6.

Troubleshooting
6- 1. Caution for electricity-related repairs
CAUTION When doing electricity-related repairs, always turn off
the key switch, unplug the battery, and discharge the
capacitor.
See "1-2-2. Capacitor - discharge" on page 3.

CAUTION Do not pull the power supply cable when removing the
battery plug.
Hold the battery plug and then pull it out.

CAUTION When removing the connector, do not pull the harness

part. Hold the connector housing part firmly, and then
unlock and remove the connector.

WARNING l When troubleshooting, apply stopper to the load

wheel and jack up the drive wheel side. And then
check the problems.
l Lift or jack up the forklift truck, and then support it
with safety blocks or rigid stands.

CAUTION Always you must set the required items when replacing
the main board.
See "1-3. Required settings" on page 4.

105
 6 Troubleshooting

6- 2. Self diagnosis function

6-2-1. Display
When the self-diagnosis function detects an abnormality
or error, the screen displays the error messages.

When detecting error

Key switch ON

2 seconds later
lNormal screen

000T0324

lMonitoring error display

B11 FET-TRAVEL The service (wrench) mark flashes.
FAIL OPERATION
TURN OFF KEY SWITCH

131T0325E

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 Troubleshooting 6

6-2-2. Error message list * The possible causes column in the following table describes only main devices.
* When replacing Main board and when initializing the memory, always set the required items. See P.4

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
• Faulty contact point
• Faulty contactor coil
•Disconnection of red / black wire between contact point and CN2-32 (main
Control voltage 1 (CN2-32) is equal to or below threshold for continuous 200 ms
contactor)
A01 CONTACTOR-M Main contactor trip during main contactor ON command. HYD
• Disconnection of contactor coil harness
(Threshold: 24V model: 9V / 48V model: 18V)
<How to check>
[SERVICE DSP.>DATA CHECKING>TRV CPU/BATT. VOLTAGE]
See P.119
Voltage difference between control voltage 1 (CN2-32) and control voltage 2 • Blown Fuse [F1]
(CN2-33) is equal to or more than threshold for continuous 100 ms during main • Disconnection of yellow / red wire between F1 fuse and CN2-33
A02 FUSE-MAIN contactor ON command. HYD <How to check>
(Threshold: 24V model: ± 12V / 48V model: ± 24V) [SERVICE DSP. >DATA CHECKING>TRV CPU/BATT. VOLTAGE]
* Error is not detected when main contactor trips. See P.119
FET-TRAVEL • Failure of travel IPM module
a) IPM error output (CN2-38) detects the high level.
B11 FAIL OPERATION Main contactor trip TRV <How to check>
b) Error detection signal is detected 5 times or more (in total).
TURN OFF KEY SWITCH See P.102
• Disconnection or failure of travel current sensor (U phase)
Offset of travel current sensor (U phase) neutral voltage (CN2-58) is out of range <How to check>
B12 C. SENSOR_U-T Main contactor trip TRV
of 2.5V ± 0.488V for continuous 100 ms. [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
See P.119
• Disconnection or failure of travel current sensor (W phase)
Offset of travel current sensor (W phase) neutral voltage (CN2-66) is out of range <How to check>
B13 C. SENSOR_W-T Main contactor trip TRV
of 2.5V ± 0.488V for continuous 100ms [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
See P.119
a) S
 ensor input voltage (CN4-125, CN4-126) is 0.5V or 4.5V for continuously • Disconnection or failure of accelerator sensor
ACCELERATOR 100ms. <How to check>
B14 Shutoff for Travel operation TRV
TURN OFF KEY SWITCH b) S
 um of sensor input voltage (CN4-125, CN4-126) is out of range of 5V ± 1.25V [SERVICE DSP. >DATA CHECKING>TRV CPU/ACCEL. SENSOR]
for continuous 100ms. See P.119
• Disconnection or failure of OIS sensor
PRESEN. SENSOR Shutoff for Travel operation Sensor input voltage (CN4-105) is 0.5V or 4.5V continuously. <How to check>
B16 TRV
TURN OFF KEY SWITCH Shutoff for Hydraulic operation * Error is not detected for FCS cabin model. [SERVICE DSP. >DATA CHECKING>TRV CPU/OIS SWITCH]
See P.119
Traction motor • Disconnection or failure of traction motor speed sensor
Following states is detected for continuous 10sec at the same time. <How to check>
Traction motor : torque limit
• Accelerator sensor input 50% [SERVICE DSP. >DATA CHECKING>TRV CPU/TRV-MOTOR SPEED]
• Traveling speed ＜ 0.1km/h See P.119
B17 SENSOR-TRV Front wheel (R) *Front wheel (L) (opiton) • Disconnection or failure of front wheel (R) speed sensor and Front wheel (L)
Front wheel (R) : Anti slip function is Following states is detected for continuous 10sec at the same time. speed sensor
disabled. • Accelerator sensor input 50% <How to check>
*Front wheel (L) (opiton) • Drive angle 40% Front wheel (R) See P.119 (F-WHEEL SPEED R)
• Front wheel traveling speed ＜ 0.5km/h Front wheel (L) See P.122 (F-WHEEL SPEED L)
FET-HYD • Failure of hydraulic IPM module
IPM error output (CN2-39) detects high level.
C21 FAIL OPERATION Main contactor trip HYD <How to check>
Error detection signal is detected 5 times of more (in total).
TURN OFF KEY SWITCH See P.102
• Disconnection or failure of hydraulic current sensor (U phase)
Offset of hydraulic current sensor (U phase) neutral voltage (CN2-54) is out of <How to check>
C22 C. SENSOR_U-H Main contactor trip HYD
range of 2.5V ± 0.488V for continuous 100ms. [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
See P.122
• Disconnection or failure of hydraulic current sensor (W phase)
Offset of hydraulic current sensor (W phase) neutral voltage (CN2-62) is out of <How to check>
C23 C. SENSOR_W-H Main contactor trip HYD
range of 2.5V ± 0.488V for continuous 100ms. [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
See P.122

