CONTROL SYSTEM SECTION CS CONTENTS TECHNICAL DESCRIPTION . System METER PANEL, Meters, Indicators and Lamps 08-12 Setting Adjustment Items (Normal Mode) .. .CS-13 Mater Panel Explanation 08-14 LOD MONITOR ......00..eeceeeee004 +0825 ‘Adjustment Mode CS-25 Manager Mode 8.32 Diagnostic Mode 08-35 Table of Error Code CS-46 PRECAUTIONS . LOCATION OF UNITS (LAYOUT) Standard Equipment Tit Leveling Device (Option) CONTROLLER Removal and Installation OS-5t Construction 08-63 Connector {Terminal layout) 08-54 Contraller Element Inspection CS-56 UNIT INSPECTION AND ADJUSTMENT . .CS-62 Control System (08-62 Knob Position Control System (Option) . . . .CS-73) Tl Leveling Device (Option) 8-74 TROUBLE DIAGNOSTIC PROCEDURES . .CS-77 Precautions CS-77 How To Follow Flow Char cs-78 ‘Symbol Identitication 8-79 Voltage and Resistance Measurement Procedures cS-80 TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM .. -CS-81 TROUBLE DIAGNOSIS FOR DRIVING. SYSTEM TROUBLE DIAGNOSIS FOR LOADING SYSTEM .. TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM . TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM .. REFERENCE DATA OF CONTROL SYSTEM .. CS-105 Main Print Board CS-105 FET Drive for Drive Control CS-109 FET Drive for Pump Control CS-109 Condenser Board vee 08-110 st of Error Code cst Display of Controller Internal Error Code. . . .CS-113 Method for Inspection According to Error Code CS-114 Controller Terminal Voltage see+ 08-128 Controller Trouble Sympiom by Meter Display . . see+ 08-132 7 \ caution Before changing any components (Le. lamps, fuses, meter panels) or disconnecting any wiring. Always turn OFF the key switch and disconnect battery. This will reduce the possibility of damage to the controller system. Whenever towing this truck always ensure key is in OFF position and battery is disconnected (unplugged) to reduce possible damage to electrical system.TECHNICAL DESCRIPTION System Model (J1B1/T1B2 Series) 4 J battery tui Sekt is | easiod {_tevetoonser_ Parking brake i) Main print board [ Gontror valve atch (Gitte thst) [ Tilt Rorizontal awit rit angie sn (Option) [ Giipresive wensar cc | Uitksenser | (Option) [Tie angie sensor) un ee Li__f-“Peconection valve (Onton) comcaneTECHNICAL DESCRIPTION System (Cont'd) Correlation Diagram of System Drive System Ss Contactor = Tit Renzontal SW | Ea] (OPT) Leoong tanh Tit anale sensor eal [ were: FECom) - cru (Drive ‘Pump i Load sensor ao aot SSS ny [tm Ss wi of weal | [rane] | xe [C20] sea: || tas | [Meee oe we || Be Son || "3 | ose = sensor|| SW sw (OPT) | ‘ Litt owor!P corraction 7 tit nonzontal valve CS-3TECHNICAL DESCRIPTION System (Cont'd) ‘AC Motor Control jecison torquelspeed of AG motor by tuck specication signal FETs maxe ewiching operation by PWM gral Barer fn 8 pa cuttent wil + FEacany [lee suoptieg 1 AC moter : CPU beara i sensor ve |g] Pe SPRL sive tem i signal Drive | circuit eatgy | censor Pum Pump |_| Lineod sonal le PS Motor Z| i aignat [—%) || contot Wector i A sono i oures command ie pace PT ‘eotded by AC motor Digi! conv target vale current om | sonst J Sr FS sensor terme ero ® ramp lrommang and current senso [Feedback le Drive System Function tn Function Caine Dive contol pe Thaaton ator AC varervacor conte Dive contra ‘Speed contol With tuning speed acceleration contra Pieganeration contr ‘Switchback, brake, acooieralor off regeneration fae caral Power love! steps+ accurate adjustment 6 stepsy/Acceleration Level (8 steps Performance adjustment Regeneration level (8 steps each) Antizol (8 steps) ‘Ani vol central ‘Ani sol braking ferce contr on Sop. Various titan ‘Shed, Figh ft height, power Gu brake, parking brake) rive contol Induetion motor AG inverer vector control Drive contol ‘Speed contil by loscing operation a Fogoneration contr Loading reganoration when loading operation stopped Performance adust Power lvl @ stops + accurate aust 5 stops) Accoloration Level (2 stops) Various imation High IF Peght, high ering epeed, cutout when reverse Seve, BUM GR ‘Mast lowering control Mast lowering lock when Key switch is off Cs-4TECHNICAL DESCRIPTION System (Cont'd) Drive System Function (Cont'd) Tem Function Out Dive conel pe Tlacvonie controled hyaraule power seerng Drive conte thos ‘Common pump mor conrolfor lading PS contol ‘Control uncton Staring wih seorng operation detocoalsteaing speed senang canal Knob poston contre csnati va conta one Compansate steering angle and te angle ost by megnetl e Tener conte facolesion FA SW. Loading, Seat “aoe ruck mode changeover by meter ncieaton Meter communication Meter daplay of various iruck conditions, dlagnoses and adjustments Log iv Tonetion ‘Sart of each truck by pass word input ‘System contrl agnosis iunetion Diagrasis function in normal made/eall chcking/dalog checking “Adjustment funtion Driv, pump, power slesring system adjustment and memory “contol ‘uiomati power of/Parking brake warring eae (Cooling ‘an dive/External accessory source relay/lasher Truk model varstion| ‘Aulomatie model variation change by harness Feature of Drive System © Maintenance free AC Traction/Pump Motors Pump motor is used for PS © Accessories concentrated control Various model changing function (Same controllet for various models) Lift lowering, PS valve control Flasher control ‘Cooling fan control (Including external fan) Electric source relay (Auto power off, valve electric source) © High technology for superior function and high reliability by adoption of sensors with high performance AC motor digital control adopting S2bit RISC CPU ‘Adoption of HEV (Hybrid Electric Vehicte) high responsible items such as resolver CAN (Controller Area Network) communication between units CS-5TECHNICAL DESCRIPTION System (Cont'd) Comparison of Forklift Motor Control Category Main circuit construction Fest Disadvantage + No emooth direction change (By ‘magnetic contactor pitching) «Drive intermittent regenerative + Commonly used (Most popular | {(fonlactor changeover—no good ry Siperence in market ‘+ Regular maintenance must be jvstem Ate conplicate construction a S2mH oh (mechanical k able include fow | point of contactor). Smooth canto by wing veto | Ser ee at |+ Regenerative torque control is | #mission) system} SM control/High speed control ceurvertorave conto} NOTE I: Induction Motor ‘SM: Synchronous Motor CS-6TECHNICAL DESCRIPTION System (Cont'd) ‘OC motor (serles type) contra! Determine ine target valiage (ahopping duty ale) 1 supply to DC motor based on acoelerator signal Drake teh, drection awiteh, meter uplayseting ‘Supply controled OG voltage by awitshing main transistor n accordance ih chopper signa! — Tagervorage — a ¢eropai ya) (neckties) Lops $ a 3 feraoars] || [Gener . Ps board | KE Gries ont value Grate tm Chopping I ‘chopping|L & Field, 4 iy fate sonal eu ois \ \ Career sana (400!) ‘Compare te diy rate Career viangle wave (400 Hz), prosuce chopper sgral Tnputvakage to ‘OC motor {AC (IM) motor control [eampare 12 mor speed and fed on aocelerator eg brako sien, dracon suite, motor splay setting ote ‘signal requensy/amptiuds) to Career Inangia wave (10 KH), produce PWM (iecz[ecse) [oa] a | (PU board a seus 4} |Controt value| ‘Vector ae JP iSpoea [2] Conner E>] ehase |(corear ec = as 0) y ‘Spooa * Determine the lve ourent and toraue cutront ‘ Cateulato wequency and ampiiuaa ot 3p ‘ytage baced on feed ack signal from epe ‘sengor and ourent sensor ‘Supply 3 phase AC vetage bY sSwitahing 8 main vansistor in accordance wi PHM slgnal CS-7TECHNICAL DESCRIPTION System (Cont'd) Principle of AC Motor you End Rng Eng Conductor in Caged Aluminum Stator os i [Qe teams net He a current sirection 4, =a] Magnetic force eae peannetic Electromagnetic 7 Current