7FBR RM Vol2 CE352

foreword_vol2.
fm 1 ページ２０１２年７月１０日火曜日午前８時４５分
FOREWORD
This Manual (Volume 2) contains electrical wiring diagrams, diagnosis and
service procedures of electrical controller and display of the TOYOTA ELEC-
TRICAL POWERED FORKLIFT 7FBR10 to 18 series.
For maintenance, specifications and repair procedure for the chassis, body
and material handling system, please refer to Volume 1 (Pub. No. CE351)
issued simultaneously.
Please use these manuals for providing quick, correct servicing of the corre-
sponding forklift models.
This manual deals with the above models as of July, 2012. Please under-
stand that disagreement can take place between the descriptions in the man-
ual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18

REPAIR MANUAL VOL.1 (Pub. No. CE351)
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18, 20, 25, 30
sec_index_E_vol2.fm 1 ページ２０１２年７月１６日月曜日午後４時２分
SECTION INDEX
NAME SECTION
INSTRUCTION MANUAL NMF

GENERAL 0
BATTERY 1
CHARGER 2
CONTROLLER 3
DISPLAY 4
TROUBLESHOOTING 5
MOTOR 6
DRIVE UNIT 7
SUSPENSION & CASTER WHEEL 8
STEERING 9
FRONT BRAKE & AXLE 10
REAR BRAKE 11
BODY 12
MATERIAL HANDLING SYSTEM 13
MAST 14
CYLINDER 15
OIL PUMP 16
OIL CONTROL VALVE 17
HYDRAULIC PIPING 18
TBC•EPS 19
APPENDIX 20
ELECTRIC WIRING DIAGRAM 21
Section indicated by solid characters are included in this manual.
Section indicated by half-tone characters: Refer to vol. 1 (Pub. No. CE351).
03E_controller.book 1 ページ２０１２年７月１０日火曜日午前８時２４分
3-1
CONTROLLER
Page
ELECTRICAL COMPONENTS NMF
LAYOUT DRAWING ..............................................3-2
0
LAYOUT OF CONTROLLER CABLES...................3-3
1
EPS CONTROLLER................................................3-4
2
COMPONENTS ........................................................3-4
MAIN CONTROLLER..............................................3-5 3
CONNECTOR-PIN ASSIGNMENT ..............................3-6 4
CONNECTOR INSPECTION ......................................3-10 5
REMOVAL·INSTALLATION .......................................3-29 6
DRIVE/PUMP AC DRIVER......................................3-31 7
REMOVAL·INSTALLATION .......................................3-31
8
CONTACTOR PANEL .............................................3-32
9
COMPONENTS ........................................................3-32
CONTACTOR PANEL
10
INSTALLATION PROCEDURE ................................3-33 11
CONTACTOR PANEL INSULATING
RESISTANCE TEST PROCEDURE ..........................3-36
12
REMOVAL·INSTALLATION .......................................3-37 13
ACCELERATOR LEVER.........................................3-39 14
GENERAL ...............................................................3-39 15
COMPONENTS ........................................................3-40 16
REMOVAL·INSTALLATION .......................................3-41
17
LIMIT SWITCH INSTALLATION PROCEDURE .............3-42
18
OCL MEASUREMENT ............................................3-44
19
20
21
3-2
ELECTRICAL COMPONENTS LAYOUT DRAWING
Contactor panel
Main controller
Drive AC driver
Pump AC driver
Cooling fan
Panel bracket
DC/DC controller
EPS controller
G42803TA001_
Connector cable
Harness
03E_controller.book 3 ページ
Cable Contactor panel

Short bar Main harness N1 CHG cable N
Installing sequence of cable N1 portion
To the battery plug

２０１２年７月１０日
Short bar
N1 N
火曜日
30°
45°
P2
P1 W W
60°
午前８時２４分
60° PW
Connector cable P1
V V
LAYOUT OF CONTROLLER CABLES
45° PV
CHG cable P1 45°
Caution for installation U U

1.The angles at which cables are shown
assembled are for reference only. 30° Main harness 30° Main harness
PU
During actual assembly, run the cables
so that they do not touch adjacent P4(D) P4(P)
terminals. 30°
2.Terminal tightening torque
T = 11 to 15 N·m Pump AC driver
Drive AC driver
(112 to153 kgf·cm)
[8.1 to 11.1 ft·lbf] To the pump motor
P4 Short bar
To the drive motor
To the transformer ASSY To the transformer ASSY

Put the P4 mark on this side
ASC cable
G42803TA017_
3-3
9
8
7
6
5
4
3
2
1
0
11
21
20
19
18
17
16
15
14
13
12
10
NMF
3-4
EPS CONTROLLER
COMPONENTS
QB
JX
QH
BP
ET NG
BL
PU
91611-40812 PT
MA
60
37
ES
CD
KR
73
66 PZ
77 IM
IR
02 77
JS
FT IM
PQ
MV FT
JL CB
BD
IR
IM AP
PC
G42803ZZ001_
No. Parts name No. Parts name