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 6 Troubleshooting

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
Lift 1 switch remains in ON state for continuous 1000 ms after lift 2 switch turns
• Failure of lift SW (high speed/ low speed)
C24 SWITCH-LIFT ON (In normal conditions, operation sequence is lift 1 switch ON lift 2 switch HYD
• Installation position adjustment defect
ON).
• Blown EPS (F2) fuse
EPS power supply voltage is 10V for continuous 100ms.
D30 FUSE-EPS Travel speed reduced by half. DSP • Disconnection of red wire between F2 fuse and CN8-B1
* Error is not detected when the main contactor trips.
• Faulty contact point (main contactor)
• Disconnection or failure of torque sensor.
T. SENSOR-EPS Travel speed reduced by half. Sensor input voltage (CN5-162) is 0.5V or 4.5V for continuous 10ms.
D31 DSP • Installation adjustment defect
TURN OFF KEY SWITCH Shutoff for Power steering operation * Error is not detected when main contactor trips.
See P.82, P.99
a) E rror is detected when port input L is detected continuously for 100 times when
upper step is ON.
FET-EPS Travel speed reduced by half.
D32 b) E rror is detected when port input H is detected continuously for 100 times DSP • Failure of main board
TURN OFF KEY SWITCH Shutoff for Power steering operation
when lower step is ON.
* Error is not detected when main contactor trips , and when EPS voltage is 15V.
• Disconnection of EPS motor (if error occurs when operating steering.)
a) C urrent is ± 3A for continuous 1000ms for Duty output is 75% or 25%. • Failure of main board (if error occurs as soon as turning on key SW.)
Travel speed reduced by half.
D33 C. SENSOR-EPS b) Current sensor neutral offset is ± 5A. DSP <How to check>
Shutoff for Power steering operation
*E
 rror is not detected when main contactor trips, and when EPS voltage is 15V. [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>EPS-MOTOR CURRENT]
See P.126
Proportional valve current of either of lift, tilt, reach Att.1 and Att.2 is in either of
following states for 100ms:
a) P roportional valve current input value 900mA.
• Failure of OPT board
b) When any hydraulic operation is not commanded, proportional valve current
• Disconnection of solenoid valve harness
FET-AOS input value 145mA. AOS
E40 Main contactor trip *C  onditions for detecting error vary if truck is Lift remote control specifications.
TURN OFF KEY SWITCH c) When any hydraulic operation is commanded, proportional valve current input (option)
For details of setting AOS and Lift remote control specifications,
value 145mA.
See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Error is detected only in following condition.
Att.1→number of hydraulic valve : 4, 5
Att.2→number of hydraulic valve : 5
• Disconnection or failure of lift lever potentiometer
Either of following states is detected for continuous 100ms.
<How to check>
a) When (S1 + S2) - 5.0V exceeds ± 0.625V
L. SENSOR-LIFT AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>LIFT SENSOR ]
E41 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V.
TURN OFF KEY SWITCH (option) * C
 onditions for detecting error vary if truck is Lift remote control specifications.
*S1：OPT board lift lever potentiometer signal 1 (CN2-3）
For details of setting AOS and Lift remote control specifications,
S2：OPT board lift lever potentiometer signal 2 (CN2-23）
See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of tilt lever potentiometer
a) When (S1 + S2) - 5.0V exceeds ± 0.625V <How to check>
L. SENSOR-TILT AOS
E42 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V. [SERVICE DSP. >DATA CHECKING>OPT CPU>TILT SENSOR ]
TURN OFF KEY SWITCH (option)
*S1：OPT board tilt lever potentiometer signal 1 (CN2-5） For details of setting AOS and Lift remote control specifications,
S2：OPT board tilt lever potentiometer signal 2 (CN2-25） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of reach lever potentiometer
a) When (S1 + S2) - 5.0V exceeds ± 0.625V <How to check>
L. SENSOR-RCH AOS
E43 Shutoff for Hydraulic control b) S1 or S2 is 0.5V or 4.5V. [SERVICE DSP. >DATA CHECKING>OPT CPU>REACH SENSOR ]
TURN OFF KEY SWITCH (option)
*S1：OPT board reach lever potentiometer signal 1 (CN2-7） For details of setting AOS and Lift remote control specifications,
S2：OPT board reach lever potentiometer signal 2 (CN2-27） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Either of following states is detected for continuous 100ms. • Disconnection or failure of Att.1 lever potentiometer
Error is detected when the value set in hydraulic valve number setting is 4 or 5. <How to check>
L. SENSOR-ATT1 a) When (S1 + S2) - 5.0V exceeds ± 0.625V AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>ATT.1 SENSOR ]
E44 Shutoff for Hydraulic control
TURN OFF KEY SWITCH b) S1 or S2 is 0.5V or 4.5V. (option) * C
 onditions for detecting error vary if truck is Lift remote control specifications.
*S1：OPT board Att.1 lever potentiometer signal 1 (CN2-9） For details of setting AOS and Lift remote control specifications,
S2：OPT board Att.1 lever potentiometer signal 2 (CN2-29） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).

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 Troubleshooting 6

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
Either of following states is detected for continuous 100ms. • Disconnection or failure of Att.2 lever potentiometer
Error is detected when the value set in hydraulic valve number setting is 5. <How to check>
L. SENSOR-ATT2 a) When (S1 + S2) - 5.0V exceeds ± 0.625V AOS [SERVICE DSP. >DATA CHECKING>OPT CPU>ATT.2 SENSOR ]
E45 Shutoff for Hydraulic control
TURN OFF KEY SWITCH b) S1 or S2 is 0.5V or 4.5V. (option) * C
 onditions for detecting error vary if truck is Lift remote control specifications.
*S1：OPT board Att.2 lever potentiometer signal 1 (CN2-11） For details of setting AOS and Lift remote control specifications,
S2：OPT board Att.2 lever potentiometer signal 2 (CN2-31） See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
a) 5
 seconds have passed after turning key SW ON.
Lowest fork height switch is detected after key SW is turned ON.
[Encoder reel type]
Lift current position Lowest setting value -300 (100mm), or
Lift current position Highest setting value +300 (100mm) • Mistake of lift end setting
When all the above conditions of a) are detected for continuous 500 ms. <How to check>
[SERVICE DSP. >AOS SETTING>LIFT]
b) During AOS automatic fork height stop control
Lift standard position is not detected. • Failure or installation mistake of lowest limit lift sensor
Lift fork height does not change for continuous 2000 ms. AOS
E46 M. SENSOR-LIFT AOS emergency stop
When all the above conditions of b) are detected. (option)
• Failure, disconnection, or installation mistake of lift height detection encoder
c) During height limit function operation <How to check>
During manual operation [SERVICE DSP. >DATA CHECKING>EPS/OPT CPU>LIFT HEIGHT]
Lift standard position is not detected. For details of setting AOS and Lift remote control specifications,
During lift-up See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
Lift analog input value is 1/2 or more than maximum.
Lift height does not change for continuous 2000 ms.
When all above conditions of c) are detected.
Error is detected when either of above conditions a) to c).
Input value of potentiometer for horizontal detection are analogue value 1 and 2. • Failure, disconnection, or installation mistake of tilt horizontal detection
a) 'FORK LEVEL' button of the AOS switch box is ON (LED is lit). potentiometer
b) Signal voltage of the tilt lever potentiometer (OPT board CN2-20) is 0.5V or 4.5V. AOS <How to check>
E47 M. SENSOR-TILT
(option)) [SERVICE DSP. >DATA CHECKING>EPS/OPT CPU>TILT-HRZN. SENSOR ]
Error occurs when both the conditions are detected simultaneously for For details of setting AOS and Lift remote control specifications,
continuous 100 ms. See "FBR-80 AOS/Lift remote control Service Manual" (SM15-010).
a)Sensor input voltage (CN5-161 or CN5-160) is 0.5V or 4.5V for continuous • Disconnection or failure of drive angle sensor
Travel speed restricted to 5km/h 100 ms. • Installation adjustment defects
F50 STEER. SENSOR (reduction in turning speed) b)Sum of voltage of cross type 2 wires (CN5-161 + CN5-160) is 4.5V or 5.5V DSP <How to check>
steering end stop function OFF for continuous 100ms. [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>ANGLE SENSOR ]
* Error is not detected when main contactor trips. See P.126
• Disconnection or failure of lift pressure sensor
<How to check>
F52 VALVE SENSOR Sensor input voltage (CN4-124) is 4.7V or 0.3V for continuous 100ms. HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/LIFT-PRES. SENSOR]
See P.122
a) F
 an power supply voltage is 5V for continuous 1 second while fan is stopped
(detection of disconnection).
• Disconnection, failure or, non-mounting of fan
F53 FAN b) F
 an power supply voltage is 15V for continuous 1 second during fan drive DSP
• Failure of main board
(FET fault detection).
* The truck 2 ton or above equipped with fan only.
TOTAL TIMER • Defect of battery
G60 Shutoff for Charging In normal charging, equalize charging does not complete within 16 hours. DSP
CHARGE STOPPED • Failure of transformer
a) High voltage:Control voltage is 70V for three times in 10ms while charging (48V model)
Control voltage is 35V for three times in 10ms while charging (24V model) • Defect of battery
VOLTAGE-CHG
G61 Shutoff for Charging b) Low voltage:Control voltage is 46V for continuous 5 seconds while charging (48V model) DSP • Failure of transformer
CHARGE STOPPED
Control voltage is 23V for continuous 5 seconds while charging (24V model) • Detachment of battery plug while charging
*Control voltage：CN5-133

