Codigo de Fallas FBC25N2

CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
Chapter 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

1. General Information
1.1 Before Replacing Devices
Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the following
items before replacing devices (logic unit, logic card, power supply card, inverters and inverter DSP cards):
- Loose battery connectors
- Abnormal wire harness connections
- Loose connectors or pins pushed back in connector.
- Broken, bent or loose connector pins
- Dirty connectors
If connectors are dirty, remove and clean the connectors.
Refer to 2-2 "How to Clean Harness Connectors and System Components".
- Ensure that the main harness is not short-circuited to the forklift truck body by using the following procedures:
(1) Measure voltage between battery cable positive, negative and forklift truck frame. If voltage is found
above 5 volts this should be cleared before continuing additional troubleshooting procedures.
(2) Disconnect battery plug and discharge the inverters before working on electrical system.
(3) Disconnect connector E-01 of logic unit. Check continuity between E01-13 (508) and forklift truck
body (logic unit installation bolts, etc.).
No continuity Continuity
(4) Normal (5) Repair or replace harness.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a new one.
Be sure to check the above items and replace carefully.
1.2 Connection of the Service Tool
(1) Turn OFF the key switch.

(2) Remove the cup holder 1
(3) Find the connector to the service tool near the logic
unit.
(4) Remove the cover and connect the PC as shown.
(5) Turn ON the key switch.
(6) Start the service tool software.
2
608633
1. Diagnostic code display 2. Logic unit
2-1
1.3 How to Clean Harness Connectors and System Components
(1) Open-circuits are often caused by dirty harness

connectors and components. Dust together with
greasy matter forms grime which, in time, penetrates
electrical connections resulting in loose metal-to-metal
contact or, for worse, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components should be cleaned at each
periodic inspection and when servicing the forklift
truck. Instead of a commonly used solvent, use
electronic parts cleaner (in the manner illustrated on 1
the right).
608634
1. Electronic parts cleaner
Electronic parts cleaner

SE000003
Note: The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
(2) After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray
contact surface activator onto contact surfaces.
Install and remove the connector several times to wet 1
the surfaces thoroughly with the activator liquid.
After coupling up the connector, make sure that it is in
locked state.
1) 608635
1. Electronic parts cleaner 1) Contact surface activator
Contact surface activator

SE000003
Note:
- Do not spray too much liquid into the connector.
- Do not completely fill connectors with Nyogel from kit or you may push pins out of connector.
- Cleaner liquid reacts differently with some resins (plastic materials).
*: Products contained in Terminal Maintenance Kit (SE000003)
2-2
2. List of Diagnostic Codes
Code No. Diagnostic code name Code No. Diagnostic code name
E0 Traction motor, Overheating H1 Lift lever, Faulty setting
E2 Pump motor, Overheating H2 Tilt lever, Faulty setting
E5 Traction inverter, Overheating H3 Attachment 1 lever, Faulty setting
E7 Pump inverter, Overheating H4 Attachment 2 lever, Faulty setting
14 Traction motor, Current sensor fault 60 Meter panel, Communication fault
15 Traction motor, Over-current 61 Logic card, Initialize failure
16 Traction mother, Stall timer 62 Logic unit, Fault
34 Pump motor, Current sensor fault 63 Traction inverter, Fault
35 Pump motor, Over-current 65 Pump inverter, Fault
40 Line contactor, Fault 72 Contactor, Coil fault
45 Traction motor, Fault 74 Hydraulic lock solenoid, Fault
47 Pump motor, Open 75 Electromagnetic brake, Solenoid fault
49 Steering motor, Fault 76 IPS buzzer, Fault
51 Accelerator sensor, Fault 78 Battery, Voltage too low
52 Traction motor, Pulse input fault 79 Battery, Voltage too high
57 Pump motor, Pulse input fault Lo Battery, Consumption too much
E Direction lever or accelerator, Faulty setting (Lo) Battery, Consumption much
(E) Seat switch, Faulty setting for traction None Brake fluid, Low level
(L) Seat switch, Faulty setting for hydraulic None RTC battery, Low
2-3
3. Troubleshooting
3.1 Traction Motor, Overheating (E0)
Diagnostic code: E0
Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power
Situation
steering operations. Service tool "Alarm status" and "E0" displayed.
Overheating of traction motor, faulty traction motor or thermal sensor, faulty or open harness wiring, faulty
Possible
traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag, abnormality in
cause
front axle, and faulty meter panel.
Trigger of Motor temperature is out of range of -25 °C to 150 °C (-13 °F to 302 °F).
this code Recovers when motor temperature is in range of -20 to 70 °C (-4 to 158 °F).
Checks
(1) Let forklift truck cool for 15 minutes.

Overheat indicator ON Overheat indicator OFF
(2) Traction motor becomes normal.

If problem reoccurs
(3) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(4) Adjust brake.
(5) Lift front wheels, and disengage parking brake.

Turn key switch to OFF, rotate front wheels.
Confirm there is no difference in rotation load between right
and left wheels.
No difference Difference
(6) Check if forklift truck is

operated on steep upgrade or
to pull large cargo load.
Normal
(7) Perform inverter discharging work. See page 1-48.
(9) Replace traction motor

(8) Replace traction motor.
or front axle.
See Chassis & Mast. See Chassis & Mast.
2-4
With service tool
(10) Confirm temperature of traction motor with input/

Without service tool output monitor.
Less than -20 ºC (-4 º F) -20 ºC to 70 ºC
or more than 70 ºC (158 º F) (-4º F to 158º F)
(11) Disconnect battery plug. Wait until traction motor

(12) Disconnect battery plug.
temperature becomes close to room temperature.
(14) Troubleshoot meter panel by referring Display

Communication Fault (60)-(4).
(15) Disconnect connector E-10 of traction motor thermal

sensor. Measure resistance between E-10-2 (701) and E-10-1
(700) at motor side.
581 Ω at 20 °C (68° F)
(Min. 555 Ω, Max. 607 Ω)
For resistance at
temperature other than 20
°C (68° F), see table in the
illustration. Out of range
Thermal
(16) Disconnect connector E-06 of traction inverter.
Check continuity between E-06-1 and E-10-1 (700). (17) Replace traction motor. See Chassis & Mast.
Check continuity between E-06-2 and E-10-2 (701).
Continuity No continuity
Power
supply
(18) Check continuity between E-01-3 (707) and E-06-17
(707).
Check continuity between E-01-6 (707) and E-06-20 (710).
CAN
(19) Disconnect connector E-02 of logic unit.
(20) Connect connector E-01, then turn ON power again. (21) Repair or replace harness.
2-5
(22) Measure voltage between E-06-17 (707) and E-06-20

(710). Confirm value is 14V ± 2V.
Normal Abnormal
(24) Replace logic unit power supply card. See page 1-58.
With service tool
Without service tool
(25) Ensure all connectors are connected. Check Run Time
Diagnosis data. See page 1-43.
The latest data is "E0". Not "E0"
(26) Disconnect battery (27) Troubleshoot meter

plug, then perform inverter panel by referring Display
discharging work. See Communication Fault (60)-
page 1-48. (4).
(28) Replace traction inverter DSP card. See page 1-53.
2-6
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
E-02 E-06 Traction inverter
0 to 5V
CAN 5 P 470 476
P 3 Inside Inside Line contactor
P/G 0 to 5V P/G of of
6 471 477 4 F
O cover case
705 14
O Fuse
15
5 R/B 706
12V R/B 16 P
R 14V R 17
Power 3 R/W 707
8V R/W 18 DSP N Battery (-)
4 708 IMS
B GND B 20 card card
6 710 U 10
5V *1 R
1
Power supply card GND B 2 V 11
E-01 12V R 5 Flat
cable W 12
0 to 5V L
E-01 6
0 to 5V W
7
GND B 19
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 - E-06 E-09
1 2 Traction motor
E-09 3 4
709 B 3 Speed
sensor W 12
704
W 2 M V 11
703 L 4 3~
U 10
702
R 1 Thermal
B sensor
701 2 341Ω [150°C (302°F)]
700
R 1 125Ω [-30°C (-22°F)]
E-10
E-10
1 2
*1: With connector disconnected
608636
2-7
3.2 Pump Motor, Overheating (E2)
Diagnostic code: E2
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power
Situation
Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump
Possible
motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or hydraulic
cause
lines, and faulty meter panel.
Trigger of Motor temperature is out of range of -25 °C to 150 °C (-13 °F to 302 °F).
this code It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158°F).
Checks

(2) Pump motor becomes normal.

If problem reoccurs
(3) Check if forklift truck is operated to lift large cargo load.
Normal
(5) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(7) Repair or replace gear

(6) Replace pump motor. pump or piping.
See Chassis & Mast. With service tool See
Chassis & Mast.
With service tool
(8) Confirm temperature of pump motor with input/output

Without service tool monitor.
(9) Disconnect battery plug. Wait until pump motor

temperature becomes close to room temperature.