02 EPS controller IR Screw
37 Board ASSY JL Screw
60 Contactor ASSY, PS JS Screw
66 Heatsink JX Bolt
73 Bracket KR Bar
77 Transistor MA Rubber
AP Cover MV Harness
BD Screw NG Spacer
BL Bolt PC Harness
BP Washer, plate PQ Wiring
CB Grommet PT Bracket
CD Nut PU Box
ES Washer, spring PZ Wiring
ET Washer, plate QB Rubber
FT Resistor QH Cushion
IM Screw
3-5
MAIN CONTROLLER
NMF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
G85703001_
18
Caution:
When replacing the main controller, always check the part No.
19
20
21
3-6
CONNECTOR-PIN ASSIGNMENT
A24 A25 A26 A27
G42803ZZ002_
A24
No. Terminal name Circuit mode Remarks
102 --- ---
103 --- ---
104 --- ---
105 VBBT VBBT VBBT
106 --- ---
107 --- ---
108 --- ---
109 --- ---
110 --- ---
111 --- ---
112 --- ---
113 --- ---
114 --- ---
115 --- ---
116 --- ---
117 --- ---
118 --- ---
119 VBBA VBBA VBBA
120 VBKY VBKY VBKY
121 --- ---
122 --- ---
123 POTA- VRA- ACCELERATOR SENSOR GND
124 --- ---
125 --- ---
126 --- ---
127 --- ---
128 POTA+ VRA1+ ACCELERATOR SENSOR 1 POWER SUPPLY
129 --- ---
ATTACHMENT 1 LEVER SENSOR POWER
130 48VON+ VRAT1+
SUPPLY
131 SST VRAT2+
SUPPLY
132 20VON+ VRAT3+
SUPPLY
133 POT- POT- GND3
134 --- VRB2+ BRAKE SENSOR 2 POWER SUPPLY
135 --- VRB1+ BRAKE SENSOR 1 POWER SUPPLY
3-7
A25
67 --- FNDC1 FAN1
68 FNDC2 FNDC2 FAN2
69 --- VBMBSL VBMBSOL
70 --- VBMBSL VBMBSOL
71 --- SOLCOM SOLCOM
72 --- SOLCOM SOLCOM
73 --- SLS+ KNOB, MPS+
74 --- OACC3 ACCESSORY 3 (for FORWARD)
75 20VON- OACC2 ACCESSORY 2 (for REVERSE)
76 VERR- LS- GND2
77 48VON- OACC1 ACCESSORY 1 (for BRAKE)
78 --- RY2- RYR2
79 --- RY1- RYR1
80 --- SLS- KNOB-
81 --- MPS- SLDM- (MPS-)
82 --- SLLL- LIFT-
83 --- SLUL- UNLOAD-
84 --- SLTBL- TILTR-
85 --- SLTFL- TILTF-
86 LSL1 VRA12 ATTACHMENT 1 LEVER SENSOR 2
87 LSAT1 VRA11 ATTACHMENT 1 LEVER SENSOR 1
88 --- VRT2 TILT LEVER SENSOR 2
89 LST VRT1 TILT LEVER SENSOR 1
90 CSBAT CSBAT BATTERY CURRENT SENSOR
91 --- VRB2 BRAKE SENSOR 2 (combined with SW)
92 --- POT- GND4
93 --- CHK5V 5V POWER SUPPLY for CHECK
94 LSL2 VRA22 ATTACHMENT 2 LEVER SENSOR 2
95 LSAT2 VRA21 ATTACHMENT 2 LEVER SENSOR 1
96 POTA1 VRA1 ACCELERATOR SENSOR 1
97 --- VRTRA TIRE ANGLE SENSOR
98 POTA2 VRA2 ACCELERATOR SENSOR 2
99 --- VRB1 BRAKE SENSOR 1 (combined with SW)
100 --- VRS SWING ANGLE SENSOR
101 CSBAT- CSBAT- BATTERY CURRENT SENSOR GND
3-8
A26
32 --- SLSW+ SWING+
33 --- SLSW+ SWING-
34 DGND DGND DISPLAY GND
35 KYSAT KYSAT KEYSTART
36 N2 N2 N2
37 LS- LS- GND4
38 SMTSA SMTSA SMTSA
39 --- IPL+ SHOCK SENSOR POWER SUPPLY
40 CAN2H CAN2H CAN2H
41 CAN2L CAN2L CAN2L
42 CAN1H CAN1H CAN1H
43 CAN1L CAN1L CAN1L
STEERING WHEEL ANGLE SENSOR AND ULTRA
44 --- SSTR+
SONIC SENSOR POWER SUPPLY (combined use)
45 D7V D7V DISPLAY POWER SUPPLY
46 --- CHK15V 15V POWER SUPPLY for CHECK
47 --- CHK33V 3.3V POWER SUPPLY for CHECK
48 --- VRTA TILT ANGLE SENSOR
49 --- VRL2 LIFT LEVER SENSOR 2
50 --- IPL2 SHOCK SENSOR 2
51 SSTMA SSTMA SSTMA
52 SMTSK SMTSK SMTSK
53 SSTMK SSTMK SSTMK
54 --- OPTSS2 OPTSS2
55 --- SH2-1 LIFTING HEIGHT SWITCH 2-1
56 VERR+ SHL HEIGHT LIMIT SWITCH
57 --- VRL1 LIFT LEVER SENSOR 1
58 --- SYR YAW RATE SENSOR
59 --- VRH HEIGHT SENSOR
60 --- SPLF PRESSURE SENSOR
61 --- IPL1 SHOCK SENSOR 1
62 --- SH2-2 LIFTING HEIGHT SWITCH 2-2
63 --- STK AUTOMATIC FORK LEVELING SWITCH
64 OLM+ OLM+ LASER POINTER POWER SUPPLY
65 --- VRA32 ATTACHMENT 3 LEVER SENSOR 2
ATTACHMENT 3 LEVER SENSOR 1
66 LSR VRA31
(SWITCH for 4/5-way)
3-9
A27
1 B48V B48V B80V(B48V)
2 VBMB VBMB VBMB
3 CBAT+ CBAT+ MB, P+
4 N2 N2 N2
5 N2 N2 N2
6 N2 N2 N2
7 --- N2 N2
8 --- MP- MP-
9 CBAT- CBAT- MB-
10 CSBAT+ CSBAT+ BATTERY CURRENT SENSOR POWER SUPPLY
11 --- SYR- YAW RATE SENSOR GND
12 --- SPLF+ PRESSURE SENSOR POWER SUPPLY
13 --- SYR+ YAW RATE SENSOR POWER SUPPLY
14 PSACC+ PSACC+ ACCESSORY POWER SUPPLY
POWER SUPPLY for MINI LEVER SWITCH (LOAD
15 --- PSSW+ METER, AUTOMATIC FORK LEVERING and
SWITCH for 4/5-WAY SW)
16 --- CHKG CHKG
17 SS- OPT2 OPT2
18 LSD SDM SEAT SWITCH
19 --- DSR DIRECTION SWITCH REVERSE
20 LSPA SPB PARKING BRAKE SWITCH
21 --- OPTSSC OPTSSC
22 --- SH1 LIFTING HEIGHT SWITCH 1
23 LSB SWA SWA
STEERING WHEEL ANGLE SENSOR 3
24 TRC/L SSTRC
(only SSC combined with SW)
25 --- OPTSS1 OPTSS1
26 --- DSF DIRECTION SWITCH FORWARD
27 --- LSOPT1 LSOPT1
28 --- SLM LOAD METER
29 --- BMP BMP
30 NS SSTR1
31 RS SSTR2
3-10
Disassembly Procedure
Overhauling the control panel is rarely necessary. In most cases, failed parts is replaced after finding out
the cause of the failure from inspection.
Therefore, make sure to repair correctly by referring to the figures of configuration and ASSY.
Caution for Part Replacement
• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of
tightening may cause other failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When
connecting them again, be sure to confirm with the record and tags to prevent incorrect connection.
Incorrect connection may cause other failure.
• Always apply new silicon grease when reassembling parts originally coated with silicon grease.
Otherwise, overheating may occur.
• After installation, check that there is no interference of the bar and harness connection with other
portion.
Additionally, before installation, perform continuity inspection on points by the tester.
(Refer to 3-37 for points to be inspected by the tester.)
CONNECTOR INSPECTION
How to read the list
Tester Probe (+)
Tester Probe (–)

Connector pin No.
Connector No. ⇔ Connector No. Conditions Standard Remarks

A24-1 A24-26
Key switch OFF, DSF ON. Approx. 0 V
(45, DSF) (51, LS-)
Terminal name
Electric Level No. Conditions for measurement
3-11
Main Controller
A24
CN101 A25
CN102 A26
CN103 A27
CN104
G85703016_
A24 connector basic conditions (battery plug connected, key switch ON)
A24-1 — — —
A24-2 — — —
A24-3 — — —
A24-4 A27-4
— Approx. 48 V
(41, VBBT) (N2, N2)
A24-5 — — —
A24-6 — — —
A24-7 — — —
A24-8 — — —
A24-9 — — —
A24-10 — — —
A24-11 — — —
A24-12 — — —
A24-13 — — —
A24-14 — — —
A24-15 — — —
A24-16 — — —
A24-17 — — —
A24-18 A27-4 Battery stored Approx. 48 V
(49, VBBA) (N2, N2) Battery pulled out Approx. 0 V
A24-19 A27-4 Key switch OFF Approx. 0 V
(43, VBKY) (N2, N2) Key switch ON Approx. 48 V
A24-20 — — —
A24-21 — — —
A24-22
— — —
(50, POTA-)
A24-23 — — —
A24-24 — — —
A24-25 — — —
A24-26 — — —
3-12

A24-27 A24-32
— Approx. 5 V
(53, POTA+) (51, POT-)
A24-28 — — —
(73, 48VON+) (51, POT-) Key switch ON Approx. 1.5 V
(324, SS+) (51, POT-) Key switch ON Approx. 1 V
(75, 20VON+) (51, POT-) Key switch ON Approx. 1.2 V
A24-32
— — —
(51, POT-)
A24-33 — — —
A24-34 — — —
A25-1 — — —
FAN stopped
A25-2 A27-4 (OFF operation with ACTIVE TEST) Approx. 48 V
(100, FNDC2) (N2, N2)
FAN ON (ON operation with ACTIVE TEST) Approx. 0 V
A25-3 — — —
A25-4 — — —
A25-5 — — —
A25-6 — — —
A25-7 — — —
A25-8 — — —
(76, 20VON-) (51, POT-) Key switch ON Approx. 0 V
A25-10
— — —
(72, VERR-)
(74, 48VON-) (51, POT-) Key switch ON Approx. 0 V
A25-12 — — —
A25-13 — — —
A25-14 — — —
A25-15 — — —
A25-16 — — —
A25-17 — — —
A25-18 — — —
A25-19 — — —
Key switch OFF, Lift lever in the neutral
position Approx. 5 V
A25-20 A24-32
(60, LSL1) (51, POT-) Key switch OFF, during lift lever lift-up
operation Approx. 0 V
Key switch OFF, Attachment 1 lever in the