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 6 Troubleshooting

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
*ELECTRIC OUTAGE* • Disconnection for AC connection detection line (CN7-2)
Charging timer stop AC connection detected as OFF while charging.
CHARGE STOPPING... • Failure of power supply while charging
G62 DSP
*ELECTRIC OUTAGE* • Detachment of battery plug while charging
Charging timer stop AC connection detected as OFF longer than set time while charging. • Open phase of input power source
CHARGE STOPPED
a) D
 eviation of 3-phase peak current is 10A (8A for 24V model) for continuous 5 seconds.
CURRENT-CHG • Failure of transformer
G63 Shutoff for Charging b) D
 eviation of 3-phase peak current is 40A (20A for 24V model) for continuous 5 seconds. DSP
CHARGE STOPPED • Disconnection or failure of charging current sensor
c) Neutral offset electric current is 5A.
a) Charging plug temperature is 110°C during charging mode. • a) Defect of contact point of charging plug
Shutoff for Charging b) Charging plug temperature is -999°C or during charging mode (detection of • b), c) Defect or disconnection of thermistor
PLUG-CHG
G64 Horn sound (sounds for 15 minutes at disconnection). DSP <How to check>
CHARGE STOPPED
10s intervals when settings is ON.) c) Charging plug temperature is -44°C and difference of two wires is 10°C [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>PLUG TEMPERATURE]
during charging mode. See P.126
a) E ffective motor current value is equal to or more than maximum current set
value for continuous 100ms. • Overcurrent of traction motor current
Maximum current set (When motor starts) • Disconnection or failure of travel current sensor
IPM: 400A 318A • Short-circuit of traction motor
CURRENT-TRV IPM: 600A 474A (FBR35/40)
H70 Main contactor trip TRV • Mistake of model setting (current limitation value is different.)
TURN OFF KEY SWITCH b) When overcurrent detection (POE) hardware detects overcurrent threshold for
more than 20 times. <How to check>
Overcurrent threshold [SERVICE DSP. >DATA CHECKING>TRV CPU/T-CUR. SENSOR]
IPM: 400A 450 Apeak See P.119
IPM: 600A 670 Apeak (FBR35/40)
a) T he effective motor current value is more than maximum current set value for
continuous 100ms. • Overcurrent of hydraulic motor current
Maximum current set (At the time of motor start) • Disconnection or failure of hydraulic current sensor
IPM: 400A 318A • Short-circuit of hydraulic motor
CURRENT-HYD IPM: 600A 474A
H71 Main contactor trip HYD • Mistake of model setting (current limiting value is different.)
TURN OFF KEY SWITCH b) When overcurrent detection (POE) hardware detects overcurrent threshold for
more than 20 times. <How to check>
Overcurrent threshold [SERVICE DSP. >DATA CHECKING>HYD CPU/H-CUR. SENSOR]
IPM: 400A 450 Apeak See P.122
IPM: 600A 670 Apeak (FBR35/40)
• Overcurrent of EPS motor
EPS POE signal is detected for total 20 times.
H72 CURRENT-EPS Travel speed reduced by half. DSP • Short-circuit of EPS motor
* Error is not detected when main contactor trips.
• Failure of main board
[High voltage detection]
(Main contactor trip: 66V (48V model) or 33V (24 model))
• Mistake of model setting
• Battery plug came off during regeneration operation.
a) L ow voltage check
(Error is not displayed; however, it is stored in the error history.)
During contactor ON command,
a) L
 ow voltage check 24V:Power supply voltage (Main Power supply voltage 1 (CN2-32)) is 12V [Low voltage detection]
Shutoff for Travel operation for continuous 100ms ( 24V (48V model) or 12V (24V model))
• Interruption of control voltage (loosening of bolt, connector)
H73 VOLTAGE-TRV 48V:Power supply voltage (Main Power supply voltage 1 (CN2-32)) is 24V TRV
b) H
 igh voltage check for continuous 100ms • Failure of battery
Main contactor trip b) High voltage check • Faulty contact point (main contactor)
24V:Power supply voltage (Main Power supply voltage 2 (CN2-33)) is 33V • Mistake of model setting
48V:Power supply voltage (Main Power supply voltage 2 (CN2-33)) is 66V • Battery plug came off when the key SW is turned ON.
(Error is not displayed; however, it is stored in the error history.)
<How to check>
[SERVICE DSP. >DATA CHECKING>TRV CPU>BATT. VOLTAGE]
See P.119