2-8
(13) Disconnect connector E-11 of pump motor thermal

sensor. Measure resistance between E-11-2 (721) and E-11-1
(720).
581 Ω at 20 °C (68° F)
(Min. 555 Ω, Max. 607 Ω)
For resistance at
temperature other than 20
°C (68° F), see table in the
illustration. Abnormal
Thermal
(14) Disconnect connector E-05 of pump motor inverter.
(15) Secure harness if loose.
Replace inverter if wire breaks. See page 1-49.
Power
supply

(500).
CAN
(18) Connect connector P8, then turn ON power again. (19) Repair or replace harness.

Normal Abnormal
2-9
With service tool


page 1-48. (4).
(26) Replace pump motor inverter DSP card. See page 1-53.
2-10
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
E-02 E-05 Pump inverter
5 P 470
0 to 5V 470 P 3
CAN P/G Inside Inside Line contactor
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502 12V 502 R/B 16 P
R 14V 500 R 17
Power 3 R/W 500
8V 501 R/W 18 DSP N Battery (-)
4 501 IMS
B GND 503 B 20 card card
6 503 U 13
5V *1 R 1
Power supply card GND B V 14
2 Flat
E-01 12V R
5 cable W 15
E-01 0 to 5V L 6
0 to 5V W
7
15 13 11 9 - 5 3 - GND B 19
16 14 12 10 - 6 4 -
E-05 E-27
1 2
E-27 Pump motor
3 4
729 B 3 Speed
W 2 sensor W 15
724 M V 14
723 L 4 3~
U 13
R
722 1 Thermal
B sensor
721 2 341Ω [150°C (302°F)]
R
720 1 125Ω [-30°C (-22°F)]
*1: With connector disconnected E-11

E-11
1 2
608637
2-11
3.3 Traction Inverter, Overheating (E5)
Diagnostic code: E5
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Situation
Normal pump motor and power steering operations. Service tool "Alarm status" and "E5" displayed.
Overheating of traction inverter, faulty traction inverter thermal sensor, open harness wiring, faulty traction
Possible
inverter PC board, abnormal power supply of logic unit, faulty temperature of traction inverter, and faulty
cause
meter panel.
Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F).
Trigger of
Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F).
this code
It becomes normal when temperature is in range of -20 to 70 °C (-4 to 158 °F).
Checks

(2) Traction inverter becomes normal.

If problem reoccurs
(3) Check if forklift truck is operated on steep upgrade or to
pull large cargo load.
Normal
Check heat sink grease applied on inverter mounting
surface. Heat sink grease film should be thin and even.
Normal Abnormal
(6) Clean mounting surface,

(5) Replace traction inverter. apply heat sink grease,
See page 1-49. then install inverter.
See page 1-49.
With service tool
(7) Confirm temperature of controller and head capacitor

Without service tool with input/output monitor.
(8) Disconnect battery plug. Wait until inverter temperature

becomes close to room temperature.

2-12
Thermal
(12) Remove traction inverter DSP card cover, then check
harness looseness or wire breakage. See page 1-53
Normal Abnormal
Power
supply
(13) Disconnect connector E-06 of traction inverter.

CAN
Check continuity between E-06-14 (705) and E-06-15(705).

(710). Confirm value is 14V±2V.
Normal Abnormal
With service tool

page 1-48. (4).
(24) Replace pump motor inverter DSP card. See page 1-53.
If fault remains
2-13
(25) Disconnect battery plug, then perform inverter

discharging work. See page 1-48.
(26) Replace traction inverter. (DSP card is normal.)

See page 1-49.
2-14
E-02 E-06
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - - - 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
0 to 5V
CAN 5 P 470
P 3
476 Inside Inside Line contactor
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O 14 cover case
705
O Fuse
15
5 R/B 12V R/B
706 16 P
R 14V R 17
Power 3 R/W 707
4 708 IMS
6 710 U 10
R 1
Power supply card B V 11
E-01 2
R Flat Controller
5 cable thermistor W 12
E-01 L 6
W Capacitor
7 thermistor
15 13 11 9 - 5 3 - B 19
16 14 12 10 - 6 4 -
E-06 E-09
1 2 Traction motor
E-09 3 4
DSP flat B Speed
cable 709 3 12
W sensor W
704 2 M V 11
Inverter L 3~
case 703 4 U 10
702
R 1 Thermal
B sensor
DSP card 701 2
700
R 1
391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-10
E-10
1 2
608638
2-15
3.4 Pump Inverter, Overheating (E7)
Diagnostic code: E7
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power
Situation
Possible Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter
cause PC board, abnormal power supply of logic unit, faulty temperature of pump inverter, and faulty meter panel.
Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F).
Trigger of
Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F).
this code
It becomes normal when temperature is in range of -20 to 70 °C (-4 to 158 °F).
Checks

(2) Pump inverter becomes normal.

If problem reoccurs
(3) Check if forklift truck is operated of lift large cargo load.
Normal
Check heat sink grease applied on inverter mounting
surface. Heat sink grease film should be thin and even.
Normal Abnormal
(6) Clean mounting surface,

(5) Replace pump inverter. apply heat sink grease,
See page 1-49. then install inverter.
See page 1-49.
With service tool
(7) Confirm temperature of controller and head capacitor

Without service tool with input/output monitor.
(8) Disconnect battery plug. Wait until inverter temperature

becomes close to room temperature.

2-16
Thermal
(12) Remove pump inverter DSP card cover, then check
harness looseness or wire breakage. See page 1-53.
Normal Abnormal
(13) Disconnect connector E05 of pump inverter.

CAN

Normal Abnormal
With service tool

page 1-48. (4).
(24) Replace pump inverter DSP card. See page 1-53.

If fault remains
2-17

(26) Replace pump inverter. (DSP card is normal.)

See page 1-49.
2-18
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
CAN 5 P 470
0 to 5V 470 P 3
Inside Inside
P/G Line contactor
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502 12V 502 R/B 16 P
R 14V 500 R 17
Power 3 R/W 500
4 501 501 IMS
6 503 503 U 13
R 1
2 Flat Controller
E-01 R
5 cable thermistor W 15
E-01 L 6
W Capacitor
7 thermistor
15 13 11 9 - 5 3 - B 19
16 14 12 10 - 6 4 -
E-05 E-27
1 2
E-27 3 4
Pump motor
DSP flat 729
B 3 Speed
cable W sensor W 15
724 2 M V 14
Inverter L 3~
case
723 4 U 13
722
R 1
Thermal
B sensor
DSP card 721 2
720
R 1 391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-11
E-11
1 2
608642
2-19
3.5 Traction Motor, Current Sensor Fault (14)
Diagnostic code: 14
Display: "14". All forklift truck operations inhibited. This fault occurs only when turning ON power. Line
Situation
contactor OPEN and steering contactor HOLD.
Possible Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty traction inverter DSP card, faulty
cause traction inverter, faulty main harness, and faulty logic unit.
Trigger of
When turning ON power, current sensor voltage is out of range of -120 A to 120 A.
this code
Checks
(1) Disconnect battery plug, then perform inverter discharging work. See page 1-48.
(2) Disconnect connector E-06 of traction inverter and

remove DSP cover. Check DSP flat cable for looseness or
wire breakage.
Normal Abnormal
8V power
supply

(4) Secure DSP flat cable if loose.
(708).
Abnormal and
Continuity
No continuity
CAN
Abnormal and
Continuity
No continuity
(6) Connect connector E-01 to logic unit, then turn ON

(7) Repair or replace harness.
power again.

(710).
Confirm value is 8V ± 2V.
Normal Abnormal
2-20
(10) Replace traction inverter DSP card. See page 1-53. (11) Replace logic unit power supply card. See page 1-58.
If fault remains
(12) Perform inverter discharging work, then replace
traction inverter. (DSP card is normal.) See page 1-49.
2-21
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
0 to 5V U current sensor
CAN 5 P 470 476
P 3
Inside Inside Line contactor
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O 14 cover case
705
O Fuse
15
5 R/B 706 12V R/B 16 P
R 707 14V R 17
Power 3 R/W 8V R/W 18 DSP N Battery (-)
4 708 IMS
B 710 GND B 20 card card
6 U 10
R 1
Power supply card B 2 V 11
E-01 R Flat
5 cable W 12
E-01 L 6
W V current sensor
7
15 13 11 9 - 5 3 - B 19
16 14 12 10 - 6 4 -
E-06 E-09
1 2 Traction motor
E-09 3 4
DSP flat B Speed
cable 709 3 12
W sensor W
704 2 M V 11
Inverter L 3~
case 703 4 U 10
702
R 1 Thermal
DSP card 701
B 2
sensor
700
R 1
391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-10
E-10
1 2
608644
2-22
3.6 Traction Motor, Over-Current (15)
Diagnostic code: 15
Situation Display: "15". All forklift truck operations inhibited. Line contactor OPEN and steering contactor HOLD.
Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty traction inverter DSP card, faulty
Possible
traction inverter, faulty traction motor, faulty contact or wire breakage of traction motor speed sensor harness,
cause
faulty main harness, and faulty logic unit.
Trigger of Motor current is more than 1018 Arms (Moment). Motor current is more than 990 Arms (Fixed time 1).
this code Motor current is more than 985 Arms (Fixed time 2).
(2) Check traction motor and terminal for burning and smell.
Normal Abnormal
(3) Confirm cable looseness and improper connections

(4) Replace traction motor.
(U, V, and W phases) for traction inverter and motor.
Normal Abnormal

remove DSP cover. Check DSP flat cable for looseness or (6) Secure cable if loose or connect cable correctly.
wire breakage.
Normal Abnormal
(7) Confirm connection of traction motor speed sensor (8) Secure DSP flat cable if loose.
connector E-09. Replace inverter if wire breaks. See page 1-49.
Normal Abnormal
Sensor
(9) Disconnect connectors E-06 and E-09.
Check continuity between E-06-6 and E-09-4 (703). (10) Connect connector securely.
8V power
supply
2-23

(708).
Check continuity between E-01-6 (710) and E-06-20 (710)
CAN

power again.