Approx. 5 V
A25-21 A24-32 neutral position
(63, LSAT1) (51, POT-) Key switch OFF, during attachment 1 lever
3-13

A25-22 — — —
Key switch OFF, Tilt lever in the neutral
A25-23 A24-32 Approx. 5 V
position
(61, LST) (51, POT-)
Key switch OFF, during tilt lever operation Approx. 0 V
A25-24 A25-35
— Approx. 2.5 V
(304, CSBAT) (305, CSBAT-)
A25-25 — — —
A25-26 — — —
A25-27 — — —
Key switch OFF, Lift lever in the neutral
Approx. 5 V
A25-28 A24-32 position
(68, LSL2) (51, POT-) Key switch OFF, during lift lever lift-down
A25-29 — — —
Key switch OFF, Accelerator lever in the
Approx. 2.3 V
(52, POTA1) (51, POT-) Key switch OFF, change amount when tilting Approx.
the accelerator lever forward or backward. 0.5 V to 4 V
A25-31 — — —
Key switch OFF, Accelerator lever in the
Approx. 2.3 V
(54, POTA2) (51, POT-) Key switch OFF, change amount when tilting Approx.
the accelerator lever forward or backward. 0.5 V to 4 V
A25-33 — — —
A25-34 — — —
A25-35
— — —
(305, CSBAT-)
A26-1 — — —
A26-2 — — —
A26-3
— — —
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Approx. 48 V
A26-5
— — —
(N2, N2)
A26-6
— — —
(51, LS-)
A26-7
— Immeasurable —
(307, SMTSA)
A26-8 — — —
A26-9 — — —
A26-10 — — —
A26-11
(145, CAN1H)
A26-12
(146, CAN1L)
3-14

A26-13 — — —
A26-14 A26-3
— Approx. 6.5 V
(16, D7V) (14, DGND)
A26-15 — — —
A26-16 — — —
A26-17 — — —
A26-18 — — —
A26-19 — — —
A26-20
(309, SSTMA)
A26-21
(308, SMTSK)
A26-22
(310, SSTMK)
A26-23 — — —
A26-24 — — —
A26-25 A27-4
— Approx. 0 V
(71, VERR+) (N2, N2)
A26-26 — — —
A26-27 — — —
A26-28 — — —
A26-29 — — —
A26-30 — — —
A26-31 — — —
A26-32 — — —
A26-33 A26-6
— Approx. 5 V
(306, OLM+) (51, LS-)
A26-34 — — —
Key switch OFF, Reach lever in the neutral
A26-35 A24-32 Approx. 5 V
position
(62, LSR) (51, POT-)
Key switch OFF, during reach lever operation Approx. 0 V
A27-1 A27-4
— Approx. 48 V
(41, B48V) (N2, N2)
(44, VBMB) (N2, N2) Key switch ON Approx. 48 V
A27-3 A27-9 Key switch ON Approx. 11 V
(1, CBAT+) (2, CBAT-) Key switch OFF Approx. 0 V
A27-4
— — —
(N2, N2)
A27-5
— — —
(N2, N2)
A27-6
— — —
(N2, N2)
A27-7 — — —
A27-8 — — —
3-15

A27-9 A27-3
Battery plug disconnected Approx. 20 Ω
(2, CBAT-) (1, CBAT+)
A27-10 A25-35
— Approx. 5 V
(303, CSBAT+) (305, CSBAT-)
A27-11 — — —
A27-12 — — —
A27-13 — — —
A27-14 A27-4
— Approx. 14 V
(336, PSACC+) (N2, N2)
A27-15 — — —
A27-16 — — —
(325, SS-) (N2, N2) Key switch ON Approx. 0 V
A27-18 A26-6 Key switch OFF, Floor switch ON Approx. 0 V
(67, LSD) (51, LS-) Key switch OFF, Floor switch OFF Approx. 5 V
A27-19 — — —
A27-20 A26-6
— Approx. 0 V
(70, LSPA) (51, LS-)
A27-21 — — —
A27-22 — — —
A27-23 A26-6 Key switch OFF, Brake switch release Approx. 0 V
(65, LSB) (51, LS-) Key switch OFF, Brake switch lock Approx. 5 V
A27-24 A26-6
— Approx. 5 V
(77, TRC/L) (51, LS-)
A27-25 — — —
A27-26 — — —
A27-27 — — —
A27-28 — — —
A27-29 — — —
A27-30 A26-6
— Approx. 5 V
(85, NS) (51, LS-)
A27-31 A26-6
— Approx. 5 V
(97, RS) (51, LS-)
3-16
Drive AC Driver
CN110
A28
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
G85703017_
A28-1 — — —
A28-2 — — —
A28-3 — — —
A28-4 — — —
A28-5 — — —
A28-6 — — —
A28-7 — — —
A28-8 —
— Approx. 48 V
(42, KYSAT) (N1, N1)
A28-9 —
— Approx. 5 V
(86, STDM+) (N1, N1)
A28-10 — Approx. 1 V
—
(87, STDM) (N1, N1) to 4 V
A28-11 — — —
A28-12 — — —
L: approx. 0.5 V
A28-13 —
— or
(80, SSD2) (N1, N1)
H: approx. 1.5 V
L: approx. 0.5 V
A28-14 —
— or
(79, SSD1) (N1, N1)
H: approx. 1.5 V
A28-15 —
— Approx. 15 V
(78, SSD+) (N1, N1)
A28-16
(146, CAN1L)
A28-17
(145, CAN1H)
A28-18 — — —
A28-19 — — —
A28-20 — — —
A28-21 — — —
A28-22 — — —
A28-23 — — —
3-17
CN111
A29
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
G85703019_
A29-1 — — —
A29-2 — — —
A29-3 — — —
A29-4 — — —
A29-5 — — —
A29-6 —
— Approx. 0 V
(152, SETP1) (N1, N1)
A29-7 — — —
A29-8 —
— Approx. 48 V
(42, KYSAT) (N1, N1)
A29-9 —
— Approx. 5 V
(88, STPM+) (N1, N1)
A29-10 — Approx.
—
(89, STPM) (N1, N1) 1 V to 4 V
A29-11 — — —
A29-12 — — —
A29-13 — — —
L: approx. 0.5V
A29-14 —
— or
(82, SSP1) (N1, N1)
H: approx. 1.5V
A29-15 —
— Approx. 15 V
(81, SSP+) (N1, N1)
A29-16
(146, CAN1L)
A29-17
(145, CAN1H)
A29-18 — — —
A29-19 — — —
A29-20 — — —
A29-21 — — —
A29-22 — — —
A29-23 —
— Approx. 0 V
(152, SETP-) (N1, N1)
3-18
Contactor Panel
CN135
A32
1 2 3
4 5
6
7 8
9 10 11
G42803ZZ015_
A32-1 A32-4 Battery plug disconnected, and the A32
(2, CBAT-) (1, CBAT+) connector disconnected Approx. 20 Ω
A32-2 P2 terminal Battery plug disconnected, and the A32

(P2, P2) (P2, P2) Approx. 0 Ω
connector disconnected
A32-3 A32-5 Apply the negative probe to the A32-5 to
(303, CSBAT+) (305, CSBAT-) measure voltage. Approx. 5 V
A32-4 A32-1 Apply the negative probe to the A32-4 to

(1, CBAT+) (2, CBAT-) measure voltage. Approx. 11 V
A32-5
— — —
(305, CSBAT-)
(P2, P2) (P2, P2) Approx. 0 Ω
(44, VBMB) (P3, P3) Approx. 0 Ω
Apply the negative probe to the A32-5 to
A32-8 A32-5 measure voltage.
(304, CSBAT) (305, CSBAT-) Drive motor, pump motor, all auxiliary Approx. 2.5 V
machines OFF
(360, VBBTS) (P3, P3) Approx. 0 Ω
(P3, P3) (P3, P3) Approx. 0 Ω
A32-11 — — —
3-19
Display
CN70
M3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
G85703019_
M3 connector basic conditions (battery plug connected, key switch ON)

