity
CN103-11(145) - CN110-17(145) Continuity
CN103-12(146) - CN110-16(146) Continuity
CN110-8(42) - CN110-17(145) No continuity
CN103-4(42) - CN103-5(N2) No continuity
Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
Motor driver inspection
1. Replace the drive motor driver with the pump motor driver.
2. Connect the battery plug and turn the key switch ON to con-
firm the error occurs.
(Ignore the error codes 32-1 and 32-3.)
Judgment
Result Procedure
33-3error occurs. The motor driver that is drive motor driver before replace-
ment
33-1error occurs. Main controller defect
Error Code: 33-3

Failure mode: Main controller to Pump motor driver CAN
communication abnormality
CAUTION
• If AD-5 or AD-6 occurs, perform troubleshooting for AD-5 or AD-6 first.
Probable cause
▪ Harness defect
▪ Pump motor driver failure
Related part
CN103-4 (42,KYSAT) CN111-8 (42,KYSAT)

CN103-11 (145,CAN1H) CN111-17 (145,CAN1H) Drive
Pumpmotor
motor
CN103-12 (146,CAN1L) CN111-16 (146,CAN1L) driver
driver
Main controller CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Step 1
2. After disconnection the CN103, CN104, CN111 connector,
3. Connect the CN103, CN104, CN111 connector, connect the
battery plug.
Especially if the pump motor driver has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
Step 2
Harness inspection
2. Disconnect the CN103, CN104 and CN111 connectors 3
NOTICE!
CN111 CN104, CN111 connectors disconnected, and visually
1 2 3 4 5 6
1 2 3 4 5 6 7 8
check inside the connector and the caulked portion of its
7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
wire for defects.
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN103-4(42) - CN111-8(42) Continuity
CN103-11(145) - CN111-17(145) Continuity
CN103-12(146) - CN111-16(146) Continuity
Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
Motor driver inspection
1. Replace the drive motor driver with the pump motor driver.
2. Connect the battery plug and turn the key switch ON to con-
firm the error occurs.
(Ignore the error codes 32-1 and 32-3.)
Judgment
Result Procedure
Pump motor driver failure
33-1error occurs. The motor driver that is pump motor driver before replace-
ment is defect.
Error Code: 61-1

Failure mode: Load sensor open circuit abnormality
Probable cause
▪ Harness defect
▪ Load sensor defect
Related part
CN104-12 (58,SPLF+) CN91-1
Main controller CN103-29 (59,SPLF) CN91-2

Load sensor
CN101-32 (51,POT-) CN91-3
Step 1
2. Disconnect the CN91 connector and visually inspect there
are no problems inside the connector and on the wire
caulking.
3. Connect the CN91 connector, and connect the battery plug.
4. Turn the key switch ON and check for errors.
Judgment
Result Procedure
61-1 error Go to Step 2
No 61-1 error Connector connection defect
Step 2
Load sensor inspection
2. Disconnect the CN91 connector, and short between CN91-1 3
and CN91-2 on the main harness side with SST
(09230-13700-71).
CN91 3. Connect the battery plug, and turn the key switch ON to
check for errors.
1
Judgment
Result Procedure
61-2 error Load sensor defect
No 61-2 error Go to Step 3
Step 3
Harness inspection
2. Disconnect the CN91, CN101, CN103, and CN104 connect-
ors and SST.
CN103 3. Inspect conduction of the harness.
CN91
NOTICE!
1 1 2 3 4 5 6
Turn the key switch OFF, disconnect the battery plug, the
2 7 8 9 10 11 12 13 14 15 16
CN91, CN101, CN103 and CN104 connectors, and SST, and
17 18 19 20 21 22 23 24 25 26 27
3
28 29 30 31 32 33 34 35
conduct after visually inspecting there are no problems in-
side the connector, and on the wire caulking.
CN101
CN104
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN104-12 (58) - CN91-1 (58) Conduction *1
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 CN103-29 (59) - CN91-2 (59) Conduction *1 *2
28 29 30 31 32 33 34 26 27 28 29 30 31 CN101-32 (51) - CN91-3 (51) Conduction *2
*1: Connect CN91-1 and CN91-2 on the harness side through
SST (09230-13700-71) and check if there is continuity between
CN104-12 and CN103-29.
CN103-29 and CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 61-2

Failure mode: Load sensor short circuit abnormality
Probable cause
▪ Connector connection failure
▪ Load sensor failure
▪ Harness failure
▪ Main controller failure
Related part
CN104-12 (58,SPLF+) CN91-1
Main controller CN103-29 (59,SPLF) CN91-2

Load sensor
CN101-32 (51,POT-) CN91-3
Step 1
2. Disconnect the CN91 connector, and visually inspect there
caulking.
Judgment
Result Procedure
No 61-2 error Connector connection defect
Step 2
Load sensor inspection
Judgment
Result Procedure
61-1 error Load sensor defect
Step 3
Harness inspection
2. Disconnect the CN91, CN101, CN103 and CN104 connect-
ors.
3. Inspect conduction of the harness.
NOTICE!
CN91 CN101 Turn the key switch OFF, disconnect the battery plug, the
CN91, CN101, CN103 and CN104 connectors, and conduct
1 1 2 3 4 5 6 7
after visually inspecting there are no problems inside the
2 8 9 10 11 12 13 14 15 16 17
connector, and on the wire caulking.
18 19 20 21 22 23 24 25 26 27
3
28 29 30 31 32 33 34

CN101-32 (51) - CN91-3 (51) Conduction *1
CN103-29 and CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 62-1

Failure mode: Tilt angle sensor open circuit abnormality
Probable cause
▪ Tilt angle sensor defect
▪ Harness defect
Related part
CN101-20 (57,VRTA+) CN86-1
Main controller CN103-17 (56,VRTA) CN86-2 Tilt angle sensor
CN101-32 (51,POT-) CN86-3
Step 1
caulking.
Judgment
Result Procedure
No 62-1 error Connector contact defect
Step 2
Tilt angle sensor inspection
2. Disconnect the CN86 connector and short between CN86-1 3
and CN86-2 on the main harness side with SST2.
check for errors.
CN86
1 2 3
Judgment
Result Procedure
62-2 error Tilt angle sensor defect
Step 3
Harness inspection
2. Disconnect the CN101 connector, CN103 connector and
SST.
NOTICE!
CN86
Turn the key switch OFF, disconnect the battery plug, the
1 2 3 CN101 connector, the CN103 connector and SST, and con-
duct after visually inspecting there are no problems inside
CN101 CN103 the connector, and on the wire caulking.
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 CN101-20 (57) - CN86-1 (57) Conduction *1
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
CN103-17 (56) - CN86-2 (56) Conduction *1
*1: Connect between CN86-1 and CN86-2 with SST2, and con-
duction can be checked between CN101-20 and CN103-17.
Judgment
Result Procedure
NG Harness defect
Error Code: 62-2

Failure mode: Tilt angle sensor short circuit abnormality
Probable cause
▪ Tilt angle sensor defect
▪ Harness defect
Related part
CN101-20 (57,VRTA+) CN86-1
Main controller CN103-17 (56,VRTA) CN86-2 Tilt angle sensor
CN101-32 (51,POT-) CN86-3
Step 1
caulking.
Judgment
Result Procedure
Step 2
Tilt angle sensor inspection
check for errors.
Judgment
Result Procedure
62-1 error Tilt angle sensor defect
Step 3
Harness inspection
NOTICE!
CN86 CN101
1 2 3 after visually inspecting there are no problems inside the
1 2 3 4 5 6 7 connector, and on the wire caulking.
8 9 10 11 12 13 14 15 16 17 (Refer to "BEFORE TROUBLESHOOTING".)
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 Inspected place Standard
CN101-32 (51) - CN86-3 (51) Conduction *1
*1: Connect between CN86-2 and CN86-3 with SST2, and con-
duction can be checked between CN103-17 and CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 64-1

Failure mode: Lift lock solenoid open circuit abnormality
CAUTION
• If the 64-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
Probable cause
▪ Lift lock solenoid harness defect
▪ Lift lock solenoid defect
Related portion
CN101-1 (3,SOLLU+) CN88-2
CN102-16 (4,SLLL-) CN88-1
CN103-5 (N2,N2)
Main controller Lift
Lift lock
lock
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
1. Turn the key switch OFF and disconnect the battery plug,
disconnect the CN88 connector and visually check inside
the connector and the caulked portion of its wire for defects.
2. Connect the CN88 connector, connect the battery plug and
then turn the key switch ON to check for errors.
Judgment
Result Procedure
64-4 error occurs. Track down the cause of the 64-4 error.
No error occurs. Go to step 2
STEP2
Error recheck
1. Lower the lift to see if an error occurs.
3
Judgment
Result Procedure
64-1 error does not occur. Connector contact defect
64-1 error occurs. Go to step 3
STEP3
Lift lock solenoid inspection
2. Disconnect the connector CN88 and measure the resist-
ance of the lift lock solenoid
(Resistance between CN88-1 and CN88-2). Standard value:
7 to 17 Ω (approx. 10 Ω at 20°C)
CN102 3. Turn the key switch OFF and disconnect the battery plug.
CN88 1 2 3 4 5 6 7 nectors and check the harnesses for their continuities.
1 2 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
NOTICE!
28 29 30 31 32 33 34 35 Turn the key switch OFF, disconnect the battery plug, dis-
CN101 CN103 nectors, and visually check inside each connector and the
caulked portion of each wire for defects.
1 2 3 4 5 6 7 1 2 3 4 5 6 (Refer to "BEFORE TROUBLESHOOTING.")
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 Portion to be inspected Standard
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN101-1 - CN88-2 Continuity *1
*1: Connect the CN88 connector and measure the resistance
between CN101-1 and CN102-16 to see if it falls between 7 and
17 Ω (approx. 10 Ω at 20°C)
Judgment
Result Procedure
Portion where a problem was found during a check of the lift
OK
lock solenoid or its harness. Main controller defect
Error Code: 64-2

Failure mode: Lift lock solenoid short circuit abnormality
CAUTION
Probable cause
Related portion
CN101-1 (3,SOLLU+) CN88-2
CN102-16 (4,SLLL-) CN88-1
CN103-5 (N2,N2)
Lift lock
lock
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
disconnect the CN88 connector, and visually check inside
Judgment
Result Procedure
No error occurs. Go to step 2
STEP2
Error recheck
1. Lower the lift to see if an error occurs.
3
Judgment
Result Procedure
STEP3
ance of the lift lock solenoid
(Resistance between CN88-1 and CN88-2). Standard value:
7 to 17 Ω (approx. 10 Ω at 20°C)
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Harness inspection
nectors and check the harnesses for their continuities.
NOTICE!
CN102 nectors, and visually check inside each connector and the
CN88 1 2 3 4 5 6 7 (Refer to "BEFORE TROUBLESHOOTING.")
1 2 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN88-2 - CN88-1 No continuity
CN102-16 - P2 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 64-3

Failure mode: Lift lock solenoid drive circuit abnormality
CAUTION
Probable cause
Related portion
CN101-1 (3,SOLLU+) CN88-2
CN102-16 (4,SLLL-) CN88-1
CN103-5 (N2,N2)
Lift lock
lock
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Harness inspection
disconnect the CN88 connector and visually check inside
STEP2
ance of the lift lock solenoid. Apply the lift solenoid com-
pulsorily by using Active Test and check if an error occurs.
(Resistance between CN88-1 and CN88-2)
Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
STEP3
Harness inspection
2. Disconnect the CN101, CN102, CN103 and CN104 con- 3
NOTICE!
CN102
CN88 1 2 3 4 5 6 7 connect the CN88, CN101, CN102, CN103 and CN104 con-
1 2 8 9 10 11 12 13 14 15 16 17 18 19 nectors, and visually check inside each connector and the
20 21 22 23 24 25 26 27 caulked portion of each wire for defects.
28 29 30 31 32 33 34 35 (Refer to "BEFORE TROUBLESHOOTING.")
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN102-16 - P3 No continuity
28 29 30 31 32 33 34
Judgment
Result Procedure
Portion where a problem was found during a check of the lift
OK
lock solenoid or its harness. Main controller defect
Error Code: 64-4

Failure mode: Lift lock solenoid short/open circuit abnormality
CAUTION
Probable cause
Related portion
CN101-1 (3,SOLLU+) CN88-2
CN102-16 (4,SLLL-) CN88-1
CN103-5 (N2,N2)
Lift lock
lock
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
1. Turn the key switch OFF, disconnect the battery plug, dis-
connect the CN88 connector, and visually check inside the
connector and the caulked portion of its wire for defects.
2. Connect the CN88 connector, connect the battery plug, and
Judgment
Result Procedure
STEP2
2. Disconnect the connector CN88 and measure the resist- 3
ance of the lift lock solenoid.
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 3
STEP3
Harness inspection
CN102 NOTICE!
CN88 1 2 3 4 5 6 7
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101 CN103 Portion to be inspected Standard
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 CN101-1 - CN103-5 No continuity
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
*1: Connect the CN88 connector and measure the resistance
17 Ω (approx. 10 Ω at 20°C)
Judgment
Result Procedure
NG Harness defect
Error Code: 65-1

Failure mode: Tilt control solenoid open circuit abnormality
CAUTION
Probable cause
▪ Tilt control solenoid defect
▪ Tilt control solenoid harness defect
Related part
CN101-2 (6,SLTFB+) CN89-2
CN102-19 (7,SLTFL-) CN89-1
CN103-5 (N2,N2)
Main controller Tilt solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Error recheck
Judgment
Result Procedure
No error occurs. Go to Step 2
Step 2
Error recheck
1. Tilt the mast forward to check again if an error occurs.
3
Judgment
Result Procedure
65-1 error occurs. Go to Step 3
Step 3
Tilt control solenoid inspection
ance of the tilt control solenoid.
Judgment
Result Procedure
OK Go to Step 4
Step 4
Harness inspection
CN102 NOTICE!
CN89
1 2 3 4 5 6 7
1 2 connect the CN89, CN101, CN102, CN103 and CN104 con-
8 9 10 11 12 13 14 15 16 17 18 19 nectors, and visually check inside each connector and the
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101 CN103 Inspected place Standard
CN101-2 - CN89-2 Conduction *1
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 CN101-2 - CN103-5 No conduction
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102-19 - CN103-5 No conduction
*1 : Connect CN89, and it can be checked that the measured
resistance value between CN101-2 and CN102-19 is approx.
10 Ω.
Judgment
Result Procedure
Portion where a problem was found during a check of the tilt
OK
control solenoid or its harness. Main controller defect
Error Code: 65-2

Failure mode: Tilt control solenoid short circuit abnormality
CAUTION
Probable cause
Related part
CN101-2 (6,SLTFB+) CN89-2
CN102-19 (7,SLTFL-) CN89-1
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Error recheck
2. Visually inspect inside the connector of CN89, and on the
Judgment
Result Procedure
65-3 error occurs. Track down the cause of the 65-3
Step 2
Error recheck
1. Tilt the mast forward to check again if an error occurs.
3
Judgment
Result Procedure
Step 3
Judgment
Result Procedure
NG Tilt control solenoid defect
OK Go to Step 4
Step 4
Harness inspection
NOTICE!
connect the CN89, CN101, CN102, CN103, and CN104 con-
CN102 nectors, and conduct after visually inspecting inside the
CN89
connector, and on the wire caulking for errors.
1 2 1 2 3 4 5 6 7 (Refer to "BEFORE TROUBLESHOOTING".)
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN89-2 - CN89-1 No conduction
CN102-19 - P2 No conduction
Judgment
Result Procedure
NG Harness defect
Error Code: 65-3

Failure mode: Tilt control solenoid drive circuit abnormality
CAUTION
Probable cause
Related part
CN101-2 (6,SLTFB+) CN89-2
CN102-19 (7,SLTFL-) CN89-1
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Error recheck
Judgment
Result Procedure
OK Go to Step 2
Step 2
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN102 NOTICE!
CN89
1 2 3 4 5 6 7
1 2 connect the CN89, CN101, CN102, CN103, and CN104 con-
8 9 10 11 12 13 14 15 16 17 18 19 nectors, and conduct after visually inspecting inside the
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101 Inspected place Standard
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN102-19 - P3 No conduction
28 29 30 31 32 33 34 CN101-2 - CN102-19 No conduction
Judgment
Result Procedure
Portion where a problem was found during a check of the tilt
OK
control solenoid or its harness. Main controller defect
Error Code: 65-4

Failure mode: Tilt control solenoid open/short circuit abnormality
CAUTION
Probable cause
Related part
CN101-2 (6,SLTFB+) CN89-2
CN102-19 (7,SLTFL-) CN89-1
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Error recheck
Judgment
Result Procedure
65-4 error not occur. Connector contact defect
Connector contact defect Go to Step 2
Step 2
Judgment
Result Procedure
NG Tilt control solenoid defect
OK Go to Step 3
Step 3
Harness inspection
CN102 NOTICE!
CN89
1 2 3 4 5 6 7
1 2 connect the CN89, CN101, CN102, CN103, and CN104 con-
8 9 10 11 12 13 14 15 16 17 18 19 nectors, and conduct after visually inspecting inside the
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101 CN103 Inspected place Standard
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 CN101-2 - CN103-5 No conduction
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102-19 - CN103-5 No conduction
*1 : Connect CN89, and it can be checked that the measured
resistance value between CN101-2 and CN102-19 is approx.
10 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: 66-1

Failure mode: Abnormal matching value of tilt and load sensor
Probable cause
▪ The tilt horizontal angle matching value is outside the specified matching range.
▪ The forward tilt angle matching value is outside the specified matching range.
▪ The load sensor matching value is outside the specified matching range.
Related part
Main controller
Step 1
1. Conduct a tilt horizontal angle matching and tilt forward tilt
angle matching.
Judgment
Result Procedure
66-1 error displayed Main controller defect
66-1 error not displayed Use the device as it is.
Error Code: 67-1