direction {Caged induction motor is most popular AC induction motor. ‘The rotor structure of caged induction motor ie a shape that conductor constuction is covered isolated ron (See lett drauing) 1aee AC curtent tlw through stator col, rotation force of rotor is mage by mutual elect between his electromagnetic and Induction current in rotor This is principle of AC motor rotation Each col is wound from 'U phase’ V phase’ and "W phase’, and connacted as above drawing The rotation electromagnetic as shown let drawing is created by flowing three pase AC currant irom "U,V ana 'W ‘The root stoppes in rotation electromagnetic moves Init atea ralatively, {An induction current is born in conductor moving in electromagnet area by the right hand rule of Fleming ‘The rotor is rotated by the force of Fleming's lft hand rule.TECHNICAL DESCRIPTION System (Cont'd) Knob Position Control System (Option) (GOM) This ensures that the steering knob position constantly reflects the correct tire angle. ural level for the tire angle sensor must be adjusted individually for each vehicle. (To absorb any variants in sensor mounting nd vehicle differences. put Ourput ‘Steering wheel angle sensor ‘angle 1 signal ‘Steering wheel angle sensor Steoring whos! cheered Power steering ccarection solencic ‘Sizeing wheel angle sensor neutral signel “Tro angie sensor cs-9TECHNICAL DESCRIPTION System (Cont'd) Knob Position Control System (Option) (GOM) (Cont'd) CS-10TECHNICAL DESCRIPTION System (Cont'd) Tilt Leveling Device (Option) When forward tis commanded while the tit leveling switch is ON, the tit operation automatically stops as soon as the fork is held al & level position Titieveing Suiich Vehicle concition Tit operation ‘ON OFF . ° = ‘Stops al level poston Unladen — — ° Normal operation {No tt leveling) o = ‘Stops when switch is pressed Loaded e & = ° Normal operation {No tit leveing) *= No tlt leveling is performed in backward ting ** When the fork is loaded and at a lft up level, the tit operation is stopped as soon as the tlt leveling switch is pressed. + Onoe the tt leveling is activated, the operator cannot perform further tit operations unless the tit leveling switch and tit operation lever are restored, NOTE: The neutral level forthe tlt angle sensor must be adjusted individually for each vehicle. (To absorb any variants in sensor mounting and mast differences.) With a completed vehicle, hold the mast upright (with the fork held at a lavel position) and register the til angle sensor value at that time in controler. CS-11METER PANEL Meters, Indicators and Lamps CS-12METER PANEL Setting Adjustment Items (Normal Mode) papsirention | SCR T paustment eas Fenoten name | mncnnaieo tetas oe The items displayed become faded, and the display beck OFF a becomes brighter. Teron aaah . none CP PoH>M=E5 Lock ON raseceee) | rumene — | Cogtge = ene ertied —| ck on Ban ANS our Sue 3 Rian evA our € wil € ay Ceckseting | pusneui +fn2 [anew [Theale erensea ori ony Soaareed—] Lock OFF Push FRO [ ~The dls decrase, othe day 5 back Fish Sting cope isn Tow > wing > ay Bisnis Ho € Wings € Dey am esting | pusneno sens [ pisnent | Tred naasod. ory sacred] Lock OFF Se Anne Senng compet Fish FE DAOC > PLEVEL Bisnve DAG € PEEL cceeatontoe | Pash ru: +eN4 [Push FN = Lockon Bisnne = Bush FNS Sang con Daa ong remiss | nr sens | sh Nbiome soting compl Lexkon fect Teneo sein BanAT Treagis noead (Sr loader | Pash Pve-+ ens [Posh FR The dts deceased Loon Bont opto Bish Satg corn. vapmens Troma nonie | Ts c988th6 meted ote ncn viens | splayed. Function locfuriack Push PND + FNS, Push FNS Push PND Puan ns Push FN eush PN “The function LCD contrast, clock setting and alarm setting cannot bo locked inthe lock ON postion. CS-13METER PANEL Meter Panel Explanation Description The meter panel consists of two sections: LCD (Liquid Crystal Display) monitor and function keys. 1. Function keys Function keys control the LCD contrast, display changes and other adjustments. Function key operation is described in the individual part descriptions and in the items related to agjusiment NOTE: In case an neorrect operation is performed, the malfunction code shall be displayed occasionally. If the malfunction code is displayed, tured the key switch to the OFF position and then turn it to the ON. position again 2. LOD When the key switch is in the ON position, backlighting makes the disolays clearly visible to the forklift operator. It displays normal operation (battery capacity meter, hour meter, clock, steering wheel angle gauge, speedometer, etc.), malfunction and agjustrient data, Driver Recognition Mode ee Bi 0. Bo Seu secure @ el ‘e Key onion sures on. When an inconaet passat int input again sing the correct passwora. ey NASSWORD © ‘EY v>RESNORD ® BBBH ne |G caret 10.00 ane | D| Sorrow | corr Registering a password can restrict the drivers of the forkit You can register a password for up to § persons, Cs-14METER PANEL se Jeo Swine + aie [Raion] tation enay nen the vehicle speed has exceeded speed 12 ce © HA! “e a When the vehicle speed has exceeded speed FBG le cea oe| © c=si00| @ {BUZZER sounds. Meter Panel Explanation (Cont'd) LCD Contrast “The display contrast (lighter or darker) can be adjusted in 11 steps. Push function key FN1, the letters are dark and the display is dimmed. Push function key FN2, the letter are ight and the display is brightened, Hour Meter (4 Mode) This hour meter has 4 modes (tunctions). 1. Key "ON" time 8*@ ; Equal to the total operating hours when the oy onitch isin the ON postion 2. Operating time @4 : Equal to the traveling or loading time (the time for whichever operation in progress is displayed). 8, Traveling time © : Equal to the total time that the traction motor is operational 4. Loading time =all: Equal to the total time that the forks are operational iting and iting). 5. Instantaneous energy consumption indicator “8 : Electric, power consumed by each operation is displayed (When - {rrinus| KW is displayed, the regeneration mark is displayed, too). “The hour meter operates when the key switch is in the ON position, and it indicates the total operating period in hours (key “ON" time). Speedometer “The speedometer shows forklit speed in either Iclometers per hour (knvh) or mites per hour (mph). The maximum vehicle speed and speed alarm can both be set, NOTE: ‘Speedometer factory settings at time of shipping: Maximum speed: 20 km/h (12 MPH) Setting speed range: 1 - 20 km/h (3 - 12 MPH) Forklift spead alarm 1 - 2 setting: 25 km/h (16 MPH) Forklift spead alarm 1 setting range (WSL1}: 5 - 25 knvh @- 16 MPH) Forklift spead alarm 2 setting range (WSL2}: WSL1 - 25 knvh (WSL1 - 16 MPH) For speed alarm seiting, refer to "Adjusiment Mode”. CS-15METER PANEL csuosr2 ‘ renin ‘Sno eswoara ® @ ‘ge @ csuosr2 Meter Panel Explanation (Cont'd) ple Load Indicator (Option) (GOM) Cargo weight is displayed, Display cond The vehicle speed is 3 km/h (2 MPH) or less. For 5 seconds after cargo lifting has been stopped. Display range: 100 kg (220 Ib) to maximum load * in vehicies equipped with a 2F or 3F mast, tne cargo weight is displayed by converting the pressure from the full-free cylinder. Therefore, if a load is applied which exceeds the full-free range, it may not be possible to display the cargo weight. Default Setting Perform the initial val following postion. setting after operating the vehicle into the Mast: vertical Lift: 30 cm (11.8 in) up (no load or tare weight (palette, etc) condition) NOTE: if tho vohicl is equipped with the tit horizontal function (option), simple loac indicator (option), the mast angle and the load indicator are sat to the zero position after performing the inital value setting, 1. When FN1 and FNS are pressed at the same time, the clock display switches to the inital value setting scroon. 