M3-1 M3-2
— Approx. 6.3V
(128, CHG7V) (130, CHGGND)
M3-2
— — —
(130, CHGGND)
M3-3
— — —
(169, TGND)
M3-4
— — —
(14, DGND)
M3-5 M3-4
— Approx. 6.3 V
(16, D7V) (14, DGND)
M3-6 M3-3
— Approx. 5 V *1
(162, ITKY3) (169, TGND)
M3-7 — — —
M3-8 M3-3
— Approx. 5 V *1
(160, ITKY1) (169, TGND)
M3-9
(166, OTKY3)
M3-10
(165, OTKY2)
M3-11
(164, OTKY1)
M3-12 M3-3
— Approx. 0 V *1
(167, LEDTKY1) (169, TGND)
M3-13 — — —
M3-14 — — —
M3-15
(146, CAN1L)
M3-16
(145, CAN1H)
M3-17 — — —
M3-18 M3-36
— Approx. 48 V *2
(43, VBKY) (N1, N1)
M3-19 M3-3
— Approx. 3 V *1
(168, LEDTKY2) (169, TGND)
M3-20 M3-3
— Approx. 5 V *1
(161, ITKY2) (169, TGND)
3-20

M3-21 M3-3
— Approx. 5 V *1
(163, IPSTKY1) (169, TGND)
M3-22 M3-4
— Approx. 5 V
(123, SW1) (14, DGND)
M3-23 M3-4
— Approx. 5 V
(122, SW2) (14, DGND)
M3-24 M3-4
— Approx. 5 V
(121, SW3) (14, DGND)
M3-25 M3-4
— Approx. 5 V
(129, CHGAC) (14, DGND)
L: approx. 1.8 V
M3-26 M3-4
— or
(140, SLLT) (14, DGND)
H: approx. 2.7 V
M3-27 — — —
M3-28 — — —
M3-29 M3-4
— Approx. 0 V
(125, LED3) (14, DGND)
M3-30 M3-4
— Approx. 0 V
(126, LED2) (14, DGND)
M3-31 M3-4
— Approx. 0 V
(127, LED1) (14, DGND)
M3-32 M3-4
— Approx. 0 V
(124, LED4) (14, DGND)
M3-33 M3-4
— Approx. 6.3 V
(132, CHGMS) (14, DGND)
M3-34 — — —
M3-35 — — —
M3-36
— — — *2
(N1, N1)
*1 PIN CODE ENTRY SYSTEM
*2 Cold storage specification only
3-21
Ten-Key (W/ PIN code entry system)
CN33
M1
5 4 3 2 1
10 9 8 7 6
G85703020_

M1-1 M1-7
— Approx. 5 V
(160, ITKY1) (169, TGND)
M1-2 M1-7
— Approx. 5 V
(161, ITKY2) (169, TGND)
M1-3 M1-7
— Approx. 5 V
(162, ITKY3) (169, TGND)
M1-4
(165, OTKY2)
M1-5 M1-7
— Approx. 0 V
(167, LEDTKY1) (169, TGND)
M1-6 M1-7
— Approx. 5 V
(163, IPSTKY1) (169, TGND)
M1-7
— — —
(169, TGND)
M1-8
(164, OTKY1)
M1-9
(166, OTKY3)
M1-10 M1-7
— Approx. 3 V
(168, LEDTKY2) (169, TGND)
3-22
Charger Switch Box (Option)
CN68
M2
6 5 4 3 2 1
12 11 10 9 8 7
G85703021_

M2-1 M2-3
— Approx. 6.3 V
(132, CHGMS) (130, CHGGND)
M2-2 M2-3
— Approx. 5 V
(129, CHGAC) (130, CHGGND)
M2-3
— — —
(130, CHGGND)
M2-4 M2-3
— Approx. 6.3 V
(128, CHG7V) (130, CHGGND)
M2-5 M2-3
— Approx. 5 V
(121, SW3) (130, CHGGND)
M2-6 M2-3
— Approx. 5 V
(122, SW2) (130, CHGGND)
M2-7 M2-3
— Approx. 5 V
(123, SW1) (130, CHGGND)
M2-8 M2-3
— Approx. 0 V
(124, LED4) (130, CHGGND)
M2-9 M2-3
— Approx. 0 V
(125, LED3) (130, CHGGND)
M2-10 M2-3
— Approx. 0 V
(126, LED2) (130, CHGGND)
M2-11 M2-3
— Approx. 0 V
(127, LED1) (130, CHGGND)
M2-12 — — —
3-23
Battery Electrolyte Level / Temperature Sensor
N1
CN35
G85703023_
N1 connector basic conditions (battery plug connected, key switch ON)

L: approx. 1.8 V
N1 M3-4
Connected with display or
(140, SLLT) (14, DGND)
H: approx. 2.7 V
EPS CONTROLLER
A35-1 A35-3
— Approx. 20 V
(338, B20V+) (339, B20V-)
A35-2 A35-10
— Approx. 20 V
(11, S20V+) (12, S20V-)
A35-3
(339, B20V-)
A35-4 A35-17
— Approx. 48 V
(3, SOLL+) (N2, N2)
A35-5 A35-17
— Approx. 48 V
(329, SOLBC+) (N2, N2)
(360, VBBTS) (N2, N2) Key switch ON Approx. 48 V
A35-7 — — —
A35-8 A35-17
(P2, P2) (N2, N2) Battery plug connected Approx. 48 V
A35-9 — — —
A35-10
(12, S20V-)
A35-11 A35-17
— Approx. 37 V
(4, SOLL-) (N2, N2)
A35-11 A35-4
(4, SOLL-) (3, SOLL+)
A35-12 A35-17
— Approx. 48 V
(331, SOLBS+) (N2, N2)
A35-13 A35-17
— Approx. 48 V
(332, SOLBS-) (N2, N2)
A35-13 A35-12
(332, SOLBS-) (331, SOLBS+)
A35-14 A35-17
— Approx. 48 V
(327, SOLS+) (N2, N2)
A35-15 A35-17
— Approx. 48 V
(328, SOLS-) (N2, N2)
A35-15 A35-14
Battery plug disconnected Approx. 5.5 Ω
(328, SOLS-) (327, SOLS+)
3-24

A35-16 A35-17
— Approx. 0 V
(330, SOLBC-) (N2, N2)
A35-16 A35-5
(330, SOLBC-) (329, SOLBC+)
A35-17
— — —
(N2, N2)
A35-18 — — —
A36-1 A36-22
— Approx. 5 V
(58, SPL+) (300, BPOT-)
L: approx. 0.7 V
A36-2 A36-22
— or
(334, SSFL) (300, BPOT-)
H: approx. 1.4 V
A36-3 — — —
A36-4 — — —
A36-5 A36-22
Lift at the lowest position Approx. 0 V
(90, MH1) (300, BPOT-)
A36-6 A36-22
(91, MH2-1) (300, BPOT-) Lift at the lowest position Approx. 5 V
A36-7 — — —
A36-8 — — —
A36-9
(295, SATBK)
A36-10
(294, SATBA)
A36-11
(296, SBTAA)
A36-12
(307, SMTBA)
A36-13
(309, SBTMA)
A36-14 A36-22
— Approx. 15 V
(333, SSF+) (300, BPOT-)
L: approx. 0.7 V
A36-15 A36-22
— or
(335, SSFR) (300, BPOT-)
H: approx. 1.4 V
A36-16 A36-22
— Approx. 5 V
(316, VRAH+) (300, BPOT-)
A36-17 A36-22
— Approx. 5 V
(176, SST+) (300, BPOT-)
A36-18 A36-22 Approx.
—
(59, SPL) (300, BPOT-) 0.3 V to 4.5 V
A36-19 A36-22 Changed from the right stroke end to the left Approx.
(177, SST) (300, BPOT-) stroke end 0.3 V to 2.9 V
A36-20 A36-22 Approx.
Turned the steering wheel
(317, VRAH) (300, BPOT-) 0.5 V to 4.5 V
A36-21 A36-22
— Approx. 0 V
(301, BLS-) (300, BPOT-)
3-25