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 Troubleshooting 6

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
[High voltage detection]
(Main contactor trip: 66V (48V model) or 33V (24 model))
• Mistake of model setting
• Battery plug came off during regeneration operation
a) Low voltage check
(Error is not displayed; however, it is stored in the error history.)
During contactor ON command,
a) L
 ow voltage check 24V:Power supply voltage (Main Power supply voltage 1 (CN2-32) ) is 12V [Low voltage detection]
Shutoff for Hydraulic operation for continuous 100ms ( 24V (48V model) or 12V (24V model))
• Interruption of control voltage (loosening of bolt, connector)
H74 VOLTAGE-HYD 48V:Power supply voltage (Main Power supply voltage 1 (CN2-32) ) is 24V HYD
b) H
 igh voltage check for continuous 100ms • Failure of battery
Main contactor trip b) High voltage check • Faulty contact point (main contactor)
24V:Power supply voltage (Main Power supply voltage 2 (CN2-33) ) is 33V • Mistake of model setting
48V:Power supply voltage (Main Power supply voltage 2 (CN2-33) ) is 66V • Battery plug came off when the key SW is turned ON
(Error is not displayed; however, it is stored in the error history.)
<How to check>
[SERVICE DSP. >DATA CHECKING>HYD CPU>CONTROL VOLTAGE]
See P.122
• Excessive stationary steering
Current limiting value 10A a) Board temperature is 100°C
REDUCE DUTY-OPERATION- <How to check>
H75 * stationary steering is not possible, b) Root mean-square current (sampling 100ms) of latest 60 seconds is 15A DSP
EPS [SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>BORAD TEMPERATURE]
travel steering is possible threshold.
See P.122
• Temperature of travel IPM module is 105°C.
Error is not detected when thermistor harness disconnection.
REDUCE DUTY-OPERATION-
H76 Travel limit (Stop at 120°C) Travel IPM thermistor is at 105°C for continuous 1000ms. TRV <How to check>
TRV
[SERVICE DSP. >DATA CHECKING>TRV CPU/TRV-FET TEMP.]
See P.119
• Temperature of the Hydraulic IPM module is 105°C.
Error is not detected when thermistor harness disconnection.
REDUCE DUTY-OPERATION-
H77 Hydraulic limit (Stop at 120°C) Hydraulic IPM thermistor is at 105°C for continuous 1000ms. HYD <How to check>
HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/HYD-FET TEMP.]
See P.122
a) D uring initial communication in set data, 1000ms have passed without
receiving initial value request after power supply relay is turned ON.
FAIL BUS SYSTEM-AOS b) During initial communication in set data, 1000ms have passed after receiving • Disconnection or mistake in connection of harness and OPT board
H78 Shutoff for Hydraulic operation DSP
TURN OFF KEY SWITCH first initial value request without receiving the completion flag. • Failure of main board, OPT board
c) When reception of control data is interrupted continuously for 1000ms after
receiving completion flag.
• Failure of main board V15 power source
<How to check>
H79 VOLTAGE-GATE Main contactor trip Gate voltage (CN2-36/CN2-37) is 10V for continuous 100ms. TRV
[SERVICE DSP. >DATA CHECKING>TRV CPU/FET-GATE VOL.]
See P.119
[High voltage detection]
(Main contactor trip: 66V (48V model) or 33V (24 model))
• Mistake of model setting
• Battery plug came off during regeneration operation
(Error is not displayed; however, it is stored in the error history.)
a) L
 ow voltage check
24V: Control voltage (CN5-133) is 12V for continuous 100ms. [Low voltage detection]
48V: Control voltage (CN5-133) is 24V for continuous 100ms. ( 24V (48V model) or 12V (24V model))
• Interruption of control voltage (loosening of bolt, connector)
H80 VOLTAGE-CTL DSP
b) High voltage check • Failure of battery
24V: Control voltage (CN5-133) is 33V. • Faulty contact point (main contactor)
48V: Control voltage (CN5-133) is 66V. • Mistake of model setting
• Battery plug came off when the key SW is turned ON
(Error is not displayed; however, it is stored in the error history.)
<How to check>
[SERVICE DSP. >DATA CHECKING>EPS/DSP CPU>CONTROL VOLTAGE]
See P.126

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 6 Troubleshooting

Code Error Message Truck response when error is detected Conditions for detecting error CPU Possible Cause
• Failure of main board
<How to check>
H81 VOLTAGE-OUT1 Main contactor trip External output voltage 1 (5V) is 3.7V for continuous 100ms. HYD
[SERVICE DSP. >DATA CHECKING>HYD CPU/EXTERNAL PS VOL.>PS5V]
See P.122
• Failure of main board
• Short-circuit of harness in 5V power supply sensor
• Voltage drop of V5A power supply
H82 VOLTAGE-OUT2 Main contactor trip External output voltage 2 (5V) is 3.9V for continuous 100ms. HYD
<How to check>
[SERVICE DSP. >DATA CHECKING>HYD CPU/EXTERNAL PS VOL.>FUSE]
See P.122
• Defect of X1 relay coil
• Disconnection of X1 relay coil harness
FAIL BUS SYSTEM-TRV
H83 Shutoff for Travel operation Fail in communication between each CPU of main board. DSP • Defect of X1 relay contact point
TURN OFF KEY SWITCH
• Failure of main board
• Disconnection of CAN-BUS communication harness
• Defect of X1 relay coil
• Disconnection of X1 relay coil harness
FAIL BUS SYSTEM-HYD
H84 Shutoff for Hydraulic operation Fail in communication between each CPU of main board. DSP • Defect of X1 relay contact point
TURN OFF KEY SWITCH
• Failure of main board
• Disconnection of CAN-BUS communication harness
• EEPROM read failure when data is recovered by key SW OFF/ON.
• Data corruption when data is recovered by resetting the configuration.
a) Fail in reading data from memory • Failure of board
H85 FAIL BUS SYSTEM-MEMORY DSP
b) Fail in writting data to memory <How to reset the memory settings>
[SERVICE DSP. >SERVISE DISP.>MOMORY INITIAL>SETTING]
See P.116
RELEASE ACCEL LEVER TO
Shutoff for Travel operation Accelerator is turned ON at the time of turning key SW ON. TRV
NEUTRAL

ASSUME CURRECT STANDING Error display after one second of leaving seat (continuous), shutoff for travel
Shutoff for Travel operation TRV
POSITION operation after two seconds of leaving seat (continuous).

RELEASE HYD.LEVER TO
Shutoff for Hydraulic operation Hydraulic lever is turned ON at the time of turning key SW ON. HYD
NEUTRAL

a) Shutoff for Travel operation Battery front loading switch is turned ON when travel or hydraulic operation.
RETRACT THE BATTERY TRV
b) Shutoff for Hydraulic operation * Only for battery front loading model

REDUCE THE LOAD Load is heavier than configured load for continuous one second or more. DSP

REFILL HYDRAULIC OIL When fork oil shortage is detected within 2 seconds after key SW ON. DSP

REPLENISH REFINED WATER

Voltage is 2.0V for 20 times or more in 1000ms. DSP
FOR BATTERY

CHARGE BATTERY Battery indicator is detected level two or less. DSP

When "STOP" button of AOS switch is pressed.

FAIL OPERATION-AOS Shutoff for Hydraulic operation DSP
* Only AOS specification model

When inconsistency is found in configured fork height in memory mode.