Failure mode: Lifting height switch short/open circuit abnormality
Probable cause 3
▪ Harness defect
▪ Lift height switch defect
Related components
Lifting height switch
CN103-6 (51,LS-) CN92-1
Main controller CN104-22 (90,SH1) CN92-2
CN103-24 (91,SH2-1) CN92-3
Step1
Error recheck
2. Disconnect the CN92 connector, and visually check inside
3. Connect the CN92 connector and the battery plug, turn the
key switch ON, and then raise the lift from its lowermost to
uppermost position to see if an error occurs.
Judgment
Result Procedure
67-1 error occurs Go to Step 2
67-1 error does not occur Connector contact defect
Step2
Inspection of lifting switch input value
1. Turn the key switch OFF and check the value of SH using
the Analyzer menu.
[ANL] I/O M.HANDLING 2/8 (SH)
Judgment
Result Procedure
SH: Other than 000* (* represents either 0
Go to Step 3
or 1.)
SH: 000* (* represents either 0 or 1.) Go to Step 5
Step3
Inspection of lifting switch input value
1. Lower the lift to its lowermost position.
4. Turn the key switch ON and check the value of SH using
the Analyzer menu.
[ANL] I/O M.HANDLING 2/8 (SH)
Judgment
Result Procedure
SH: Other than 000* (* represents either 0
Go to Step 4
or 1.)
SH: 000* (* represents either 0 or 1.) Lifting height switch defect
Step4
Harness inspection
2. Disconnect the CN103 and CN104 connectors and check
the harnesses for their continuities.
Judgment
Result Procedure
Harness defect
NG
Go to Step 5
Step5
1. Is the lifting height switch equipped?
Judgment
Result Procedure
YES Go to Step 6
NO Go to Step 9
Step6
Individual inspection of mast lifting height
1. Visually check the state of the lifting switch when an error is
detected. 3
Judgment
Result Procedure
Lifting height switch arm is held.
Go to Step 7
(Low lifting height)
Lifting height switch arm is released.
Go to Step 10
(High lifting height)
Step7
Individual inspection of the lifting height switch as a single unit
1. Keep the conditions under which the error occurs.
4. Check for continuity on the switch side.
CN92 CN103
Portion to be checked Standard
1 2 3 1 2 3 4 5 6 CN103-6 - CN92-1 Continuity
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN103-24 - CN92-3 Continuity
CN104 CN92-1 - CN92-2 No Continuity
1 2 3 4 5 6 7 CN92-2 - CN92-3 No Continuity
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Judgment
Result Procedure
OK Go to Step 8
NG Lifting height switch defect
Step8
Harness inspection
Judgment
Result Procedure
NG Harness defect
Go to Step 9
OK
Step9
Harness inspection
Judgment
Result Procedure
OK
Go to Step 10
NG Harness defect
Step10
Lifting height switch inspection
1. Keep the conditions under which the error occurs.
4. Check for continuity on the switch side.
Judgment
Result Procedure
NG Lifting height switch defect
OK Go to Step 11
Step11
Harness inspection
1. Disconnect the 103 and CN104 connectors and check the
harnesses for their continuities.
CN103 NOTICE!
Perform this check with the battery plug and the CN92,
1 2 3 4 5 6 CN102, CN103 and CN104 connectors disconnected.
7 8 9 10 11 12 13 14 15 16
Visually check inside each connector and the caulked por-
17 18 19 20 21 22 23 24 25 26 27
tion of each wire for defects.
28 29 30 31 32 33 34 35
CN104 Portion to be checked Standard
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 CN104-22 - CN103-24 No continuity
26 27 28 29 30 31
Judgment
Result Procedure
NG Harness defect
Error Code: 67-5

Failure mode: Lift height 800 mm switch short circuit abnormality
3
CAUTION
• Lift from the lift lowest state to the highest state slowly, and if 67-1 occurs in any lift height, take a
higher priority on troubleshooting of 67-1.
Probable cause
▪ Lift height 800 mm switch defect
▪ Harness defect
Related part
Lift height
Lifting heightswitch
switch
CN103-6 (51,LS-) CN92-1
CN104-22 (90,SH1) CN92-2
CN103-24 (91,SH2-1) CN92-3

Main controller
CN103-34 (420,VRA32) CN260-2
Lifting
Lift height
height
800mm
800 mmswitch
switch
CN103-6 (51,LS-) CN260-1
Step 1
1. Turn the key switch OFF in the lift at the lowest state, and
disconnect the battery plug.
2. Visually inspect inside the connector of CN260, and on the
3. After disconnecting the CN260, and connectors, connect
the battery plug, and turn the key switch ON.
4. Lift until both the lift height 800 mm switch lever and the lift
height switch lever are released, and check for errors.
NOTICE!
Be cautious that the standard of inspection contents differs
depending on the condition of the lift height 800 mm switch
lever and the lift height switch lever.
Judgment
Result Procedure
Step 2
Lift height 800 mm switch inspection
tery plug, and turn the key switch ON.
3. Lift until both the lift height 800 mm switch lever and the lift
height switch lever are released, and check for errors.
NOTICE!
Be cautious that the standard of inspection contents differs
depending on the condition of the lift height 800 mm switch
lever and the lift height switch lever.
Judgment
Result Procedure
No 67-5 error Lift height 800 mm switch defect
Step 3
Harness inspection
NOTICE!
CN260
1 2 3 4 5 6 after visually inspecting there are no problems inside the
7 8 9 10 11 12 13 14 15 16 1 2 3 connector, and on the wire caulking for errors.
17 18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING".)
28 29 30 31 32 33 34 35

CN103-34 (420) - CN260-2 (420) Conduction *1
CN103-6 (51) - CN260-1 (51) Conduction *1
*1: Connect between CN260-1 and CN260-2 with SST2, and
conduction can be checked between CN103-6 and CN103-34.
Judgment
Result Procedure
NG Harness defect
Error Code: 68-1

Failure mode: Height reel sensor open circuit abnormality
Probable cause 3
▪ Lifting height sensor defect
▪ Lifting height sensor harness defect
▪ Lowermost lift position matching value is outside the specified matching range.
Related portion
CN101-32 (51,POT-) CN93-1
Main controller CN101-24 (219,VRH+) CN93-2 Lifting height

sensor
sensor
CN103-28 (220,VRH) CN93-3
STEP1
Error recheck
then turn the key switch ON to check how the vehicle oper-
ates and if an error occurs.
Judgment
Result Procedure
STEP2
Lifting height sensor inspection
2. Disconnect CN93 and connect CN93-2 to CN93-3 on the
harness side through SST8.
the error code.
Judgment
Result Procedure
68-2 error occurs. Lifting height sensor defect
STEP3
Harness inspection
3. Check each harness for its continuity.
CN101
NOTICE!
1 2 3 4 5 6 7 connect CN93, CN101 and CN103 and perform the check
8 9 10 11 12 13 14 15 16 17
without connecting SST.
18 19 20 21 22 23 24 25 26 27 CN93 Portion to be inspected Standard
28 29 30 31 32 33 34
1 2 CN101-24 - CN93-2 Continuity *1
CN103
3 4 CN103-28 - CN93-3 Continuity *1, *2
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
SST8 and check if there is continuity between CN101-24 and
CN103-28.
CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 68-2

Failure mode: Height reel sensor short circuit abnormality
Probable cause 3
Related portion
CN101-32 (51,POT-) CN93-1

sensor
sensor
CN103-28 (220,VRH) CN93-3
STEP1
Error recheck
then turn the key switch ON to check how the vehicle oper-
ates and if an error occurs.
Judgment
Result Procedure
STEP2
Lifting height sensor inspection
the error code.
Judgment
Result Procedure
68-1 error occurs. Lifting height sensor defect
STEP3
Harness inspection
3. Check each harness for its continuity.
NOTICE!
connect CN93, CN101 and CN103 and perform the check
CN101
CN93 Portion to be inspected Standard
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3 4 CN93-3 - CN93-2 No continuity
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 *1: Connect CN93-2 and CN93-3 on the harness side through
CN103-28.
Judgment
Result Procedure
NG Harness defect
Error Code: 68-3

Failure mode: Height reel sensor timeout abnormality
Probable cause 3
Related portion
CN101-32 (51,POT-) CN93-1

sensor
sensor
CN103-28 (220,VRH) CN93-3
STEP1
Visual check of lifting height sensor
1. Is the wire broken.
2. Is the wire wound around or pulled out of the reel correctly
when the lift is raised to or lowered from an elevated posi-
tion? (V mast: all mast height, FSV mast: high lifting height
only)
Judgment
Result Procedure
NG Lifting height sensor defect
OK Go to step 2
STEP2
Check of lifting height sensor input value
then turn the key switch ON.
4. Check the value of VRH using the Analyzer menu.
[ANL] I/O M.HANDLING 2/8
NOTICE!
Raise the lift to an elevated position.
Then, further raise the lift by 1 m from this position and
check the change in the value of VRH at that time.
Judgment
Result Procedure
Change in VRH value: 0.5 or more Normal (Connector contact defect)
Change in VRH value: Less than 0.5 Go to step 3
STEP3
Harness inspection
2. Disconnect the CN93, CN101 and CN103 connectors and
check the harnesses for their continuities.
CN101
NOTICE!
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN103
3 4 CN103-28 - CN93-3 Continuity *1 *2
1 2 3 4 5 6 CN101-32 - CN93-1 Continuity *1
17 18 19 20 21 22 23 24 25 26 27 CN93-2 - CN93-1 No continuity
28 29 30 31 32 33 34 35
CN103-28.
CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 68-4

Failure mode: Height reel sensor lowermost position abnormality
Probable cause 3
Related portion
CN101-32 (51,POT-) CN93-1

sensor
sensor
CN103-28 (220,VRH) CN93-3
STEP1
Check lowermost lift position matching value
1. Has the lowermost lift position value been changed before
error code appears.
Judgment
Result Procedure
Perform lowermost lift position matching. (Refer to chapter
MATCHING)
Changed
68-4 error does not occur after matching
Normal
Not changed. Go to step 2
STEP2
Visual check of lifting height sensor
1. Is the wire broken.
2. Is the wire wound around or pulled out of the reel correctly
when the lift is raised to or lowered from an elevated posi-
tion.
Judgment
Result Procedure
NG Lifting height sensor defect
OK Go to step 3
STEP3
Error recheck
then turn the key switch ON.
Judgment
Result Procedure
68-4 error does not occur Connector contact defect
STEP4
Harness inspection
2. Disconnect the CN93, CN101 and CN103 connectors and 3
CN101
NOTICE!
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN103
3 4 CN103-28 - CN93-3 Continuity *1 *2
1 2 3 4 5 6 CN101-32 - CN93-1 Continuity *1
28 29 30 31 32 33 34 35
CN103-28.
CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 68-5

Failure mode: Height reel sensor matching abnormality
Probable cause
Related portion
Main controller
STEP1
1. Perform lowermost lift position matching.
Refer to DISPLAY Service function and MATCHING
chapter.
Judgment
Result Procedure
68-5 error does not occur after matching Normal
68-5 error occurs after matching Main controller defect
Error Code: 71-1

Failure mode: Tire angle sensor open circuit abnormality
Probable cause 3
▪ Tire angle sensor defect
▪ Harness defect
Related part
CN101-23 (316,VRTRA+) CN97-3
CN102-31 (317,VRTRA) CN97-2

Main controller Tire angle sensor
CN102-26 (51,POT-) CN97-1
Step 1
2. Visually check inside the connector of CN9, and the caulked
portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
3. Visually check inside the connector of After connecting the
CN97 connector, connect the battery plug and turn key
switch ON to confirm error.
Judgment
Result Procedure
Step 2
Tire angle sensor inspection
2. Disconnect the CN97 connector, and connect between
CN97-3 and CN97-2 with SST2.
3. Reconnect the battery plug and turn the key switch ON, and
check the error code.
CN97
1 2 3
Judgment
Result Procedure
71-2error occurs. Tire angle sensor defect
Step 3
Harness inspection
2. Disconnect the CN101, CN102, and CN97 connector, and
inspect harness with SST disconnected.
CN101
NOTICE!
1 2 3 4 5 6 7 Turn the key switch OFF, disconnect the battery plug and
8 9 10 11 12 13 14 15 16 17 the CN101, CN102 and CN97 connectors and with SST dis-
18 19 20 21 22 23 24 25 26 27 CN97 connected visually check inside each connector and the
28 29 30 31 32 33 34 caulked portion of each wire for defects.
CN102 1 2 3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
CN101-23(316) - CN97-3(316) Continuity
20 21 22 23 24 25 26 27 CN102-31(317) - CN97-2(317) Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: 71-2

Failure mode: Tire angle sensor short circuit abnormality
Probable cause 3
▪ Harness defect
Related part
CN101-23 (316,VRTRA+) CN97-3
CN102-31 (317,VRTRA) CN97-2

CN102-26 (51,POT-) CN97-1
Step 1
2. Visually check inside the connector of CN97, and the
caulked portion of its wire for defects.
3. Visually check inside the connector of After connecting the
CN97 connector, connect the battery plug and turn key
switch ON to confirm error.
Judgment
Result Procedure
Step 2
Harness inspection
check the harnesses.
CN101
NOTICE!
8 9 10 11 12 13 14 15 16 17 the CN101, CN102 and CN97 connectors and visually check
18 19 20 21 22 23 24 25 26 27 CN97 inside each connector and the caulked portion of each wire
28 29 30 31 32 33 34 for defects.
CN102 1 2 3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN102-26(51) - CN97-1(51) Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
OK Go to Step 3
NG Harness defect
Step 3
2. Disconnect the CN97 connector, then connect the CN101
Judgment
Result Procedure
71-2 error occurs. Main controller defect
71-1 error occurs. Tire angle sensor defect
Error Code: 71-3

Failure mode: Tire angle sensor anchoring abnormality
Probable cause 3
▪ Harness defect
Related part
CN101-23 (316,VRTRA+) CN97-3
CN102-31 (317,VRTRA) CN97-2

CN102-26 (51,POT-) CN97-1
Step 1
2. Visually check inside the connector of CN97, and the
plug and turn the key switch ON to confirm error with turning
steering wheel.
Judgment
Result Procedure
Step 2
Judgment
Result Procedure
71-1 error does not occur. Go to Step 4
Step 3
and CN102 connectors. Connect between CN97-3 and CN
97-2 for harness side with SST2 connected.
CN97
1 2 3
Judgment
Result Procedure
71-2 error occurs. Tire angle sensor defect
71-2 error does not occur. Go to Step 4
Step 4
Harness inspection
check the harnesses.
CN101
NOTICE!
8 9 10 11 12 13 14 15 16 17 the CN101, CN102 and CN97 connectors and visually check
18 19 20 21 22 23 24 25 26 27 CN97 inside each connector and the caulked portion of each wire
28 29 30 31 32 33 34 for defects.
CN102 1 2 3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
CN101-23(316) - CN97-3(316) Continuity
20 21 22 23 24 25 26 27 CN102-31(317) - CN97-2(317) Continuity
28 29 30 31 32 33 34 35
CN102-26(51) - CN97-1(51) Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 72-1

Failure mode: Steering angle sensor SS1 open circuit abnormality
CAUTION
• The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is ro-
tated.
Probable cause
▪ Steering angle sensor harness defect
▪ Steering angle sensor defect
Related part
CN103-13 (311,SSTR+) CN19-1
CN104-30 (312,SSTR1) CN19-3
Main controller CN19-4 Steering

Steering
CN104-31 (313,SSTR2)
angle sensor
CN104-24 (314,SSTRC) CN19-5
CN103-6 (51,LS-) CN19-2
Step 1
Error recheck
2. Connect the CN19 connector, connect the battery plug, turn
the key switch ON, and turn the steering wheel to see if an
error occurs.
Judgment
Result Procedure
Step 2
Check for Analyzer menu (SSTR)
1. Turn the key switch ON and check the value of SSTR using
the Analyzer menu. 3
2. Inspection the checking the state, turning the steering
wheel.
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
[ANL] I/O STEERING 1/1
SSTR
Judgment
Result Procedure
SSTR: 0** (* represents either 0 or 1.) Go to Step 3
Step 3
disconnect the CN19 connector. After that, connect CN19-2
to CN19-3 (on the main harness side) through SST2 to
short them, and then connect the battery plug and turn the
key switch ON.
the Analyzer menu.
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: 1** (* represents either 0 or 1.) Steering angle sensor defect
Step 4
Harness inspection
2. Disconnect the CN104 connectors and check the harnesses
for their continuities.
NOTICE!
connect CN19, CN102, CN103 and CN104 and perform the
check without connecting SST. Visually check inside each
CN104
connector and the caulked portion of each wire for defects.
CN19
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 Portion to be inspected Standard
3 4 5 6
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-30.
Judgment
Result Procedure
NG Main harness defect
Step 5
the CN19 connector, connect the battery plug and turn the
key switch ON.
the Analyzer menu.
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: 0** (* represents either 0 or 1.) Steering angle sensor defect
Step 6
Harness inspection
2. Disconnect the CN104 connectors and check the harnesses 3
NOTICE!
CN104
CN19
1 2 3 4 5 6 7
3 4 5 6
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-30.
Judgment
Result Procedure
Error Code: 72-2

Failure mode: Steering angle sensor SS2 open circuit abnormality
CAUTION
tated.
Probable cause
Related part
CN103-13 (311,SSTR+) CN19-1
CN104-30 (312,SSTR1) CN19-3

Steering
CN104-31 (313,SSTR2)
angle sensor
CN104-24 (314,SSTRC) CN19-5
CN103-6 (51,LS-) CN19-2
Step 1
Error recheck
error occurs.
Judgment
Result Procedure
72-2 error occurs Go to Step 2
Step 2
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: *0* (* represents either 0 or 1.) Go to Step 3
Step 3
key switch ON.
the Analyzer menu.
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: *1* (* represents either 0 or 1.) Steering angle sensor defect
Step 4
Harness inspection
NOTICE!
CN104
CN19
1 2 3 4 5 6 7
3 4 5 6
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-31.
Judgment
Result Procedure
Step 5
1. Turn the key switch OFF, disconnect the CN19 connector,
connect the battery plug and turn the key switch ON.
the Analyzer menu.
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: *0* (* represents either 0 or 1.) Steering angle sensor defect
Step 6
Harness inspection
NOTICE!
CN104 connect CN19, CN102, CN103 and CN104 and perform the
CN19 check without connecting SST. Visually check inside each
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 (Refer to "BEFORE TROUBLESHOOTING.")
3 4 5 6
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-31.
Judgment
Result Procedure
Error Code: 72-3

Failure mode: Steering angle sensor SSC open circuit abnormality
CAUTION
tated.
Probable cause
Related part
CN103-13 (311,SSTR+) CN19-1
CN104-30 (312,SSTR1) CN19-3