(710).
Confirm value is 8V ± 2V
Normal Abnormal
(16) Disconnect battery plug, then perform inverter discharging work.
If fault remains
If fault remains
(20) Perform inverter discharging work, then install traction
inverter and replace traction motor.
2-24
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
0 to 5V
CAN 5 P 470 476
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O cover case
705 14
O Fuse
15
5 R/B 12V R/B
706 16 P
R 14V R
Power 3 R/W 707
8V R/W
17
N Battery (-)
4 708 18 DSP IMS
B GND B card
6 710 20 card U 10
R
1
E-01 2
12V R Flat
5 cable W 12
E-01 0 to 5V L
6
0 to 5V W
7
GND B
15 13 11 9 - 5 3 - 19
16 14 12 10 - 6 4 -
E-06 E-09
1 2 Traction motor
E-09 3 4
DSP flat 709
B 3 Speed
cable W sensor W 12
704 2 M V 11
Inverter 703
L 4 3~
case U 10
702 R 1 Thermal
B sensor
DSP card 701 2
700
R 1
391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-10
E-10
1 2
608645
2-25
3.7 Traction Motor, Stall Timer (16)
Diagnostic code: 16
Possible Stall current flowed more than set time (#20) in traction motor, faulty traction inverter current sensor, shorted
cause harness wiring, faulty traction inverter DSP card, and faulty logic unit.
Trigger of
Stall timer set time (set by Setup Option #20) is measured while stalling.
this code
Checks
(1) Turn OFF power, then turn ON power again. Confirm diagnostic code display.
No warning, problem recurs Diagnostic code 14
(2) Confirm stall timer set time of Setup Option #20. (3) See troubleshooting for code "14". See page 2-20.
Maximum value set Larger value can be set
(4) Check to see if forklift truck is operated with heavy cargo

(5) Change set time. See page 1-30.
load or on steps when motor stalls.
Normal steeps Heavy load Note: The more stall occurs, the more overheating occurs.
Operate forklift truck under normal condition.

(7) Operate under normal condition.

remove DSP cover, then check DSP flat cable for looseness
or wire breakage. See page 1-43.
Normal Abnormal
Power
supply

(10) Secure harness if loose. Replace traction inverter if wire
(706).
breaks. See page 1-49.
Normal Abnormal
2-26
CAN
Abnormal and
Continuity
No continuity

power again.
CAN
(14) Measure voltage between E-06-16(706) and E-06-
20(710).
2-27
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
CAN 5 P 470 476
P 3
Inside Inside Line contactor
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O 14 cover case
705
O Fuse
15
5 R/B 706
12V R/B 16
P
R 14V R 17
Power 3 R/W
707
4 708 IMS
6 710 U 10
R 1
E-01 2
R Flat
5 cable W 12
L
E-01 6 V current sensor
W
7
B
15 13 11 9 - 5 3 - 19
16 14 12 10 - 6 4 - E-06 E-09
1 2
Traction motor
E-09 3 4
B Speed
709 3 12
W sensor W
704 2 M V 11
703
L 4 3~
U 10
702
R 1 Thermal
B sensor
701 2
R 391Ω [-30°C (-22°F)] to
700 1 1407Ω [160°C (320°F)]
E-10
E-10
1 2
608646
2-28
3.8 Pump Motor, Current Sensor Fault (34)
Diagnostic code: 34
Display: "34". All forklift truck operations inhibited. This fault occurs only when turning ON power.
Situation
Line contactor OPEN and steering contactor HOLD.
Possible Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty pump inverter DSP card, faulty pump
cause inverter, faulty main harness, and faulty logic unit.
Trigger of
When turning ON power, current sensor voltage is out of range of -120 A to 120 A.
this code
Checks
(2) Disconnect connector E-05 of pump inverter and remove

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V power
supply
(3) Check continuity between E-01-4 (501) and E-05-18 (501). (4) Secure DSP flat cable if loose.
Check continuity between E-01-6 (503) and E-05-20 (503). Replace pump inverter if wire breaks. See page 1-49.
CAN

power again.

(503).
Normal Abnormal
2-29
(10) Replace pump inverter DSP card. See page 1-53. (11) Replace logic unit power supply card. See page 1-58.
If fault remains
(12) Perform inverter discharging work, then replace pump
inverter. (DSP card is normal.) See page 1-49.
2-30
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
CAN 5 P 470
P 3
470 Inside Inside
P/G 0 to 5V P/G of of Line contactor
6 471 471 4
O cover case F
726 14
O Fuse
15
5 R/B 502
12V 502 R/B 16
P
R 14V 500 R 17
Power 3 R/W 500
4 501 IMS
6 503 U 13
R
1
2 Flat
E-01 R
5 cable W 15
L 6
E-01
W V current sensor
7
B
15 13 11 9 - 5 3 - 19
16 14 12 10 - 6 4 -
E-05 E-27
1 2
E-27 3 4 Pump motor
DSP flat B Speed
729 3 W 15
cable W 2 sensor
724 M V 14
Inverter 723
L 4 3~
case U 13
722
R 1
Thermal
721
B 2 sensor
DSP card R 391Ω [-30°C (-22°F)] to
720 1 1407Ω [160°C (320°F)]
E-11
E-11
1 2
608647
2-31
3.9 Pump Motor Over-Current (35)
Diagnostic code: 35
Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty pump inverter DSP card, faulty pump
Possible
inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main
cause
harness, and faulty logic unit.
Trigger of Motor current is more than 1018 Arms (Moment). Motor current is more than 990 Arms (1 mS).
this code Motor current is more than 985 Arms (1.6 mS).
Checks
(2) Check pump motor and terminal for burning and smell.
Normal Abnormal
(3) Confirm cable looseness and improper connections (U, V,

(4) Replace pump motor.
W phases) for pump inverter and motor.
Normal Abnormal

DSP cover. Check DSP flat cable for looseness or wire (6) Secure cable if loose or connect cable correctly.
breakage.
Normal Abnormal
(7) Confirm connection of pump motor speed sensor (8) Secure DSP flat cable if loose.
connector E-27. Replace pump inverter if wire breaks. See page 1-49.
Normal Abnormal
Sensor
Check continuity between E-05-6 and E-27-4 (723). (10) Connect connector securely.
8V power
supply
2-32

(501).
Check continuity between E-01-6 (503) and E-05-20(503).
CAN

power again.
(15) Measure voltage between E-05-18 (501) and E-05-

20(503).
Normal Abnormal
If fault remains
If fault remains
(20) Perform inverter discharging work, then install pump
inverter and replace pump motor
2-33
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
CAN 5 P 470 470 P 3
Inside Inside
P/G Line contactor
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502 12V 502 R/B 16 P
R 14V 500 R 17
Power 3 R/W 500
4 501 IMS
6 503 U 13
R
1
2 Flat
E-01 12V R
5 cable W 15
E-01 0 to 5V L
6
0 to 5V W
7 V current sensor
15 13 11 9 - 5 3 - GND B 19
16 14 12 10 - 6 4 -
E-05 E-27
1 2
E-27 3 4
Pump motor
DSP flat 729
B 3 Speed
cable W sensor W 15
724 2 M V 14
Inverter 723
L 4 3~
case U 13
722 R 1
Thermal
721 B 2 sensor
DSP card R 391Ω [-30°C (-22°F)] to
720 1 1407Ω [160°C (320°F)]
E-11
E-11
1 2
608648
2-34
3.10 Line Contactor, Fault (40)
Diagnostic code: 40
Display: "40". Traction and pump motor operation inhibited. Line and steering contactor HOLD.
Situation
If this fault occurs before steering contactor CLOSE, all operations inhibited except mast lowering operation.
Possible Break of line fuse, faulty line contactor, faulty traction inverter or pump inverter, faulty DSP card in traction
Trigger of
Inverter voltage data is checked when contactor is closed.
this code
Checks
(1) Turn OFF power, then turn ON power again. Confirm diagnostic code display.
Diagnostic code 40 Diagnostic code 63 or 65
(2) Block wheels, then confirm line contactor operation in (3) See troubleshooting for code "63" or "65".
self-diagnosis mode [14]. See page 1-41. See page 2-76 or page 2-79.
Not operated Operated
With service tool
(4) Check DC voltage of pump and traction inverters with (5) Disconnect battery plug, then perform
monitor. These values should be same as battery voltage. inverter discharging work. See page 1-48.
Traction inverter value Pump inverter value
abnormal abnormal
(6) Replace traction inverter. See page 1-49.
(7) Disconnect battery (8) Disconnect battery If fault remains
plug, then perform inverter plug, then perform inverter
discharging work. See discharging work. See (9) Disconnect battery plug, then perform
page 1-48. page 1-48. inverter discharging work. See page 1-48.
(10) Replace traction (11) Replace pump

(12) Replace pump inverter. See page 1-49.
inverter. See page 1-49. inverter. See page 1-49.