RACK MISSET DSP
* Only AOS specification model

112

6- 3. Trouble when an error message does not appear
6-3-1. Trouble of error non-occurrence
The defects that occur if error cannot be detected or if there is a mistake in setting are mentioned below.
Trouble
Display does not work.
Sheet switch does not
work.
Load meter (lift pressure sensor)
is not displayed correctly.
Laser pointer does not
work.
Voltage error occurs when
key SW turned ON.
Hour meter does not work.
Traveling speed is slow.
Start speed is slow for
about 5 seconds, and then
achieve to full speed.
(The plugging force is weak or none.)
The start speed is fast only failed and disconnected.
for few seconds, and then
slow down.
*F or high-performance
model only
Steering force of left and
right are different.
Turning speed is slow.
Charging screen does not display
when charging plug is connected.
Troubleshooting 6
Possible Cause Reference
[Backlight OFF]
Failure of display
Failure of main board V12 power supply
Connector connection failed, 12V power supply harness
disconnected. (CN5-136, CN5-137)
[Backlight ON]
Failure of display
CAN-BUS communication harness disconnected. (CN5-156, CN5-164)
Display termination resistor harness is not connected.
* Truck can be operated even without display.
*S ettings cannot be changed Possible by using maintenance tool
* Built-in charger not available Charge by stationary charger
Failure of display
Flat cable disconnected, contact failed.
Defective sheet switch
* Truck can be operated even sheetswitch does not work.
*S ettings cannot be changed Possible by using maintenance tool
* Built-in charger not available Charge by stationary charger
Load meter (lift pressure sensor) option is not set. See page 58
Load meter (lift pressure sensor) is not set. See page 42.
Laser pointer option is not set. See page 56.
Laser pointer operation is not set. See page 20.
Mistake of model setting See page 47.
Hour meter START is not set. See page 40.
After tire replacement, tire diameter is not corrected. Hence, anti-
See page 41.
slip control is not working correctly.
Slowest speed limit is enabled.
(Speed limit, speed control, LIMITED SPEED (IO))
Brake wire is stretched, brake disk is not fully released.
Traction motor speed sensor failed and disconnected.
See page 119.
[SERVICE DSP. >DATA CHECKING>TRV CPU>TRV-MOTOR SPEED]
N mode or ECO mode are selected.
Front wheel (R) speed sensor failed and disconnected.
[SERVICE DSP. >DATA CHECKING>TRV CPU> See page 119.
F-WHEEL SPEED R]
Front wheel (R) speed sensor and Front wheel (L) speed sensor
[SERVICE DSP. >DATA CHECKING>TRV CPU>
See page 119.
F-WHEEL SPEED R]
[SERVICE DSP. >DATA CHECKING>HYD CPU>
See page 122.
F-WHEEL SPEED L]
Neutral of torque sensor is shifted.
See page 126.
[SERVICE DSP. >DATA CHECKING>EPS/DSPCPU>STEERING SENSOR]
LMT. SPEED (TURN) is set to slow speed.
If terminal of lift height detection switch is disconnected, speed
decelerates by 1km/h during rotation.
㼂㻡 㻢 㻝㻥㻞 Power supply (+5V)
㟁※㻔㻗㻡㼂㻕 See page 48.
㧗ᥭ㧗䝬䝇䝖䛾䜏
Only for high lift height mast 㻭㻢 㻢 㻝㻥㻥 㼀 ಙྕ
Signal
White
䝅䝻
㻳㻺㻰 㻢 㻝㻤㻞 㻳㻺㻰
Black
䜽䝻
㻿㻞㻟 㻢 㻝㻣㻜 㼀 ᥭ㧗᳨ฟ䝇䜲䝑䝏
Lift height detection switch
Built-in charger option is OFF. See page 59.
113
 6 Troubleshooting

6- 4. Error history memory

6-4-1. Error history memory (LATEST 10)
<Recently detected latest 10 errors>

The special command ; Press the switch

in order of
while pressing switch on the
manager screen.

lSERVICE DSP. screen

Press
to select ERROR HISTORY.

131T0322

lERROR HISTORY screen

Press
to select LATEST 10 .
131T0323

lLATEST10 screen

Display and select 10 errors with

Error ID
131T0326

Display the detection date, time

and error count (total number of
times) of the selected error ID.
131T0327

NOTE When key switch is turn OFF, the current error is

recorded. Next time when key is turned ON, if the same
error occurs within 2 seconds, the error history will not
be saved considering that the error will continue.
114
 Troubleshooting 6

6-4-2. Error history memory (ALL)

<All errors detected in past>
The special command ; Press the switch
in order of
while pressing switch on the
manager screen.

lSERVICE DSP. screen

Press
to select ERROR HISTORY.

131T0322

lERROR HISTORY screen

Press to select ALL.

131T0330

lALL screen

$ $ % % % Display a list of Error IDs and
select
% & & ) )
* Highlighted: Error is displayed
) + + + +
131T0376

131T0332

Display the detection date, time and error count (total

number of times) of the selected error ID.

NOTE l Error occurrence date and time is updated to the most recent date
and time when error occurs.
lWhen key switch is turn OFF, the current error is recorded. Next time when
key is turned ON, if the same error occurs within 2 seconds, the error
history will not be saved considering that the error will continue.
115
 6 Troubleshooting

6-4-3. Memory initialize (Setting/error history reset)

Reset each setting or error history.
The special command ; Press the switch
in order of
while pressing switch on the
manager screen.

lSERVICE DSP. screen

Press to select
MEMORY INITIAL.

131T0335

lEMEMORY INITIALIZE selection screen

Press to select SETTING

or ERROR.

Item Details
131T0336
Resets all settings to default
values.
SETTING
* Model is reset to FBR15.
lEMEMORY INITIALIZE screen * Error history is not reset.
ERROR Resets only the error history.

Select "YES" to initialize.

131T0337

CAUTION l It takes about 1 second to complete the memory

initialization. In the meantime, do not perform
operations such as turning key OFF and turning
power off. Data might get damaged.
l If initialization is done with SETTING, you need to set
again.
See "1-3-1. Settings for main board replacing /
Memory initialization" on page 4.

116
 Troubleshooting 6

6- 5. I / O monitor check
6-5-1. Display method
The special command ; Press the switch
in order of
while pressing switch on the
manager screen.

lSERVICE DSP. screen

Press
to select DATA CHECKING.

131T0344

lDATA CHECKING screen

Press to select CPU

according to the measurement
item.

131T0345

NOTE OPT CPU is displayed only when AOS option setting is

ON.

117
 6 Troubleshooting

6-5-2. Travel CPU monitor (TRV CPU)

l TRV CPU (Travel CPU monitor) screen

'$7$
㸦759&38㸧 02725&855(17 )(77(03(5$785(
75902725&855(17 㸦75$9(/㸧 㸦75$9(/㸧

759)(77(03
759027257(03 $ 506 GHJ

'$7$
㸦759&38㸧 &855(176(1625 $&&(/(5$7256(1625
7&856(1625 㸦75$9(/㸧

$&&(/6(1625 6(1625ࠉࠉ9 6(1625ࠉࠉ9
6(1625 63$5( 6(1625ࠉࠉ9 6(1625ࠉࠉ9

'$7$
㸦759&38㸧 %$77(5<92/7$*( *$7(92/7$*(
%$7792/7$*( %()25($'-9 㸦)(702'8/(㸧

)(7*$7(92/ &217$&7259
28738792/ 635 )86(ࠉࠉ9 9

'$7$
㸦759&38㸧 %5$.(6:,7&+ 2,66:,7&+
%5$.(6:,7&+

2,66:,7&+
,138792/ 63$5( 9 9

'$7$
㸦759&38㸧 0272563((' )5217:+((/63(('
7590272563((' 㸦75$9(/㸧 㸦5,*+7㸧

):+((/63(('5
&2817 &2817

'$7$
㸦759&38㸧 ,2 759 ,2 759 >3257$@
,2 3257$ +(; %&$
 
5$0 3257% %,1$5< 
3257' 

15 Bit 0 Bit
131T0603

118
 Troubleshooting 6

l TRV CPU (Travel CPU monitor)