Steering
CN104-31 (313,SSTR2)
angle sensor
CN104-24 (314,SSTRC) CN19-5
CN103-6 (51,LS-) CN19-2
Step 1
error occurs.
Judgment
Result Procedure
Step 2
STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: **0 (* represents either 0 or 1.) Go to Step 3
Step 3
key switch ON.
the Analyzer menu.
3. STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: **1 (* represents either 0 or 1.) Steering angle sensor defect
Step 4
Harness inspection
NOTICE!
CN103, CN104 and CN19 connectors disconnected, and
visually check inside the connector and the caulked por-
CN104
tion of its wire for defects.
CN19 (Refer to "BEFORE TROUBLESHOOTING")
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 3 4 5 6 CN104-24 - CN19-5 Continuity *1
26 27 28 29 30 31
CN104-24.
Judgment
Result Procedure
Step 5
1. Turn the key switch OFF and disconnect the CN19 con-
nector, connect the battery plug and turn the key switch ON.
the Analyzer menu.
3. STD Display:
[ANL] 5 IO4 5-06 (SSTR)
Multi-function/ DX:
SSTR
Judgment
Result Procedure
SSTR: **0 (* represents either 0 or 1.) Steering angle sensor defect
Step 6
Harness inspection
NOTICE!
CN104
tion of its wire for defects.
CN19 (Refer to "BEFORE TROUBLESHOOTING")
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 3 4 5 6 CN104-24 - CN19-5 Continuity *1
26 27 28 29 30 31
CN104-24.
Judgment
Result Procedure
Error Code: 72-4

Failure mode: Steering angle sensor power circuit open circuit
abnormality
CAUTION
• Turning the steering angle sensor without turning the steering wheel may cause error code 72-4 to
be set.
Probable cause
Related part
CN103-13 (311,SSTR+) CN19-1
CN104-30 (312,SSTR1) CN19-3

Steering
CN104-31 (313,SSTR2)
angle sensor
CN104-24 (314,SSTRC) CN19-5
CN103-6 (51,LS-) CN19-2
Step 1
error occurs.
(If the steering wheel cannot be turned easily, perform this
check with the direction switch in the Forward or Reverse
position.)
Judgment
Result Procedure
72-4 error does not occur. Connector contact defect 3
Step 2
Inspection the check of sensor supply voltage
4. Check the supply voltage to the sensor.
CN19-1, CN19-2, CN19-1 to CN19-2
Judgment
Result Procedure
Approx. 0 V Go to Step 3
Approx. 15 V Go to Step 4
Step 3
Harness inspection
NOTICE!
CN103 CN19 connector and the caulked portion of each wire for defects.
1 2 3 4 5 6 1 2
7 8 9 10 11 12 13 14 15 16 3 4 5 6 Portion to be inspected Standard
17 18 19 20 21 22 23 24 25 26 27 CN103-13 - CN19-1 Continuity *1
28 29 30 31 32 33 34 35
CN103-6.
Judgment
Result Procedure
Step 4
then connect CN19. Connect the battery plug and turn the
key switch ON.
Track down the cause of 72-1 (SSTR1).
Proceed to identify the cause of 72-2 (SSTR2).
Error Code: 73-1

Failure mode: Knob position correcting solenoid open circuit
abnormality
CAUTION
• If 73-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 73-3.
Probable cause
▪ Knob position correcting solenoid harness defect
▪ Knob position correcting solenoid defect
Related part
CN102-7 (329,SLS+) CN98-2
CN102-14 (330,SLS-) CN98-1
CN103-5 (N2,N2)
Main controller Steering knob
correcting
correcting
CN104-4 (N2,N2) solenoid
solenoid
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
2. After disconnection the CN98 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
3. Connect the CN98 connector, connect the battery plug.
Judgment
Result Procedure
Step 2
1. Using [ACTIVE TEST], forcibly turn on the output of the
steering knob position synchronizer solenoid to see if an er- 3
ror occurs.
STD Display:
[ANL]7 ACT 7-01 (STEERING SOL)
Multi-function/DX:
STEERING SOL
Judgment
Result Procedure
Step 3
Steering knob position synchronizer solenoid inspection
3. Inspect the solenoid resistance.
Judgment
Result Procedure
NG Knob position correcting solenoid defect
OK Go to Step 4
Step 4
Harness inspection
CN102
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN98 tion of its wire for defects.
CN103 (Refer to "BEFORE TROUBLESHOOTING".)
1 2
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 CN102-7 - CN98-2 Continuity *1
17 18 19 20 21 22 23 24 25 26 27 CN102-14 - CN98-1 Continuity *1
28 29 30 31 32 33 34 35
*1 : In case of the OK in the steering knob position synchronizer
solenoid, connect the CN98 connector and measure the resist-
ance between CN102-7 and CN102-14. And it is OK if this res-
istance is between 7 and 17 Ω (approx. 10 Ω at 20°C).
Judgment
Result Procedure
NG Harness defect、Main controller defect
Error Code: 73-2

Failure mode: Knob position correcting solenoid short circuit
abnormality
3
CAUTION
to 73-3.
Probable cause
Related part
CN102-7 (329,SLS+) CN98-2
CN102-14 (330,SLS-) CN98-1
CN103-5 (N2,N2)
correcting
correcting
solenoid
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Judgment
Result Procedure
Step 2
1. Using [ACTIVE TEST], forcibly turn on the output of the
steering knob position synchronizer solenoid to see if an er-
ror occurs.
STD Display:
[ANL]7 ACT 7-01 (STEERING SOL)
Multi-function/DX:
STEERING SOL
Judgment
Result Procedure
Step 3
7 to 17Ω
CN98-1 - CN98-2
(approx.10Ω : 20°C)
Judgment
Result Procedure
OK Go to Step 4
Step 4
Harness inspection
NOTICE!
1 2 3 4 5 6 7 visually check inside the connector and the caulked por-
CN98 8 9 10 11 12 13 14 15 16 17 18 19 tion of its wire for defects.
1 2 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING".)
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: 73-3

Failure mode: Knob position correcting solenoid power circuit
abnormality
CAUTION
to 73-3.
Probable cause
Related part
CN102-7 (329,SLS+) CN98-2
CN102-14 (330,SLS-) CN98-1
CN103-5 (N2,N2)
correcting
correcting
solenoid
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
NOTICE!
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to Step 2
Step 2
Harness inspection
NOTICE!
CN102 CN102, CN103 and CN104 connectors disconnected, and
CN98 1 2 3 4 5 6 7 tion of its wire for defects.
1 2 8 9 10 11 12 13 14 15 16 17 18 19 (Refer to "BEFORE TROUBLESHOOTING")
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Inspected place Standard
Judgment
Result Procedure
NG Harness defect
OK Portion where a problem was found during a check of the
knob position correcting solenoid or its harness.
Error Code: 73-4

Failure mode: Knob position correcting solenoid open/short circuit
abnormality
CAUTION
to 73-3.
Probable cause
Related part
CN102-7 (329,SLS+) CN98-2
CN102-14 (330,SLS-) CN98-1
CN103-5 (N2,N2)
correcting
correcting
solenoid
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Step 1
Judgment
Result Procedure
Step 2
Judgment
Result Procedure
OK Go to Step 3
Step 3
Harness inspection
CN102
NOTICE!
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN98 tion of its wire for defects.
CN103 (Refer to "BEFORE TROUBLESHOOTING".)
1 2
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 CN102-14 - CN98-1 Conduction *1
28 29 30 31 32 33 34 35
*1: In case of the OK in the steering knob position synchronizer
solenoid, connect the CN98 connector and measure the resist-
ance between CN102-7 and CN102-14. And it is OK if this res-
istance is between 7 and 17 Ω (approx. 10 Ω at 20°C).
Judgment
Result Procedure
NG Harness defect
Error Code: 74-1

Failure mode: Abnormal matching value for tire angle
CAUTION
• If 71-1,71-2,71-3 occurs, give priority to troubleshooting for 71-1,71-2,71-3. After that, perform the fol-
lowing.
Probable cause
▪ Tire angle matching defect
Related part
Main controller
Step 1
1. Perform tire angle matching.
Judgment
Result Procedure
NG matching Go to Step 2
OK matching Go to Step 3
Step 2
Tire angle sensor voltage inspection
1. Check the tire angle sensor voltage.
STD Display: 3
[ANL] IO4 5-01 (VRTRA)
Multi-function/DX:
VRTRA
Tire angle position Voltage
When straight running condition 1.83V - 2.51V
Judgment
Result Procedure
Go to Step 3
Outside standard value Tire angle sensor assembly defect. After reassemble, perform
matching and Step 3.
Within standard value Main controller defect
Step 3
Error recheck
2. After 30 seconds, reconnect the battery plug and turn on the
After 30 seconds, reconnect the battery plug and turn the
key switch ON.
Judgment
Result Procedure
74-1error does not occur. Tire angle matching defect
Error Code: G5-1

Failure mode: Shock sensor 1 open circuit abnormality
CAUTION
• Error code G5-1 or G5-4 (For G5-4, read the numbers in brackets, which refer to the corresponding
error code, connector number, etc.)
Probable cause
▪ Shock sensor harness defect
▪ Shock sensor defect
Related part
CN103-8 (300,IPL+) CN130-3
CN103-30 (301,IPL1) CN130-2 Shock sensor 1
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
connect the CN130 connectors, and visually check inside
2. Connect the CN130 connector, connect the battery plug,
and turn the key switch ON to see if an error occurs.
Judgment
Result Procedure
G5-1 error does not occur. Connector contact defect
G5-1 error occurs. Go to Step 2
Step 2
Shock sensor 1 inspection
2. Disconnect the CN130 connector and connect the CN130-3 3
to CN130-2 on the harness side through SST2.
the error code.
Judgment
Result Procedure
G5-2 error occurs. Shock sensor 1 defect
Step 3
Harness inspection
NOTICE!
CN103
1 2 3 4 5 6 CN130 tion of each wire for defects.
7 8 9 10 11 12 13 14 15 16
1 2 3
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN103-30 - CN130-2 Continuity *1 *2
*1: Connect CN130-2 and CN130-3 on the harness side
through SST2 and check if there is continuity between
CN103-30 and CN103-8.
CN103-32 and CN103-30
Judgment
Result Procedure
NG Harness defect
Error Code: G5-2

Failure mode: Shock sensor 1 short circuit abnormality
CAUTION
Probable cause
Related part
CN103-8 (300,IPL+) CN130-3
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
disconnect the CN130 connectors, and visually check inside
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN101
1 2 3 4 5 6 7
CN130 tion of each wire for defects.
8 9 10 11 12 13 14 15 16 17 1 2 3
18 19 20 21 22 23 24 25 26 27 Inspected place Standard
28 29 30 31 32 33 34
CN103-32 and CN103-30
Judgment
Result Procedure
NG Harness defect
Error Code: G5-3

Failure mode: Shock sensor 1 neutral voltage abnormality
CAUTION
Probable cause
Related part
CN103-8 (300,IPL+) CN130-3
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
and turn the key switch ON to see if an error occurs. (after
one minute)
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 3
28 29 30 31 32 33 34
CN103-32 and CN103-30
Judgment
Result Procedure
NG Harness defect
Error Code: G5-4

Failure mode: Shock sensor 2 open circuit abnormality
CAUTION
Probable cause
Related part
CN103-8 (300,IPL+) CN130-3
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
2. Disconnect the CN129 connector and connect the CN129-3 3
to CN129-2 on the harness side through SST2.
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN103 without connecting SST.
1 2 3 4 5 6 CN129 tion of each wire for defects.
7 8 9 10 11 12 13 14 15 16
1 2 3
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Inspected place Standard
CN103-19 - CN129-2 Continuity *1 *2
through SST2 and check if there is continuity between CN103-8
and CN103-19.
CN101-32 and CN103-19.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-5

Failure mode: Shock sensor 2 short circuit abnormality
CAUTION
Probable cause
Related part
CN103-8 (300,IPL+) CN130-3
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
Inspect the check of shock sensor 1
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 3
28 29 30 31 32 33 34
CN101-32 and CN103-19.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-6

Failure mode: Shock sensor 2 neutral voltage abnormality
CAUTION
Probable cause
Related part
CN103-8 (300,IPL+) CN130-3
CN101-32 (51,POT-) CN130-1

Main controller
CN129-3
CN129-1
Step 1
Error recheck
and turn the key switch ON to see if an error occurs. (after
one minute)
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 3
28 29 30 31 32 33 34
CN101-32 and CN103-19.
Judgment
Result Procedure
NG Harness defect
Error Code: H1-1

Failure mode: Lift lever potentiometer open circuit abnormality
CAUTION
• If the lever was removed for a check, be sure to perform matching after installing it.
• The H1-4 error may occur if the key switch is turned on while the lift lever is being operated.
• For the mini lever specification, CN115 is changed into CN162 and CN116 is changed into CN163.
Probable cause
▪ Lift lever potentiometer harness defect
▪ Lift lever potentiometer defect
Related part
CN101-25 (28,VRL+) CN115-4
CN103-26 (20,VRL1) CN115-2

LiftLift
lever
lever
Main controller potentiometer
CN103-18 (21,VRL2) CN115-3
CN102-26 (51,POT-) CN115-1
Step 1
Error recheck
Judgment
Result Procedure
H1-1 error does not occur. Connector connection defect
H1-1 error One of these errors occurs. Go to Step 2
Step 2
Lift lever potentiometer inspection
2. Replace the lift lever potentiometer connector (CN115) with 3
the tilt lever potentiometer connector (CN116).
the error code.
Judgment
Result Procedure
H2-1 error One of these errors occurs.
Lift lever potentiometer defect
H1-4, H2-4 can be ignored.
Step 3
Harness inspection
2. Disconnect the CN101,CN102 and CN103 connectors and
CN101 NOTICE!
With the battery plug and the CN115, CN101, CN102 and
1 2 3 4 5 6 7 CN103 connectors disconnected, visually check inside
8 9 10 11 12 13 14 15 16 17 each connector and the caulked portion of each wire for
18 19 20 21 22 23 24 25 26 27 defects.
28 29 30 31 32 33 34 CN115
CN103
1 2 3 4
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 CN103-18 - CN115-3 Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: H1-2

Failure mode: Lift lever potentiometer short circuit abnormality
CAUTION
Probable cause
Related part
CN101-25 (28,VRL+) CN115-4
CN103-26 (20,VRL1) CN115-2

LiftLift
lever
lever
CN103-18 (21,VRL2) CN115-3
CN102-26 (51,POT-) CN115-1
Step 1
Error recheck
Judgment
Result Procedure
H1-2 error does not occur. Connector connection defect
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN103 connectors disconnected, visually check inside
each connector and the caulked portion of each wire for
CN102 defects.
CN115
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 Inspected place Standard
20 21 22 23 24 25 26 27 CN102-26 - CN115-1 Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H1-3

Failure mode: Lift lever potentiometer output gap abnormality
CAUTION
Probable cause
Related part
CN101-25 (28,VRL+) CN115-4
CN103-26 (20,VRL1) CN115-2

LiftLift
lever
lever
CN103-18 (21,VRL2) CN115-3
CN102-26 (51,POT-) CN115-1
Step 1
Error recheck
and visually check inside the CN115 connector and the
3. Perform matching of the lift lever potentiometer and see if
any error occurs.
Judgment
Result Procedure
H1-3 error does not occur after matching Connector contact defect
Lift lever matching does not complete Go to Step 2
Step 2
the error code.
Judgment
Result Procedure
Tilt lever matching complete Go to Step 3
Tilt lever matching does not complete
Step 3
Harness inspection
NOTICE!
defects.
CN115
1 2 3 4 Inspected place Standard
Judgment
Result Procedure
OK
(*Perform matching after troubleshooting.)
NG Harness defect
Error Code: H1-4

Failure mode: Lift lever potentiometer neutral abnormality
CAUTION
Probable cause
Related part
CN101-25 (28,VRL+) CN115-4
CN103-26 (20,VRL1) CN115-2

LiftLift
lever
lever
CN103-18 (21,VRL2) CN115-3
CN102-26 (51,POT-) CN115-1
Step 1
Error recheck
Judgment
Result Procedure
H1-4 error does not occur. Connector contact defect
H1-4 error occurs. Go to Step 2
Step 2
2. Check if the lift lever potentiometer is installed correctly. 3
4. Perform matching of the lift lever potentiometer. Refer to
DISPLAY Service function and MATCHING chapter.
Judgment
Result Procedure
OK Incorrect installation
NG Lift lever potentiometer defect
Error Code: H1-5

Failure mode: Abnormal matching value for lift lever potentiometer
CAUTION
Probable cause
Related part
CN101-25 (28,VRL+) CN115-4
CN103-26 (20,VRL1) CN115-2

LiftLift
lever
lever
CN103-18 (21,VRL2) CN115-3
CN102-26 (51,POT-) CN115-1
Step 1
1. Matching of the lift lever potentiometer. Refer to DISPLAY
Service function and MATCHING chapter.
Judgment
Result Procedure
After the completion of matching, H1-5 error
Matching has been made correctly. Use the device as it is.
does not occur.
occurs.
Error Code: H2-1

Failure mode: Tilt lever potentiometer open circuit abnormality
3
CAUTION
• The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.
• For the mini lever specification CN116 is changed into CN163 and CN115 is changed into CN162.
Probable cause
▪ Tilt lever potentiometer harness defect
▪ Tilt lever potentiometer defect
Related part
CN101-28 (29,VRT+) CN116-4
CN102-23 (22,VRT1) CN116-2

TiltTilt
lever
lever
CN102-22 (23,VRT2) CN116-3
CN102-26 (51,POT-) CN116-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
Tilt lever potentiometer inspection
2. Replace the tilt lever potentiometer connector (CN116) with
the lift lever potentiometer connector (CN115).
the error code.
Judgment
Result Procedure
Tilt lever potentiometer defect
Step 3
Harness inspection
CN101 NOTICE!
1 2 3 4 5 6 7 CN103 connectors disconnected, visually check inside
8 9 10 11 12 13 14 15 16 17 each connector and the caulked portion of each wire for
18 19 20 21 22 23 24 25 26 27 defects.
28 29 30 31 32 33 34 CN116
CN102
1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN102-22 - CN116-3 Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H2-2

Failure mode: Tilt lever potentiometer short circuit abnormality
3
CAUTION
Probable cause
Related part
CN101-28 (29,VRT+) CN116-4
CN102-23 (22,VRT1) CN116-2

TiltTilt
lever
lever
CN102-22 (23,VRT2) CN116-3
CN102-26 (51,POT-) CN116-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN102 defects.
CN116
1 2 3 4 5 6 7
20 21 22 23 24 25 26 27 CN102-26 - CN116-1 Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H2-3

Failure mode: Tilt lever potentiometer output deviation abnormality
3
CAUTION
Probable cause
Related part
CN101-28 (29,VRT+) CN116-4
CN102-23 (22,VRT1) CN116-2

TiltTilt
lever
lever
CN102-22 (23,VRT2) CN116-3
CN102-26 (51,POT-) CN116-1
Step 1
Error recheck
1. Turn the key switch OFF, disconnect the battery plug, and
visually check inside the CN116 connector and the caulked
portion of its wire for defects.
3. Perform matching of the tilt lever potentiometer and see if
any error occurs.
Judgment
Result Procedure
H2-3 error does not occur after matching Connector contact defect
Tilt lever matching does not complete Go to Step 2
Step 2
3. Connect the battery plug and turn the key switch ON. Per-
form matching of the lift lever potentiometer.
Judgment
Result Procedure
Lift lever matching complete Go to Step 3
Tilt lever matching does not complete
Step 3
Harness inspection
NOTICE!
defects.
CN116
1 2 3 4 Inspected place Standard