(14) Check to see if line contactor tip moves smoothly.

Check line contactor tip for melting.
Normal Abnormal
2-35
(15) Measure resistance of contactor coil.

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range
(16) Disconnect connectors E-01, E-04, and B-16.

Check continuity between E-01-14 (509) and B-16-5 (508).
Check continuity between B-16-5 (508) and G-107 (134). (17) Replace line contactor. See Chassis & Mast.
Check continuity between B-16-1 (541) and G-109.
(18) Perform inverter discharging work, then replace logic

unit logic card. See page 1-57.
2-36
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 - 56 - 52 50 48 - 44
60
Power supply card

E-01
Y 508
13 B-16
14 Y/B 509
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
Logic
E-04 B-16
508
W/B -
5 542 G-19 133 G-106
L W/L Line
Line contactor 59 540 2 540
contactor
+ Traction inverter
G-108
Pump inverter
Fuse
W/L -
134 G-107
Steering
contactor
Steering R R +
contactor 60 541 1 541 G-109
608649
2-37
3.11 Traction Motor, Open (45)
Diagnostic code: 45
Faulty contact or wire breakage of traction motor cable, faulty traction motor, faulty contact or wire breakage
Possible of traction inverter connector, faulty contact of DSP flat cable in traction inverter, wire breakage of main
cause harness, faulty logic unit power supply card, faulty traction inverter DSP card, faulty traction inverter, and when
restarting after motor shorted.
Trigger of Motor voltage is abnormal when power is turned ON.
this code Current does not flow when torque instruction is requested.
Checks
(2) Check traction inverter and motor for cable looseness

and improper contact.
Normal Abnormal
(3) Disconnect traction motor cables from inverter.

(4) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
Less than 1Ω 1Ω or more
(6) Measure resistance between terminals of both cable

(5) Check connector E-06 of traction inverter for looseness.
ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(7) Disconnect connector E-06 of (8) Connect connector securely.

traction inverter and remove DSP
cover. Check DSP flat cable for
looseness or wire breakage.
Normal Abnormal (9) Replace traction motor. (10) Replace motor cables.
Gate power
supply

(706).
2-38
CAN

power again.

(710).
If fault remains
2-39
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
0 to 5V
CAN 5 P 470 476
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O cover case
705 14
O Fuse
15
5 R/B 12V R/B
706 16 P
R 14V R
Power 3 R/W 707
8V R/W
17
N Battery (-)
4 708 18 DSP IMS
B GND B card
6 710 20 card U 10
R
1
E-01 2
R Flat
5 cable W 12
E-01 L 6
W
7
15 13 11 9 - 5 3 - B 19
16 14 12 10 - 6 4 -
E-06 E-09
1 2 Traction motor
E-09 3 4
DSP flat 709
B 3 Speed
cable W sensor W 12
704 2 M V 11
Inverter 703
L 4 3~
case U 10
R
702 1 Thermal
B sensor
DSP card 701 2
R 391Ω [-30°C (-22°F)] to
700 1 1407Ω [160°C (320°F)]
E-10
E-10
1 2
608650
2-40
3.12 Pump Motor, Open (47)
Diagnostic code: 47
Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of
Possible pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness,
cause faulty logic unit power supply card, faulty pump inverter DSP card, faulty pump inverter, and when restarting
after motor shorted.
Trigger of Motor voltage is abnormal when power is turned ON.
this code Current does not flow when rotational speed instruction is requested.
Checks
(2) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(3) Disconnect pump motor cables from inverter.

(4) Secure cable if loose.
Measure resistance of motor cables (U, V, and W phases).
Less than 1Ω 1Ω or more
(6) Measure resistance between terminals of both cable

(5) Check connector E-05 of pump inverter for looseness.
ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(7) Disconnect connector E-05 of (8) Connect connector securely.

pump inverter and remove DSP
cover. Check DSP flat cable for
looseness or wire breakage.
Normal Abnormal (9) Replace pump motor. (10) Replace motor cables.
Gate power
supply

(502).
2-41
CAN

power again.
(16) Measure voltage between E-05-16 (502) and E-05-

20(503). Confirm value is 12V ± 1V.
If fault remains
2-42
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
5 P 470
0 to 5V 470 P 3
CAN P/G Inside Inside Line contactor
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502
12V 502 R/B 16 P
R 14V R
Power 3 R/W 500 17
500
8V R/W N Battery (-)
4 501 501 18 DSP IMS
6 503 503 U 13
R
1
2 Flat
E-01 R 5
cable W 15
E-01 L 6
W
7
15 13 11 9 - 5 3 - B 19
16 14 12 10 - 6 4 -
E-05
E-27
1 2
E-27 3 4
Pump motor
DSP flat 729 B 3 Speed
cable W sensor W 15
724 2 M V 14
Inverter L 3~
723 4 U 13
case R 1
722 Thermal
721
B 2 sensor
DSP card R 391Ω [-30°C (-22°F)] to
720 1 1407Ω [160°C (320°F)]
E-11
E-11
1 2
608651
2-43
3.13 Steering Motor, Fault (49)
Diagnostic code: 49
Situation Display: "49". All forklift truck operations inhibited. Line contactor OPEN and steering contactor OPEN.
Possible
Faulty steering motor, faulty steering contactor, faulty harness, and faulty logic unit.
cause
Trigger of
Steering motor's warning signal is high (open), when steering motor warning signal is ON.
this code
Checks
(2) Disconnect connectors E-03 and F-09.
(3) Check continuity between E-04-56 (537) and F-09-02 (537), and check continuity between E-04-55 (536) and F-09-01 (536).
(4) Connect connectors. (5) Repair or replace harness.
(6) Block wheels, then confirm steering contactor operation in self-diagnosis mode [16]. See page 1-41.
Not operated Operated
(7) Disconnect battery plug, then perform inverter discharging work. See page 1-48
(8) Check to see if steering contactor tip moves smoothly. (9) Check steering motor cable's looseness and improper
Check steering contactor tip for melting. contact.
Normal Abnormal Normal Abnormal
(10) Replace steering (11) Secure cables if

motor. looseness.
(12) Measure resistance of contactor coil.

[44 Ω at -30 C°(-22 °F) to 65 Ω at 80 C°(176 F°)]
Within range Out of range
2-44
(13) Disconnect connectors E-01, E-04, B-16, and F-09.

Check continuity between B-16-5 (508) and G-107 (134).
(14) Replace steering contactor. See Chassis & Mast.
Check continuity between B-16-1 (541) and G-109.
Check continuity between E-04-56 (537) and F-09-2 (537).

2-45
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 - 56 - 52 50 48 - 44
60
Power supply card

E-01
Y 508
13 B-16
14 Y/B 509
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
Logic
E-04 B-16
508
W/B -
5 542 G-19 133 G-106
L W/L Line
Line contactor 59 540 2 540
contactor
+ Traction inverter
G-108
Pump inverter
Fuse
W/L -
134 G-107
Steering
contactor
Steering R R +
contactor 60 541 1 541 G-109
F-09
2 1
E-04 F-09
+
Steering motor Y/R

enable 62 556 1
Steering motor
Steering motor 56 Y/L 537 2
warning detector
-
505649
2-46
3.14 Accelerator Sensor, Fault (51)
Diagnostic code: 51
Possible
Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, and faulty logic unit.
cause
Accel sensor 1 voltage is out of range from 0.15 to 4.2 V.
Trigger of
Accel sensor 2 input value multiplied by two is out of range from 0.15 to 4.2 V.
this code
Difference in input between accelerator sensors 1 and 2 (multiplied by two) is 0.4 or more.
Checks
(1) Raise front wheels until they clear floor.
(3) Check link length of accelerator pedal.