Item Details/Connector – Pin No. Check method

TRV-MOTOR Traction motor effective current Traction motor current measurement See P.89
CURRENT
TRV-FET TEMP. Travel IPM module temperature Error "H76 REDUCE DUTY-OPERATION-TRV" is occurred
when temperature is 105°C.
Travel stopped when temperature is 120°C.
After this error is occurred, it was resolved by detecting
temperature 100°C.
Stop operation and decrease temperature for a while.
T-CUR. SENSOR Travel current sensor voltage Normal: 2.5V±0.488V with SENSOR1 and 2 (neutral)
(neutral 5.0V) Error condition: In other than normal range, "B12 / B13
SENSOR1:CN2-58 C.SENSOR_U/W-T" error occur.
SENSOR2:CN2-66
ACCEL. Accelerator sensor voltage Normal: 2.5V±0.03V with SENSOR 1 and 2 in accelerator neutral
SENSOR (neutral 2.5V) Error condition:
SENSOR1:CN4-125 (1) Voltage of SENSOR 1 or 2 is equal to or 4.5V or 0.5V
SENSOR2:CN4-126 (2) Sum of SENSOR 1 and 2 is out of range 5.0V±1.25V
"B14 ACCELERATOR" error occurs due to (1) or (2).
Adjustment : See P.97

BATT. VOLTAGE Battery voltage • [CONTACTOR]: Normal: Battery voltage (24/48V)

[CONTACTOR]: Error condition: 24V model: 9V
CN2-32 (Contactor contact) 48V model:  18V. Error occurred in A01
[FUSE]: connector (main)
CN2-33 (battery voltage) • [FUSE]: Normal: Battery voltage (24/48V)
Error condition: When F1 fuse (325A) is melted, error
occurred in A02 fuse (main).
㻞㻠㻛㻠㻤㼂 㻹㻭㻵㻺
Line Connector
䝷䜲䞁
䝁䝛䜽䝍
㻯㻼㼁
No.
㻺㼛㻚 㻯㻺㻌䕕 䝢䞁㻺㼛㻚
Pin No.
RedBlack#
䜰䜹䜽䝻䠀
㻮㻞 㻞 㻟㻞 㼀㻘㻴 Contactor
䝁䞁䝍䜽䝍᥋Ⅼ contact
䜰䜹

㻹㻯
Red

YellowRed#
䜻䜰䜹䠀
㻮㻟 㻞 㻟㻟 㼀㻘㻴 Battery
䝞䝑䝔䝸㟁ᅽ voltage
㻲㻝
㻗
㻟㻞㻡㻭

FET-GATE VOL. Gate drive circuit power supply Normal: Approximately 15V
voltage CN2-36 & CN2-37 Error condition: gate voltage error occurs in H79 when voltage is 10V
BRAKE SWITCH Brake switch Normal: Depress the brake pedal 0V / Release the brake pedal 5V
CN5-140 Error: 5V does not change even if pedal is depressed
Travel not possible
* Brake switch failed, harness disconnected
OIS SWITCH OIS switch sensor voltage Normal:Ride forklift truck (Brake pedal depress) CN4-105 signal
OIS SWITCH: voltage 2.5V±0.6V
CN4-105 (Sensor signal Get off forklift truck (brake pedal release) CN4-105
voltage) signal voltage 1.0V±0.4V
Error condition: Error occurs in B16 OIS sensor when sensor signal
voltage CN4-105 is 4.5V or 0.5V.
TRV-MOTOR Traction motor encoder count Normal: When traction motor (brake disc) is rotated 1 turn travel
SPEED (Number of output pulses of forward direction, the count increases from 0 to 256.
traction motor speed sensor) Error: Count does not increase (disconnection, sensor failure)
* Travel speed becomes slow if traction motor speed sensor
fails and sensor harness disconnects.
F-WHEEL Right front wheel encoder Normal:When right load wheel rotates 1 turn in forward direction,
SPEED R count the count increases from 0 to 180.
(Number of output pulses of Error: Count does not amount to 180 (disconnection, sensor failure)
* If front wheel speed sensor is defective or sensor harness is
speed sensor of front wheel (R))
disconnected, the start speed gets slower for a few seconds
and then the speed increases to maximum.

119
 6 Troubleshooting

6-5-3. Travel I/O port table

Address Pin No Bit IN/OUT Initial Contents Remarks
68 1 IN L Over-current detection
66 3 IN L Serial communication receive
65 4 OUT L Serial communication transmission
Traction motor speed sensor phase
62 6 IN L 0 or 5V
A
Traction motor speed sensor phase
61 7 IN L 0 or 5V
PA B
Front wheel (R) speed sensor phase
60 8 IN L 0 or 5V
A
Front wheel (R) speed sensor phase
58 9 IN L 0 or 5V
B
56 10 OUT L Over-current selection
55 11 OUT L Over-current selection

46 2 IN L POE0
45 3 IN L High lift height detection
CANbus
CANbus date transmission CH0
42 6 OUT L communication
PB (control)
(between CPUs)
CANbus
41 7 IN L CANbus date receive CH0 (control) communication
(between CPUs)

34 4 IN L Neutral
33 5 IN L Forward
32 6 IN L Backward
PD ON when "L"
29 9 IN L Travel inhibitor (CN3-74)
from 1 to 0
ON when "L"
28 10 IN L Travel speed reduction (CN3-73)
from1 to 0

25 2 OUT H Suspension lock

24 3 OUT H Forward transmission
23 4 OUT H Backward transmission
20 7 OUT L LED receive
19 8 OUT H Brake transmission
Travel gate signal output When chopper
17 9 OUT H
(phase U lower) stopped PE9
Travel gate signal output When chopper
15 11 OUT H
E-L (phase U upper) stopped PE11
Travel gate signal output When chopper
13 12 OUT H
(phase V lower) stopped PE12
Travel gate signal output When chopper
12 13 OUT H
(phase W lower) stopped PE13
Travel gate signal output When chopper
10 14 OUT H
(phase V upper) stopped PE14
Travel gate signal output When chopper
9 15 OUT H
(phase W upper) stopped PE15
8 16(1Bit) OUT L Right front wheel brake H-bridge circuit output
7 17(2Bit) OUT L Right front wheel brake H-bridge circuit output
E-H
6 18(3Bit) OUT L Left front wheel brake H-bridge circuit output
4 20(5Bit) OUT L Left front wheel brake H-bridge circuit output
H : High 1 L : Low 0

120
 Troubleshooting 6

6-5-4. Hydraulic CPU monitor (HYD CPU)

l HTD CPU (Travel CPU monitor) screen

'$7$㸦+<'&38㸧 02725&855(17 )(77(03(5$785(

+<'02725&855(17 㸦+<'㸧 㸦+<'㸧

+<')(77(03
+<'027257(03 $ 506 GHJ

'$7$㸦+<'&38㸧 &855(176(1625 35(6685(6(1625 +25,=216(1625

+&856(1625 㸦+<'㸧 㸦/,)7㸧 㸦7,/7㸧

/,)735(66(1625 6(1625ࠉࠉ9
7,/7+5=16(1625 6(1625ࠉࠉ9 9 9

'$7$㸦+<'&38㸧 &21752/92/7$*( (;7(51$/3692/

&21752/92/7$*( %2$5')86(&+(&.