Judgment
Result Procedure
OK
NG Harness defect
Error Code: H2-4

Failure mode: Tilt lever potentiometer neutral abnormality
3
CAUTION
Probable cause
Related part
CN101-28 (29,VRT+) CN116-4
CN102-23 (22,VRT1) CN116-2

TiltTilt
lever
lever
CN102-22 (23,VRT2) CN116-3
CN102-26 (51,POT-) CN116-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
2. Check if the lift lever potentiometer is installed correctly.
4. Perform matching of the tilt lever potentiometer. Refer to
Judgment
Result Procedure
NG Tilt lever potentiometer defect
Error Code: H2-5

Failure mode: Abnormal matching value for tilt lever potentiometer
3
CAUTION
Probable cause
Related part
CN101-28 (29,VRT+) CN116-4
CN102-23 (22,VRT1) CN116-2

TiltTilt
lever
lever
CN102-22 (23,VRT2) CN116-3
CN102-26 (51,POT-) CN116-1
Step 1
1. Matching of the tilt lever potentiometer. Refer to DISPLAY
Service function and MATCHING chapter.
Judgment
Result Procedure
does not occur.
occurs.
Error Code: H3-1

Failure mode: Attachment 1 lever potentiometer open circuit
abnormality
CAUTION
• The H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being oper-
ated.
Probable cause
▪ Attachment 1 lever potentiometer harness defect
▪ Attachment 1 lever potentiometer defect
Related part
CN101-29 (30,VRAT1+) CN119-4
CN102-21 (24,VRA11) CN119-2

Attachment 1
Attachment 1
Main controller leverlever
CN102-20 (25,VRA12) CN119-3 potentiometer
potentiometer
CN102-26 (51,POT-) CN119-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
Attachment 1 lever potentiometer inspection
2. Replace the attachment 1 lever potentiometer connector 3
(CN119) with the lift lever potentiometer connector (CN115).
the error code.
Judgment
Result Procedure
Attachment 1 lever potentiometer defect
Step 3
Harness inspection
CN101 NOTICE!
1 2 3 4 5 6 7 CN101 and CN102 connectors disconnected, visually check
8 9 10 11 12 13 14 15 16 17 inside each connector and the caulked portion of each wire
18 19 20 21 22 23 24 25 26 27 for defects.
28 29 30 31 32 33 34 CN119
CN102
1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN102-20 - CN119-3 Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H3-2

Failure mode: Attachment 1 lever potentiometer short circuit
abnormality
CAUTION
ated.
Probable cause
Related part
CN101-29 (30,VRAT1+) CN119-4
CN102-21 (24,VRA11) CN119-2

Attachment 1
Attachment 1
potentiometer
CN102-26 (51,POT-) CN119-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
CN101 and CN102 connectors disconnected, visually check
inside each connector and the caulked portion of each wire
CN102 for defects.
CN119
1 2 3 4 5 6 7
20 21 22 23 24 25 26 27 CN102-26 - CN119-1 Continuity
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H3-3

Failure mode: Attachment 1 lever potentiometer output deviation
abnormality
CAUTION
ated.
Probable cause
Related part
CN101-29 (30,VRAT1+) CN119-4
CN102-21 (24,VRA11) CN119-2

Attachment 1
Attachment 1
potentiometer
CN102-26 (51,POT-) CN119-1

Step 1
Error recheck
connect the CN119 connector, and visually check inside the 3
turn the key switch ON.
3. Perform matching of the attachment 1 lever potentiometer
and see if any error occurs.
Judgment
Result Procedure
H3-3 error does not occur after matching. Connector contact defect
Attachment 1 lever matching does not com-
Go to Step 2
pete.
Step 2
2. Replace the attachment 1 lever potentiometer connector
form the matching of the lift lever potentiometer.
Judgment
Result Procedure
Lift lever matching does not complete
Step 3
Harness inspection
NOTICE!
CN101 and CN102 connectors disconnected, visually check
inside each connector and the caulked portion of each wire
for defects.
CN119
1 2 3 4
Judgment
Result Procedure
OK
NG Harness defect
Error Code: H3-4

Failure mode: Attachment 1 lever potentiometer neutral abnormality
3
CAUTION
ated.
Probable cause
Related part
CN101-29 (30,VRAT1+) CN119-4
CN102-21 (24,VRA11) CN119-2

Attachment 1
Attachment 1
potentiometer
CN102-26 (51,POT-) CN119-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
2. Check if the attachment 1 lever potentiometer is installed
correctly.
4. Perform matching of the attachment 1 lever potentiometer.
chapter.
Judgment
Result Procedure
NG Attachment 1 lever potentiometer defect
Error Code: H3-5

Failure mode: Abnormal matching value for attachment 1 lever
potentiometer
3
CAUTION
ated.
Probable cause
Related part
CN101-29 (30,VRAT1+) CN119-4
CN102-21 (24,VRA11) CN119-2

Attachment 1
Attachment 1
potentiometer
CN102-26 (51,POT-) CN119-1
Step 1
1. Matching of the attachment 1 lever potentiometer. Refer to
Judgment
Result Procedure
does not occur.
occurs.
Error Code: H4-1

Failure mode: Attachment 2 lever potentiometer open circuit
abnormality
CAUTION
ated.
Probable cause
Related part
CN101-30 (31,VRAT2+) CN120-4
CN102-29 (26,VRA21) CN120-2

Attachment
Attachment 1
2
potentiometer
CN102-26 (51,POT-) CN120-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
CN101 NOTICE!
With the battery plug and the CN120, CN101 and CN102
1 2 3 4 5 6 7 connectors disconnected, visually check inside each con-
8 9 10 11 12 13 14 15 16 17 nector and the caulked portion of each wire for defects.
18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING.")
28 29 30 31 32 33 34 CN120
CN102
1 2 3 4 CN101-30 - CN120-4 Continuity
1 2 3 4 5 6 7 CN102-29 - CN120-2 Continuity
8 9 10 11 12 13 14 15 16 17 18 19 CN102-28 - CN120-3 Continuity
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H4-2

Failure mode: Attachment 2 lever potentiometer short circuit
abnormality
CAUTION
ated.
Probable cause
Related part
CN101-30 (31,VRAT2+) CN120-4
CN102-29 (26,VRA21) CN120-2

Attachment
Attachment 1
2
potentiometer
CN102-26 (51,POT-) CN120-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
the error code.
Judgment
Result Procedure
Step 3
Harness inspection
NOTICE!
connectors disconnected, visually check inside each con-
nector and the caulked portion of each wire for defects.
CN120
1 2 3 4 5 6 7 Inspected place Standard

8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 CN102-26 - CN120-1 Continuity
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H4-3

Failure mode: Attachment 2 lever potentiometer output deviation
abnormality
CAUTION
ated.
Probable cause
Related part
CN101-30 (31,VRAT2+) CN120-4
CN102-29 (26,VRA21) CN120-2

Attachment
Attachment 1
2
potentiometer
CN102-26 (51,POT-) CN120-1

Step 1
Error recheck
connect the CN120 connector, and visually check inside the 3
3. Perform matching of the attachment 2 lever potentiometer
and see if any error occurs.
Judgment
Result Procedure
H4-3 error does not occur after matching. Connector contact defect
Attachment 2 lever matching does not com-
Go to Step 2
pete.
Step 2
2. Replace the attachment 2 lever potentiometer connector
form matching of the lift lever potentiometer.
Judgment
Result Procedure
Lift lever matching does not complete
Step 3
Harness inspection
NOTICE!
connectors disconnected, visually check inside each con-
nector and the caulked portion of each wire for defects.
CN120
1 2 3 4
Judgment
Result Procedure
OK
NG Harness defect
Error Code: H4-4

Failure mode: Attachment 2 lever potentiometer neutral abnormality
3
CAUTION
ated.
Probable cause
Related part
CN101-30 (31,VRAT2+) CN120-4
CN102-29 (26,VRA21) CN120-2

Attachment
Attachment 1
2
potentiometer
CN102-26 (51,POT-) CN120-1
Step 1
Error recheck
Judgment
Result Procedure
Step 2
2. Check if the attachment 2 lever potentiometer is installed
correctly.
4. Perform matching of the attachment 2 lever potentiometer.
chapter.
Judgment
Result Procedure
NG Attachment 2 lever potentiometer defect
Error Code: H4-5

Failure mode: Abnormal matching value for attachment 2 lever
potentiometer
3
CAUTION
ated.
Probable cause
Related part
CN101-30 (31,VRAT2+) CN120-4
CN102-29 (26,VRA21) CN120-2

Attachment
Attachment 1
2
potentiometer
CN102-26 (51,POT-) CN120-1
Step 1
1. Matching of the attachment 2 lever potentiometer. Refer to
Judgment
Result Procedure
does not occur.
occurs.
Error Code: H5-1

Failure mode: Lift proportional solenoid open circuit abnormality
(lever pull side)
CAUTION
• If the H5-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Probable cause
▪ Lift push solenoid harness defect
▪ Lift push solenoid defect
▪ Lift pull solenoid harness defect
▪ Lift pull solenoid defect
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
CN101-17 (10,SLPL-) CN78-1 solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
2. Disconnect the CN78 and CN87 connectors, and visually 3
wire for defects.
3. Connect the CN78 and CN87 connector, connect the bat-
tery plug, and turn the key switch ON to see if an error oc-
curs.
Judgment
Result Procedure
H5-6 error occurs. Track down the cause of the H5-6 error.
H5-6 error does not occur. Go to step 2
STEP2
Error recheck
1. Push and hold down the lift lever and pull and hold it up for
more than 1 second each to check if an error occurs.
Judgment
Result Procedure
H5-1 error occurs. Go to step 3
STEP3
Lift solenoid inspection
2. Disconnect the CN78 and CN87 connectors and measure
the resistance of the lift solenoid.
3. Check the resistance of lift proportional valve solenoid
(PULL).
NOTICE!
connect the CN78 connector, visually check each terminal
and the caulked portion and coating of each cable for de-
fects.
CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
1 2 3 4 5 6 7 connect the CN78, CN87, CN101, CN103 and CN104 con-
CN78 8 9 10 11 12 13 14 15 16 17 nectors, and visually check inside each connector and the
18 19 20 21 22 23 24 25 26 27 caulked portion of each wire for defects.
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
28 29 30 31 32 33 34 35
*1: Connect CN78 to the solenoid and measure the resistance
12 Ω (approx. 7 Ω at 20°C).
Judgment
Result Procedure
NG Lift solenoid or harness defect
Error Code: H5-2

Failure mode: Lift proportional solenoid short circuit abnormality
(lever pull side)
3
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
2. Disconnect the CN78 and CN87 connectors, and visually
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold up the lift lever and pull and hold it down for
Judgment
Result Procedure
STEP3
(PULL).
NOTICE!
fects.)
CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4 8 9 10 11 12 13 14 15 16 17
5 6 7 8
28 29 30 31 32 33 34 CN78-5 - CN78-1 No continuity *1
Judgment
Result Procedure
NG Harness defect
Error Code: H5-3

Failure mode: Lift proportional solenoid open circuit abnormality
(lever push side)
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold down the lift lever and pull and hold it up for
Judgment
Result Procedure
STEP3
(PUSH).
NOTICE!
connect the CN87 connector, and visually check inside
defects.
CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
8 9 10 11 12 13 14 15 16 17 nectors, and visually check inside each connector and the
CN87
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 CN101-16 - CN87-1 Continuity *1
28 29 30 31 32 33 34 35
Judgment
Result Procedure
Error Code: H5-4

Failure mode: Lift proportional solenoid short circuit abnormality
(lever push side)
3
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold up the lift lever and pull and hold it down for
Judgment
Result Procedure
STEP3
(PUSH).
NOTICE!
connect the CN87 connector, and visually check inside
defects.
CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4
8 9 10 11 12 13 14 15 16 17
Judgment
Result Procedure
NG Harness defect
Error Code: H5-5

Failure mode: Lift proportional solenoid power circuit abnormality
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
3. Check the resistance of lift proportional valve solenoid.
NOTICE!
connect the CN78 and CN87 connectors, and visually
wire for defects.

CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment 3
Result Procedure
Lift proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Harness inspection
NOTICE!
CN78
1 2 3 4 CN101 nectors, and visually check inside each connector and the
5 6 7 8
1 2 3 4 5 6 7
CN87 8 9 10 11 12 13 14 15 16 17 Portion to be inspected Standard
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN78-5 - CN78-1 No continuity *1
1 2 3 4
5 6 7 8 CN101-17 - P2 No continuity
Judgment
Result Procedure
Error Code: H5-6

Failure mode: Lift proportional solenoid open/short circuit
abnormality (lever pull side/lever push side)
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-5

Lift push
solenoid
CN101-16 (11,SLPS-) CN87-1
CN78-5
Lift
Liftpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Check if the HB-2 error has also occurred.
Judgment
Result Procedure
HB-2 error occurs. Track down the cause of the HB-2 error.
HB-2 error does not occur. Go to step 3
STEP3
3. Check the resistance of lift proportional valve solenoid.
NOTICE!
connect the CN78 and CN87 connector, visually check each
terminal and the caulked portion and coating of each cable
for defects.
CN78-5 - CN78-1 6 to 12 Ω
CN87-5 - CN87-1 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Lift solenoid defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN78
5 6 7 8
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
5 6 7 8 17 18 19 20 21 22 23 24 25 26 27 CN78-5 - CN78-1 No continuity *1
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H6-1

Failure mode: Tilt proportional solenoid open circuit abnormality
(lever pull side)
3
CAUTION
Probable cause
▪ Tilt push solenoid harness defect
▪ Tilt push solenoid defect
▪ Tilt pull solenoid harness defect
▪ Tilt pull solenoid defect
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
CN101-12 (33,STPL-) CN78-2 solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
tery plug, and turn the key switch ON to see if any error oc-
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold down the tilt lever and pull and hold it up for
Judgment
Result Procedure
STEP3
Tilt solenoid inspection
the resistance of the tilt solenoid.
3. Check the resistance of tilt proportional valve solenoid
(PULL).
NOTICE!
fects.
CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
1 2 3 4
5 6 7 8
CN101-6 - CN78-6 Continuity *
1 2 3 4 5 6
CN101-12 - CN78-2 Continuity *
7 8 9 10 11 12 13 14 15 16
28 29 30 31 32 33 34 35
*: Connect CN78 to the solenoid and measure the resistance
Judgment
Result Procedure
NG Tilt solenoid or harness defect
Error Code: H6-2

Failure mode: Tilt proportional solenoid short circuit abnormality
(lever pull side)
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold up the tilt lever and pull and hold it down for
Judgment
Result Procedure
STEP3
(PULL).
NOTICE!
fects.
CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN78 caulked portion of each wire for defects.
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H6-3

Failure mode: Tilt proportional solenoid open circuit abnormality
(lever push side)
3
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
tery plug, and turn the key switch ON to see if any error oc-
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold down the tilt lever and pull and hold it up for
Judgment
Result Procedure
STEP3
(PUSH).
NOTICE!
defects.
CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN87
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 CN101-13 - CN87-2 Continuity *1
28 29 30 31 32 33 34 35
Judgment
Result Procedure
Error Code: H6-4

Failure mode: Tilt proportional solenoid short circuit abnormality
(lever push side)
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold up the tilt lever and pull and hold it down for
Judgment
Result Procedure
STEP3
(PUSH).
NOTICE!
defects.
CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4
8 9 10 11 12 13 14 15 16 17
Judgment
Result Procedure
NG Harness defect
Error Code: H6-5

Failure mode: Tilt proportional solenoid power circuit abnormality
3
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
NOTICE!
wire for defects.

CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
Tilt proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Harness inspection
NOTICE!
CN78
CN101
1 2 3 4 nectors, and visually check inside each connector and the
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4
Judgment
Result Procedure
Error Code: H6-6

Failure mode: Tilt proportional solenoid open/short circuit
3
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-6

Tilt push
solenoid
CN101-13 (34,STPS-) CN87-2
CN78-6
Tilt
Tiltpull
pull
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
Judgment
Result Procedure
STEP3
NOTICE!
connect the CN78, CN87 connectors, and visually check in-
side each connector and the caulked portion of each wire
for defects.
CN78-6 - CN78-2 6 to 12 Ω
CN87-6 - CN87-2 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN78
5 6 7 8
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
28 29 30 31 32 33 34 35
*1 : Connect CN78 to the solenoid and measure the resistance
Judgment
Result Procedure
NG Harness defect
Error Code: H7-1

Failure mode: Attachment 1 proportional solenoid open circuit
abnormality (lever pull side)
CAUTION
Probable cause
▪ Attachment 1 push solenoid harness defect
▪ Attachment 1 push solenoid defect
▪ Attachment 1 pull solenoid harness defect
▪ Attachment 1 pull solenoid defect
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold down the attachment 1 lever and pull and
hold it up for more than 1 second each to check if an error
occurs.
Judgment
Result Procedure
STEP3
Attachment 1 solenoid inspection
the resistance of attachment 1 solenoid.
3. Check the resistance of attachment 1 proportional valve
solenoid (PULL).
NOTICE!
fects.
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
Judgment
Result Procedure
NG Attachment 1 solenoid or harness defect
Error Code: H7-2

Failure mode: Attachment 1 proportional solenoid short circuit
3
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
1. Push and hold up the attachment 1 lever and pull and hold it
down for more than 1 second each to check if an error oc-
curs.
Judgment
Result Procedure
STEP3
solenoid (PULL).
NOTICE!
fects.
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Attachment 1 solenoid defect
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4 8 9 10 11 12 13 14 15 16 17
5 6 7 8
Judgment
Result Procedure
NG Harness defect
Error Code: H7-3

abnormality (lever push side)
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
occurs.
Judgment
Result Procedure
STEP3
solenoid (PULL).
NOTICE!
fects.
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN87
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 CN101-11 - CN87-3 Continuity *1
28 29 30 31 32 33 34 35
Judgment
Result Procedure
Error Code: H7-4

babnormality (lever push side)
3
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
curs.
Judgment
Result Procedure
STEP3
solenoid (PUSH).
NOTICE!
defects.
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4
8 9 10 11 12 13 14 15 16 17
Judgment
Result Procedure
NG Harness defect
Error Code: H7-5

Failure mode: Attachment 1 proportional solenoid power circuit
abnormality
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
solenoid.
NOTICE!
wire for defects. 3
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
Attachment 1 proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Harness inspection
NOTICE!
CN78
1 2 3 4 CN101 nectors, and visually check inside each connector and the
5 6 7 8
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
1 2 3 4
Judgment
Result Procedure
Error Code: H7-6

Failure mode: Attachment 1 proportional solenoid open/short circuit
CAUTION
Probable cause
Related portion
CN101-6 (32,SLTA1+) CN87-7

Attachment
Attachment 11
push solenoid
CN101-11 (37,SA1PS-) CN87-3
CN78-7
Attachment
Attachment 11
CN101-10 (36,SA1PL-) CN78-3 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
Judgment
Result Procedure
STEP3
solenoid.
NOTICE!
for defects.
CN78-7 - CN78-3 6 to 12 Ω
CN87-7 - CN87-3 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN78
5 6 7 8
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H8-1

3
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
occurs.
Judgment
Result Procedure
STEP3
solenoid (PULL).
NOTICE!
fects.
CN78-8 - CN78-4 6 to 12 Ω
CN87-8 - CN87-4 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
Judgment
Result Procedure
Error Code: H8-2

CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
curs.
Judgment
Result Procedure
STEP3
solenoid (PULL).
NOTICE!
fects.
CN78-8 - CN78-4 6 to 12 Ω
CN87-8 - CN87-4 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN101
1 2 3 4 8 9 10 11 12 13 14 15 16 17
5 6 7 8
Judgment
Result Procedure
NG Harness defect
Error Code: H8-3

3
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
occurs.
Judgment
Result Procedure
STEP3
solenoid (PUSH).
NOTICE!
defects.
CN78-8 - CN78-4 6 to 12 Ω
CN87-8 - CN87-4 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
NG Attachment 2 proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN87
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 CN101-15 - CN87-4 Continuity *1
28 29 30 31 32 33 34 35
Judgment
Result Procedure
Error Code: H8-4

CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
curs.
Judgment
Result Procedure
STEP3
solenoid (PUSH).
NOTICE!
fects.
CN78-8 - CN78-4 6 to 12 Ω
CN87-8 - CN87-4 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
NOTICE!
CN87 CN101
nectors, and visually check inside each connector and the
1 2 3 4 1 2 3 4 5 6 7 (Refer to "BEFORE TROUBLESHOOTING.")
8 9 10 11 12 13 14 15 16 17
5 6 7 8
Judgment
Result Procedure
NG Harness defect
Error Code: H8-5

Failure mode: Attachment 2 proportional solenoid power circuit
abnormality
3
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
solenoid.
NOTICE!
wire for defects.
CN78-8 - CN78-4 6 to 12 Ω
CN87-8 - CN87-4 (approx. 7 Ω at 20°C)
Judgment
Result Procedure
Attachment 2 proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Harness inspection
NOTICE!
CN78
CN101
1 2 3 4 nectors, and visually check inside each connector and the
5 6 7 8
8 9 10 11 12 13 14 15 16 17
1 2 3 4
Judgment
Result Procedure
Error Code: H8-6

Failure mode: Attachment 2 proportional solenoid open/short circuit
CAUTION
Probable cause
Related portion
CN101-5 (9,SLLA2+) CN87-8

Attachment 2
push solenoid
CN101-15 (40,SA2PS-) CN87-4
CN78-8
Attachment
Attachment 22
CN101-14 (39,SA2PL-) CN78-4 pull
pullsolenoid
solenoid
Main controller
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
wire for defects.
curs.
Judgment
Result Procedure
STEP2
Error recheck
Judgment
Result Procedure
STEP3
solenoid.
NOTICE!
for defects.
6 to 12 Ω (approx.
CN78-8 - CN78-4, CN87-8 - CN87-4
7 Ω at 20°C)
Judgment
Result Procedure
OK Go to step 4
STEP4
Harness inspection
CN101 NOTICE!
CN78
5 6 7 8
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: HB-1

Failure mode: Proportional solenoid power supply RY1 contact open
circuit abnormality
3
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
F7
CN136-6
CN136-6(19, VBMBSL)
(19,F7)
CN102-5 (17,SOLCOM) CN127-8 (17,SOLCOM) CN127-6 (19,VBMBSL)

CN102-6 (17,SOLCOM)
RY1
CN102-13 (335,RY1) CN127-4 (335,RY1) CN127-2 (97,FAN+)
CN101-3 (97,FAN+)
CN101-5 (9,SLLA2+) CN87-5
Lift PUSH
CN101-16 (11,SLPS-) CN87-1 solenoid
solenoid
CN101-17 (10,SLPL-) CN78-1
Lift
Lift PULL
PULL
CN78-5 solenoid
solenoid
CN101-6 (32,SLTA1+) CN87-6
Tilt PUSH
CN101-13 (34,STPS-) CN87-2 solenoid
solenoid
Main
Main CN101-12 (33,STPL-) CN78-2
controller Tilt
Tilt PULL
PULL
CN78-6 solenoid
solenoid
CN87-7
ATT1 PUSH
CN101-11 (37,SA1PS-) CN87-3 solenoid
solenoid
CN101-10 (36,SA1PL-) CN78-3
ATT1
ATT1 PULL
PULL
CN78-7 solenoid
solenoid
CN87-8
ATT2
ATT2 PUSH
PUSH
solenoid
CN101-14 (39,SA2PL-) CN78-4
ATT2
ATT2 PULL
PULL
CN103-5 (N2,N2) CN78-8 solenoid
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
Judgment
Result Procedure
HB-1 error does not occur. Connector contact defect
HB-1 error occurs. Go to step 2
STEP2
Harness inspection
CN101 CN102 NOTICE!
With the battery plug and the CN101, CN102, and CN127
1 2 3 4 5 6 7 1 2 3 4 5 6 7 connectors disconnected, visually check inside each con-
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 nector and the caulked portion of each wire for defects.
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING.")
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
Portions to be checked Standard
CN127 CN136
1 2 3 1 2 3 4 CN102-5 - CN127-8 Continuity
4 5 6 7 8 5 6 7 8
Judgment
Result Procedure
NG Harness defect
Relay defect
OK If the symptom persists after replacement of the relay, there
should be any other problems, so replace the Main controller.
Error Code: HB-2

Failure mode: Proportional solenoid power supply load short circuit
abnormality
3
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
F7
CN136-6
CN136-6(19, VBMBSL)
(19,F7)

CN102-6 (17,SOLCOM)
RY1
CN102-13 (335,RY1) CN127-4 (335,RY1) CN127-2 (97,FAN+)
CN101-3 (97,FAN+)
CN101-5 (9,SLLA2+) CN87-5
Lift PUSH
solenoid
CN101-17 (10,SLPL-) CN78-1
Lift
Lift PULL
PULL
CN78-5 solenoid
solenoid
CN101-6 (32,SLTA1+) CN87-6
Tilt PUSH
solenoid
Main
Main CN101-12 (33,STPL-) CN78-2
controller Tilt
Tilt PULL
PULL
CN78-6 solenoid
solenoid
CN87-7
ATT1 PUSH
solenoid
CN101-10 (36,SA1PL-) CN78-3
ATT1
ATT1 PULL
PULL
CN78-7 solenoid
solenoid
CN87-8
ATT2
ATT2 PUSH
PUSH
solenoid
CN101-14 (39,SA2PL-) CN78-4
ATT2
ATT2 PULL
PULL
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
2. Disconnect the CN127, CN87 and CN78 connectors, and
visually check inside the connector and the caulked portion
of its wire defects.
3. Connect the CN127, CN87 and CN78 connector, connect
the battery plug, and turn the key switch ON to see if an er-
ror occurs.
Judgment
Result Procedure
STEP2
Harness inspection
2. Disconnect the CN101, CN102, CN103, CN104, CN87 and
CN78 connectors and check the harnesses for their continu-
ities.
CN101 CN102 NOTICE!
With the battery plug and the CN101, CN102, CN103,
1 2 3 4 5 6 7 1 2 3 4 5 6 7 CN104, CN87 and CN78 connectors disconnected, visually
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 check inside each connector and the caulked portion of
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 each wire for defects.
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 (Refer to "BEFORE TROUBLESHOOTING.")
CN104 Portions to be checked Standard
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
Judgment
Result Procedure
NG Harness defect
Error Code: HB-3

Failure mode: Proportional solenoid power supply RY1 overcurrent
abnormality
3
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
F7
CN136-6
CN136-6(19, VBMBSL)
(19,F7)

CN102-6 (17,SOLCOM)
RY1
CN102-13 (335,RY1) CN127-4 (335,RY1) CN127-2 (97,FAN+)
CN101-3 (97,FAN+)
CN101-5 (9,SLLA2+) CN87-5
Lift PUSH
solenoid
CN101-17 (10,SLPL-) CN78-1
Lift
Lift PULL
PULL
CN78-5 solenoid
solenoid
CN101-6 (32,SLTA1+) CN87-6
Tilt PUSH
solenoid
Main
Main CN101-12 (33,STPL-) CN78-2
controller Tilt
Tilt PULL
PULL
CN78-6 solenoid
solenoid
CN87-7
ATT1 PUSH
solenoid
CN101-10 (36,SA1PL-) CN78-3
ATT1
ATT1 PULL
PULL
CN78-7 solenoid
solenoid
CN87-8
ATT2
ATT2 PUSH
PUSH
solenoid
CN101-14 (39,SA2PL-) CN78-4
ATT2
ATT2 PULL
PULL
solenoid
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
STEP1
Error recheck
Judgment
Result Procedure
STEP2
Harness inspection
NOTICE!
check inside each connector and the caulked portion of
each wire for defects.
1 2 3
4 5 6 7 8 Portions to be checked Standard
Judgment
Result Procedure
NG Harness defect
Relay defect
OK If the symptom persists after replacement of the relay, there
should be any other problems, so replace the Main controller.
Error Code: COLD DCR (Safety motor)

Failure mode: Drive motor driver temperature low
1. If the warning indicator is ON, leave the truck for 20 to 30
minutes at normal temperature (0 to 40℃) with the key 3
switch ON.
Error Code: COLD PCR (Safety motor)

Failure mode: Pump motor driver temperature low
1. If the warning indicator is ON, leave the truck for 20 to 30
minutes at normal temperature (0 to 40℃) with the key
switch ON.
3.5 NO ERROR CODE IS DISPLAYED

When an error is displayed or the spanner mark is ON, always give a priority to the
error or the mark.
3.5.1 Power related

Control category/Power related
Phenomena that
occur on the Faulty part/mode Check method Measures
vehicle
Emergency power shut-down ▪ Release the emer-
button body : - gency power shut-
Pushed state of the switch down button
Inspect the battery
voltage :
Battery : Low voltage Check the battery plug ▪ Charge the Battery
OFF state
and battery voltage
Key switch body : ▪ Inspect and replace
Open failure the key switch
Emergency power shut-down ▪ Inspect and replace

button body : the emergency power
Open failure shut-down button
Key switch harness : - ▪ Check the harness

Disconnection, short circuit, and repair or replace it
The power cannot and leakage problem (Harness, if necessary.
be applied when the battery plug, connector, F5 ▪ Replace F5 fuse
key switch and/or fuse, and F6 fuse (80V ▪ Replace F6 fuse (80V
the numeric key is vehicle)) vehicle)
operated
(The display is not [PIN code entry (OPT)] ▪ Check the harness
displayed and the Numerical key harness : - and repair or replace it
vehicle does not Open failure if necessary.
move) Check operation of each
switch :
Check a specific switch
does not respond (LED,
and buzzer sound)
In the combination of
[PIN code entry (OPT)] (1,2,3), the combination of
▪ Replace the numeric
Numerical key body : (4,5,6), the combination of
key body
Failure of each switch (7,8,9), and the combina-
tion of (OFF, 0, ON).
When there are switches
that respond and do not
respond in each combina-
tion, it is certainly a switch
failure.
[PIN code entry (OPT)] Check if PIN is registered ▪ Register PIN in the
Display : PIN not registered in the Administrator menu Administrator menu

Phenomena that
vehicle
[Telematics equipped vehicle 3
(OPT)] ▪ Check the harness
- and repair or replace it
Keypad harness : if necessary.
Open failure
[Telematics equipped vehicle Check operation of each
(OPT)] switch :
Check all or only a spe- ▪ Replace the keypad
Keypad body : cific switch do not re- body
Internal failure spond (Green LED or Red
Failure of each switch LED ON)
▪ Using TruckCom
(SST), switch the op-
[Telematics equipped vehicle erator authentication
(OPT)] function of the keypad
-
Keypad body : body to server man-
Not server management agement
(Refer to replacing the
keypad)
[Telematics equipped vehicle
(OPT)]
Check PIN code is re- ▪ Register PIN code in
Operation management sys- gistered in the Web site the Web site
tem :
PIN code not registered
The power cannot
be applied when the ▪ From the Vehicle
key switch and/or [Telematics equipped vehicle Management screen
the numeric key is (OPT)] in the Web site, start
operated communication (Per-
Operation management sys- - mission to manage
(The display is not tem :
displayed and the the vehicle is re-
PIN code cannot be down- quired) or start com-
vehicle does not loaded
move) munication forcibly us-
ing Truck-Com (SST)
[PIN code entry (OPT) or
Telematics equipped vehicle
(OPT)]
Display power and grand har- ▪ Check the harness
ness : and repair or replace it
Disconnection, short circuit, if necessary.
and leakage problem (Harness - ▪ Replace the display
and connector)
▪ Replace the main con-
Display : Internal failure troller
Main controller :
Internal failure (D7V and
DGND)
[Telematics equipped vehicle
(OPT)]
CAN bridge controller power ▪ Check the harness
and grand harness : and repair or replace it
Disconnection, short circuit, - if necessary.
and leakage problem (Harness ▪ Replace the CAN
and connector) bridge controller
CAN bridge controller :
Internal failure

Phenomena that
vehicle
Display power and grand har-
ness : ▪ Check the harness
Disconnection, short circuit, and repair or replace it
Display is not dis- and leakage problem (Harness if necessary.
played and connector) -
▪ Replace the display.
(The vehicle moves)
Display : Internal failure ▪ Replace the main con-
Main controller : troller.
Internal failure
3.5.2 Traveling
Control category/Traveling
Phenomena that
occur on the Faulty part/mode Check method Measures 3
vehicle
Check the warning display *Not an error
and warning sound on the
display The warm-up function
may be activated for a few
*Depending on how a seconds after the key
customer uses (for ex- switch is turned ON to
Warm-up function at low tem- ample, leaving a vehicle protect the controller.
perature protection activated in low temperature for a
long duration), when the Note that traveling and
warning-up function is ac- load handling operations
tivated, the warning is dis- are unavailable during
played and the warning warming-up. Perform this
sound notifies the cus- operations after the warn-
tomer. ing sound stops.
After the key is turned
ON, set acceleration-off
and direction neutral
After the key is turned ON, it is once, and then conduct
not set to accelerator pedal off - traveling operation.
and direction neutral Until acceleration-off and
direction neutral are de-
tected, traveling cannot
Unable to travel (the be conducted.
drive motor does not Inspect the direction
rotate) or cannot switch by using an ana-
climb a slope sud- lyzer :
denly Direction switch body : Accelerator full-closed ▪ Inspect and replace
Open failure state the switch
Direction switch harness : Operate the direction ▪ Check the harness
Disconnection, and short circuit switch to check ON/OFF and repair or replace it
(Harness and connector) (When forward and re- if necessary.
verse are ON at the same
time, traveling cannot be
conducted)
Accelerator sensor body :
Internal failure Inspect the accelerator
Accelerator sensor installed sensor by using an ana- ▪ Inspect and replace
part : lyzer : the sensor
Link, installed part breakage, Direction neutral state
and damage Perform accelerator full- ▪ Check the harness
closed to full-open, and and repair or replace it
Accelerator sensor harness : if necessary.
Disconnection, short circuit, check the input signal
and leakage problem (Harness change
and connector)
Accelerator sensor Full-open,
full-close matching value : Check the matching value ▪ Perform matching
Does not match with the vehicle on the matching screen again.
state
Phenomena that
vehicle
Brake sensor body :
Internal failure
Inspect the brake sensor ▪ Inspect and replace
Brake sensor installed part :
by using an analyzer : the sensor
Link, installed part breakage,
Direction neutral state
and damage ▪ Check the harness
Perform brake full-closed
Brake sensor harness : to full-open, and check and repair or replace it
Disconnection, short circuit, the voltage change if necessary.
and leakage problem (Harness
and connector)
Brake sensor Full-closed, oper-
ating point matching : Check the matching value ▪ Perform matching
Unable to travel (the Does not match with the vehicle on the matching screen again.
drive motor does not state
rotate) or cannot Seat switch body : Inspect the seat switch by ▪ Inspect and replace
climb a slope sud- Open failure using an analyzer : the seat
denly Direction neutral, acceler-
Seat switch harness : ator full-closed state ▪ Check the harness
Disconnection (Harness and Sit on the seat and leave and repair or replace it
connector) the seat to check ON/OFF if necessary.
Inspect the brake/drive
motor :
Brake : In the battery plug OFF, ▪ Inspect, repair, and
Dragging (Internal failure) the parking brake re- replace the brake
Drive motor : leased, and front wheels ▪ Inspect, repair, and
Drive motor fixation, and drag- raised state replace the drive mo-
ging (Internal failure) turn the tires with your tor
hands to check if they ro-
tate
Drive motor speed sensor
body : Inspect the drive motor
Internal failure speed sensor voltage by ▪ Inspect, adjust, and
using an analyzer : replace the drive mo-
Drive motor speed sensor in-
In sitting on the seat, dir- tor speed sensor
stalled part :
ection forward, and brake
Gap adjustment failure ▪ Check the harness
released state
Drive motor harness : Operate the accelerator, and repair or replace it
Unable to travel (the Disconnection, short circuit, and check the speed if necessary.
drive motor does not and leakage problem (Harness sensor voltage change
rotate) or cannot and connector)
climb a slope sud-
Inspect the drive motor
denly
Drive motor driver : current sensor voltage by
using an analyzer : ▪ Replace the drive mo-
Internal failure
In sitting on the seat, dir- tor driver
Motor cable : ection forward, and brake ▪ Check the cable and
Disconnection, short circuit, released state repair or replace it if
and leakage problem (Cable Operate the accelerator, necessary.
and machine stand) and check the current
sensor voltage change
Phenomena that
vehicle
[Australian spec (OPT), Seat- 3
belt interlock (OPT)]
Seatbelt switch body : Inspect the seatbelt
Open failure (Internal damage) switch by using an ana- ▪ Inspect and replace
Short failure (Internal damage) lyzer : the seatbelt (buckle)
Seatbelt switch line (Signal and Direction neutral, acceler- ▪ Check the harness
ground) : ator all-closed state and repair or replace it
Unable to travel (the Disconnection failure (Harness Put the seatbelt ON/OFF, if necessary.
drive motor does not and connector) and check ON/OFF
rotate) or cannot Short and leakage failure (Har-
climb a slope sud- ness and connector)
denly
[Australian spec (OPT), Seat- Return the direction lever
belt interlock (OPT)] to neutral, remove the
Incorrect operating procedure seatbelt once, and while -
(The seatbelt is not put on after seated, put the seatbelt
seated) on to start traveling.
Main controller : Internal failure -
troller
[V mast] Inspect the lift height
Fork height 800 mm switch 800mm switch by using
▪ Inspect, adjust, and
body : an analyzer :
replace the switch
Open failure In NL state
▪ Check the harness
Lift height 800 mm switch har- Operate the lift from low- and repair or replace it
[Australian spec ness : est position to most up-
(OPT)] if necessary.
Disconnection problem (Har- ward position, and check
3 km/h is the max- ness and connector) ON/OFF.
imum speed Display settings :
Mast type setting is not Check the setting value
▪ Correct the setting
matched (The spanner mark on the matching screen.
ON)
troller
[V mast] Inspect the lift height
Fork height 800 mm switch 800mm switch by using
▪ Inspect, adjust, and
body : an analyzer :
replace the switch
Short failure In NL state
Lift height 800 mm switch har- Operate the lift from low- and repair or replace it
ness : est position to most up-
if necessary.
Short circuit and leakage prob- ward position, and check
[Australian spec lem (Harness and connector) ON/OFF
(OPT)] Display settings :
The speed is not lim- The setting are not in Australian Check the setting value
▪ Change the setting
ited when the mast specification (Option set AUS. on the option set screen.
is raised SPEC)
Display settings :
Mast type setting is not Check the setting value
matched, and the hour meter is on the matching screen.
not started (The spanner mark ▪ Hour meter start
Check the hour meter.
ON)
troller
Phenomena that
vehicle
[Australian spec Display settings :
Check the setting value
(OPT)] Does not match the mast type ▪ Correct the setting
on the matching screen.
The lift height that data with the vehicle state
speed is limited is ▪ Replace the main con-
different troller
[Telematics
*Not an error
equipped vehicle Check the warning display
Vehicle performance control is
(OPT)] and warning sound on the Contact the administrator,
applied due to shock detection and request to release the
Traveling control is display
control.
applied
[Telematics＆POC
*Not an error
equipped vehicle The limitation works because of
(OPT)] Check the red LED of Contact the administrator,
answering "NG" for the pre-op-
POC. and request to release the
Traveling control is eration check (important item).
control.
applied
3.5.3 SAS-ε (OPT) Traveling control