2. When FNS is pressed, the intial values are set and the screen retums to the clock display. Over Setting Weight (OM) \When this tunction is used, i the cargo weight on the lit exceeds the value that has been set as the alarm weight, a buzzer and an indicator wil alert the operator. CS-16METER PANEL (oe HP Frans rs (am ni t owas soars Meter Panel Explanation (Cont'd) Alarm Weight Setting (GOM) 1. When FN4 and FNS are pressed at the same time, the clock display svitches to the alarm weight setting screen, 2. Push FAI to increase the weight (in increments of 20 kg (44 Ib). 3. Push FN2 to decrease the weight (in increments of 20 kg (44 tb, 4, Push and hold for § seconds to increase/decrease in increments of 200 kg (440 tb) 5. When FNS is pressed, the alarm weight is set and the screen rotums to the clock display. Regeneration Mark When the instantaneous energy consumption indicator is displayed and then when - (minus) KW is displayed, the regeneration mark is displayed, ‘00 CS-17METER PANEL B Mode a Mode & Mode ® (Factor setting) Mode “SP rosh nt aa FH" eee Push-FNO"L Push Pe (Minute adjustment) Push FA Pash Ht iceytahe-wook justment) “rus Pas" Meter Panel Explanation (Cont'd) Power Mode In this mode, the power level for traveling and loading operation ccan be adjusted. Each time function key FNS is pressed, the power mode is switched. Mode M: Manual made: “The power levels for traveling and loading can be individually set according fo customer requests. Factory detaults: Traveling power level: Level 1 Loading pewer level: Level 1 ‘Adjustable range for traveling and loading power levels: Levels 1 - 5 For traveling and loading power level, rer to "Adjustment Mode". Mode E: Economy mode: For work requiring operation time to be saved or customers using the machine for a long time (Traveling and loading power level Level 1) Mode P: Power mode: Factory setting (Traveling and loading power levels: Level 3) Mode H: High-power mode: For work or customers requiring higher power (Traveling and loading power leves: Level 5) Clock / Alarm / Acceleration Adjustment Clock / Alarm When the key switch is in the ON position, both the day and time are displayed, Push function keys FN1 and FN2 simultaneously. The time set mode wil appear, ‘AM and PM hour adjustment: The hour display will advance by 1 hour each time function key FN1 or FN? is pushed. Minute adjustment: The minute display will advance by 1 minute each time function key FN1 or FN2 is pushed. Day-of-the week adjustment: The day-of-the-week display will advance by one day each time function key FN1 or FN? is pushed ‘Atter setting the clock to the correct time, push function key FNS. “The adjusted time will appear, and the clock will retun to its original letter mode, NOTE: * Push function key FNI to increase the numerical value or advance ‘one day of the week. * Push function key FN2 to decrease the numerical value or reverse fone day of the week CS-18METER PANEL Meter Panel Explanation (Cont'd) Clock / Alarm / Acceleration Adjustment (Cont’d) Clock / Alarm (Cont'd) * Push function keys FN2 and FN4 simultaneously. The alam time set mode wil appear. This sting is the same procedre forthe tine cot + fan alarms set," * appears next to the tine display, When the preset time reached the buzzer sounds to not the Operator Press function key FNS to stop the buzzer. The day of the week can be set to every day (ALL: every day). Acceleration Adjustment This contrat adjusts acceleration during forkift starting and subsequent operation, ‘Simultaneously press function keys FN1 and FN4, The clock will move to the traction acceleration control mode. The accelevation level can be adjusted in a series of 8 steps. For faster eoceleration (Quick): Push function key FN1 Each time the key is pushed, the acceleration level (speed) will increase by 1 step. For slower acceleration (Slow): Push function key FN2, Each time the key is pushed, the acceleration level (speed) will decrease by 1 step. For slower acceleration (Slow): Push function key FN2, Each time the key is pushed, the acceleration level (speed) will decrease by 1 step. Aiter setting the acceleration level, push function key FNS. The acceleration level will appear, and clock will return to its original letter mode, NOTE: Acceleration factory setting at time of shipping: D-ACC NOM SET: Lovol 6 (Permissible setting range: Level 1 - 8) * After acceleration level adjustment, operate the forklift, slowly and carefully until you become accustomed to the new acceleration level. Be especially careful when the acceleration level has been increased. Higher acceleration levels can cause loads to shift, to fall off or to be unstable during starts. CS-19METER PANEL Push FN" and “FN o£ Push FN Meter Panel Explanation (Cont'd) Pump Acceleration Adjustment ‘Simultaneously push function keys FN1 and FN. Next, push {function key FN3. The clock will move to the pump acceleration control mode. ‘The accelevation level can be adjusted in a series of 8 steps. For faster ecceleration (Quick): Push function key FN1. Each time the key is pushed, the acceleration level (speed) will increase by 1 step, For slower aoceleration (Slow): Push function key FN2. Each time the key is pushed, the acceleration level (speed) will decrease by 1 step. After setting the acceleration level, push function key FNS, The pump ‘acceleration level will appear, and the clock will return to its original letter mode, NOTE: Pump acceleration factory setting at lime of shipping: P-LEVEL SET: Level 6 (Permissible setting range: Level 1 - 8) ae * After pump acceleration level adjustment, operate the forklift mast control slowly and carefully (up, down and {ilt) until you become accustomed to the new pump. acceleration level. Be especially careful when the acceleration level has been increased. Higher pump acceleration levels can cause loads to shift, to fall off or to be unstable during starts. Parking Brake Warning Mark This mark is cisplayed whenever the parking brake pedal sin the locked postion. The mark disappears whenever the parking brake pedal is released, Seat Belt Warning Mark This lamp inaicates that the seat beit is not fastened securely, it will lights up ifthe seat belt is not fastened when the ignition switch is tured to the ON position, and it will tur off when the seat belt is fastened, cs-20METER PANEL Meter Panel Explanation (Cont'd) Malfunction and Warning Indications C0 (Liquid Crystal Ovsplay) L N pz ‘wrench mati as Mattunetion message Battery warning Se Ei(16 Joc ©| > |e oa| © esse com @ — af @ SP eo Ney puin-ens Ores LS ler” Se eeaenee lrnereronaee)| GB) @| cisoiayes SEE Salen ne 16. |i 3 © |% |sam-roe| © oo te 05| © ary malncton ocr when the ey sith nthe ON poston the LCD wil show a wrench mark oF a battery mark * G24" ‘Simultaneously, the LCD wil display letters expizin the details of the rmaffunction. NOTE: During forkitt operation, periodically check the battery capacity, Make every effort to recharge the battery before the battery waming mark * 223" and wrench mark * 2°" appear. Wrench merk 2% The controller and the sensors act together to regulate the forklit's electrical system. The wrench mark will appear whenever one of the ‘malfunctions listed below occurs. Simultaneously, the LCD will show an indicaticn explaining the details of the malfunction. * Control system malfunction (Traction, Cargo-handling, Power steering) * Overheating controller or motor * Low brake fluid level * Low battary fluid level Cs-21METER PANEL Sz 7A L|["6. oes) Ld DO