A36-22
— — —
(300, BPOT-)
A36-23 A36-22
— Approx. 0 V
(178, SST-) (300, BPOT-)
A36-24
(297, SBTAK)
A36-25
(308, SMTBK)
A36-26
(310, SBTMK)
A37-1 — — —
A37-2 — — —
A37-3 A36-22 Battery plug connected Approx. 5 V
(324, SS+) (300, BPOT-) Key switch ON Approx. 1 V
A37-4 A36-22
— Approx. 5 V
(98, RS+) (300, BPOT-)
A37-5 A36-22
— Approx. 5 V
(83, NS+) (300, BPOT-)
A37-6 — — —
A37-7 — — —
A37-8 A36-22
— Approx. 5 V
(137, TRC/L+) (300, BPOT-)
A37-9 — — —
A37-10 — — —
A37-11 A36-22 Battery plug connected Approx. 4 V
(325, SS-) (300, BPOT-) Key switch ON Approx. 0 V
A37-12 A36-22
— Approx. 5 V
(99, RS-) (300, BPOT-)
A37-13 A36-22
— Approx. 5 V
(84, NS-) (300, BPOT-)
A37-14 — — —
A37-15 — — —
A37-16 A36-22
— Approx. 4 V
(138, TRC/L-) (300, BPOT-)
Z4 connector basic conditions (F3 fuse removed, battery plug connected, key switch ON)
Z4-1 — — —
Z4-2
(173, SH1-)
Z4-3
(172, SH1+)
Z4-4
(175, SH2-)
Z4-5
(174, SH2+)
3-26
Steering wheel turned left Approx.

Z4-6 Z4-7 12 V to 15 V
(154, TMPS3G) (155, TMPS3E) Steering wheel turned right or in neutral 1 V or less
position
Z4-7 Z4-6 TMPS connector removed, Battery plug OFF,
(155, TMPS3E) (154, TMPS3G) key switch OFF 1 kΩ to 100 kΩ

(157, TMPS4E) (156, TMPS4G) key switch OFF Approx. 100 kΩ
Z4-9 Z4-8 Steering wheel turned right 0 V to 15 V

(156, TMPS4G) (157, TMPS4E) Steering wheel turned left or stopped turning 1 V or less
Z4-10 Z4-11 Steering wheel turned right 12 V to 15 V
(158, TMPS1G) (159, TMPS1E) Steering wheel turned left or in neutral position 1 V or less
(159, TMPS1E) (158, TMPS1G) key switch OFF 1 kΩ to 100 kΩ

(171, TMPS2E) (170, TMPS2G) key switch OFF Approx. 100 kΩ
Z4-13 Z4-12 Steering wheel turned left 0 V to 15 V

(170, TMPS2G) (171, TMPS2E) Steering wheel turned left or stopped turning 1 V or less
Z4-14 — — —
Z27 connector basic conditions (battery plug disconnected, key switch OFF)
Z27-1 A35-17 Battery plug connected, Key switch ON,
(P22, P22) (N2, N2) MPS ON Approx. 48 V
Z27-2 — — —
Z27-3 Z27-4
— Approx. 68 Ω
(9, MPS-) (10, MPS+)
Z27-4 A35-17
(10, MPS+) (N2, N2) Battery plug connected, Key switch ON Approx. 48 V
Z27-5 — — —
3-27
DC/DC Controller
Controller No.
Manufacturing No.
Connector pins layout
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
A33
G42803ZZ006_
A33-1 A33-17
— Approx. 20 V
(338, B20V+) (339, B20V-)
A33-2 A33-18
— Approx. 20 V
(11, S20V+) (12, S20V-)
(75, 20VON+) (N2, N2) Key switch ON Approx. 1.2 V
A33-4 A33-20
— Approx. 0 V
(71, VERR+) (72, VERR-)
A33-5 A33-20
— Approx. 5 V
(85, NS) (72, VERR-)
A33-6 A33-20
— Approx. 5 V
(77, TRC/L) (72, VERR-)
A33-7 A33-32
— Approx. 5 V
(137, TRC/L+) (N2, N2)
A33-8 A33-32
— Approx. 5 V
(98, RS+) (N2, N2)
A33-9 A33-32
— Approx. 5 V
(83, NS+) (N2, N2)
(73, 48VON+) (N2, N2) Key switch ON Approx. 1.5 V
A33-11 — — —
A33-12 — — —
A33-13 A33-32
— Approx. 48 V
(360, VBMB) (N2, N2)
A33-14 A33-32
— Approx. 48 V
(360, VBMB) (N2, N2)
A33-15 — — —
A33-16 A33-32
— Approx. 48 V
(41, B48V) (N2, N2)
3-28

A33-17
(339, B20V-)
A33-18
(12, S20V-)
(76, 20VON-) (N2, N2) Key switch ON Approx. 0 V
A33-20
— — —
(72, VERR-)
A33-21 A33-20
— Approx. 5 V
(97, RS) (72, VERR-)
A33-22 — — —
A33-23 A33-32
— Approx. 5 V
(138, TRC/L-) (N2, N2)
A33-24 A33-32
— Approx. 5 V
(99, RS-) (N2, N2)
A33-25 A33-32
— Approx. 5 V
(84, NS-) (N2, N2)
(74, 48VON-) (N2, N2) Key switch ON Approx. 0 V
A33-27 — — —
A33-28 — — —
A33-29 — — —
A33-30 A33-32
— Approx. 48 V
(360, VBMB) (N2, N2)
A33-31 — — —
A33-32
— — —
(N2, N2)
3-29
Bolt
REMOVAL·INSTALLATION
EPS controller
Bolt Removal Procedure
1 Disconnect the battery plug.
2 Remove the front panel.
3 Remove the instrument panel.
Note:
See page 2-8 for the removal procedure.
4 Remove the EPS controller.

(Bolts at 3 places)
G42803DA003_
5 Follow the procedure below to remove the cooling fan.

(1) Disconnect the connector of the cooling fan.
Bolt
(2) Remove the cooling fan set bolt.
Then remove the cooling fan.
(3) Disconnect the diagnosis connector and remove
the fuse block.
(4) Remove the cooling fan.
Connector
Cooling fan
Fuse block
Diagnosis
connector
Bolt
G42803TA012_
3-30
Bolt
Connector
Connector
Bolt
G42803TA003_
6 Follow the procedure below to remove the main controller.

(1) Disconnect the connector from the main controller (connectors at 4 places) and DC/DC controller.
(2) Remove the main controller set bolt.
DC/DC controller
Main controller
W/DC/DC controller
Main controller
G42803DA006_
(3) Remove the main controller W/DC/DC controller.

3-31
DRIVE/PUMP AC DRIVER
Short bar
Harness
Cable
T = 13 ± 2 N·m
(132.6 ± 20 kgf·cm)
[9.6 ± 1.5 ft·lbf]
Harness Harness
Cable
Cable
T = 13 ± 2 N·m
(132.6 ± 20 kgf·cm)
[9.6 ± 1.5 ft·lbf]
Short bar G42803TA018_
Removal Procedure
1 Disconnect the cable, harness and remove the short bar from the drive / pump AC driver.
2 Remove the drive / pump AC driver set bolt.

Tightening torque:
T = 5.5 N·m (56.1 kgf·cm) [4.1 ft·lbf]
Bolt
Bolt
G42803TA005_
3 Remove the drive / pump AC driver.