Normal Abnormal
(4) Perform inverter discharging work. (5) Adjust accelerator pedal linkage.
(6) Disconnect connectors H-11, E-02, and E-03 of logic unit.
(7) Check continuity between E-02-20 (518) and H-11-5.

Check continuity between E-03-28 (528) and H-11-2
(Sensor voltage).
(8) Check continuity between E-02-24 (519) and H-11-4, 6

(557).
Check continuity between E-02-25 (520) and H-11-1,3 (558).

(10) Replace accelerator pedal.
If fault remains
(12) Install accelerator pedal, then replace logic unit logic

card.
2-47
(13) Connect connector H-11 and E-02. Turn ON power and check voltage between H-11-4 and H-11-1, and between H-11-6
and H-11-3.
5V Not 5V
(14) Turn OFF power.

Short-circuit H-11-4 and H-11-5, and short-circuit H-11-6 and H-11-2.
Turn ON power and check accelerator voltage with service tool.
5V Not 5V
(15) Turn OFF power.

Open H-11-4 and H-11-5, H-11-2.
Short-circuit H-11-1 and H-11-5, and Short-circuit H-11-3 and H-11-2.
Turn ON power and check accelerator voltage with service tool.
0V Not 0V
(16) Replace accelerator pedal. (17) Disconnect battery plug.
(18) Replace logic unit logic card.
2-48
E-02
25 - - 19 17 15 - - 9 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2 H-11
*1 *2 *3
*4 *5 *6
Logic
E-02 H-11
G/R 519
+5 V 24 4
Analog Input 1 20 G/W 518 5
G/B 1
GND 25 520
G/R 557 6
G/Y 528
Analog Input 2 28 2
G/B 558 3
E-03
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
608652
2-49
3.15 Traction Motor, Pulse Input Fault (52)
Diagnostic code: 52
Faulty contact of traction inverter connector, faulty connection of traction motor connector and cable, faulty
Possible
12V input voltage of traction inverter, faulty contact or wire breakage of traction motor speed sensor harness,
cause
faulty traction inverter DSP card, and faulty traction motor speed sensor.
Trigger of
Motor rotation speed is more than 5800 min-1.
this code
Checks
(2) Check to see if traction motor cables (U, V and W-phases)

are connected to traction inverter properly.
Normal Abnormal
(3) Check to see if connector E-06 of traction inverter is

(4) Connect cables properly.
fastened securely.
Normal Abnormal
(5) Check to see if connector E-09 of traction motor speed

(6) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
Check continuity between E-06-5 and E-09-1 (702). (8) Secure DSP flat cable if loose.
Check continuity between E-06-6 and E-09-4 (703). Replace pump inverter if wire breaks.
Check continuity between E-06-7 and E-09 -2(704). See page 1-49.
Power
supply
(9) Check continuity between E-01-3 (707) and E-06-17 (707).

2-50
CAN

power again.

Normal Abnormal
If fault remains
traction motor. (DSP card is normal.)
2-51
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
0 to 5V
CAN 5 P 470 476
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O cover case
705 14
O Fuse
15
5 R/B 12V R/B
706 16 P
R 14V R
Power 3 R/W 17
707
8V R/W N Battery (-)
4 708 18 DSP IMS
B GND B card
6 710 20 card U 10
R 1
E-01 2
12V R Flat
5 cable W 12
0 to 5V L
E-01 6
0 to 5V W
7
GND B
15 13 11 9 - 5 3 - 19
16 14 12 10 - 6 4 -
E-06 E-09
1 2 Traction motor
E-09 3 4
709 B 3 Speed
W sensor W 12
704 2 M V 11
703
L 4 3~
U 10
702
R 1 Thermal
B sensor
701 2
700
R 1
391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-10
E-10
1 2
608653
2-52
3.16 Pump Motor, Pulse Input Fault (57)
Diagnostic code: 57
Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable, faulty 12V
Possible
input voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness, faulty
cause
pump inverter DSP card, and faulty pump motor speed sensor.
Trigger of
Motor rotation speed is more than -200 min-1 and is more than 5800 min-1. Motor rotates in reverse.
this code
Checks
(2) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(3) Check to see if connector E-05 of pump inverter is

(4) Connect cables properly.
fastened securely.
Normal Abnormal
(5) Check to see if connector E-27 of pump motor speed

(6) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
Check continuity between E-05-6 and E-27-4 (723). (8) Fasten connector securely.
Power
supply

2-53
CAN

power again.

(503).
Normal Abnormal
If fault remains
motor. (DSP card is normal.)
2-54
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
5 P 470
0 to 5V 470
P 3
CAN P/G Inside Inside
Line contactor
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502 12V 502 R/B 16 P
R 14V 500 R 17
Power 3 R/W 500
4 501 IMS
6 503 U 13
R 1
2 Flat
E-01 12V R
5 cable W 15
0 to 5V L 6
E-01
0 to 5V W
7
GND B 19
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-05
E-27
1 2
E-27 3 4
Pump motor
729 B 3 Speed
W 2 sensor W 15
724 M V 14
723 L 4 3~
U 13
R
722 1 Thermal
B sensor
721 2
720
R 1 391Ω [-30°C (-22°F)] to
1407Ω [160°C (320°F)]
E-11
E-11
1 2
608654
2-55
3.17 Direction Lever or Accelerator, Faulty Setting (E)
Diagnostic code: E
Display: "E". All forklift truck operations inhibited. Line contactor and steering contactor OPEN when turning
Situation ON power.
Line contactor OPEN (when forklift truck stops) and steering contactor HOLD except when turning ON power.
Key switch turned ON while direction lever was left either in FORWARD or REVERSE position, key switch turned
Possible
ON while accelerator pedal was depressed, seat switch turned OFF while running, faulty direction lever switch,
cause
faulty accelerator sensor, faulty main harness, and faulty logic unit.
Detects the following signal when turning ON power:
Trigger of
Direction lever: F or R
this code
Accelerator sensor voltage: More than 1.4 V
Checks
(1) Move direction lever to NEUTRAL and release accelerator pedal.

If fault remains
(2) Turn OFF power. Move direction lever to NEUTRAL,
release accelerator pedal, then turn ON power again.
With service tool
(3) Check direction lever and accelerator sensor operations (4) Turn ON power in diagnosis mode. Inspect direction
with input/output monitor. lever and accelerator sensor. See page 1-40.
(5) Turn OFF power. (faulty unit only)

Direction lever Accelerator sensor
(6) Disconnect connector B-09 of direction lever. (7) Turn ON power in diagnosis mode. Inspect direction
Turn ON power. lever and accelerator sensor. See page 1-40.
Normal (E)
(8) Replace direction lever. (9) Disconnect connectors E-03 and E-02 of logic unit.
(10) Check short circuit between E-03-43 (529) and E-03-36

(525), and between E-03-43(529) and E-03-37 (526).
Not shorted Shorted
(11) Disconnect battery (12) Repair or replace main

plug. harness.
(13) Replace logic unit logic card. See page 1-55.
2-56
E-02
25 - - 19 17 15 - - 9 7 5 3 1 H-11
- 24 - 20 18 - - - - 8 6 4 2
1 2 3
4 5 6
Logic
E-02 H-11
+5 V 24 G/R 519 4
Analog Input 1 20 G/W 518 5
G/B 520 1
GND 25
G/R 557 6
G/Y 528
Analog Input 2 28 2
G/B 558 3
E-03
- - 37 35 33 - - - B-9
- - 38 36 34 32 - 28
1 2 2 1
3 4 4 3
E-03
B-9
Forward 37 W/L 526 0/12V W/L
3 526 F
Reverse 36 W/R 525 0/12V
4 525
W/R
R Direction lever
Y/B Y/B
GND 43 529 8 529
E-04 B-8
B-8
E-04
1 2 3 4 4 3 2 1
63 - 59 57 55 - 51 49 - - 43 5 6 7 8 8 7 6 5
64 62 60 58 56 - 52 50 48 - 44
608661
2-57
3.18 Seat Switch, Faulty Setting for Traction ((E))
Diagnostic code: (E)

Display: "E" blinking. All forklift truck operations inhibited. Line contactor and steering contactor OPEN when
Situation turning ON power. Line contactor OPEN (when forklift truck stops) and steering contactor HOLD except when
turning ON power.
Possible Operator not in the seat, seat switch turned OFF during running, improper seat suspension adjustment, faulty
cause seat switch, faulty main harness, and faulty logic unit.
Trigger of
Detects seat switch opening when turning ON power or while running.
this code
Checks
(1) If this fault occurred while running If this fault occurred when turning ON power
(2) Stop forklift truck, then move direction lever to NEUTRAL.

Sit properly in operator's seat and release accelerator pedal.
If fault remains Normal
Fail-safe function
(3) Turn OFF power. Sit in the seat, then turn ON power
again.
If fault remains
(4) Turn OFF power.
(5) Adjust seat suspension.