(;7(51$/3692/ 36 9 9
)$192/7$*( 9 )86(ࠉࠉ9

'$7$㸦759&38㸧 )5217:+((/63(('
):+((/63(('/ 㸦/()7㸧

&2817

'$7$㸦+<'&38㸧 ,2 +<' ,2 +<' >3257$@

,2 3257$ +(; &$
 
5$0 3257% %,1$5< 
3257' 

15 Bit 0 Bit 131T0605

121
 6 Troubleshooting

l HYD CPU (Hydraulic CPU monitor)

Item Details/Connector – Pin No. Check method

HYD-MOTOR Hydraulic motor effective See hydraulic motor current measurement See P.91
CURRENT current

HYD-FET TEMP. Hydraulic IPM Error "H77 REDUCE DUTY-OPERATION-HYD" occurs when
Module temperature temperature is 105°C.
Hydraulic stopped when temperature is 120°C.
After this error is occurred, it was resolved by detecting
temperature 100°C.
Stop operation and decrease temperature for a while.
H-CUR. Hydraulic current sensor Normal: 2.5V±0.488V with SENSOR1 and 2 (neutral)
SENSOR voltage (neutral 5.0V) Error condition: In other than normal range, "C22/C23
SENSOR1:CN2-54 C.SENSOR_U/W-H" error occur.
SENSOR2:CN2-62
LIFT-PRES. Lift Sensor signal voltage (CN4-124)
SENSOR pressure sensor voltage When 4.7V and 0.3V , "F52 VALVE SENSOR" error
CN4-124 occurs.
TILT-HRZN. Tilt
SENSOR Horizontal sensor voltage

CONTROL Control voltage Normal: Battery voltage (24/48V)

VOLTAGE Travel/ hydraulic CPU control
voltage
a) Low voltage check: CN2-32
b) High voltage check: CN2-33
EXTERNAL PS External output 5VPower-supply
VOL. voltage (V5, V5A)
PS5V: 5V series sensor power
supply voltage
FUSE: 5V system sensor power
supply fuse in main board
F-WHEEL Left front wheel encoder count
SPEED L Number of output pulses of
speed sensor of front wheel (L)
*Equipped in high-performance
model only
Error condition:Under following conditions, "H73 VOLTAGE-
TRV/ H74 VOLTAGE-HYD" error occur.
a) Low voltage check
During contactor ON command
24V : voltage 12V for continuous 100ms
48V : voltage 24V for continuous 100ms
b) High voltage check
24V : 33V detected
48V : 66V detected
PS5V :
Normal: 5V
FUSE :
Normal: 5V
Normal: When left load wheel rotates 1 turn in reverse direction,
the count increases from 0 to 180.
Error: Count does not amount to 180 (disconnection, sensor
failure)
* If both of front wheel speed sensor (L) and (R) are
disconnected, the start speed gets slower for a few seconds
and then the speed increases to maximum.

122
 Troubleshooting 6

6-5-5. Hydraulic micro switch I / O monitor check

lDATA CHECKING screen

Press
to select PUMP(HYD) CPU.

131T0609

lDATA CHECKING screen (Lower layer)

'$7$㸦+<'&38㸧
,2 Press to select I/O.

5$0

131T0605

lDATA CHECKING screen (Lower layer)

,2㸦+<'㸧
3257$

3257%
3257' Press to select PORT "D".
131T0606

lMonitor screen 131T0607

,2 +<' >3257'@

+(; &$ Check according to the following
%,1$5<  table


8 Bit 0 Bit

Connector-
Bit IN/OUT Item Remarks
Pin No.
0 IN CN4-104 Lift 1 switch When SW is ON, 0 bit changes from 1 to 0 (terminal voltage 5V 0V)
1 IN CN4-103 Lift 2 switch When SW is ON, 1 bit changes from 1 to 0 (terminal voltage 5V 0V)
2 IN CN4-102 Tilt switch When SW is ON, 2 bit changes from 1 to 0 (terminal voltage 5V 0V)
3 IN CN4-101 Reach switch When SW is ON, 3 bit changes from 1 to 0 (terminal voltage 5V 0V)
4 IN CN4-100 Att.1 switch When SW is ON, 4 bit changes from 1 to 0 (terminal voltage 5V 0V)
5 IN CN6-169 Att.2 switch When SW is ON, 5 bit changes from 1 to 0 (terminal voltage 5V 0V)
Tilt horizontal
6 IN CN6-168 When SW is ON, 6 bit changes from 1 to 0 (terminal voltage 5V 0V)
stop switch
Battery front
8 IN CN4-123 When SW is ON, 8 bit changes from 1 to 0 (terminal voltage 5V 0V)
loading switch

123
 6 Troubleshooting

6-5-6. Hydraulic I/O port table

Address Pin No Bit IN/OUT Initial Contents Remarks
68 1 IN L Over-current detection
66 3 IN L Serial communication receive
65 4 OUT L Serial communication transmission
62 6 IN L Spare speed sensor phase A 0 or 5V
PA 61 7 IN L Spare speed sensor phase B 0 or 5V
60 8 IN L Front wheel (L) speed sensor phase A 0 or 5V
58 9 IN L Front wheel (L) speed sensor phase B 0 or 5V
56 10 OUT L Over-current selection
55 11 OUT L Over-current selection

46 2 IN L POE0
CANbus date transmission CH0
PB 42 6 OUT L
(control)
41 7 IN L CANbus date receive CH0 (control)

40 0 IN L Lift 1 switch ON when "L" from 1 to 0

38 1 IN L Lift 2 switch ON when "L" from 1 to 0
37 2 IN L Tilt switch ON when "L" from 1 to 0
35 3 IN L Reach switch ON when "L" from 1 to 0
PD 34 4 IN L Attachment 1 switch ON when "L" from 1 to 0
33 5 IN L Attachment 2 switch ON when "L" from 1 to 0
32 6 IN L Tilt horizontal stop switch ON when "L" from 1 to 0
31 7 IN L Lift lock ON when "L" from 1 to 0
30 8 IN L Battery front loading switch ON when "L" from 1 to 0

27 0 OUT H Main contactor

27 1 OUT H Lift lock valve
25 2 OUT H Fan
20 7 OUT L LED input ON when "H" from 1 to 0
Hydraulic gate signal output When chopper
17 9 OUT H
(phase U lower) stopped PE9
Hydraulic gate signal output When chopper
15 11 OUT H
(phase U upper) stopped PE11
E-L
Hydraulic gate signal output When chopper
13 12 OUT H
(phase V lower) stopped PE12
Hydraulic gate signal output When chopper
12 13 OUT H
(phase W lower) stopped PE13
Hydraulic gate signal output When chopper
10 14 OUT H
(phase V upper) stopped PE14
Hydraulic gate signal output When chopper
9 15 OUT H
(phase W upper) stopped PE15
H : High 1 L : Low 0

124
 Troubleshooting 6

6-5-7. EPS/DSP CPU monitor (EPS/DSP CPU)

l EPS/DSP CPU (EPS/display CPU monitor) screen
'$7$㸦(36'63&38㸧 02725&855(17 (36 %2$5'7(03(5$785( '5,9($1*/(
(3602725&855(17 /,0,7$