Pump AC driver
Drive AC driver
G42803DA009_
Installation Procedure
The installation procedure is the reverse of the removal procedure.
3-32
CONTACTOR PANEL
COMPONENTS
Current sensor
P1-P2 Short bar
Insulating sheet
P3 Short bar
Contactor ASSY
F1 Fuse
Harness
Fuse block
P4 Short bar
Terminal
G42803TA006_
3-33
CONTACTOR PANEL INSTALLATION PROCEDURE

1 Tightening torque view
18 13 2 14
10
17
11
16
12 6 15
G42803ZZ004_
No. Tightening torque N·m (kgf·cm) [lbf·in] No. Tightening torque N·m (kgf·cm) [lbf·in]
1 11 to 15 (112 to 153) [8.1 to 11.1] 10 2.0 to 3.0 (20 to 31) [1.48 to 2.21]
2 7.8 to 11.8 (80 to 120) [5.75 to 8.71] 11 K
3 11 to 15 (112 to 153) [8.1 to 11.1] 12 K
4 7.8 to 11.8 (80 to 120) [5.75 to 8.71] 13 K
5 K 14 K
6 11 to 15 (112 to 153) [8.1 to 11.1] 15 K
7 7.8 to 11.8 (80 to 120) [5.75 to 8.71] 16 K
8 2.0 to 3.0 (20 to 31) [1.48 to 2.21] 17 K
9 K 18 1.3 to 1.7 (13 to 17) [0.96 to 1.25]
3-34
2 How to use the F1 fuse separately

Install the F1 fuse while checking the number and color seal attached on the fuse.
Application models 1.0 to 1.3 ton 1.5 to 1.8 ton
Outline drawing
5 4
Orange Yellow
G42803DA011 G42803DA012
Numeral 5 4
Color seal Orange Yellow
Rated current (A) 360 410
3 F1 fuse installing direction

Install the F1 fuse in direction shown below.
G42803TA008_
3-35
4 Installing angle of P2 harness and P3 harness, and lapping sequence of P3 harness

Install with angles of P2 harness and P3 harness, and the lapping sequence of the nut, washer and terminal on
P3 harness portion as shown below.
P2 Harness
(White - Green,
Yellow)
Nut
Spring washer
30° or more
Washer
Harness
terminal
P3 Harness Aluminum bar
(White - Yellow)
P3 Harness
30° (Yellow - Black)
30°
60° 60°
G42803DA014_
5 Fuse block
10A
10A
10A
3 2
3 2
10A
4 1 4 1
G42803ZZ005
3-36
CONTACTOR PANEL INSULATING RESISTANCE TEST PROCEDURE
Make sure to perform an insulating resistance test.
P1
Base
CN135
A32
A32
1 2 3
P4
4 5
6
7 8
9 10 11
A32
Measurement place
instruction view
G42803TA009_
Measurement place
No. (Measure the insulating resistance between A and B.) Standard Locator
A B
P1, P4, A32 Insulation
1 Base DC 500 V applied
(Only No.1, 4 Pin: Reference above chart) resistance
10 MΩ more
2 P1, P4 A32 (Only No.1, 4 Pin: Reference above chart) tester
3-37
Removal Procedure
1 Remove the main controller.
(See page 3-30)
2 Remove the upper cover.
Upper cover
G42803TA010_
3 Disconnect the drive driver terminals from 4 points.
Drive driver
terminals
G42803TA013_
4 Disconnect the cable and the connector.
Cable
G42803TA011_
Connector
G42803TA014_
3-38
Contactor panel 5 Remove the contactor panel mounting bolt, and

remove the contactor panel.
Note:
Refer to page 3-34 for "CONTACTOR PANEL
INSTALLATION PROCEDURE".
G42803TA019_
3-39
ACCELERATOR LEVER
GENERAL
7
9
8
G42803TA015_

1 Accelerator lever 6 Arm
2 Flange bolt (for installing) 7 Cam
3 Sensor shaft 8 Limit switch (for auxiliaries)
4 Accelerator sensor 9 Plate
5 Spring
3-40
COMPONENTS
2
6
5
1
3
4
7
8
9
10
12
13
14
15
16 11
17
20
21
22
19 18
G42803TA016_

1 Knob 12 Screw
2 Accel lever 13 Nut
3 Bush 14 Arm
4 Spring 15 Washer plate
5 Plate 16 Bush
6 Flange bolt 17 Sensor shaft
7 Plate 18 Bracket
8 Bush 19 Nut
9 Cam 20 O-Ring
10 Locktite bolt 21 Accelerator sensor
11 Limit switch 22 Screw
3-41
Instrument panel
Removal Procedure
1 Remove the instrument panel.
Note:
See page 2-8 for the removal procedure.
G42803DA018
2 Remove the pad.

Pad
G42803DA019
3 Remove the knob, remove the accelerator lever

mounting bolt, and then pull out the accelerator lever
downward.
Accelerator lever
G42803DA020
3-42
LIMIT SWITCH INSTALLATION PROCEDURE
Screw
Direction switch (LH) Direction switch (RH)

Screw
Screw tightening torque
T = 0.4 to 0.85 N·m (4.1 to 8.7 kgf·cm)
[0.30 to 0.63 ft·lbf]
Details of A portion Details of B portion

Fix the direction switch to the plate by the tie wrap at the The direction switch with yellow tape attached to the cable
portion attached with yellow tape. close to the direction switch should be installed on the right.
Then fold back the harness of the right direction switch and
adjust the length.
Apply esso beacon 325 to

all around of the pipe.
C
D
Details of C
Apply esso beacon 325 to the Details of D portion
portion
inside and collar of the bush.
Apply esso beacon 325 to the
inside and collar of the bush.
Apply esso beacon 325 to
all around of the spring.
G42803ZZ009_
3-43
Screw tightening torque

T = 1.57 to 2.35 N·m
(16.0 to 24.0 kgf·cm)
[1.16 to 1.73 ft·lbf]
Circuit diagram
1 2 3 4
(+) (PS) (-) (PS2)
Terminal alignment
1 2 4 3
G42803DA021_
Adjust the PS1 output value to 2.40 ± 0.1 V at the accelerator sensor neutral position. (Voltage applied: 5.0 ± 0.1 V)
After adjustment, tighten the screw.
Tightening torque: 1.57 to 2.35 N·m (16.0 to 24.0 kgf·cm) [1.16 to 1.73 ft·lbf]
3-44
Wood piece
OCL MEASUREMENT
[For drive circuit]
1 Preparation before measurement
(1) Make the fork tips contact a wall or steel pole with
a rated load on the forks. Be sure to place a piece
of wood between the fork tip and the wall.
G42803ZZ016_
(2) Turn on the SST by pressing the POWER key on

the unit.
SST 09140-13130-71
POWER key
G85703033_
(3) Press the mode key twice to switch to the

AC+DC A measurement mode.
AC+CD A measurement mode display
MODE key
G85703034_
(4) Press the SAMPL key to set the display update

rate to “SLOW”.
Display update rate
SAMPL key
G42803ZZ012_
3-45
SHIFT key enabled display (5) After pressing the SHIFT key, press the CLEAR
key to start zero point adjustment. (Pressing the
CLEAR key makes the “ADJ” indicator flash and
switches the unit to zero point adjustment mode.
When the “ADJ” indicator stays on after flashing,
zero point adjustment is completed.)
SHIFT key
CLEAR key
Zero point adjustment complete display G42803ZZ013_
2 Measurement work
(1) Set the clamp sensor of the SST on the motor
cable.
Note:
Set the clamp sensor so that the cable is positioned in
the center of the clamp with the clamp sensor aligned
perpendicular to the cable.
G85703037_
3-46
(2) Turn on the key switch and set the direction

switch to “Forward”. Gradually depress the
accelerator lever to full throttle and hold there.
The SST will start measurement automatically.
Note:
• The SST start measurement automatically as soon
as forward motion starts. Be sure to wait for
approximately 20 seconds before reading the
measurement value. “O.L.” (Overflow alert) may be
displayed during the first 10 seconds, or the
displayed value may not be stable for a while.
G42803ZZ017_
• If the measurement value is not stable after

SHIFT key enabled display approximately 20 seconds, retry measurement by
pressing the SHIFT key down then the PEAK/Hz key
to enable filter setting as shown in the illustration.
• Measurement can be done in this mode (AC+DC A
mode, Display update mode: SLOW) also. However,
when using other modes, motor current frequency
in forward motion is only 10 Hz or below and current
measurement cannot be obtained.
OCL Standard Value:
SHIFT key PEAK/Hz key Drive motor
Model Current (A)
7FBR10 - 18 205 - 280
Filter setting display