Faulty seat switch position
(7) Disconnect connector G-10, then short-circuit between

terminals (544) and (522). Turn ON power again.

(9) Replace seat switch.
2-58
(10) Disconnect connectors E-03 and E-04 of logic unit.

Check continuity between C-10-2 (544) and E-04-43 (544).
(11) Replace logic unit logic card. See page 1-57. (12) Repair or replace main harness.
2-59
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
Logic unit
E-03
0/12V G/W
521 32 Seat belt switch
0/12V L/W
522 33 Seat switch
Seat belt switch
C-10 Logic
3 521
E-04
1 522
GND G/B
2 544 544 43 GND
Seat switch
C-10 E-04
1 2 3
63 - 59 57 55 - 43
51 49 - -
64 62 44
60 58 56 - 52 50 48 -
608662
2-60
3.19 Seat Switch, Faulty Setting for Hydraulic ((L))
Diagnostic code: (L)

Display: "L" blinking. All forklift truck operations inhibited. Line contactor and steering contactor OPEN when
turning ON power.
Possible Operator not in the seat, seat switch turned OFF during pump motor operation, improper seat suspension
cause adjustment, faulty seat switch, faulty main harness, and faulty logic unit.
Trigger of
Detects seat switch opening when turning ON power or during pump operation.
this code
Checks
If this fault occurred during

(1) If this fault occurred when turning ON power
pump motor operation
(2) Sit in the seat, then stop pump motor operation.

Fail-safe function
again.
If fault remains
(4) Turn OFF power.
(5) Adjust seat suspension.

Faulty seat switch position
(7) Disconnect connector C-10, then short-circuit between

terminals (544) and (522). Turn ON power again.

(9) Replace seat switch.
2-61
(10) Disconnect connectors E-03 and E-04 of logic unit.

2-62
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
Logic unit
E-03
0/12V G/W
521 32 Seat belt switch
0/12V L/W
522 33 Seat switch
Seat belt switch
C-10 Logic
3 521
E-04
1 522
GND G/B
2 544 544 43 GND
Seat switch
C-10 E-04
1 2 3
63 - 59 57 55 - 43
51 49 - -
64 62 44
60 58 56 - 52 50 48 -
608662
2-63
3.20 Lift Lever, Faulty Setting (H1)
Diagnostic code: H1
Display: "H1" blinking. All forklift truck operations inhibited. Line contactor and steering contactor OPEN when
turning ON power.
Possible Key switch turned ON while operating lift lever, faulty lift switches 1 and 2, faulty lift down switch, faulty main
cause harness, and faulty logic unit.
Trigger of
Detects lift microswitch 1 or 2, when turning ON power.
this code
Checks


Fail-safe function
again without lift operation.
If fault remains
(4) Turn OFF power.
(5) Disconnect connector B-15 of microswitch. Sit in the seat,

then turn ON power again.

(7) Replace lift switch 1 or 2.
(8) Check continuity between E-04-52 (535) and B-15-8

(535).
Check continuity between E-04-51 and B-15-1 (534).
Check short circuit between B-15-8 (535) and B-15-5 (554).
Continuity, Not shorted No continuity, Shorted
(9) Disconnect battery plug. (10) Repair or replace main harness.
2-64
B-15 E-04
63 - 59 57 55 - 43
51 49 - -
1 2 3 4 4 3 2 1 64 62 44
5 6 7 8 8 7 6 5
60 58 56 - 52 50 48 -
Logic
B-15 E-04
0/12V L
8 535 52 Lift 1
1
0/12V
534 G 51 Lift 2
5 L/B 554
GND
Logic
E-04
529 Y/B 43
608663
2-65
3.21 Tilt Lever, Faulty Setting (H2)
Diagnostic code: H2
turning ON power.
Possible
Key switch turned ON while operating tilt lever, faulty tilt switch, faulty main harness, and faulty logic unit.
cause
Trigger of
Detects tilt microswitch when turning ON power.
this code
Checks


Fail-safe function
again without lift operation.
If fault remains
(4) Turn OFF power.


(7) Replace lift switch.

(533).
2-66
B-15 E-04
63 - 59 57 55 - 43
1 2 3 4 4 3 2 1 51 49 - -
64 62 44
5 6 7 8 8 7 6 5 60 58 56 - 52 50 48 -
Logic
B-15 E-04
2
0/12V W
533 50
Tilt
5 L/B 554
GND
Logic
E-04
L/B
544 43
608664
2-67
3.22 Attachment 1 Lever, Faulty Setting (H3)
Diagnostic code: H3
turning ON power.
Possible Key switch turned ON while operating attachment 1 or 2 lever, faulty attachment 1 or 2 switch, faulty main
cause harness, and faulty logic unit.
Trigger of
Detects attachment 1 or 2 microswitch when turning ON power.
this code
Checks


Fail-safe function
again without attachment 1 or 2 operation.
If fault remains
(4) Turn OFF power.


(7) Replace attachment 1 or 2 switch.

(532), E-04-48 and B-15-4 (531).
Check short circuit between B15-3 (532), and B-15-5 (554).
2-68
B-15 E-04
63 - 59 57 55 - 43
51 49 - -
1 2 3 4 4 3 2 1 64 62 44
60 58 56 - 52 50 48 -
5 6 7 8 8 7 6 5
Logic
E-04
B-15
O
4 YL
0/12V
531 531 48
3 YL 532 0/12V Lg
532 49
5 L/B 554
GND
Logic
E-04
Y/B
529 43
608665
2-69
3.23 Attachment 2 Lever, Faulty Setting (H4)
Diagnostic code: H4
turning ON power.
Possible Key switch turned ON while operating attachment 2 lever, faulty attachment 2 switch, faulty main harness, and
cause faulty logic unit.
Trigger of
Detects attachment 2 microswitch when turning ON power.
this code
Checks


Fail-safe function
again without attachment 2 operation.
If fault remains
(4) Turn OFF power.


(7) Replace attachment 2 switch.

(531).
Check short circuit between B15-4 (531) and B-15-5 (554).
2-70
B-15 E-04
63 - 59 57 55 - 43
51 49 - -
1 2 3 4 4 3 2 1 64 62 44
60 58 56 - 52 50 48 -
5 6 7 8 8 7 6 5
Logic
E-04
B-15
O
4 YL
0/12V
531 531 48
3 YL 532 0/12V Lg
532 49
5 L/B 554
GND
Logic
E-04
Y/B
529 43
505687
2-71
3.24 Meter Panel, Communication Fault (60)
Diagnostic code: 60
Situation Display: "60". Normal forklift truck operation.
Possible
Faulty main harness, faulty meter panel, and faulty logic unit.
cause
Trigger of Communication is impossible.
this code Meter panel is abnormal.
Checks
(2) Disconnect connector E-02 of controller. Disconnect

connector E-24 of meter panel.
(3) Check to see if these are shorted to other signal cables. (4) Repair or replace harness.
Not shorted shorted
(5) Replace meter panel. (6) Repair or replace harness.

If fault remains
2-72
E-24
E-02
25 - - 5 3 1 1 2 㪄㪄㪄㪄
19 17 15 - - 9 7
- 24 -
20 18 - - - - 8 6 4 2 㪄㪄㪄㪄㪄㪄
Logic E-24
E-02
P 470
0 to 12V
472 P 1
CAN, H 5
Display
P/G 0 to 12V P/G 2
CAN, L 6 471 473
608655
2-73
3.25 Logic Card, Initialize Failure (61)
Diagnostic code: 61
Possible Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
cause and faulty logic unit.
Trigger of
Setup Option data is in abnormal setting range.
this code
Checks
(1) Turn OFF power, then turn ON power in Setup Option Group 3 setting. See page 1-24
(2) Set Setup Option Group 3 data. See page 1-33.
(3) Set Setup Option default data. See page 1-24.
(4) Turn ON power in "RUN" mode. See page 1-24.

If fault remains
(5) With service tool, set Setup Option Group 3 data.
(6) With service tool, set Setup Option default data.

If fault remains
(10) With service tool, set Setup Option default data.
2-74
3.26 Logic Unit, Fault (62)
Diagnostic code: 62
Possible
Faulty EEPROM data and faulty logic unit.
cause
Trigger of ROM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from
this code check data. RAM of logic card is faulty.
Checks
(1) Turn OFF power, then turn ON power in Setup Option Group 3 setting. See page 1-24.
(2) Set Setup Option Group 3 data.
(3) Set Setup Option default data.
(4) Turn ON power in "RUN" mode. See page 1-24.

Diagnostic code "61"
If fault remains "62"
(6) See troubleshooting for code "61". See page 2-74.