%2$5'7(03(5$785( $'-GLJLW GHJV
'5,9($1*/( &85$$ GHJ GHJ

'$7$㸦(36'63&38㸧 67((5,1*6(1625 $1*/(6(1625 %$77(5</(9(/

67((5,1*6(1625 㸦+$1'/(6,'(㸧 㸦'5$,9(6,'(㸧 6(1625

$1*/(6(1625 9
%$77/9/6(1625 9 9 9

'$7$㸦(36'63&38㸧 &21752/92/7$*( 3/8*7(03(5$785(

&21752/92/7$*(

:,1.(5/$0392/ %()25($'- 9 3/8* GHJ
3/8*7(03(5$785( $)7(5$'- 9 3/8* GHJ

'$7$㸦(36'63&38㸧 &+$5*(&2817
&+$5*(&2817 727$/ 

1250$/&+* 
/2:7(03 

'$7$㸦(36'63&38㸧 ,2㸦'63㸧 ,2 '63 >3257$@

,2 3257$ +(; )(
 
5$0 3257% %,1$5< 
3257' 

131T0608
15 Bit 0 Bit

125
 6 Troubleshooting

lEPS/DSP CPU (display CPU monitor)

Item Details/Connector – Pin No. Check method
EPS-MOTOR LIMIT: Limit value ADJ
CURRENT ADJ: Neutral correction
value Normal: Within ±106 digit =Current sensor neutral correction value is
within ± 5A.
CUR : EPS motor current
Error condition:"D33 C.SENSOR-EPS" error occurs out of above range.
/ root-mean-square
current Sensor inside main board is defective.
BOARD EPS board temperature "H75 REDUSE DUTY-OPERATION-EPS" error occurs at 100 °C
TEMPERATURE (near EPS FET) When error occurs, current limiting value is controlled at 10A.
DRIVE Drive angle (Straight 0°), Display of drive turning angle.
ANGLE speed at drive angle
STEERING Torque sensor Normal: 2.5V±0.1V when the steering wheel does not operated.
SENSOR (neutral 2.5V) Error condition: "D31 T.SENSOR-EPS" error occurs is out of range of
CN5-162 (Sensor signal 0.5V to 4.5V.
voltage) Adjustment : See P.82, P.99
ANGLE Turning angle (drive angle) Normal: B
 oth SENSOR 1 and 2 are in 2.5V±0.1V when drive wheel is
SENSOR sensor (straight 2.5V) in straight position.
SENSOR1 : CN5-161 Error condition: "F50 STEER. SENSOR" error occurs when SENSOR 1
SENSOR2 : CN5-160 or 2 is out of range of 0.5V to 4.5V.
Adjustment : See P.98
BATT. LVL. Liquid level gauge sensor Normal: 5V output
SENSOR voltage Error condition: When outputting pulse waveform (battery liquid level is
CN3-97 low), "REPLENISH REFINED WATER FOR BATTERY
(option)" is displayed.
CONTROL Control voltage Normal: Battery voltage (24/48V)
VOLTAGE (Before and after correction) Error condition: "H80 VOLTAGE-CTL" error occurs when detection
CN5-133 continues for 100ms.
24V model: 12V or 33V
48V model: 24V or 66V
PLUG Charger plug temperature Error condition:
TEMPERATURE During charging mode, 110°C temperature of charger plug is detected.
During charging mode, -999°C temperature of charger plug is
detected.(disconnection)
During charging mode, that charger plug temperature is -44°C and
difference of two lines is 10°C is detected.
In above conditions, "G64 PLUG-CHG CHARGE STOPPED" error
occurs.
CHARGE Charge count Display charge count
COUNT

126
 Troubleshooting 6

6-5-8. DSP I/O port table

Address Pin No Bit IN/OUT Initial Contents Remarks
Serial communication receive CH0
69 0 IN L
(EEPROM)
Serial communication transmission
68 1 OUT L
CH0 (EEPROM)
Serial clock transmission CH0
67 2 OUT L
(EEPROM)
Serial communication receive CH1
66 3 IN L Monitor receive
(Debugging monitor)
PA Serial communication transmission
65 4 OUT L Monitor transmission
CH1 (Debugging monitor)
63 5 IN H Key start (CN5-148) ON when "L" from 1 to 0
56 10 IN H Headlight switch (CN5-147) ON when "L" from 1 to 0
55 11 IN H Horn switch (CN5-146) ON when "L" from 1 to 0
54 12 IN H Tilt level sensor ON when "L" from 1 to 0
53 13 IN H Charging interlock switch (only for RB) ON when "L" from 1 to 0
52 14 IN H Chopper error detection 1 Phase A H when "L"
51 15 IN H Chopper error detection 2 Phase AA H when "L"

CANbus date transmission CH1 CANbus communication

49 0 OUT L
(LCD) (LCD)
CANbus communication
47 1 IN L CANbus date receive CH1 (LCD)
(LCD)
46 2 IN L EPS current hard trip POE
PB AC (Charger plug ) connection Three-phase AC
43 5 IN L
detection detection
CANbus date transmission CH0 CANbus communication
42 6 OUT L
(control) (between CPUs)
CANbus communication
41 7 IN L CANbus date receive CH0 (control)
(between CPUs)

40 0 IN H Key switch (CN5-149) ON when "L" from 1 to 0

38 1 IN H Parking brake switch (only for FB) ON when "L" from 1 to 0
37 2 IN H Brake oil level sensor (only for FB) ON when "L" from 1 to 0
35 3 IN H Hydraulic oil level sensor (CN6-173) ON when "L" from 1 to 0
PD
34 4 IN H Over-load sensor (CN6-172) ON when "L" from 1 to 0
32 6 IN L Serial communication receive CH2 (RTC)
31 7 OUT L Serial communication transmission CH2 (RTC)
30 8 OUT L Serial clock transmission CH2 (RTC)

27 0 OUT H Electromagnetic switch output ON when "L" from 1 to 0

27 1 OUT H Power supply relay output ON when "L" from 1 to 0
24 3 OUT H AUTO charging LED ON when "L" from 1 to 0
23 4 OUT H EQUAL charging LED ON when "L" from 1 to 0
22 5 OUT H RESERVE charging LED ON when "L" from 1 to 0
21 6 OUT H Headlight output ON when "L" from 1 to 0
E-L
20 7 OUT H MCPU (LED) ON when "L" from 1 to 0
18 10 OUT H Horn output ON when "L" from 1 to 0
13 12 OUT L EPS gate signal output
12 13 OUT H Directional switch (L) output ON when "L" from 1 to 0
10 14 OUT L EPS gate signal output
9 15 OUT H Directional switch (R) output ON when "L" from 1 to 0
8 16(0Bit) OUT L 11V power supply (LCD power supply) ON when "H" from 0 to 1
3V power supply (laser pointer
7 17(1Bit) OUT L ON when "H" from 0 to 1
power supply)
E-H
6 18(2Bit) OUT H Fan output ON when "L" from 1 to 0
4 20(4Bit) OUT H EEPROM chip selection Writing when "L"
2 21(5Bit) OUT L RTC chip enable ON when "H" from 1 to 0
H : High 1 L : Low 0
127
MEMO

128