Control category/SAS-ε (OPT) Traveling control
Phenomena that
vehicle
Inspect the load sensor
Load sensor body :
voltage by using an ana- ▪ Inspect and replace
Internal damage
lyzer : In NL state the sensor
Load sensor harness :
Operate the lift from low- ▪ Check the harness
Disconnection, short circuit,and
est position to most up- and repair or replace it
leakage problem (Harness and
ward position (relief), and if necessary.
connector)
check the voltage change
Display settings :
Does not match the tire dia- Check the tire diameter
▪ Correct the settings
meter data with the vehicle on the matching screen.
state
*Not an error
Traveling control influ-
ences attachment, and
own weight of the mast
also influences the
vehicle’s forward and re-
verse stability; therefore, it
Heavy attachment, and high lift is treated as load weight.
-
height mast Speed control may be ap-
In case of no load, plied even with no load if
speed control is ap- the own weight of inner
plied in the high lift and middle mast is heavy
height for the heavy class attach-
ment and high lift height
mast among the FSV
masts.
After the most upward lift-
ing, the relief pressure re-
mains in the lift cylinder
pressure that detects with
the load sensor, and it
cannot be distinguished
with the hauling state of
Detect the lift relief pressure - weight load.
After lift relief, by lowering
a little, the relief pressure
is released; therefore,
when it causes a problem
in operation, use by
lowering a little from the
most upward lifting state.
troller

Phenomena that
vehicle
Load sensor body :
Internal damage
Disconnection, short circuit,
and connector)
Inspect the lift height
Lift height switch body : switch by using an ana- ▪ Inspect and replace
Always detect the low lift height lyzer : In NL state the switch
Lift switch harness : Operate the lift from low- ▪ Check the harness
Disconnection, and short circuit est position to most up- and repair or replace it
(Harness and connector) ward position, and check if necessary.
ON/OFF
[Height selector (OPT) +
Vmast]
Lifting height sensor main
body : Check the lifting height
Dragging and improper winding sensor, using an ana-
▪ Check the sensor, and
of wire lyzer :
replace it if necessary.
Installation of lifting height In NL state
Even though load is sensor : Operate the lift from low-
and repair or replace it
hauled, speed con- Breakage of sensor installation est position to most up-
if necessary.
trol is not applied in portion, breakage of wire rout- ward position (relief), and
the high lift height ing portion check the voltage change
Lifting height sensor harness :
Disconnection, short circuit or
leakage (Harness, connector)
Vmast]
Lifting height sensor lowermost Check the matching value ▪ Perform matching
position matching value : on the matching screen. again.
Does not match with the vehicle
state
Display settings :
Disabling the Traveling control
setting disabled. Check the setting values
▪ Change the settings
Load sensing speed control dis- on the option set screen.
abled. (Option set ASC W/
LOAD, MODE)
Display settings :
▪ Correct the settings
state
troller

Phenomena that
vehicle
Inspect the lift height 3
Lift height switch body :
switch by using an ana- ▪ Inspect and replace
Always detect the high lift
lyzer : In NL state the switch
height
Lift height switch harness :
Disconnection, and short circuit
ward position, and check if necessary.
(Harness and connector)
ON/OFF
Vmast]
body : Check the lifting height
Dragging and improper winding sensor, using an ana-
of wire lyzer :
In low lift height, replace it if necessary.
Installation of lifting height In NL state
speed control is ap- ▪ Check the harness
sensor : Operate the lift from low-
plied when load is and repair or replace it
Breakage of sensor installation est position to most up-
hauled if necessary.
portion, breakage of wire rout- ward position (relief), and
ing portion check the voltage change
Vmast]
state
troller
Display settings :
Check setting value on
Maximum speed control, and ▪ Change the settings
the matching screen.
low speed setting
Regardless of lift
Display settings :
height and load, the
speed control is al- ▪ Correct the setting
ways applied
state
troller
3.5.4 SAS-ε (OPT) Turn speed control

Control category/SAS-ε (OPT) Turn speed control
Phenomena that
vehicle
▪ Inspect and replace
Tire body : tires
Type, diameter, and air pres- -
sure ▪ Inspect and repair air
pressure
Load sensor body :
Internal damage
and connector)
Load sensor no load matching
value : Check the matching value ▪ Perform matching
Does not match with the vehicle on the matching screen. again.
state
No stability during Lift height switch harness : Operate the lift from low- ▪ Check the harness
traveling Disconnection, and short circuit est position to most up- and repair or replace it
(Speed control is dif- (Harness and connector) ward position, and check if necessary.
ficult during turning ON/OFF
or no control is ap- [Height selector (OPT) +
plied) Vmast]
body :
Check the lifting height
Dragging and improper winding
sensor, using an ana- ▪ Check the sensor, and
of wire
lyzer : In NL state replace it if necessary.
Installation of lifting height
sensor :
Breakage of sensor installation
portion, breakage of wire rout-
ing portion
Vmast]
state
Control category/SAS-ε (OPT) Turn speed control

Phenomena that
vehicle
Tire angle sensor body : 3
Internal failure
Inspect the tire angle
Tire angle sensor installation :
sensor voltage by using ▪ Inspect and replace
Installed part breakage, and
an analyzer : the sensor
damage
Direction neutral, acceler- ▪ Check the harness
Tire angle sensor harness : ator full-closed state and repair or replace it
Steer and check the if necessary.
voltage change
and connector)
Matching value of the tire angle

sensor at the straight traveling
Check the matching value ▪ Perform matching
angle :
on the matching screen. again.
state
Drive motor speed sensor
No stability during body :
traveling Internal failure
the sensor
(Speed control is dif- Drive motor speed sensor har-
ficult during turning ▪ Check the harness
ness :
or no control is ap- - and repair or replace it
plied) if necessary.
and connector) ▪ Replace the drive mo-
tor driver
Drive motor driver :
Internal failure
Display settings :
Does not match the mast type ▪ Correct the setting
on the matching screen.
data with the vehicle state
Display settings :
▪ Correct the setting
state
Display settings :
Turn speed control setting dis- Check the setting value
abled. (Option set CURVE on the option set screen.
CONT)
troller
3.5.5 Handling & power steering

Control category/Handling and power steering
Phenomena that
vehicle
Check the warning display *Not an error
and warning sound on the The warm-up function
display may be activated for a few
*Depending on how a seconds after the key
customer uses (for ex- switch is turned ON to
Warm-up function at low tem- ample, leaving a vehicle protect the controller.
perature protection activated in low temperature for a Note that traveling and
long duration), when the load handling operations
warming-up function is ac- are unavailable during
tivated, the warning is dis- warming-up.
played and the warning Perform this operations
sound notifies the cus- after the warning sound
tomer. stops.
Pump motor speed sensor
body : Internal failure Inspect the Pump motor
Unable to handle, ▪ Inspect, adjust, and
Pump motor speed sensor in- speed sensor voltage by
and steering is replace the pump mo-
stalled part : using an analyzer :
heavy tor speed sensor
Gap adjustment failure In sitting on the seat
(In all load handling, ▪ Check the harness
steering, and direc- Pump motor harness : Operate the direction, and
tion operation, the Disconnection, short circuit, check the speed sensor
if necessary.
handling motor does and leakage problem (Harness voltage change
not rotate) and connector)
Inspect the pump motor
Pump motor driver :
current sensor voltage by
Internal failure ▪ Motor cable check, re-
using an analyzer :
Motor cable : pair, and replace
In sitting state on the seat
Disconnection, short circuit, ▪ Replace the pump
Operate the direction, and
and leakage problem (Cable motor driver
check the current sensor
and machine stand)
voltage change
▪ Inspect, repair, and
replace the load hand-
Load handling pump :
ling pump
Fixation -
Pump motor : Fixation
replace the Pump mo-
tor
troller

Phenomena that
vehicle
Load handling lever poten- 3
tiometer body :
Internal failure Inspect the load handling
lever potentiometer
Load handling lever poten-
voltage by using an ana-
tiometer attachment : ▪ Inspect and replace
lyzer :
Installed part breakage, and the sensor
In unseated state on the
damage ▪ Check the harness
seat
Load handling lever poten- and repair or replace it
Operate the load handle
tiometer harness : if necessary.
lever forward tilt to rear
tilt, and check the voltage
change.
and connector)
Inspect the seat switch by

Seat switch body : ▪ Inspect and replace
using an analyzer :
Open failure the seat
Load handling lever neut-
Seat switch harness : ral state ▪ Check the harness
Disconnection (Harness and and repair or replace it
Sit on the seat and leave
connector) if necessary.
the seat to check ON/OFF
Load handling only
is not possible
Load handling pump : replace the load hand-
(In steering, and dir-
Leakage ling pump
ection operation, ro- -
tate the pump motor Priority valve : ▪ Inspect, repair, and
with the direction op- Leakage and fixation replace the priority
eration) valve
[Australian spec (OPT), Seat-
belt interlock (OPT)]
Seatbelt switch body : Inspect the seatbelt
Open failure (Internal damage) switch by using an ana- ▪ Inspect and replace
Short failure (Internal damage) lyzer : the seatbelt (buckle)
Seatbelt switch line (Signal and Load handling lever in the ▪ Check the harness
ground) : neutral state Put the seat- and repair or replace it
Disconnection failure (Harness belt ON/OFF, and check if necessary.
and connector) ON/OFF
Short and leakage failure (Har-
ness and connector)
[Australian spec (OPT), Seat- Return the load handling
belt interlock (OPT)] lever to neutral, remove
the seatbelt once, and
Incorrect operation procedure while seated, put the seat- -
(The seatbelt is not put on after belt on to start load hand-
seated) ling operation.
troller
Unable to descent Set the descent lock
(Able to ascend, and Descent lock valve : solenoid ON in the active
replace the descent
other load handling Fixation (Internal damage) test, and conduct descent
lock valve
is possible) operation
Unable to forward tilt
Set the forward tilt lock
only ▪ Inspect, repair, and
Forward tilt lock valve : solenoid ON in the active
(Able to tilt rear, and replace the forward tilt
Fixation (Internal damage) test, and conduct forward
other load handling lock valve
tilt operation
is possible)

Phenomena that
vehicle
The start of load ▪ Correct the settings
handling movement
Display settings : If fine adjustment is ne-
is fast. Check the setting OCV
Does not match the OCV start- cessary, adjust activation
Or, the displacement starting current on the
ing current data with the vehicle current of tuning after set-
of the load handling matching screen.
state ting the OCV starting cur-
lever until moving is
large. rent.
Inspect the direction
Direction switch : Open failure
lyzer : the switch
Direction switch harness : Accelerator full-closed ▪ Check the harness
Disconnection problem (Har- state and repair or replace it
ness and connector)
Operate the direction if necessary.
switch to check ON/OFF
Steering-wheel angle sensor
body :
Internal damage
Inspect the steering-wheel ▪ Inspect and replace
Steering-wheel angle sensor in-
angle sensor by using an the sensor
stallation :
analyzer :
Steering is heavy Cam or steering wheel failure ▪ Check the harness
Check the input single by
(In load handling op- Steering-wheel angle sensor conducting steering oper- and repair or replace it
eration, the pump harness : ation if necessary.
motor rotates) Disconnection, short circuit,
and connector)
replace the load hand-
Load handling pump : Leakage ling pump
Priority valve : ▪ Inspect, repair, and
-
Leakage and fixation replace the priority
PS valve : Leakage and fixation valve
replace the PS valve
troller
When ATT1 (ATT2)
Display settings :
is operated, it does
The number of oil control valve
not function Check the setting value
does not match the vehicle spe- ▪ Change the setting
(The pump motor on the option set screen.
cification (Option set 1 09 /
does not also rotate
OCV WAY)
by ATT operation)
3.5.6 SAS-ε (OPT) Tilt control

Control category/SAS-ε (OPT) Tilt control
Phenomena that
vehicle
Tilt angle sensor body :
Internal damage Inspect the tilt angle
sensor voltage by using
Tilt angle sensor installation : ▪ Inspect, adjust, and
an analyzer :
Link, installed part breakage, replace the sensor
In NL state
Operate from the forward
Tilt angle sensor harness : and repair or replace it
most tilting to the last tilt-
ing, and check the voltage
and leakage problem (Harness change.
and connector)
Horizontal matching value of
the tilt angle sensor : Check the matching value ▪ Perform matching
state
Automatic horizontal switch
Forward tilt auto- body :
matic leveling stop Open failure Inspect the automatic ho-
does not work rizontal switch by using an
Automatic horizontal switch de- analyzer : ▪ Inspect and replace
(Forward most tilting the switch
tection mechanism part : Load handling neutral
instead of stopping
Gap adjustment failure on the state ▪ Check the harness
in the horizontal pos-
detection part and repair or replace it
ition) Operate the automatic ho-
Automatic horizontal switch if necessary.
rizontal switch to check
harness : ON/OFF
Disconnection problem (Har-
ness and connector)
▪ Replace, repair, and
Inspect the tilt control replace the oil control
Oil control valve :
valve with the active test : valve
Tilt control valve fixation, and
Activation signal OFF the
leakage ▪ Inspect and replace
tilt control solenoid (for-
Tilt solenoid harness : ward tilt stop) state the solenoid
Short circuit and leakage prob- ▪ Check the harness
Conduct forward tilt, and
lem (Harness and connector) and repair or replace it
check the operation
if necessary.
troller

Phenomena that
vehicle
Tilt angle sensor body :
sensor voltage by using
Tilt angle sensor installation : ▪ Inspect, adjust, and
an analyzer :
Link, installed part breakage, replace the sensor
In NL state
Operate from the forward
most tilting to the last tilt-
ing, and check the voltage
and connector)
Forward tilt auto- Does not match with the vehicle on the matching screen. again.
matic leveling stop state
does not work
(Stops in the posi- Inspect the load sensor
tion shifted from ho- Load sensor body : voltage by using an ana-
rizontal position) Internal damage lyzer :
the sensor
Load sensor harness : In NL state
Disconnection, short circuit, Operate the lift from low-
and leakage problem (Harness est position to most up-
if necessary.
and connector) ward position (relief), and
Load sensor no load matching
value : Check the matching value ▪ Perform matching
state
troller

Phenomena that
vehicle
Tilt angle sensor body : 3
Tilt angle sensor installation : sensor voltage by using ▪ Inspect, adjust, and
Link, installed part breakage, an analyzer : In NL state replace the sensor
and damage Operate from the forward ▪ Check the harness
Tilt angle sensor harness : most tilting to the last tilt- and repair or replace it
Disconnection, short circuit, ing, and check the voltage if necessary.
and connector)
Does not match with the vehicle in the matching screen. again.
state
Load sensor body :
Internal damage
and connector)
Forward tilt auto- check the voltage change
matic leveling stop Load sensor no load matching
does not work value : Check the matching value ▪ Perform matching
(Stops on the posi- Does not match with the vehicle on the matching screen. again.
tion that the auto- state
matic horizontal Inspect the lift height
switch is pushed) Lift height switch body :
height
ON/OFF
Vmast]
body :
of wire
sensor :
ing portion

Phenomena that
vehicle
Vmast]
Forward tilt auto-
matic leveling stop Lifting height sensor lowermost Check the matching value ▪ Perform matching
does not work position matching value :
(Stops on the posi- Does not match with the vehicle
tion that the auto- state
matic horizontal
switch is pushed)
troller
Tilt angle sensor main body :
Internal damage Check the tilt angle
sensor voltage, using an
Installation of tilt angle sensor : analyzer : In NL state adjust or replace it if
The link or the installation por- necessary.
tion is broken or damaged. Tilt the mast to its forward
and backward tilt limits to
check the change in
voltage.
leakage (Harness or connector)
Tilt angle sensor leveling
When the fork is matching value : Check the matching value ▪ Replace the main con-
tilted backward for Does not match with the vehicle on the matching screen. troller.
leveling, it does not state
stop automatically in
a horizontal position. Main body of automatic fork ho-
(The fork tilts to its rizontal switch :
Open failure Check the automatic fork
backward tilt limit horizontal switch, using
without stopping in a Mechanical detection unit of an analyzer : ▪ Check the switch, and
horizontal position.) automatic fork horizontal Load handling lever in replace it if necessary.
switch : neutral
Gap in detection unit is improp- ▪ Check the harness
erly adjusted Operate the automatic and repair or replace it
fork horizontal switch to if necessary.
Automatic fork horizontal switch see if it turns on and off
harness : normally.
Disconnection (Harness, con-
nector)
troller.
When the fork is
tilted backward for See "When the fork is tilted for-
leveling, it does not ward for leveling, it does not
stop automatically in stop automatically in a hori-
- -
a horizontal position. zontal position
(The fork does not (The fork does not stop in a ho-
stop in a horizontal rizontal position.)"
position.)