Set Setup Option default data.
2-75
3.27 Traction Inverter, Fault (63)
Diagnostic code: 63
Possible Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty traction inverter DSP card, faulty
cause traction inverter, faulty main harness, and faulty logic unit.
Traction inverter is connected as pump inverter (E-06-9 is connected to GND).
Trigger of
ROM SUM value of taction inverter is different from check data.
this code
RAM of traction inverter is faulty. Communication with traction inverter is impossible.
Checks

remove DSP cover. Check DSP flat cable for looseness or
wire breakage.
Normal Abnormal
8V power
supply

(4) Refasten flat cable or replace inverter. See page 1-49.
CAN
Normal Abnormal
(6) Measure resistance of CAN with connectors E-06 and E-02 disconnected.
Resistance between E-02-5 (470) and E-02-6 (471).
120Ω ± 5% Other than 120Ω ± 5%
(7)
Transistor control Contactor control
(8) Perform CAN check of Pump Inverter

Fault (65).
2-76

When repairing harness,
repair resistor (120) on
harness.
(10) Measure resistance of CAN for traction inverter DSP card.

Resistance between CN2-3 and CN2-4 of DSP card side connectors
120Ω ± 5% Other than 120Ω ± 5%
(11) Replace traction inverter

DSP card.
(12) Connect connector E-06 of traction inverter.

Measure resistance of CAN with connector E-02 disconnected.
Resistance between E-02-5 (470) and E-02-6 (471)
60Ω ± 5% Other than 60Ω ± 5%
(13) Repair or replace

harness.
Mode
(14) Check E-06-8 and E-06-9 that pin is not inserted in.
Normal Abnormal

power again.

(710).
Normal Abnormal
2-77
E-02 E-06
25 - - 5 3 1 19 17 15 - - - 7 5 3 1
19 17 15 - - 9 7
- 24 - 6 4 2 20 18 16 14 - - - 6 4 2
20 18 - - - - 8
Logic
0 to 5V
CAN 5 P 470 476
0 to 5V
6 P/G 471 477
P/G 4 of of
F
O cover case
705 14
O Fuse
15
5 R/B 12V R/B
706 16 P
R 14V R
Power 3 R/W 707
8V R/W
17
N Battery (-)
4 708 18 DSP IMS
B GND B card
6 710 20 card U
8
Power supply card V
E-01 9
Flat
cable W
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
DSP flat
cable
Inverter
case
DSP card
608656
2-78
3.28 Pump Inverter, Fault (65)
Diagnostic code: 65
Possible Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty pump inverter DSP card, faulty pump
Pump inverter is connected as traction inverter (E-05-9 is opened).
Trigger of
ROM SUM value of pump inverter is different from check data.
this code
RAM of pump inverter is faulty. Communication with pump inverter is impossible.
Checks

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V power
supply

(4) Refasten flat cable or replace inverter. See page 1-49.
CAN
Normal Abnormal
(6) Measure resistance of CAN with connectors E-05 and E-02 disconnected.
120Ω ± 5% Other than 120Ω ± 5%
(7) Perform CAN check of

Traction Inverter Fault (63).
(8) Measure resistance of CAN for pump inverter DSP card.

Resistance between CN2-3 and CN2-4 of DSP card side connectors
120Ω ± 5% Other than 120Ω ± 5%
(9) Replace pump inverter DSP

card.
2-79
(10) Connect connector E-05 of pump inverter.

Measure resistance of CAN with connector P3 disconnected.
60Ω ± 5% Other than 60Ω ± 5%

Mode
(13) Check E-05-8 that pin is not inserted in.

Normal Abnormal

power again.

Normal Abnormal
2-80
E-02 E-05
25 - - 5 3 1
19 17 15 - - 9 7 19 17 15 - 11 9 7 5 3 1
- 24 - 6 4 2
20 18 - - - - 8 20 18 16 14 - - - 6 4 2
Logic
5 P 470
0 to 5V 470 P 3
CAN P/G Inside Inside GND
6 P/G 471
0 to 5V 471 4 of of
O cover case F
726 14
O Fuse
15
5 R/B 502 12V 502 R/B 16 P
R 14V 500 R 17
Power 3 R/W 500
4 501 501 IMS
6 503 503 U
Power supply card mode 2 9 V

E-01 Y/G 11 Flat
cable W
E-01 725
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
GND
DSP flat
cable
Inverter
case
DSP card
608657
2-81
3.29 Contactor, Coil Fault (72)
Diagnostic code: 72
Possible
Faulty line contactor, faulty steering contactor, faulty main harness, and faulty logic unit.
cause
Trigger of
With short circuit detection signal of logic card.
this code
Checks
(1)
Without service tool With service tool
(2) Find faulty contactor line contactor or steering contactor

with input output monitor.
(4) Check line contactor or steering contactor.

Line contactor Steering contactor
(5) Remove coil side terminals of line contactor. Disconnect (6) Remove coil side terminals of steering contactor.
connector E-04 of logic unit. Disconnect connector E-04 of logic unit.
(7) Check short circuit between coil terminal positive (+) (G- (8) Check short circuit between coil terminal positive (+) (G-
108) and negative (-) (G-106)of harness. 07) and negative (-) (G-06) of harness.
Not shorted Shorted Shorted Not shorted
(9) Repair or replace main

harness.
(10) Measure coil resistance. (11) Measure coil resistance.

[44Ω at -30°C (-22°F) to 66Ω at 80°C (176°F) [44Ω at -30°C (-22°F) to 66Ω at 80°C (176°F)
Abnormal Normal Abnormal Normal
(13) Replace logic unit logic (14) Replace Steering

(12) Replace line contactor.
card. See page 1-57. contactor.
2-82
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
Logic
E-02 E-06
P 0 to 5V P Traction inverter
5 470 476 3
CAN P/W 471 0 to 5V P/W
6 477 4 F
E-05
Power supply card
E-01 G 3
92 Pump inverter
Y 508
13 GW F
93 4
14 Y/B 509
Logic
E-04 B-16
130
Y/R 5R 5R -
3 G-106
L W/L Line
59 540 2 133
contactor
+
G-108
B-16
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
- Fuse
5R G-06
Steering
contactor
Y/R +
55 536 536 G-07
R
60 541
505689
2-83
3.30 Hydraulic Lock Solenoid, Fault (74)
Diagnostic code: 74
Situation Display: "74". Pump motor operation inhibited. Normal traction motor operation and power steering operation.
Possible
Faulty lift lock valve, faulty main harness, and faulty logic unit.
cause
Trigger of
this code
Checks
(2) Disconnect connector E-04 of logic unit. Disconnect connector B-03- of lift lock valve.
(3) Check short circuit between B-03-1(07) and B-03-2 (06).

Shorted Not shorted
(5) Check short circuit between lift lock valve side

(4) Repair or replace main harness. connectors. Measure coil resistance.
[40.5Ω at -30 °C (-22° F) to 52Ω at 80 °C (176 °F)]
(6) Replace logic unit logic card. See page 1-57. (7) Replace lift lock valve.
2-84
Logic B-03
E-04
G 7 1 Lift
57 538
G/B lock
58 539
6 2 valve
E-04
B-03
63 - 59 57 55 - 43 1 2
51 49 - -
64 62 44
60 58 56 - 52 50 48 -
608658
2-85
3.31 Electromagnetic Brake, Solenoid Fault (75)
Diagnostic code: 75
Possible
Faulty electromagnetic brake valve, faulty main harness, and faulty logic unit.
cause
Trigger of
this code
Checks
(2) Disconnect connector P5 of logic unit. Disconnect connector F-12 of electromagnetic brake.
(3) Check short circuit between F-12-1 (148) and F-12-2 (543).
Not shorted Shorted
(4) Check short circuit between electromagnetic brake side

(5) Repair or replace main harness.
connectors. Measure coil resistance. [Approximately 22.1Ω]
(6) Replace electromagnetic brake. (7) Replace logic unit logic card. See page 1-57.
2-86
G-57 F-12
2 1
IPS relay 1
G-57 F-12
(1.25W/R)
L Electro-
3 143 148 1
magnetic
Logic brake
2
E-04
L/W 543
64
E-04
63 - 59 57 55 - 43
D4
51 49 - -
64 62 44
60 58 56 - 52 50 48 -
1
2
C-12
505702
2-87
3.32 IPS Buzzer, Fault (76)
Diagnostic code: 76
Situation Display: "76". All operations available except for the buzzer.
Possible
Faulty IPS buzzer, faulty main harness, and faulty logic unit.
cause
Trigger of
By short circuit detection signal of logic card.
this code
Checks
(1) Disconnect battery plug then perform inverter discharging work.
(2) Disconnect connector of IPS buzzer Check circuit between C-08-1 and C-08-2 or side.
Not shorted Shorted
(3) Repair or replace main harness.
(4) Check short circuit between C-08-1 and C-08-2 or IPS buzzer.
Not shorted Shorted
(5) Replace IPS buzzer.
(6) Disconnect connector of E-03 and E-04 of Logic.