SPAS 7A canoe nmenireLy ® ee © ie Meter Panel Explanation (Cont'd) Battery Warning Mark Pump Cut Warning Pump cut warning is displayed when the battery capacity meter's remaining capacity indication changes from 2/6 to 1/6. When funciion key FNS is pressed, the display will switch, After the pump cut warning has been displayed and ten minutes have lapsed, the warning buzzer is activated along with the display shown below. When function key FNS is pressed, the display will switch. The warning buzzer continues to sound throughout that period. “The vehicle may be operated during the pump cut warning, However, move the vehicle to a safe location, and promptly charge the battery CS-22METER PANEL ® TAKS ee Meter Panel Explanation (Cont'd) Low Voltage Lock Warning If the vehicls is subjected to continuous operation after the pup ccut warning was activated, the low voltage lock warning will be activated. Then, the display will appear as shown below, and the warning buzzer will be activated \When function kay FNS is pressed, the display will switch. The warning buzzer continues to sound throughout that period The vehicle cannot be operated during the low voltage lock warning. NOTE: The interval between the first appearance of the battery warning ‘mark and warning buzzer operation is set at the time of shipping. Factory setting: 10 minutes Permissible selling range: 1 - 20 minutes For pump cut time setting, refer to “Adjustment Mode’. CS-23METER PANEL Meter Panel Explanations (Cont'd) Malfunction Indications “Afectoa system area, Tngcaton ‘Matuncton description Control System Traction, ‘Amattuncton has oooured | NOTE: Gargo-Hanging, Power” [rer sont in the fork traction system. | A doplay example is shown on steering): Units, Sensors, Further operation ofthe forkitis | the et Motors, Switches, FETS not possible. [A matuncton has occured a inthe fort cargo handing system, Further iting iting and tin) operation is not possible, Hine torn cannot he rine oe rite. TIRE ANGLE SENSOR LOW ‘A malfunction has occured in the forklt power steering system, Fort steering control is possible D/CONT TEMP SENSOR HIGH Tee EEthor the controler ortho motor is overheating. Immediately stop orkit operation, Park the frkit in sate area where there is no pedestrian or vehicular trafic. Allow the contaler andr the mater to coal — Qwesninc © * Ignoring the warning IRdcation ond continuing to operate the fork can resut in serous motor ‘Samage. Awoye stop IMO TEMP SENSOR HIGH TEMP Ether the controle or the motor is overhaating Immodatoy stop orklt operation. Park the fork in sate area where thers is no pedestrian or vehicular trafic Allow the controller andlor the meter 0 cool ‘operation immediately after the warning indication appears. Have the forklift inspected. ‘+ Check the specifications of the forklift you are using before operation as this function is not available on ‘some forklifts Essertal PUGS BRAKE FLUD LEVEL DOWN, [The brake fuld level has Fallon below the spected level Qvenu ‘+ Do not allow open flames BAT FLUID LEVEL DOWN, The batery Rud level has flan below the specitiod level. As soon as possiblo, replenish tho battery fd with cstiled water up tothe speced lava in the battery inspection or fluid replenishment area, Zi\eaurion + Exerege extreme care teen replenishing the Battery hud. Fil he Batter with cstiled water to tho spected level ony. Do not cverf,Resulting fpllage may cause & battery short circuit. Cs-24LCD MONITOR Adjustment Mode The ete tr ann be Bpaye on one seren the et NOTE: This mode is only available for qualifiad technicians to perform various adjustments on setting values other than tractionvloading acceleration adjustments in the normal mode. * Adjustment values oan be advanced or retarded by pushing ENS or PNG, respectively « Folowirg edlustment value settings, do not turn the key ‘switch to the OFF position before pressing FNS to return to the adjustment item display. Doing so will erase adjustment value settings. CS-25LCD MONITOR Adjustment Mode (Cont'd) coo Bynes @ cswosr7 CS-26LCD MONITOR Adjustment Mode (Cont'd) [Trew ‘rine sting Se ‘ting an esetmen tem | Ab eppeemanemoaat © oF ‘AUTOGRroN | ~ | Feed baanconot of Tre Angle Senor Oation) ATO Gaon moses | Tt Te Bieter etanon | Reaulation Reinsdette ert enes) L _ = [Bote id omce | Guperon mar type st equ) 7 me a a Tasos cimat pe porate * 706 Ao OH ™ 7a cai + ad + 28 420M) o eo = | pote oma 3 : [erences ware | RE NEUF VOLT Gaon) 2 sting sie of tte ie eae] Joya easing conta yates ote [gy Uroqan ma verr anon er [Seteanppea Teen leet nin (Getenupe |e HO PU YOLT A onl) ME eaLped [ow st rn vOLT uCony) ot ease) Wc TH FUR VOLT Ue) Net eauppea) (ek AT FULL VORT UConiy (Not euibed) [eR PUHVOLT ter ALL aon) ‘Roc esiopet [a spec eit hh ME [igh mast seed it enh MP Be tio lng antl ate comasre CS-27LCD MONITOR Adjustment Mode (Cont'd) 6 ton pave 26 ® —GoretGon page, tess roan woe toss toa rosa wesc i to8s, tr tose 960 6 too toa. cawoaro CS-28LCD MONITOR Adjustment Mode (Cont'd) ngs AER At canes erage % ‘ i ra [ocean “a 1008) 1 wo | 1 | unspeee “8 3508) 1 ae a « 30,6) 1 foot eartae [arsaeeed ° 50.) ‘ woo | 1 | athspece « eons ww I strone ee | 1 | ma won pce oranges 2 [cates tatn) : 100 | 1 _| iemast pump acceleration Special arrangement? « 100} 70 100 i 1 _| Pump power tt : = po el a eee F3 20 ci ea [| aga ee ee ee a Lae Tea] ean [oar pet ee C3 9.030 (vA) 0.02 os | coor Battery capacity sensor cell voltage adjustment rn ae aoa Wattery cell adjustment (5 selections) | Pe 2 24 | 00% | Key“ON" battery capacity reset cll voltage e,rrrrrlrrrr—=—r—s—stss gs [Dlcusnion 222500) | ag | Speed meter correction cofficient a 7 i a oL corr OFF Seeeeeaenee Selection of aptional relay for warning buzzer “on aim |g 25 | 1 | wang speed set fortevel 1 (anh, MPH a] CS-29LCD MONITOR Adjustment Mode (Cont'd) toon 1060 tooo toes tost tov ros roex rosy woe to6na 25_ LORD INDICATE TIME rosne Fn, Fi LOAD ONT toeac csmoaeo CS-30LCD MONITOR Adjustment Mode (Cont'd) uh Fa: Decrease the setiag value T Seling ange | ovginal setting | —-—Setengtanae | cx | astm | wat | as | 1 _| Wing speed set forievel ih MPH | oo | on | owe on Selection of seatbelt warning | |e | or | on |_| eetonatann bet nmr | ce | wm | « | wo | iSdlomt Sein Ne tor North Amevies) Ce ee =| selection of ongunge U6 5.4 86 | ee eee é 1__[ nsotight GN evel setting Special arrangement) | | spree en | HRS Ter angle mee selection or upped) | ow {0% wotage for charging (Nat equipped | | [sig genie oy ompre OTa—| aegis Tr aTgRT oe No water ling tine | daysta hee Nok equipped | L | stung value of this tem s not ds = z x TRS ee gaa em peceeres Counting ar chowana to decide eiling water “| charger lot equipped) Max filing time Not equipped) Study of etiling tine (Not equipped Study ad tine (Not eauipped Display uni seting of hpi lood inacator, cswosst CS-31LCD MONITOR Manager Mode + Adjustment values can be advanced or retarded by pushing FNS or FN4, respectively. + Following adjustment value settings, do not turn the key switch to the OFF position before pressing FNS to return to the adjustment item display. Doing so will erase adjustment value settings. CS-32LCD MONITOR Manager Mode (Cont'd) hie simultaneously pushing FN1 and FN, torn ey switen ON. secounds HEL LOGIN FUNCTION 1-PASS WORD FONCTION} 1070 ny tin to78 tore torr SPW MAR SPD. wor Ta $ a 1H Fim (Cr pw Sema LeveL work ra Fini (ew omar wer Nay Fin (Co pw accor aU LEVEL] to 7m FRE ia [ie.pw UF Spe) tom (are oe i . EL 1070 cswones CS-33LCD MONITOR Manager M jode (Cont'd) nore tem ‘Original seting | setting rende___—__T Setting and adjustment item [in se f ant x Toe | ore] Wt | =e ea ee | [eee | = [ie | | ww | tnaaaa | [sett wttgue of PW nen Seem anes eetind ue ot Pee) ai Sees tee Bdge PW nema | eee Mera ena [Tete ue i rwiaaas lec Ah awe of ery | ™ [or | oorrmen.e PW DrivesPump power level adjustment | | Sit pe | | ore OFF 20 2 2 | PW anima speed it th, MPH) a [oor ® 1 | pwerake Reve! ™ of | ora 5 | _*_[ewacceteration oFF Re ievel ™ or | or | 100 1 [ewe speed | — + 7 e — = 70 on | ora | 10 PAL speed 8) * ore [ores | too | (rw stdpeea cs 70 ofr | _oFF.70 | 100 | _* | pw-pumppewer mits) (OFF.ON1,ON2 Pw wlaening speed selection CS-34LCD MONITOR Diagnostic Mode Cus Bush FNTFNG @ Key SW: ON ‘Then push in order cf FN2, FNG, FINE, FN ‘Select diagnostic tem: Press FN or FN2 to move curser upiaown Decide diagnostic item: Press FNS. Rolorence to 2-8, SELF CHECK ® » ‘Select dlagnosti tem: Press FN or FN2 to move curser upidown Gneck diagnostic tem: Operate each device it necessary Example) Sit on tho saat Example) Seat switch turns OFF-+ON. Retum sorean: Praes FA Tine entire iter cannot be displayed on one screen, the rest ‘ofthe ita willbe an the nex! screen, Prese function switch FN and sorall a cursor to dsplay the necessary tam cswoaes CS-35LCD MONITOR Diagnostic Mode (Cont'd) ‘There are two types of diagnostic method. One type is self-diagnosis and the other is interactive diagnosis. Self-diagnosis allows for controller diagnosis of a system, while the interactive diagnosis is used for diagnosing switches and sensors. When matfunctions occur in systems or components, check and eliminate probable causes of the matfunction using either sett-ciagnostic or interactive diagnostic techniques, Atter the matfunctioning area has been repaired, confirm the matfunction has been eliminated by using the appropriate diagnostic nethod, NOTE: When checking each component, operate each component it neoessary. CS-36LCD MONITOR Diagnostic Mode (Cont'd) Meter Operation Menu While simulaneously pushing FNI and ENA, turnkey switch ON Then pushing inorder oF FN2, FHS, ENA, FN thin ten seconds. rz ERSTE re cot Den page 2 rus (ACCEL WWOLTACE Ts STEERANGIE (Fy BATT AMBIENT TEN rns 1 SEAT SUMTCH fz 7 2 FORWARD SWITCH em ra FAT Qo coroBen pages. © to28 028 csmoxes CS-37LCD MONITOR Diagnostic Mode (Cont'd) Rem Display item Reman 18 [output vonage of Acceloralor VA 3 digits, 2 decimal point 1 [Output vokage ot Accwleraior VA 3 digits, 2 decimal point 16 sate [Accelerator position contro value Saigite 10 0S __|Aeeslerator open speed Saige 1 wav Peaba raise cl UG peoobraior 3 digits, 2 decimal point if a [pect arrangement) 3 aiaite 16 = lovrput voltage of Litt sensor (JO) (Not equipped) | digits, 2 decimal point 14 = Lit sensor position control value (1G) (Not equipped) | digits w . Lit sensor operation speee (UG) (Not equipped) | dots w . [output voltage of Tit sensor (JO) (Not equipped) | digits, 2 cecimal point 1K = [Tit sensor position control value (JG) (Not equipped) | agits a 2 Hit sensor operation speec (JG) (Not equipped) |S digits a = [output vottage of rd senser (16) (Not eauipped) [9 digits, 2 decimal point 6 = lara sensor position control value (IC) (Not equippes) | digits 10 2 [a sensor operation spend (JO) (Not eauipped [a digits 1° = [output vottage of 4th senser (JO) (Not eavipped) [3 dials, 2 decimal point 10 a lth sensor position conto value (JG) (Not equipped) | digits 18 - lath sensor operation spec (JG) (Not equipped) | digits 18 -V [output vontage of Tit angle sensor (Option) 3.aais, 2 Gecimal point 7 -V____ [Set angle of Tit angio sensor voltage (Option 3 digits, 2 decimal point w wan [Outpur vonage of mast weight (Option) 3 digits, 2 decimal point Ww -V___ [Set vottage of Mast weight (Option) 3 dais, 2 decimal point 1 SV [Output vonage of Tire angia sensor (Option) 3 digits, 2 decimal point * Om [rice ante contrat value (tion) 32 digits v [stor angle control value igi az [steer speed control value 3 ails, 2 decimal point 1a leatory ambient temperature 2dits 2a [Seat ewitch 8 [Forward switeh 26 [Reverse switch Note CS-38LCD MONITOR Diagnostic Mode (Cont'd) @ GotDonpage7 toon apes Fu few zrosT ace 1020 (5 Pan oe STTER wo2t (a UD LEVELS oor | UF STH 1026 a TT SWATCH toh ox wm : . 1920 020 wom won (0 HOW Sa wou woav (a Tox STH wo (SAC VOCTRELAY rox Gs exTr RUBLE woz | Fin aes HATCH ro2ea a ENPEATORE LO Coa ton * ri im (oc ton Tae wom fai 3 PmOTOR TEM, woxe rma Career) eo (Or OTOR MAK TER tox ii ‘6 DONT AK, TEMP wor na fx Sor@enresess. & Go ton poses CS-39LCD MONITOR Diagnostic Mode (Cont'd) vem Dispiay tem Remarks 20 OFF.ON | Foot brake switch 2 OFF.ON | Parking brake switch Ga OFF.ON | Brake fluid level switch 20 oFF.0n | Lit switch oH oFF.on_ | Tit switch a OFF.ON | ard switen 2 oFF.on | am swten 2 oFF,on | sir ewiten 2 (OFF.ON | High mast awiten 2M OFF.ON | Seat belt switch aN (OFF,ON | Functon switen + 20 OFF,0N | Function suite 2 2 OFF,ON | Function switch 8 20 (OFF,ON | Function switn 4 2A OFF,ON | Function sulin 5 28 (OFF.ON | Auto light switen Special arrangement) a OFF,ON | 15 em speed limit witen 2 (OFF,ON | Tit Renzontal swith (Option) v —__| Fe-B ewiten (40) (Not equipped) ‘When te single lever ype: ON aw = _ | 5A switch (IC) Not eauippedh When ta twin aver pas OW 2x =| stom ewich 2 OFF,ON | AG vol relay (Not equipped) 2 (OFF.ON | Battery Hud evel (Nol equipped 2aa_| _OFFON | Fill pressure switch (Not equipped) aA wen0 | The temperature of present Drive motor dsplayed 8 The fomporatre of presont Drive controler ie dsplayed ae “The lomperatre of present Pump motor fs deplayed © “ae0 | The temperature of present Pump controler is dleplayed 9 a ¥ eG | The maximum emparatre of ve conaier vai Note JG! loystick loading contro! system cs-40LCD MONITOR Diagnostic Mode (Cont'd) @® coroonpacese Fr en 36 tow Ta VOUTAGELOS roan toe tore i t040 (s.sarrenr min. our oat ELUENT IOS, ENS _ Fo wa CURRENT tosh fag __ Fi me rx 038 (za.oeRamN. ENS __ TET tose peseoeeest on ws , (aman Tia TEST rose | a ns a rn (505. COMECTONWALWE —] 10 0 pesesmerst to66. , 4 a wos toot ; fa toon ZT PNEIGE worn poset 978 pesos (4c Eno 1070 fey _____ Fri 1976 tor oO. o- @ cs-41LCD MONITOR Diagnostic Mode (Cont'd) Display item T Remake uy The maxinnm temperature of Pump 7 [motor uel present mernanzed Contrlier unt present memoteed SAY |atery voitge _ The maximum vale of Sie ar ntilpresentie memarted the maximum valage of Pump maar ontipresentis meniorged. emu voltage of battery Wage nulpresent le mamorzed wnet ” ov Les intpresents memared ea The maximum current a Pump maTor on 1st Tom on a dots of co [Fags eRe He cen when I ——T Seleoid ater Uipey whe Gaply Became ad oe Lift down valve, | Gi ean oho Fla Bed Wn Pada, | | Re diss ete eng SP «© SUN.STOP | in mer test Not equipped {This tem an temofon cktypeatey arg | | Sivas GFF when F pushed the Uatay bec a oFF.on PS conection valve(Option) | Shits Sr when 0 Sed WaPdbay becomes Ber es ontmen 3 Bisheen tem aanenon, | ] Seana ga tc aa ne diy hacer oF ‘OFF.ON Tilt horizantal valve (Option) | Ger fm Ok nn Fla pushed en system maloncton, [Chvalve Wor equipped) —_ GH [eARORSTOR RUN [Satter filer dive test Not equipped) ‘eiteeS [Filler time memory 1 Nat equipped | ‘exiters [ils tie memory 2 Not equipped im veltans [ler tne memony3 iNet equippeay 7] Te tem ean Kem fon tuck ype battery charge on oo Filer stop timer (Not equipped TA__| wee veweetic en | Contrlie for memory! 78 | eanerensHe ee [Controller Eror memory? 