Phenomena that
vehicle
Tilt angle sensor main body : 3
Internal damage Check the tilt angle
sensor voltage, using an
Installation of tilt angle sensor : analyzer : In NL state adjust or replace it if
When the fork is
The link or the installation por- necessary.
tilted backward for Tilt the mast to its forward
leveling, it does not tion is broken or damaged. ▪ Check the harness
and backward tilt limits to
stop automatically in Tilt angle sensor harness : and repair or replace it
check the change in
a horizontal position. Disconnection, short circuit, if necessary.
voltage.
(The fork stops leakage (Harness or connector)
where it is when the Tilt angle sensor leveling
automatic fork level- matching value : Check the matching value ▪ Perform matching
ing switch is Does not match with the vehicle on the matching screen. again.
pressed.) state
troller.

Phenomena that
vehicle
Automatic horizontal switch
body :
Open failure Inspect the automatic ho-
rizontal switch by using an
tection mechanism part : the switch
Load handling neutral
Operate the automatic ho-
harness : ON/OFF
Disconnection problem (Har-
ness and connector)
Lift height switch body : switch by using an ana-
Always detect the low lift height lyzer : In NL state
the switch
Lift height switch harness : Operate the lift from low-
▪ Check, repair, and re-
Disconnection, and short circuit est position to most up-
place the harness
(Harness and connector) ward position, and check
ON/OFF
The mast rear tilt Vmast]
control is not con-
trolled Lifting height sensor main
body :
sensor, using an analyzer ▪ Check the sensor, and
of wire
: In NL state replace it if necessary.
sensor :
ing portion
Vmast]
state
troller

Phenomena that
vehicle
Automatic horizontal switch 3
body :
Short failure Inspect the automatic ho-
rizontal switch by using an
tection mechanism part : the switch
Load handling neutral
Operate the automatic ho-
harness : ON/OFF
Short circuit (Harness and con-
nector)
Check the forward tilt lock ▪ Replace, repair, and
Oil control valve : valve with the active test : replace the oil control
Forward tilt lock valve fixation Activation signal OFF the valve
and leakage Forward tilt solenoid (No ▪ Inspect and replace
Forward tilt solenoid harness : tilt rear tilting speed limit) the solenoid
Short circuit and leakage prob- state ▪ Check the harness
lem (Harness and connector) Conduct tilt rear tilting, and repair or replace it
and check the operation if necessary.
height
The mast rear tilt Lift height switch harness :
speed of the mast is Disconnection, and short circuit
constantly slow (Harness and connector)
ON/OFF
Vmast]
body :
of wire
sensor :
ing portion
Vmast]
state
troller

Phenomena that
vehicle
Display settings :
Forward tilt speed control set- Check the setting value
ting disabled. (Option set T F- on the option set screen.
SPD LIM)
Lift height switch harness : Operate the lift from low- ▪ Check the harness
Disconnection, and short circuit est position to most up- and repair or replace it
(Harness and connector) ward position, and check if necessary.
ON/OFF
Vmast]
body :
The forward tilt Check the lifting height
speed of the mast is of wire sensor, using an ana- ▪ Check the sensor, and
not controlled in high lyzer : In NL state replace it if necessary.
lift height Installation of lifting height
sensor :
ing portion
Vmast]
state
troller

Phenomena that
vehicle
Inspect the lift height 3
height
ON/OFF
Vmast]
body :
of wire
The mast forward tilt Installation of lifting height
speed is constantly sensor :
slow Breakage of sensor installation
ing portion
Vmast]
state
troller
3.5.7 SAS-ε (OPT) Knob compensation control or Knob

compensation control (OPT)
Control category/SAS-ε (OPT) Knob compensation control or Knob compensation control (OPT)
Phenomena that
vehicle
Tire angle sensor body :
Internal failure
Inspect the sensor voltage
Tire angle sensor installation : by using an analyzer : ▪ Inspect and replace
Direction neutral, acceler-
damage ator full-closed state ▪ Check the harness
Tire angle sensor harness : and repair or replace it
Steer and check the
voltage change.
and connector)
angle :
state
body :
Internal damage
stallation :
analyzer :
Cam or steering wheel failure ▪ Check the harness
Steering-wheel angle sensor conducting steering oper- and repair or replace it
A knob position harness : ation if necessary.
shifts to a specific Disconnection, short circuit,
position and leakage problem (Harness
(10° or more from and connector)
the straight traveling
Check the knob compens-
position)
ation valve with the active
test :
Knob compensation valve In the tire end state
body : Activation signal ON the replace the knob com-
Leakage, and fixation (Internal knob compensation solen- pensation valve
damage) oid (Bypass)/ Activation
Knob compensation solenoid signal OFF (Bypass stop), ▪ Inspect, repair and re-
and check operation at place the solenoid
harness :
Disconnection, short circuit, steering ▪ Check the harness
and leakage problem (Harness Activation signal ON : and repair or replace it
and connector) Steering spins (Light) if necessary.
Activation signal OFF :
Steering does not spin
(Heavy)
When traveling on a road
surface that is tilted to
right and left for the mov-
ing direction of a vehicle,
The road has slope -
the knob position required
for traveling straight dif-
fers when traveling on a
horizontal road surface.
Control category/SAS-ε (OPT) Knob compensation control or Knob compensation control (OPT)
Phenomena that
vehicle
A knob position 3
shifts to a specific
position ▪ Replace the main con-
(10° or more from troller
the straight traveling
position)
Internal failure
Inspect the sensor voltage
Tire angle sensor installation : by using an analyzer : ▪ Inspect and replace
damage ator full-closed state ▪ Check the harness
Tire angle sensor harness : and repair or replace it
Steer and check the
voltage change.
and connector)
angle :
state
body :
Internal damage
stallation :
analyzer :
Cam or steering wheel failure ▪ Check the harness
Steering-wheel angle sensor conducting steering oper- and repair or replace it
Knob position shifts if necessary.
harness : ation
(The knob position
at traveling straight
is not stable)
and connector)
Check the knob compens-
ation valve with the active
test :
In the tire end state
Knob compensation valve ▪ Inspect, repair, and
Activation signal ON the replace the knob com-
body :
knob compensation solen- pensation valve
Leakage and fixation
oid (Bypass)/ Activation
Knob compensation solenoid signal OFF (Bypass stop), ▪ Inspect, repair and re-
harness : and check operation at place the solenoid
Disconnection, short circuit, steering ▪ Check the harness
and leakage problem (Harness and repair or replace it
Activation signal ON :
and connector) if necessary.
Steering spins (Light)
Activation signal OFF :
Steering does not spin
(Heavy)
PS cylinder system link failure :
Eccentric pin and king pin fail- -
replace the cylinder
ure
troller
3.5.8 OPS
Control category/OPS
Phenomena that
vehicle
Inspect the seat switch by
Seat switch body : ▪ Inspect and replace
using an analyzer :
Short failure the switch
Seat switch harness : ator all-closed state ▪ Check the harness
Short circuit (Harness and con- and repair or replace it
Sit on the seat and leave
nector) if necessary.
the seat to check ON/OFF
[Australian spec (OPT), Seat- Inspect the seatbelt
Both traveling OPS belt interlock (OPT)] switch by using an ana-
and load handling lyzer : ▪ Inspect and replace
OPS do not operate Seatbelt switch body : Direction neutral, acceler- the seatbelt (buckle)
Short failure (Internal damage) ator all-closed state, load
Seatbelt switch line (Signal and handling lever neutral and repair or replace it
ground) : state if necessary.
Short circuit and leakage prob- Put the seatbelt ON/OFF,
lem (Harness and connector) and check ON/OFF
troller
Drive motor driver : ▪ Replace the drive mo-
The traveling OPS -
Internal failure tor driver
only does not oper-
ate ▪ Replace the main con-
troller
Check the tilt forwarding ▪ Replace, repair, and
Oil control valve : lock valve with the active replace the oil control
Tilt forward tilt lock valve fixa-
test : valve
tion and leakage Activation signal OFF the ▪ Inspect, repair and re-
Tilt control solenoid harness : forward tilt solenoid (For- place the solenoid
Short circuit and leakage prob- ward tilt stop) state ▪ Check the harness
lem (Harness and connector) Conduct forward tilt, and and repair or replace it
check the operation if necessary.
The load handling Check the lift lowering ▪ Replace, repair, and
OPS only does not lock valve with the active
Oil control valve : replace the oil control
operate test :
Lift descent lock valve fixation, valve
Activation signal OFF the
and leakage ▪ Inspect, repair and re-
lift lock solenoid (Lift lock)
Lift lock solenoid harness : state place the solenoid
Short circuit and leakage prob- ▪ Check the harness
Conduct lowering lift oper-
lem (Harness and connector) and repair or replace it
ation, and check the oper-
ation if necessary.
troller
3.5.9 Display
Control category/Display
Phenomena that
vehicle
Some of the following matching
items are not conducted.
▪ Accelerator pedal full-
closed matching
▪ Accelerator pedal full-open
matching
▪ Brake pedal full-closed
matching
▪ Brake pedal operating point
matching *The full-opened matching
value is cleared once for
▪ Tire straight traveling angle
the accelerator pedal
matching (For SAS (OPT),
fullclosed and full-open
knob compensation control
matching if conducted in
(OPT) or Inclination assist
[Spanner Indicator] the full-closed position
(OPT))
matching; therefore, make
An error code is not ▪ Forward tilt regulation angle Check the matching val- sure to conduct both.
displayed; however, matching (For SAS (OPT)) ues on the matching
the spanner indic- screen. *The operation point
▪ Tilt horizontal angle match- matching value is cleared
ator remains ON.
ing (For SAS (OPT)) once for the brake pedal
▪ Tilt no load matching (For full-closed and the opera-
SAS (OPT)) tion point matching if con-
ducted in the full-closed
▪ Mast type data matching
position matching; there-
(For SAS (OPT))
fore, make sure to con-
▪ Each load handling lever duct both.
neutral voltage matching
▪ Lifting height sensor lower-
most position matiching
value (For height selector
(OPT) and Vmast)
▪ Slope angle matching (For
inclination assist (OPT))
▪ Tire diameter data
[Wheel indicator]
Display settings :
Altough the vehicle Wheel indicator setting dis- Check the setting value
is stopped, the ▪ Change the setting
abled. on the option set screen.
wheel indicator is (Option set WHEEL IND)
not displayed.
Phenomena that
vehicle
The wheel indicator is equipped
only for SAS, knob position cor-
- -
recting control and Inclination
assist specification.
▪ Check the wheel, and
Tire specification :
- ▪ Check the air pres-
Type, diameter, tire pressure
sure and repair it if ne-
cessary.
[Wheel indicator]
Tire angle sensor :
After the vehicle run Internal failure
straight, the wheel
Installation of the tire angle Check the sensor voltage,
indicator does not ▪ Check the sensor, and
sensor : using an analyzer :
show that wheel is in replace it if necessary.
The installation portion is Direction switch is in neut-
straight position. ▪ Check the harness
broken or damaged. ral, drive fully closed.
Tire angle sensor harness : Turn a steering to check
if necessary.
Disconnection, short circuit or the change in voltage.
leakage
(Harness, connector)
Tire angle sensor straight angle
matching value : Check the matching value ▪ Perform matching
state
Display settings :
Load meter setting disabled. ▪ Change the setting
on the option set screen.
(Option set LOAD METER)
▪ Load is not displayed
Lift lever is not in neutral posi- when operating the lift
-
tion. lever. Put the lift lever
[Load meter] in neutral position.
The load is not dis- ▪ Load is not displayed
played. Traveling -
when traveling.
Display settings :
Cylinder diameter, mast type,
zero-point adjustment
troller.
[Load meter]
The load is always ▪ Replace the main con-
displayed during troller.
vehicle is standing.
Phenomena that
vehicle
Check the load sensor 3
voltage, using an ana-
Load sensor : Internal failure ▪ Check the sensor, and
lyzer : In NL state
Load sensor harness : replace it if necessary.
Lower and raise the lift to
Disconnection, short circuit or ▪ Check the harness
its lowermost and upper-
leakage and repair or replace it
most (relief) positions to
(Harness, connector) if necessary.
check the change in the
voltage.
▪ Make each setting
Display settings : correctly.
Cylinder diameter, mast type,
zero-point adjustment, calibra- Check the matching value * To improve the accur-
tion on the matching screen. acy, perform adjustment
on the LOAD COMPENS-
ATION screen of the load
meter matching.
▪ To measure the load
correctly,
perform a measurement
with the load lifted to a
[Load meter] height of approx. 500 mm,
The correct load is the mast raised to a ver-
not displayed. tical position and both ma-
terial handling and travel-
ing operations stopped.
* This load meter meas-
ures and calculates pres-
The measurement condition is sure on the lift cylinder.
- So, even if measuring the
not correct.
same load, the measured
value may vary depending
on the mast height, tilt
level, temperature of the
hydraulic oil, way to stop
load handling, mechanical
loss of the mast, leakage
from the oil control valve,
etc. Use this load meter
as a guide, because the
accuracy same as a scale
is not guaranteed.
troller.
3.5.10 Buzzer related

Control category/Buzzer related
Phenomena that
vehicle
Display settings :
OPS operation notification
buzzer settings disabled Check the setting values
(Option set 1 15 / BUZZER on the option set screen.
OPS operation noti- SPEC and 1 16 / SEAT
fication does not BUZZER)
sound
When the display switch
▪ When no sound is
Display : (micro switch) is pushed,
heard, replace the dis-
Built-in buzzer damage check the built-in buzzer
play
responds with a beep
Display settings :
Return-to-neutral warning
buzzer setting disabled. ▪ Change the setting
Traveling OPS re- (Option set 1 15 / BUZZER
turn-to-neutral warn- SPEC)
ing does not sound When the display switch
play
Display settings :
Return-to-neutral warning
Load handling OPS (Option set 1 15 / BUZZER on the option set screen.
return-to-neutral SPEC)
warning does not
sound When the display switch
play
Using an analyzer, in-
Parking brake switch body : spect the parking brake
Short failure switch
(Can be checked also ▪ Inspect, adjust, and
Parking brake switch as- from the ON/OFF of the replace the switch
sembly : parking indicator on the
Switch on state ▪ Check the harness
display) : and repair or replace it
Parking brake on Parking brake switch harness : Direction neutral state if necessary.
warning does not Short circuit problem Operate the parking
sound (Harness and connector) brake, and check ON/
OFF.
play
troller
Control category/Buzzer related

Phenomena that
vehicle
Using an analyzer, in- 3
Open failure switch
When traveling with sembly :
released parking parking indicator on the ▪ Check the harness
Switch off state display) :
brake, the parking and repair or replace it
brake on warning Parking brake switch harness : Direction neutral state if necessary.
sounds Disconnection problem (Har- Operate the parking
ness and connector) brake, and check ON/
OFF.
troller
Display settings :
Parking brake off warning
(Option set 1 17 / PKB
BUZZER)
Using an analyzer, in-
Open failure switch
sembly : parking indicator on the
Switch off state ▪ Check the harness
display) : and repair or replace it
Parking brake switch harness : Direction neutral state if necessary.
Parking brake off Disconnection problem
warning does not Operate the parking
(Harness and connector) brake, and check ON/
sound
OFF.
Seat switch body : Short failure Inspect the seat switch by the seat
using an analyzer :
Seat switch harness : Short cir- Sit on the seat and leave ▪ Check the harness
cuit (Harness and connector) the seat to check ON/OFF and repair or replace it
if necessary.
play
troller
Parking brake switch body :
Short failure Inspect the parking brake
switch by using an ana- ▪ Inspect, adjust, and
Parking brake switch as- lyzer : replace the switch
Parking brake off sembly :
warning keep sound- Direction neutral state ▪ Check the harness
Switch on state
ing even when the Operate the parking and repair or replace it
parking brake is Parking brake switch harness : brake, and check ON/ if necessary.
pulled Short circuit (Harness and con- OFF.
nector)
troller
3.5.11 Battery protecting function (OPT)

Control category/Battery protecting function (OPT)
Phenomena that
vehicle
Change the setting ac-
cording to the battery
Display settings : “B” the current model
Incorrect battery setting (fluid-level unit with LED
(Option set 1 02 / B UNIT) display)
”C” with fluid-level/fluid
Battery fluid-level temperature unit
warning indicator re- Fluid-level/fluid temperature ▪ Check the CN35 con-
mains ON nector
unit : -
(Battery fluid is filled) Disconnected connector (If disconnected, con-
nect)
Fluid-level / fluid temperature
unit :
▪ Replace the fluid-
Internal failure
- level/fluid temperature
(Inside fluid level harness dis-
unit
connection, and fluid level
sensor failure)
3.5.12 Shock sensor (OPT)

Control category/Shock sensor (OPT)
Phenomena that
vehicle
Display settings :
The settings screen
Simple damage detection set-
of the simple dam- Check the setting value
ting disabled. ▪ Change the setting
age detection func- on the option set screen.
(Optional set SHOCK
tion is not displayed.
SENSOR)
Vehicle collision method :
Depending on a collision
method, direction, and target it
collides, the collision value de- - -
tected by the collision sensor
changes. It does not detect all
collisions.
(When a large shock
Display settings : is generated in normal
The collision detection setting operation, and the
-
value is too large value is set to large to
When a shock is ap- (Not adequate) avoid it, the possibility
plied, the shock de- for not detecting be-
tection alarm does comes higher)
not function
Shock sensor body : Inspect each voltage of
Lowered sensitivity the shock sensor 1 and 2
by using an analyzer :
Shock sensor installation : ▪ Inspect and replace
Vehicle stopped state
Installation failure (Loose), and 2.0±0.21 V the sensor
interference ▪ Check the harness
Apply a shock on the
Shock sensor harness : and repair or replace it
sensor, and check there is
a voltage change
and leakage problem (Compare between the
(Harness and connector) sensor 1 and 2)
troller
Display settings : ▪ Change the settings
The collision detection setting (Set to a shock value
-
value is too small that does not generate
(Not adequate) in normal operation)
Shock sensor body :
Internal damage (Excessive re- Inspect each voltage of
sponse) the shock sensor 1 and 2
Shock sensor installation : by using an analyzer :
When a shock is not
Installation failure (Loose), and Vehicle stopped state ▪ Inspect and replace
applied, the shock 2.0±0.21 V the sensor
interference
detection alarm
functions Shock sensor harness : Apply a shock on the ▪ Check the harness
Disconnection, short, and leak- sensor, and check the and repair or replace it
age problem voltage change is not too if necessary.
(Harness and connector) sensitive
(When a slit exists in the har- (Compare between the
ness, a shock may be detected sensor 1 and 2)
in high frequency)
troller
3.5.13 PIN code entry system (OPT)