Check short circuit between E-03-34 (523) and E-01-3 (523) parking brake switch.
Check short circuit between E-04-44 (530) and G-64-3 (530) IPS relay.
Not shorted Shorted
(7) Replace logic unit logic card. (8) Repair or replace main harness.
2-88
E-03
B-01
- - 37 35 33 - - -
- - 38 36 34 32 - 28
1 2 3
Logic Parking brake switch

E-03 B-01
Parking brake 34 W 523 3
G-64
IPS relay 2
Y/R Br/Y
IPS buzzer 44 530 3 225 2 1 224
Logic
E-04 C-08
WARNING BUZZER
E-04
C-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 44 1
- 56 - 52 50 48 -
2
505647
2-89
3.33 Battery, Voltage Too Low (78)
Diagnostic code: 78
Possible Faulty or discharged battery, low voltage battery, improper battery voltage setting (Setup Option #41),
cause improper battery voltage adjustment setting (Setup Option #46), faulty main harness, and faulty logic unit.
Corrected battery voltage is too low. Battery voltage is corrected with #46 value.
Trigger of
36 V battery: less than 30 V
this code
48 V battery: less than 42 V
Checks
(1) Disconnect battery plug. Measure battery voltage with tester.

34 V to 55 V Abnormal
(2) Turn ON power in Setup Option Group 3 setting.

(3) Charge battery or replace with proper battery.
See page 1-24
(4) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-33.
(5) Turn OFF power and turn ON power again.

If fault remains
(7) Check continuity between E-02-19 (517) and contactor

POS G-02 (100).

(9) Repair, or replace main harness, or check fuse.
2-90
Line contactor
G-09 G-08
0.85Y
NEG
Key switch 105 105 F-11 100
G-02
POS
Logic
+
E-02
Battery
19 517
E-02
25 - - 19 17 15 - - 9 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
608660
2-91
3.34 Battery, Voltage Too High (79)
Diagnostic code: 79
Possible Faulty or highly charged battery, high voltage battery, improper battery voltage setting (Setup Option #41),
cause improper battery voltage adjustment setting (Setup Option #46), and faulty logic unit.
Corrected battery voltage is too high. Battery voltage is corrected with #46 value.
Trigger of
36 V battery: more than 42 V
this code
48 V battery: more than 60 V
Checks
(1) Disconnect battery plug. Measure battery voltage with tester.

34 V to 55 V Abnormal
(2) Turn ON power in Setup Option Group 3 setting.

(3) Replace with proper battery.
See page 1-24.
(4) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-33.
(5) Turn OFF power and turn ON power again.

If fault remains

POS G-02 (100).

(9) Repair, or replace main harness, or check fuse.
2-92
Line contactor
G-09 G-08
0.85Y
NEG
Key switch 105 105 F-11 100
G-02
POS
Logic
+
E-02
Battery
19 517
E-02
25 - - 19 17 15 - - 9 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
608660
2-93
3.35 Battery, Consumption Too Much (Lo)
Diagnostic code: (Lo)

Display: "Lo" blinking. Battery low indicator ON. All forklift truck operations inhibited.
Situation
Line contactor OPEN and steering contactor OPEN.
Possible
Extremely consumed battery, faulty main harness, and faulty logic unit.
cause
Trigger of
Corrected battery voltage is less than 22 V. Battery voltage is corrected with #46 value.
this code
Checks
(2) Check battery voltage.

22V or more Less than 22V
(3) Set #46 of Setup Option Group 3. See page 1-24. (4) Charge battery or replace with new battery.
If fault remains

POS G-02 (100).
2-94
Line contactor
G-09 G-08
0.85Y
NEG
Key switch 105 105 F-11 100
G-02
POS
Logic
+
E-02
Battery
19 517
E-02
25 - - 19 17 15 - - 9 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
608660
2-95
3.36 Battery, Consumption Much ((L0))
Diagnostic code: None

Battery low indicator blinks. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
Situation
and power steering operations.
Possible Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness, and
cause faulty logic unit.
Trigger of
Corrected battery voltage is less than 25 V. Battery voltage is corrected with #46 value.
this code
Checks
(2) Check battery voltage.

25V or more Less than 25V
(3) Set #46 of Setup Option Group 3. See page 1-24. (4) Charge battery or replace with new battery.
If fault remains

POS G-02(100).
2-96
Line contactor
G-09 G-08
0.85Y
NEG
Key switch 105 105 F-11 100
G-02
POS
Logic
+
E-02
Battery
19 517
E-02
25 - - 19 17 15 - - 9 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
608660
2-97
3.37 Brake Fluid, Low Level

Situation Lower brake fluid indicator ON. Normal forklift truck operation.
Possible
Insufficient brake fluid, faulty brake fluid level sensor, shorted wiring, faulty logic unit, and faulty meter panel.
cause
Trigger of
Sensor signal is open or shorted.
this code
Checks
(1) Check oil level in brake fluid reserve tank.

Normal Abnormal
(2) Add brake fluid. See Chassis & Mast.

With service tool
(3) Confirm brake fluid level switch with input/output

Without service tool monitor
ON OFF
(4) Disconnect battery plug, then perform inverter (5) Disconnect battery plug. Replace meter panel.
discharging work. See page 1-48. See Chassis & Mast.
(6) Disconnect connectors E-04 of logic unit and C-11 of

sensor. Check continuity between C-11 (527) and C-11 (548)
at harness side.
(7) Check continuity of brake fluid level sensor connector

coupled to C-11.
(9) Replace brake fluid level sensor.
2-98
With service tool
Without
service tool
(10) Replace meter panel. See Chassis & Mast.
If fault remains
(12) Install meter panel and replace logic unit logic card. See page 1-57.
2-99
E-03 E-04
63 - 59 57 55 - 43
- - 37 35 33 - - - 51 49 - -
64 62 44
- - 38 36 34 32 - 28 60 58 56 - 52 50 48 -
Logic Logic
E-03 E-04
38 43
0V/12V Y/B GND
529
R/W R/B
527 548
1 2 C-11
C-11
1
2
Brake fluid
sensor
608643
2-100
3.38 RTC Battery, Low

Situation Date or clock is abnormal.
Possible
Battery voltage for calendar IC is low.
cause
Trigger of
Signal from calendar IC.
this code
Checks
(1) Adjust clock value on adjustment menu of meter panel display.
(2) Date or clock is still abnormal.
(3) Replace the logic card with a new one.
2-101

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CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

Chapter 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

(4) Normal (5) Repair or replace harness.

(1) Turn OFF the key switch.

(1) Open-circuits are often caused by dirty harness

Electronic parts cleaner

(2) After checking the connector for continuity, wash it as

Contact surface activator

(1) Let forklift truck cool for 15 minutes.

(2) Traction motor becomes normal.

(4) Adjust brake.

(5) Lift front wheels, and disengage parking brake.

(6) Check if forklift truck is

(7) Perform inverter discharging work. See page 1-48.

(9) Replace traction motor

(10) Confirm temperature of traction motor with input/

(11) Disconnect battery plug. Wait until traction motor

(14) Troubleshoot meter panel by referring Display

(15) Disconnect connector E-10 of traction motor thermal

(22) Measure voltage between E-06-17 (707) and E-06-20

(23) Disconnect battery plug.

(26) Disconnect battery (27) Troubleshoot meter

(28) Replace traction inverter DSP card. See page 1-53.

*1: With connector disconnected

(1) Let forklift truck cool for 15 minutes.

(2) Pump motor becomes normal.

(5) Check oil pressure of gear pump and hydraulic lines.

(7) Repair or replace gear

(8) Confirm temperature of pump motor with input/output

(9) Disconnect battery plug. Wait until pump motor

(12) Troubleshoot meter panel by referring Display

(13) Disconnect connector E-11 of pump motor thermal

(16) Check continuity between E-01-3 (500) and E-05-17

(20) Measure voltage between E-05-17 (500) and E-02-20

(21) Disconnect battery plug.

Without service tool

(24) Disconnect battery (25) Troubleshoot meter

*1: With connector disconnected E-11

(1) Let forklift truck cool for 15 minutes.

(2) Traction inverter becomes normal.

(6) Clean mounting surface,

(7) Confirm temperature of controller and head capacitor

(8) Disconnect battery plug. Wait until inverter temperature

(11) Troubleshoot meter panel by referring Display

(13) Disconnect connector E-06 of traction inverter.

(18) Measure voltage between E-06-17 (707) and E-06-20

(19) Disconnect battery plug.

(22) Disconnect battery (23) Troubleshoot meter

(25) Disconnect battery plug, then perform inverter

(26) Replace traction inverter. (DSP card is normal.)

(1) Let forklift truck cool for 15 minutes.

(2) Pump inverter becomes normal.

(6) Clean mounting surface,

(7) Confirm temperature of controller and head capacitor

(8) Disconnect battery plug. Wait until inverter temperature

(11) Troubleshoot meter panel by referring Display

(13) Disconnect connector E05 of pump inverter.

(18) Measure voltage between E-05-17 (500) and E-05-20