7C__| was_snewsHrew [Controller Error memory 3 5 digits ewor code Last enor tie wor times wer sannati_es_[ContiolerEvor memony 4 nde bar inaction in setting column 2E__| wesanenatcew | Conti Erormemonys “or eseaesasetices [Meter nor menor | 76 | ene_suoenttew [Meter enor memory? _| = z (em Se 38.36.38) PLitit et tt ttt i yy cr cs-42LCD MONITOR Diagnostic Mode (Cont'd) ? Go toon paaest =| ™ a cRATTOCTRE] 007) ig ~ Fa i EORTOG ERASE wor TMETERSORT VERSION. SAO: eeeeeest mi woe onc CSs-43LCD MONITOR Diagnostic Mode (Cont'd) nom | _Pisptay tem emake 71__ | ERASENON | Voltage lg erase (tom 4B, 40, 40, 4E) 7a | eRAseNoN | Curent og erase item 5A, 58) 7K | ERASE,NON | Error og erase (em 7A 10 76) an w+ _ | METER SOFT Version 8 w= | CONT SOFT Version ae |enccnn (ame nen FNS oF ENA ie pushes, sei check is Begun Mauls ound, eto code i alsplayed cs-44LCD MONITOR Diagnostic Mode (Cont'd) ee 5 OS a i cS = cE ce * If an interactive diagnostic result indicates that a unit is abnormal, also check the condition of the associated harness and connector. NOTE: * The number of malfunctions which have occurred in each system is recorded in the "FAIL LOG" row an the display, without regard to the nature of the maifunctions experienced. * For unit inspection procedures, refer to “Unit Inspection and Adjustment” on page CS-62. Result of Self-Check ifthe error s not detected: Ifthe error s detected: NOTE: ‘The 3-digit number in the figure indicates the error code of the ‘component for which the error is detected. For the error code, refer to “Table of Error Code” on page CS-46. * If a self-diagnostic result indicates that an element or ‘component is abnormal, also check the condition of the associated harness and bus bar. NOTE: For element inspection procedures, refer to “Controller Element Inspection" on page CS-56. CS-45LCD MONITOR Table of Error Code Detect mode Faire pat Faimode | Ertorcode Romarks Wark Sef CONTROLLER Short 200, o ° Main contactor cs.58 O67 207 ° ° Man tse) Open 207 o o os.s8 : Low vot 404 © Battery votage a ‘Over votage 205 oO (CONT capactor ‘Abnormal 406 o : ‘Short 408 oO ° Drive FET (Open 408 o o 3-56 ‘Shot a2 ° ° Pump FET Open 419 ° ° Low output aia ° ° High output a5 ° ° Drive curent sensor notes Low output a6 ° o High ouput a7 °. ° ‘Abnormal 422 ° ° D/Mo TEMP sensor 2 Overneat 423 ° : Abnormal 726 o o DICONT TEMP sensor Overneat 227 ° Low output 30, ° ° High output a1 ° ° Pure curent sensor : Low output 492 ° ° High output 439 o o Abnormal 34 ° ° Mo TEMP sensor 8-60 : verteat 435 oO ‘Abnormal 36 © oO PICONT TEMP sensor vereat “a7 o Mo REV sensor ‘Abnormal 438 © iio REV sensor ‘Abnomal 442 o : ‘CONT communication ‘Abnormal 7 o (CONT ype select ‘Abnowral #6 © o METER ‘Meter communication ‘Abnoral CS-46LCD MONITOR Table of Error Code (Cont'd) ‘Datect nade eterence ire ‘aimode | Enor code Remarks Faire part Fel Ero cose |} — : ACTUATOR Short 300) 2 © Lt down vate can ‘Open S01 © ‘Short 502, 2 © knob postion PS conection vale e373 | cartel GOM Open 508 ° ° Option) ‘Short oA 2 3S it orzon Tat Horizontal vabe cere ‘Open 305) 2 © evga (Option) SENSOR FIRSWRCH ‘Sana ON 750) ° C502 Low output 82 2 2° Acca sensor “2 css High outout 253 ° © Low output 454 ° © 71 | Keep postion ‘Tee angle sensor C871 | conte GOM High output 485 ° ° on Tow output 756, 2 o Tit horizon Tit angle sensor os-76 a igh output 457 ° oO evice (Option) urraccet Low output 466 ° Special rangement ‘Short 468; © Tit horizon Tat H switch os74 ‘Open 769 © sevice (Option) Knob poston Steer Angle sensor Abnoemal a0 cso | contel GoM Option Weight sensor Tow output © © 5 Tit horzon csr (Oiipressure senso) [ —ragh oupur o o device (Option) Low output © Battery curent sensor e ossr High output © © enoeal 2 D0 rece ° © roca © Po receive 2 : Cs-47PRECAUTIONS Aywrrnine * Before starting to remove the controller parts, be sure to perform either a, and b. bellow. ‘a. Disconnect battery connector, and connect a 50 to 100W resistor (do not use a metal-film resistor) between the VB (positive) terminal and — (negative) terminal at controller assembly to discharge condenser. b. Wait at least 10 minutes after battery connector has been disconnected. TN cauTION * Before removing or inserting main/meter print board connectors, turn the key switch to the OFF position and remove the battery plug. Failure to do so may cause a malfunction in the print board. + Make sure the controller/meter connector cord is free from twisting when the connector is removed or inserted. ‘A twisted cord may cause poor connector contact. When removing the connector, always hold the connector body and do not pull on the cord. + When removing wiring harnesses and/or bus bars, note original positions during reassembly. * When installing a controller element which is used with insulating film, be sure to place insulating film on the contacting surface of the element and mating part. If a controller element is not used with insulating film, apply silicone-based grease to the contacting surface of the ‘element and mating part during installation. * Before checking controller elements during on-vehicle inspection, remove the wiring harnesses and bus bars. Inadvertent current flow may damage the element or other parts being checked. * Before using flow charts as a guide to troubleshoot units. and parts, become familiar with the instructions outlined under “Trouble Diagnostic Procedures”. NOTE: Controller and unit conditions are determined by checking/ measuring the resistance values (continuity) of, or voltage values produced across, various parts affected. However, this saction deals with only resistance measurement procedures. cs-48LOCATION OF UNITS (LAYOUT) Standard Equipment cs-49LOCATION OF UNITS (LAYOUT) Tilt Leveling Device (Option) CS-50CONTROLLER Removal and Installation ‘ Bie. t199-12.01. 1501-16, 120-192) = (09-12, 84-36) Nm kn) 41, Traction motor cable (U) 7, Pump motor cable 13, Contactor 2. Traction motor cable WY) 8. Pump moter cable (W) 14. attery curent sensor 8. Controller cable fs 8. Body harnass 18. Fuso Ft) Battery plug cabie (+) 10. Fusble lnk cable) 16. Boost charge resistanoa (RCH) ‘5. Traction mator cable (W) 11, Battery cable) 17. Chopper ASSY for traction motor 8. Pump motor cable (U) 12, Contactor unt 18, Chopper ASSY for pump moter Sec. A, Sec. B: Detail of minus terminal part. ©: Connector for 2 ton. 2 ton vehicle is connect connector. D: Connector for GOM. Connect connector. CS-51CONTROLLER Removal and Installation (Cont'd) NOTE: \When instalation on aluminum base of inverter units apply thermal conducthityslicon compound (Shin-Etsu Chemical Co, Ltd G-746, or equivalent) to the reverse surface of the inverter untt. ‘Applying this compound wil ensure that heats conducted ficiently to the aluminum base. Aways epply the compound when removing or replacing the inverter unt (control). Before application, check that there ere no scratches, metal dust or burrs on the surface that the compound wll be applied to, CS-52CONTROLLER Construction BBlo-11009-12,84-98) ne] oy Pat rane Ne] oy Pannen, 1 1 Bus bar) 7 1 Hamess 1 2 1 Bus bar (VB) |= Restor 3 1 ‘Chopper ASSY (er traction motor 2 7 Hostsink holder 4 1 (Chopper ASSY (or pump motor) 70 | 6 ‘Cooling fan 5 o estan at {2o0Ing fon box 6 7 Harness 2 CS-53CONTROLLER Connector (Terminal Layout) Meter System Wiring ‘ais power {Controt with a main contater ott rly omwewim armament) aan-neoNghyBalleryvotiage ON: Operate Battery votage detect eee ws: | | Battery capacity detect circuit a) Ne o—G Funetlon SW 2 ancton SW 8 Bos aeton Sw # SGD Function SW 5 ‘SW GND TEMP. sensor 1 Change levelby Adjust mode TEMP. censor 2 Mt C communication data G5>-¥] C to M communication data G+ JCONT. Brake fluid level SW ON: Lowlevel ia euzzer drive ‘ave ereut Battory fluid lovel sensor PR | Connector of Meter side ‘48 dapands on the Type AMP 174877-2 (20 pins) Battery voltage eT Contents Totes External of mater 7 Batiory voiage ‘Meter Wake up, Battery wage and capacity detect 2 Battery power + Meter