Control category/PIN code entry system (OPT)
Phenomena that
vehicle
Authentication can-
Log in with the initially re-
not be done by nu-
gistered number, and ▪ Register PIN from the
meric key.
check if PIN is registered operator authentica-
(The operation Display : PIN not registered
from the operator authen- tion menu of the ad-
sound of numeric
tication menu of the administrator function
key sounds, but lo-
ministrator function
gin fails)
Check the meter starts is
Authentication is ▪ Execute the meter
Display : Meter start not set conducted in the service
possible without en- start
function
tering PIN.
Display : Internal failure - ▪ Replace the display.
3.5.14 Slope assist (OPT)

Control category/Slope assist (OPT)
Phenomena that
vehicle
Display settings : Slope assist
setting disabled. Check the setting value
(Optional set SLOPE ASSIST) ▪ Change the setting
Inclination angle sensor body :

Internal failure
Inclination angle sensor install- ▪ Inspect and replace
ation : Inspect the sensor voltage the sensor
Installed part breakage, and by using an analyzer :
damage Check voltage change ▪ Check the harness
while the vehicle is tilted and repair or replace it
Inclination angle sensor har- if necessary.
ness : Disconnection, short cir-
cuit, and leakage problem
Matching value of the Inclina-
tion angle sensor at the hori-
The slope assist zontal position :
function does not Does not match with the vehicle
work state
Internal failure Inspect the tire angle
Tire angle sensor installation : sensor voltage by using ▪ Inspect and replace
Installed part breakage, and an analyzer : the sensor
damage Direction neutral, acceler- ▪ Check the harness
ator full-closed state and repair or replace it
Tire angle sensor harness :
Disconnection, short circuit, Steer and check the if necessary.
and leakage problem voltage change
angle :
state
troller
3.5.15 Height selector (OPT)

Control category/Height selector (OPT)
Phenomena that
vehicle
The height selector
Display settings :
function setting Check the setting value
Height selector setting disabled ▪ Change the setting
screen does not ap- on the option set screen.
(Option set H-SELECTOR)
pear.
[FSV mast] Check the lifting height
Lifting height switch main switch, using an ana-
▪ Check the switch, and
body : lyzer :
Low lifting height is always de- In NL state
tected. ▪ Check the harness
Operate the lift from low-
Lifting height switch harness : est position to most up- if necessary.
Disconnection, short circuit ward position, and check
(Harness or connector) ON/OFF
body :
of wire Check the lifting height
Installation of lifting height sensor, using an ana- ▪ Check the sensor, and
The lifting stop posi- sensor : lyzer : In NL state replace it if necessary.
tion cannot be set. Breakage of sensor installation Operate the lift from low- ▪ Check the harness
portion, breakage of wire rout- est position to most up- and repair or replace it
ing portion ward position (relief), and if necessary.
Lifting height sensor harness : check the voltage change
leakage
(Harness, connector)
[V mast]
state
troller.
Display settings : Check the setting value
Maximum height lim-
The maximum lifting height is on the lifting stop position ▪ Change the setting.
iter does not work.
not set. setting screen.
The lifting height limiter is not on the lifting stop position ▪ Change the setting.
set. setting screen.
Lifting height limit switch main Check the lifting height
Although the lifting body : ▪ Check the sensor, and
switch, using an ana-
height limit switch is Open failure adjust or replace it if
lyzer :
pressed, the lifting necessary.
Lifting height limit switch har- Vehicle stopped
height limiter does ▪ Check the harness
not work. ness : Operate the lifting height
Disconnection switch to see if the switch
if necessary.
(Harness, connector) turns on and off normally.
troller.

Phenomena that
vehicle
Lifting height limit switch main Check the lifting height 3
body : switch, using an ana-
adjust or replace it if
Although the lifting Short failure lyzer :
necessary.
height limit switch is Lifting height limit switch har- Vehicle stopped
not pressed, the lift- ness : Operate the lifting height
ing height limiter Short circuit switch to see if the switch
if necessary.
works. (Harness, connector) turns on and off normally.
troller.
The automatic height control is on the lifting stop position ▪ Change the setting.
not set. setting screen.
The height selector switch main
body :
Open failure, short circuit Check the height selector ▪ Check the height se-
Although the height switch, using an ana- lector switch, and ad-
Mechanical detection unit of the
selector switch is lyzer : just or replace it if ne-
height selector switch :
pressed, the auto- Vehicle stopped cessary.
Gap in detection unit is improp-
matic height control
erly adjusted. Operate the height se- ▪ Check the harness
does not work.
The height selector switch har- lector switch to see if it and repair or replace it
ness : turns on and off normally. if necessary.
Disconnection, short circuit
(Harness or connector)
troller.
If the loading conditions, the tilt
angle of the mast, etc at that
time are different from those
- -
when the lifting height was set,
the fork stop position may not
agree with the set position.
body :
Dragging or improper winding
of wire Check the lifting sensor
The fork stop posi- Installation of lifting height voltage, using an ana- ▪ Check the sensor and
tion is far away from sensor : lyzer : In NL state replace it if necessary.
the lifting height set Breakage of sensor installation Operate the lift from low- ▪ Check the harness
position (100 mm or portion, breakage of wire rout- est position to most up- and repair or replace it
more). ing portion ward position (relief), and if necessary.
Lifting height sensor harness : check the voltage change
leakage
(Harness or connector)
Change over time of lifting
Check the set value on
sensor detection unit :
the lifting stop position ▪ Change the setting .
setting screen.
state
troller.

Phenomena that
vehicle
▪ Check the positional
relationship among
The automatic The automatic height control
automatic height con-
height control does does not work if the maximum
- trol, maximum lifting
not work, although it lifting height or the lifting height
height and lifting
was set for sure. limit is set below it.
height limit, and set
them properly.
3.5.16 Telematics equipped type (OPT)

Control category/Telematics equipped type (OPT)
Phenomena that
vehicle
Keypad harness :
- and repair or replace it
Open failure
if necessary.
Check operation of each
switch :
Keypad body : Check all or only a spe-
▪ Replace the Keypad
Internal failure cific switch do not re-
body
Failure of each switch spond
(Green LED or Red LED
ON)
▪ Using TruckCom
(SST), switch the op-
erator authentication
function of the keypad
Keypad body :
- body to server man-
Not server management
agement.
Refer to cautions
when replacing the
keypad.
Operation management sys-
Check PIN code is re- ▪ Register PIN code in
tem :
gistered in the Web site the Web site
PIN code not registered
▪ From the Vehicle
Authentication can-
Management screen
not be done by the
in the Web site, start
keypad.
Operation management sys- communication for-
tem : cibly using “Start com-
-
PIN code cannot be down- munication” (Permis-
loaded sion to manage the
vehicle is required) or
using TruckCom
(SST)
Display power and grand har-
ness :
and leakage problem
if necessary.
▪ Replace the display.
Display : Internal failure -
Main controller :
troller
Internal failure (D7V and
DGND) ▪ Replace the CAN
bridge controller
CAN bridge controller :
Internal failure
Left the seat for three minutes *Not an error
or more after turning the key ▪ Try authentication op-
-
switch ON, authentication oper- eration again after tak-
ation was conducted ing the seat
Without authentica-
tion, the power is ap- Display settings : ▪ Change the setting
plied with key ON Operation management device Check the setting value in
(the display is dis- “NO” setting the option set screen : Operation management
played, and the (Optional set D-REC) device “YES” setting
vehicle moves)

Phenomena that
vehicle
*Not an error
Check the warning display
Travel control is ap- Vehicle performance control is ▪ Contact the Adminis-
and warning sound on the
plied applied due to shock detection trator, and request to
display
release the control.
Vehicle collision method :
Depending on a collision
method, direction, and target it
collides, the collision value de- - -
tected by the collision sensor
changes. It does not detect all
collisions.
(When a large shock
Web site settings : is generated in normal
The collision detection setting operation, and the
-
value is too large value is set to large to
When a shock is ap-
(Not adequate) avoid it, the possibility
plied, the shock de-
for not detecting be-
tection alarm does
comes higher)
not function
Shock sensor body :
Lowered sensitivity Using TruckCom (SST),
Shock sensor installation : inspect the output value of ▪ Inspect and replace
Installation failure (Loose), and the shock sensor : the sensor
interference Vehicle stopped state 0 or ▪ Check the harness
1 and repair or replace it
Shock sensor harness :
Disconnection, short circuit,and Apply a shock, and check if necessary.
leakage problem there is a value change
Shock sensor : ▪ Replace the shock
-
Internal failure sensor
Web site settings : ▪ Change the settings
The collision detection setting (Set to a shock value
-
value is too small that does not generate
(Not adequate) in normal operation)
Shock sensor body :
Internal damage (Excessive re-
sponse) Using TruckCom (SST),
When a shock is not inspect the output value of ▪ Inspect and replace
Shock sensor installation : the shock sensor : the sensor
applied, the speed
Installation failure (Loose), and Vehicle stopped state 0 or
control engages ▪ Check the harness
interference 1 and repair or replace it
Shock sensor harness : Apply a shock, and check if necessary.
Disconnection, short circuit, there is a value change
and leakage problem
▪ Replace the shock
Shock sensor : Internal failure -
sensor
Antenna :
Internal failure Check the antenna wire ▪ Replace antenna
Data are not dis- Disconnection, short circuit, and connection
played on the Web and leakage problem ▪ Move to other loca-
site during operation (Harness and connector) Use TruckCom (SST) to tions for better radio
perform GSM/GPRS test wave reception
Unable to find radio wave

Phenomena that
vehicle
Operation management system 3
setting :
The hour meter time The hour meter input setting is ▪ Change the settings
Using TruckCom (SST),
of the display is not selected to “Hour meters from
check the hour meter set- : Select ‘Hour meters from
displayed on the DHU inputs” in the input port ting of DHU2 Vehicle CAN system’
Web site setting of DHU2
3.5.17 On-vehicle charger (OPT)

Control category/On-truck charger (OPT)
Phenomena that occur
Faulty part/mode Check method Measures
in the machine stand
Display settings :
Disabled charge unit
(Option set Charger unit Check the setting values
▪ Change the dis-
STD display : in the Option Set screen
play settings
3-OPT->1 OPTSET->1 26 (Should be “YES”)
Multi-function display :
[OPT] CHARGER UNIT)
Check the power voltage :
Turn the key switch OFF,
AC power for the charger :
disconnect the charging ▪ Inspect and re-
Power supply problem or power
plug, and check each pair power
failure
power terminal voltage is
191 to 220 V
Inspect the charging plug
terminal voltage :
Charging cable : ▪ Inspect, repair,
The charging screen is Check the voltage
Disconnection, short circuit, and replace the
not shown on the display between each terminal of
and leakage problem charging cable
even when the charging the charging plug is 191
plug is connected. to 220 V
Inspect the connection :
Turn the key switch OFF,
▪ Inspect, repair,
Charger connection : disconnect the charging
and replace the
Connection failure plug, and check the con-
connection
nection on the rear side of
the charging plug outlet
Harness between operation
panel and display : ▪ Check, repair,
Disconnection, short circuit, - and replace the
and leakage problem (Harness harness
and connector)
Operation panel : Internal fail- ▪ Replace the op-
-
ure eration panel
▪ Replace the dis-
play

*Not an error
When the low speed
setting switch of the
display is pushed
Operate the display low speed and hold for two
- seconds while the
setting switch
charging plug is not
connected and the
key switch is OFF,
the charging screen
The charging screen is is displayed.
displayed on the display Harness between operation
even though the charging panel and display : ▪ Check, repair,
plug is not connected Disconnection, short circuit, and replace the
and connector)
Remove the harness
between operation panel
and display, and check ▪ Replace the op-
Operation panel : Internal fail-
the screen eration panel
ure
[Charging screen] : Dis- ▪ Replace the dis-
Display : Internal failure
play failure play.
[Others] : Charger opera-
tion panel failure
and replace the
Magnet switch : Check the thermal relay magnet switch
Thermal relay function state ▪ Inspect, repair,
and replace the
transformer
and connector)
Remove the harness
Charging does not start between operation panel
when the [START] button and display, and check
is pushed the operation button :
(The charging screen is For each button, check
shown on the display) Operation panel : Internal fail- conduction between the ▪ Replace the op-
ure button terminal and eration panel
CHGGND
Normal state is : Push the
button : Conduction
Not pushed : No conduc-
tion
Inspect the magnet switch
Magnet switch : Internal failure : Refer to “MAGNET and replace the
SWITCH ASSY” in magnet switch
CHARGER CHAPTER
play.

Magnet switch :
▪ Perform 3
Unable to shutdown
- troubleshooting
(The display in stop operation is
for F8-1 error
in charging stop state)
and connector)
Cannot stop charging
Remove the harness
after pressing the [STOP]
button
and display, and check
(Start charging is pos-
the operation button :
sible)
Check conduction
Operation panel : Internal fail- between the stop button ▪ Replace the op-
ure terminal and CHGGND eration panel
Normal state is : Push the
button : Conduction
Not pushed : No conduc-
tion
play.
and replace the
Magnet switch : Check the thermal relay magnet switch
Thermal relay function state ▪ Inspect, repair,
and replace the
transformer
▪ Use a battery
compatible with
Check compatibility the transformer
Transformer :
between battery capacity capacity
Capacity incompatible
and transformer capacity
▪ Replace the
transformer
Tap changer : Check the power voltage
▪ Tap adjustment
Tap adjustment failure and tap
Charging completes nor- Inspect the transformer :
mally but the charge is in- Transformer : Refer to “TRANS- ▪ Replace the
sufficient Internal failure FORMER ASSY” in transformer
CHARGER CHAPTER
▪ Conduct even
Inspect the battery : charging
Battery : Battery failure Refer to BATTERY
CHAPTER ▪ Replace the bat-
tery
Measure the battery
voltage value, and com-
pare with the battery
voltage value of the ana-
lyzer ▪ Replace the
Main controller : Internal failure
STD display : main controller
[ANL] 2IO 2-12
Multi-function display :
[ANL] I/O TEMP/VOLT
4/5 B48/80V

The indicator on the char- Disconnection, short circuit, - and replace the
ger operation panel does and leakage problem (Harness harness
not become ON and connector)
(Start charging is pos- ▪ Replace the op-
Operation panel : LED bulb out -
sible) eration panel
play.
and connector)
Inspect the magnet
switch : ▪ Inspect, repair,
Magnet switch : Internal failure Refer to “MAGNET and replace the
The magnet switch oper- SWITCH ASSY” in magnet switch
ates though the [START] CHARGER CHAPTER
button is not pressed Remove the harness
▪ Replace the op-
Operation panel : Internal fail- the conduction of display
eration panel
ure connector pin
Display : Internal failure [With short] : Display fail-
play.
ure
[No short] : Charger oper-
ation panel failure

*Not an error
Press the [STOP]
3
button to turn the
display OFF, and
use it as usual. After
Charging completed Check the display screen charging is com-
(Only when the completed LED [“Charging completed” pleted, if the char-
is ON) screen] : No problem ging plug is extrac-
ted without pushing
any buttons/
switches, the com-
pleted LED remains
ON.
Inspect the error :
Turn the key switch OFF, ▪ Perform
The operation panel LED Error generated connect the charging troubleshooting
comes ON/flashes though (Only when the completed LED plug, and check the error for the applic-
the charging plug is not is flashing)
code shown on the disable error code
connected. play
and connector)
Remove the harness
▪ Replace the op-
Operation panel : Internal fail- the voltage of each LED
eration panel
ure terminal on the display
side ▪ Replace the dis-
Display : Internal failure
play
[0 V] : Charger operation
panel failure
[Others] : Display failure
Display settings :
Operating day settings Check the operating day ▪ Change the dis-
(Administrator function OPERA- settings play settings
TION DAYS)
(Multi-function display Display settings : Incorrect ▪ Change the dis-
Check the clock settings
only) clock setting play settings
Even charging is per- *Not an error
formed on an operating Depending on the
day though the operating user's charging fre-
days are set quency. the auto-
Charging frequency -
matic even charging
may be conducted
on the operating
days.
Published by
1st Printing: January. 2018
Pub. No. CE213
Printed in Japan

8FBN15 30vol2

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FOREWORD

This Manual (Volume 2) contains diagnosis, service procedures of electrical

0 DIAGNOSIS CODE LIST

Overheat warning (O/H)

Battery overheat warning (BT O/H)

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

Indica- Memo Detection

1.1.1 CONTROLLER CABLES

Pump motor driver

15° 15° 30° 30°

N2 P41 Drive motor driver

Terminals tightening torque:

Pump motor driver

15° 30° 30° 30°

N2 P41 Drive motor driver

Terminals tightening torque:

CONTACTOR PANEL [15,16,18,20,25] [2402]

CONTACTOR PANEL [30] [2402]

CONTACTOR ASSY [2403]

1.3 BEFORE REPAIR

Measurement terminals Controller side of battery plug-body

Caution for part replacement

Discharge of the power condenser

1.4 CONNECTOR INSPECTION

1.4.1 How to use SST

Parts No. Purpose Remarks

Measuring Method and Standards List

Connecror No. Connector No. Conditions Standard Remarks

Terminal name Conditions for measurement

Electric Level No.

Connector pin No.

1.4.2.1 Main Controller

CN101 CN102 CN103 CN104

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

1.4.2.2 Drive motor driver

1.4.2.3 Pump motor driver

1.4.2.4 Contactor Panel ASSY

CN127 CN128 CN136 CN137

Connector No. ⇔ Connector No. Conditions Standard Remarks

1.4.2.5 Multifunction Display

Connector No. ⇔ Connector No. Conditions Standard Remarks

1.4.2.6 TEN-KEY (W/ PIN code entry system)

1.4.2.7 Transformer, Charger

1.4.2.8 Battery Fluid Level and Temperature Sensor

1.4.2.9 CAN Bridge

1.4.2.10 Telematics Unit

Pre-Operation Check device connector (POC)