power to battery + 3 Blank terminal 7 4 Brake fud level SW Tow fl vel then SW: ON 5 Seat bot SW Bait set then SW: ON, hon 6 Parking BK Key input Key pat jor Parking BK Warning Buzzer 7 Blanc terminal 7 = Blank terminal 7 o Parkeng brake SW Brake OFF then SW ON. 10 Battery tid evel sensor | _Nornal output votage is about 6V. Less than 6.5¥: Low level " Power GND Meter GND. 2 Blank terminal 7 CS-54CONTROLLER Connector (Terminal Layout) (Cont'd) Trput/Outpat_[ Pano. Contents Noter 13 OPT aay 2 ‘Ouiput: Callioad 0.1A (Open Calecton 14 OPT ray t ‘Output: Callload 0.14 (Open Callecto 15 Warning buzzer drive olay Koy OFF and PBK OFF then drive of rlay Output 16 Blank ternal 7 Blank terminal z 18 Blank terminal —— 19 (C10 M Communication data ‘Communisation data of moter eoeive payout 20 Mito © Communication data Cormmunicaton data of meter ranami Interalof meter NO Blank ternal : M02 Blank terminal Mos Function SW 1 Mos Function SW 7 MOS Function SW Input Moe Function SW 4 MO7 Function SW Mos ‘SW.OND, : Moa TEMP. sensor 1 For LOD contrast level M0 TEMP. gonsor2 CS-55CONTROLLER Controller Element Inspection + For checking each controller element, use circuit tester and measure resistance between terminals to determine Whether circuit continuity exists or not (W). For checking the current sensor, only measure vottag When checking controller elements, also check the associated hamesses and bus bars. + The following tables list resistance values measured across reepectve terminals and should be used a6 reference information. Keep in mind the resistance values vary with the type of circuit tester (such as analog or digital) used for measurements, NOTE: Measure resistance between terminals listed in the following tables to check each element. Traction Chopper Assembly, Loading Chopper Assembly Specifications Tien ‘Specticalion Tipe) TNSSFS0TES / DRIVE, NGBESOIGS / PUMP Service Data Measurement terminas | Normal valo (0) Testor | Toster | Peteenco vate) ae ee ® Lo ve [vu Severe Ta shor or= 0 leper stay | Diferent by charge conattion ot main Bee | oes rout condenser. 0.0 (shot is fully re Severalk 10.0 (short ore 0 (oper) is tay, valk = | Diferentby charge conction of main eee |e Circuit condenser. 0.0 (shart is faulty. ve | Ww Severak (0.0 (shor) or 0 (opend lef, Jew) Diferent by charge condition of main we) Cult condenser. 0.0 (shrt i faulty uN Severe LA (shor) or = A fopent is faulty, Diferent by charge conciion ot main NTU | Sevetk-e ] crit cancenser. 0 0 fet i faulty. v_IN Severalk 0.0 (shor) or = 0 (epent is fal | Diferent by charge conattion at main eee Ccrcul condenser. 0.0 (shot is faulty w [ON Seerak (0.0 (shor or = A (epent is faulty, y weral k= | Diferent by charge concition of main ee | eee cuit condenser. 0 W (short i faulty NOTE: Measurement with analog tester and circuit tester range selector must be set to "1000 1 CS-56CONTROLLER Controller Element Inspection (Cont'd) Battery Current Sensor Specifications Tom ‘Specticaion Tyee. 1L05z800805 ‘Raval current 800A Sonal volage, 70-40 a | Service Data Tem Normal im = Cuiputy | Approx 26V between Se Failed sensor Source ‘Approx. 5.0V between 12 | Fallod GPU board Fan Assembly Specifications Tem Spectication Tine 2S10ML-05W-B70-BO7 ‘6 pocesieontrolier Lleida (One piece/extenal fan Fadia ae Service Data Tr Tora 7 Fan eck wh Operon | Obraton mesh Fat cooing an CS-57CONTROLLER Controller Element Inspection (Cont'd) Contactor Assembly Specifications 7 Spectication Rated current ‘condition ratio ‘Cutout current 20008 Mechanical We Trlion oye (1) Coit (2) Coil connector csworss] Specifications T Nora NG. ‘Gol reistance POW TAI20°C GF) ‘Contact wer mit | Mavablafxed 0.5 mm (0.02 inj Max ‘Abnormal contact cswosae Contactor 6 Cover Fuse (Ft) 7. Contactor plate second side contact) Dattey cunent sensor 5. Conact aseembiy (second side contact), Boost chargo resistance (RCH) Bus bar CS-58 9. Base holder 10. Coll 11. Cai housingCONTROLLER cstoss csuotas suns Controller Element Inspection (Cont'd) Fuse Specifications oer Capacity Tibi, 1182 sores ‘S008 (1) Fuse Inspection Using a circuit tester, check continuity of each fuse. ‘Normal ndeation Continuity S NOTE: ‘The circuit lester range selector must be set to “x1 0 Boost Charge Resistance (RCH) Inspection Measurement resistance of between terminals, Normal ndleation ‘Abnoxral (ope 2007 (1) Boost charge resistance (2) Connector with red mark NOTE: The circuit tester range selector must be set to “100 0”. CS-59CONTROLLER Controller Element Inspection (Cont'd) Motor (Traction, Loading) Revolution sensor “Temperature sensor ‘Temperature Sensor Specifications Tem Resistance (1) Temperature sensor connector “racton motor oo csMoss7 Tem Normal NG Resistance ere Failed temp. Sensor Approx. 9.8 = 11.8KW. Revolution Sensor Specifications Tem Tenporalure ran ‘nti vibration 206) Type Magnetic induce (1) Temperature sensor connector cs-60CONTROLLER oss Controller Element Inspection (Cont'd) Service Data Nornal NG evolution check by revolution Faled revolution (1) Revolution sensor NOTE: \When replecing the bearing with revolution sensor (1), also remove the end cap 2) CS-61UNIT INSPECTION AND ADJUSTMENT Control System vontro Nea * Before measuring resistance values, be sure to turn the key switch to the OFF position, and disconnect the battery plug- + When checking a unt, also check the concltion of the associated harness and connector. * All units can be checked using interactive diagnostic procedures. (Refer to “LCD Monitor” on page CS-35.) NOTE: * The relative condition of a unit is evaluated by making required voltage or resistance value measurements, * This section deals with only resistance measurement procedures for unit irspection. Forward Reverse Switch For stoering angle sensor Cancel claw connector Forwardsreverse Steering angle For horn connector For forward-reverse switch connector Hoin contact For lighting and turn signal switch eonnector FLn42a| CS-62UNIT INSPECTION AND ADJUSTMENT 2 / ta) The 43 Lever position RIN|F 7 2 3 o 4 5 Control System (Cont'd) Inspection Check continuity at each lever position between the following terminals Lever postion TTrrinal with contnaty Forward Neutal Rev CS-63UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Neutra Ae Steering Wheel Angle Sensor (Option) (GOM) Sat ey A8 Specticaions \ ST = Vr Teed oad caren (A 0-0 & Low Tess than 05 oe High 26-35 Service Data angie | controler @ zi sensor | Rotation pulse 2| Fotation pulse Rotation to lft Rotation to right eo eta a a ot eg cain cs-64UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Accelerator Sensor in) 1-92 mm (2.8 = 72 mm (2.8 np 1.8.1.8 tem (0.15 = 0.19 kgem, 13-16 ind) Acoelarater sensor es.t2e0.1¥ 12 pst Veo ‘Specification Toalrensiance nay FWPLEoI [28 60 Refree vane) NL ene n2 [5.01020 Reference value) Service Data Tose par] sans ae eras Veet - E61 GO) | amaze aye Tian sack pale Ags! ~ Ept (GND) — LL sack -ages | Oe versa + When measurement, be sure to using digital tester. Because, the resistance of acceleration sensor may be destroyed depending on the model of analog tester. CS-65UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) ‘Adjustment Ifthe accelerator sensor output is not within the specified range, adjust it as follows. 1. Call up accelerator sensor diagnostic screen from interactive diagnostic display. 2. Loosen accelerator sensor securing screws. 3. While observing the accelerator sensor output on the display to check if ft is within the specified range, rotate the accelerator sensor 4, Tighten accelerator sensor securing screws. 1.5 - 1.8 Nm (0.15 - 0.19 ka-m, 13 - 16 in/Ib) CS-66UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) a nt 2 be | Agus bon + ei]: «| ‘Stopper bolt & & Pitta c1t-14, 0-10) ~_fetuin spring Accelerator pedal roar Linkage Stroke Adjustment Fully-closed position agjust ment 1. Dopress the accelerator pedal until the accelerator linkage is fully opened, 2. Rotate the stopper bolt counterclockwise by 180 degrees, and then tighten the nut, * The accolerator linkage operation should move smoothly with no binding. When releasing the pedal, immediately return itto the fully-closed position. + The return spring should be securoly installed as shown in the figure. + Move the accelerator pedal, and then check that the accelerator pedal roller moves smoothly in the groove. CS-67UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Brake Switch Inspection Check contri between brake svitch terminals when the brake pedals dearessed 8 to 12 mm [0.31 10047 in, Comnuty must xs Reference data Pada haga: 10mm Gorn|irs-25Ton 111mm (4.37 in) @.0, 3.5 fon) trom floor upper surface) Adjustment 104.2 mom (4.10 in): 1.6 +25 ton oe 120.8 mm (4.74 in): 38.0, 3.5 ton 10-12 Brake pedal wy (os ee 108) 107 mm (4.21 inj 1.6-25 ton Brake pedal a 7 317 mm (4.61 in}: 8.0, 3.5 ton 3215, 108. 132) = _ jake swt (37-50,27-36) Floor Padal stopper Master eyinger Pedal stopper aster eyinder 2 swith Pler-so (37-5.0,27- 36) 1.8 mm (0.07 in) - 2-18 Nn (ge, nt) (591.5,108- 132) Fh Nm agen, fb) Doral A 1, Adjust the height of brake pedal point P to 107 mm (4.21 in) (1.5 = 2.5 ton), 117 mm (4.61 in) (8.0, 3.5 ton) from the floor upper surface by the stopper bolt, and then tighten the lock nut. j: 12 - 15 Nm (1.3 - 1.5 kg-m, 108 - 132 in/Ib) 2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in) (pedal reight: 100 mm (3.94 in) (1.5 - 25 ton), 141 mm (4.97 in) (8.0, 35 ton), adjust the brake switch so that the brake switch is *ON’, and then tighten the lock nut. 12 - 15 Nm (1.3 - 1.5 kg-m, 108 - 132 in/Ib) 3. Make sure that the brake switch is “OFF” when the pedal is released, CS-68UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Control Valve Switches (Lift, Tilt, 3rd, 4th, 5th Switches) Inspection When the control lever is operated, continuity must exist between terminals afected, 38] [ens * Circuit continuity must be checked after removing the attected ar switch connector. iy |g33 * Check for audible sounds which indicate control valve switches are operating, * If switches do not operate, adjust the switch position, then recheck the switches operation, Refer to “Adjustment” on page CS-66. \ cS A yy cs-69UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) ‘Adjustment Using adjusting nuts © and @, adjust the dog-to-switch clearance 10 specifications indicated in the figure below. * The control valve must be set in Neutral and switches must bbe freed during clearance adjustments. Nut @ 320.7 mm (0019-1077 ny — Control valve switch er {IH Jae Cantr! valve switch 000 racket securing bolt y ‘0-07 mm (0.012 0.027 in) Detail ot A (Tit 3rd and Ath stage sections) securing bracket 03-07 mm (0012-0027 ny -i Control valve body 03-07 mm (0012-0027 Dota ofA (Lit section) cawaa92 Centering Adjustment ‘conto valve switch { a GO Wahi 1.0m (0.038) Loosen brecket securing bolts, then align the center of the control valve switch and that of the dog. cSs-70UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Lift Solenoid (Mechanical Control Valve) Specifications Fated vonage Inspection Measure resistance between lft solenoid terminals. Reference value En a4 Tire Angle Sensor (Option) (GOM) specications ono Dow Toa essere a) ate Oi Service Data ovo sour Wessun : = ‘Standard value Remarks Ww HO—eano a The vaslance wave doseanos ashe l 2 ae cared The ecanoe vate remans unchanged ell regardless of the shat rotatior Shatt eC at h> EOS ste Nt eae cs-71UNIT INSPECTION AND ADJUSTMENT Control System (Cont'd) Adjustment Sensor cover (lower) 7.2-10.8(0.8- 1.1, 60-95) “Tira angio sensor _- Santor cover (shoet metal _-Sensor cover Kingpin plate — (upper) >> Align pin wi cutout Ne (kgem, ino) Tire angle sensor fixes the kingpin plate to the kingpin as shown in the above figure, and itis @ structure in the hole of the kingpin plate to transmit tho tum of the kingpin to the tire angle sensor by engaging the shatt of the tire angle sensor. Therefore, itis necessary ‘0 assemble the tire angle sensor corractly to make the knob position control system function correctly. Notes concerning assembly are as follows. 1. When the kingpin plat is installed in the kingpin, it is necessary to insert the plate vertically in the direction shown in the above figure. 2. When the sensor shaft is engaged in the kingpin plate, itis necessary to set the plane part of the sensor shaft to the spring and the other side of the kingpin plate (lett side in the above figure) |_—-wseanonsanir | & S204 nsrt eto int side groove of Kingoin nla ES * When the tire angle sensor is removed, installed, and replaced, the neutral level adjustment must be performed for the new sensor. Kingoin CS-72UNIT INSPECTION AND ADJUSTMENT Knob Position Control System (Option) (Gom) PS Knob Position Solenoid Valve Solenoia Inspection ae Neutral Setting 1, Set reer tire to the straight-ahead position Specifications Fated votage 2 Cal resistance (9) Diese (Fefeence value) at 20°C 68H) Chock rosistance botwoon terminals using ciroult tector. 200 (65 2. Call up “Adjustment Mode > “1-2. SENSOR" 9 “16 SENSOR, INTIAL SET 3. Push function key FNS to set the vehiole t position CS-73 (0 the straight-aheadUNIT INSPECTION AND ADJUSTMENT Ls, i — out) [XX © ‘or = a aie (ck) Leveling Device (Option) Inspection Tilt Horizental Switch Check continuity, When press button: Continuity should not exist. When do not press button: Continuity should exist. ‘Mast Height Sensor Key switchis tured on with the harness connected, and move the ‘metal close to the lift up level detection switch. At this time, make sure that switch operation indicator lamp tums on. Oil Pressure Sensor Key switchs tured on and check out put voltage while connecting hares. Output voltage (V): 0.25 - 4.75 Battery voltage (V): 5 # 0.5 (Power supply - GND) Tilt Angle Sensor Key switchs tured on and check out put voltage while connecting hares. ‘Output voltage (V): 0.5 - 4.5 (2- 3) Battery voltage (V): 5 + 0.5 (1-3) cs-74UNIT INSPECTION AND ADJUSTMENT Tilt Leveling Device (Option) (Cont'd) Tilt Horizontal Solenoid Valve Check resistance Tem estan Normal 77 Valuation (2) ° Removal and Installation ‘Mast Height Sensor (Pneumatic GOM Only) Mast height sensor Bracket Mast height sensor 27 Front side 5 180 228, of beam-LWR. a 10 mm (0.4 in) Detail A cwr“T Nn hint) Tit beam CS-75UNIT INSPECTION AND ADJUSTMENT Leveling Device (Option) (Cont'd) Tilt Angle Sensor Ti gauge Plas-s0 g : KH Sensor bracket FO manna 15-18 (6160.19, 19-16) oN BB]: Nem (ha: iniop view A Setting 1. Park tre vehicle on a fa, level road 2. Set rear ie to the straight-ahead position. (Knob can take any position) 3, Set the mast to vertical 4. Raise the fork approximately 300 mm (11.8 in) from the ground. 5. Aer caling up “Adjustment Menu" “1-2. Sensor” > “16 Sensor Intl Set", push function key FN and turn "OFF" to ne NOTE: Procedure is same as “nob Position Control and Neutral Setting” as above. Setting of Tilt Horizontal (Simple Setting) Push function keys FN1 + FNS to turn the normal display to the tit horizontal setting display. Push function key FNS to set the tit leveling condition, Confirmation of Operation Check the Toverent of following table at tit forward (with tit switch: (ON) from tit back. Check operation indicated in table below. ‘Stop angio it back No toad ret? ventana (Mast standare) ovzontal Toades No movement CS-76