G85703039_
[For pump circuit]

The OCL value of the pump circuit cannot be measured
because of the following reason:
In the material handling system the relief valve in the
control valve operates at the stroke end of each cylinder.
The OCL value for the pump circuit is set at a higher level
than the current at the relief valve set pressure.
As relief occurs in the hydraulic circuit before the pump
circuit current reaches the OCL value.
OCL value > Lift relief valve value
OCL Standard Value:
Pump motor
Model Current (A)
7FBR10, 13 195 - 270
7FBR15, 18 250 - 335
04E_display.book 1 ページ２０１２年７月１０日火曜日午前７時１０分
4-1
DISPLAY
Page
GENERAL ...............................................................4-2 NMF
DETAIL DESCRIPTION...........................................4-3 0
ADMINISTRATOR FUNCTIONS .............................4-5 1
SERVICE FUNCTIONS ...........................................4-7
2
SERVICE PASSWORD ...........................................4-8
OPERATION OF SERVICE MENU SCREEN ...........4-9
3
ANALYZER..............................................................4-11 4
TUNING ...................................................................4-29 5
OPTION SET ...........................................................4-40 6
MATCHING..............................................................4-42
7
OTHERS MENU ......................................................4-53
8
9
10
11
12
13
14
15
16
17
18
19
20
21
4-2
GENERAL
The multifunction display DX adopts a full-dot matrix LCD panel to display various information in an easy-to-see
way. It is provided not only with the functions of displaying and providing vehicle information, such as vehicle speed
and remaining battery capacity, but also with functions that allow the operator (or the administrator) to set the
vehicle performance.
Difference from the multiple screen display provided on the previous model (before improvement)
• The wheel indicator (with direction indicator) has been provided as standard.
• The power meter has been added.
• The maintenance hour meter has been added.
• The integrating wattmeter has been added as an option.
In addition to these functions, it has also a maintenance function, a feeling adjustment function and a specification
setting function as service functions.
The degree of protection provided as a single part (IP code) is equivalent to IP42 (except for peripheral part of
connectors), and that provided by enclosures is equivalent to IPX4.
(6) (8)
(9)
(10)
(7) (11)
(5)
(1) (2) (3) (4)
G428ZZ051_
No. Description
(1) Switch (1): Low speed setting switch / Down switch
(2) Switch (2): Power select switch / Left switch
(3) Switch (3): Time or date select switch / Right switch
(4) Switch (4): Meter mode select switch / Enter switch
(5) Multiple screen display area
(6) OPS indicator
(7) Low speed setting indicator
(8) Spanner indicator
(9) Overheat warning indicator
(10) Battery overheat warning indicator
(11) Battery electrolyte level warning indicator
4-3
DETAIL DESCRIPTION
1. Indicator
Indicator Description
OPS indicator (Except for steel cabin spec. at extremely low temperature and in long time):
NMF
This indicator lights when the operator is not properly floor.
G428ZZ058_
0
Low speed setting indicator: 1
This indicator goes on or off each time the low speed setting switch is pressed. The indicator
lights when the low speed setting function is enabled. 2
It does not light when the low speed setting function is disabled (OFF).
The low speed can be set on both the operator setting screen and the 3
administrator setting screen. When menu lock is enabled, this setting can be made only on
G428ZZ059_
the administrator setting screen. 4
Spanner indicator: 5
This indicator blinks and the buzzer sounds if any vehicle’s error are detected.
At that time, an error code is displayed in the multiple screen display area. 6
G428ZZ060_
Overheat warning indicator:

7
This indicator lights up and the buzzer sounds if the temperature of the drive/pump motor
rises excessively. 8
At the same time, the overheated part is also displayed in the multiple screen display area.
9
G428ZZ061_
Battery electrolyte temperature warning indicator (with battery protection function):

If the battery electrolyte temperature rises above the specified temperature, this indicator 10
lights up, the buzzer sounds and the output is limited. This function helps prevent a reduction
in the battery life. 11
If the activation of this function hinders the operation, it may be disabled using the service
G428ZZ062_
function.
12
Battery electrolyte level warning indicator:
1. Without battery protection function: 13
This indicator lights if a lack of battery electrolyte is detected. If a lack of battery
electrolyte is detected when the key switch is turned on, the buzzer also sounds for 14
several seconds. Moreover, if a lack of battery electrolyte is detected while the key
switch is off, this warning indicator blinks to prompt the operator to add battery
electrolyte.
15
2. With battery protection function:
This indicator lights if a lack of battery electrolyte is detected. If a lack of battery 16
electrolyte is detected when the key switch is turned on, the buzzer also sounds for
several seconds. Moreover, if a lack of battery electrolyte is detected while the key 17
switch is off, this warning indicator blinks to prompt the operator to add battery
G428ZZ063_ electrolyte.
If the vehicle has been operated exceeding the specified hour without enough battery
18
electrolyte, the battery electrolyte level sensing vehicle performance limit indicator is
displayed in the multiple screen display area along with the hour. 19
This warning prevents from a long time operation without enough battery electrolyte, by
prompting the operator to supply battery electrolytes. 20
21
4-4
2. Battery capacity indicator

This indicates amount of charge in the battery in 10
stages.
G428ZZ064_
4-5
ADMINISTRATOR FUNCTIONS
Administrator can set the following items.
Administrator functions are protected with password so that the general operators cannot change these
settings.
Administrator Menu List
Model without PIN code entry system NMF
Setting menu Setting screen
Power mode select *1
0
Power control functions Setting of travel power control level *1
Setting of load handling power control level *1
1
Speed setting of low speed *1 2
Travel functions Speed setting of maximum speed limiter
Speed setting of overspeed alarm *1 3
Load handling functions Zero-point setting of load meter
Setting of maintenance hour meter 4
Setting of auto power off
Setting of service secondary password
5
Setting of menu lock 6
Operation day setting
Vehicle management functions (Models installed with an on-vehicle charger)
7
CO2 unit setting
(Models installed with an on-vehicle charger and provided with
battery protection function)
8
Integrating wattmeter clear setting
(Models installed with an on-vehicle charger and provided with
9
battery protection function)
*1: When menu lock setting is released, the operator can set it.
10
Model with PIN code entry system 11
Setting menu Setting screen
Registry of PINs
12
PIN code entry functions
Change of profile assignment
Delete of PINs
13
(PIN code entry system)
Profile data setting 14
Change of initial PIN
Load handling functions Zero-point setting of load meter 15
Setting of maintenance hour meter
Setting of auto power off 16
Setting of auto log off
Setting of service password
17
Setting of menu lock 18
Operation day setting
Vehicle management functions
(Models installed with an on-vehicle charger)
19
CO2 unit setting
(Models installed with an on-vehicle charger and provided with battery
protection function)
20
Integrating wattmeter clear setting
(Models installed with an on-vehicle charger and provided with battery
21
protection function)
PIN code (PIN: Personal Identification Number)
4-6
Password Entry Procedure

Caution:
• Always operate switches on the display with a fingertip. If a sharp pointed tool is used, the switch may
be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning.
Step Display Operation Vehicle response
Press switch (2) and When pressing the switches,

switch (4) at the same a short beep sounds, and
1
time for more than after 2 seconds another
Switch (2) Switch (4) 2 seconds. short beep sounds.
G428ZZ100_
Press switch (3) within 10

2 A short beep sounds.
seconds.
Switch (3)
G428ZZ101_
Press switch (3) within

10 seconds.
Switch (3)
G428ZZ101
Within 10 seconds, press When pressing the switches,

switch (2) and switch (4) a short beep sounds, and
4
at the same time for more after 2 seconds repeated
Switch (2) Switch (4) than 2 seconds. short beeps sound.
G428ZZ100_
When the secondary password has been set:

Password screen is displayed. Enter the password.
5
When the secondary password has not been set:
Skip this screen.
G428ZZ228_
6 Administrator menu screen is displayed automatically.
G428ZZ229_
4-7
SERVICE FUNCTIONS
General
In the multifunction display DX, aside from the general functions that an operator or an administrator normally use,
the following service functions for use by the service staff for vehicle maintenance and specification setting are also
provided.
The service functions are protected by the password so that the important internal data will not be damaged by the
customer’s misuse.
Service Function List
When used
Function Description Vehicle Controller
Others
delivery replacement
Displays the electrical
system status and reads Upon vehicle
Analyzer — —
the error information abnormality
detected by controllers.
Makes fine adjustment of
{ As requested
Tuning traveling and load —
*2 by customer
handling functions.
Sets each vehicle option
{
Specification setting and other specifications. — —
*2,*3
Option set *1
Each control function Enables or disables each {
— —
enable / disable control function. *2,*3
Updates voltage values of
Traveling function sensor signals under the {
— —
/ SAS-R standard vehicle *2,*4
condition.
Matching
{ When it is
Load meter Sets the load meter. —
*3 necessary
Makes the speedometer {
Tire data — —
reading appropriate. *2
Starts each count for hour
meter, odometer, trip {
Meter start { —
meter and maintenance *3
meter.
Enables simultaneous
Before
operation of traveling and
Demo mode — — starting the
load handling before
hour meter
starting the hour meter.
Initialize a set value with { When it is
Others menu To default set the default value.
—
*2,*3 necessary
Service secondary Sets the service { When it is
—
password setting secondary password. *3 necessary
Administrator’s secondary Delete the administrator’s { As requested
—
password clear secondary password. *3 by user
Resets the charger { When it is
Reset of charger counter —
counter to 0. *3 necessary
Adjusts the contrast of the { As requested
Contrast —
display screen. *3 by user
*1: This is for matching the controller and Multifunction display DX control to the options or functions installed on
the vehicle and not for enabling / disabling each option or control function itself.
*2: Main controller
*3: Multifunction display DX
*4: EPS controller
4-8
SERVICE PASSWORD
Caution:
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be
damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning. If the SERVICE MENU cannot be displayed after several attempts, the system may be faulty.
Password Entry Procedure
Step Display Operation Vehicle response
When pressing the switches, a

Press switch (2), switch (3)
short beep sounds, and after 2
1 and switch (4) at the same
seconds another short beep
Switch (2) Switch (4) time for more than 2 seconds.
sounds.
Switch (3) G42804ZZ001_

seconds.
Switch (4)
G42804ZZ002_

seconds.
Switch (1)
G42804ZZ003_
Within 10 seconds, press When pressing the switches, a

switch (2) and switch (3) at short beep sounds, and after 2
4
the same time for more than seconds repeated short beeps
Switch (2) Switch (3) 2 seconds. sound.
G42804ZZ004_
When the service secondary password has been set:

Secondary password screen is displayed. Input the secondary
5 password.
Other:
This screen is skipped.
G42804ZZ005_
6 Service function initial screen is displayed for 5 seconds.
G42804ZZ006_
7 ANALYZER MENU screen is automatically displayed.
G42804ZZ007_
4-9
OPERATION OF SERVICE MENU SCREEN

Service initial screen
After 5 seconds that the service initial screen has been
displayed, the ANALYZER MENU screen will be displayed
with the item DIAG MEMORY selected.
The service menus are divided into the following 6
classifications, and among these, selection can be made
with switch (2) and switch (3).
1. [ANL] ANALYZER MENU
2. [TUN] TUNING MENU
3. [OPT] OPTIONSET MENU
G42804ZZ008_
4. [MAT] MATCHING MENU
5. [etc.] OTHER MENU
6. [ ] END of SERVICE MENU
Switch (1): Selecting the item next to the one among the menu classification selected currently.
Switch (2): Selecting the menu classification leftward.
Switch (3): Selecting the menu classification rightward.
Switch (4): Moving to the selected (execution) setting screen.
ANALYZER MENU
TUNING MENU
OPTIONSET MENU
MATCHING MENU
OTHER MENU
END of SERVICE MENU
G42804ZZ009_
4-10
ANALYZER MENU screen

Reads out information about the error detected by a controller and indicates the operating state of the electric
system of the vehicle.
TUNING MENU screen
Fine adjusts the settings for traveling control, load handling control, etc.
OPTION SET MENU screen
Adjusts the display and the controllers according to the specifications of each vehicle or the control conditions set
for it.
MATCHING MENU screen
Updates the sensor output voltages and the set values stored in the memories of the display and each controller.
OTHER MENU screen
This allows you to:
• Start each meter.*1
• Switch demo mode.*1
• Initialize the settings.
• Set a service secondary password.
• Clear the administrator’s secondary password.
• Clear charge count.*2
• Adjust the contrast of the LCD display.
*1: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not displayed on the
OTHERS MENU screen.
*2: “CHARGER CNT CLR” is displayed only in case of models provided with an on-vehicle charger.
END of SERVICE MENU

From this screen, you can move to a status screen.
4-11
ANALYZER
General
The analyzer functions are designed to make it easy to check and troubleshoot the control system by displaying its
state through communications between the multifunction display DX and each controller.
By switching the multifunction display DX to analyzer mode, it becomes possible to check the operation state of
each sensor and actuator used for the traveling, load handling, EPS, SAS-R and OPS functions, and also to read
information about errors detected by controllers, which helps check the operation state of each function and reduce
the repair time in the event of a failure.
Thus, the use of the analyzer function ensures fast and easy servicing.
The analyzer has the following functions:
(1) Diagnostic memory function (DIAG MEMORY)
The controller stores up to 10 error codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these error codes and indicates them on the display.
Each error code is displayed with its detection time as the key ON hour meter reading.
(2) In/Out monitor function (I/O MONITOR)
This function displays the analog input values from individual sensors and switches in the traveling, load
handling, EPS, SAS-R, and OPS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(a) I/O TEMP/VOLT
Displays the temperature of each electrical functional part and the analog input voltage detected by
each controller at each potential.
(b) I/O TRAVELING
Displays the traveling control / swing control switch ON / OFF state and analog input voltages from
respective sensors.
(c) I/O M. HANDLING
Displays the load handling control switch ON / OFF state and analog input voltages from respective
sensors.
(d) I/O STEERING
Displays the analog input voltages from respective sensors for EPS control.
(e) I/O OTHERS
Displays the other switch ON / OFF state and analog input voltages from respective sensors.
(3) Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the
selected item in order to permit operation check of that function.
(4) Program version display (VERSION)
Displays program version of each controller.
(5) Error code display during occurring
Displays one error code for the error occurred currently on each screen of I/O MONITOR and ACTIVE
TEST.
4-12
Analyzer Screen Item List

Screen Display
Analyzer menu screen Description
No. item
1. DIAG MEMORY 1/2 to 2/2 1 to 10 Indications of errors occurred

TDM Drive motor temperature
TDMDH Drive AC driver heat sink temperature
1/6
TDMDB Drive AC driver board temperature
TDMDC Drive AC driver condenser temperature
TPM Pump motor temperature
TPMDH Pump AC driver heat sink temperature
2/6
TPMDB Pump AC driver board temperature
TPMDC Pump AC driver condenser temperature
TMCB Main controller board temperature
2. I/O TEMP/VOLT 3/6
TPSDB EPS controller board temperature
TSLLT Battery electrolyte temperature
4/6
TDSP Display board temperature
B48V Battery voltage
5/6 VBKY Voltage after key switch
VBMB Voltage after MB contactor
VDMD Drive AC driver main circuit voltage
6/6 VPMD Pump AC driver main circuit voltage
VBBTS Battery voltage (EPS input)
SPEED Drive speed
SPDPS EPS vehicle speed input
1/5 Accelerator sensor 1 voltage
VRA
Accelerator sensor 2 voltage
SWBK Brake switch
VRTRA Tire angle sensor voltage
SH Lifting height switch
2/5
SPLF Load sensor voltage
SPDPS EPS controller input vehicle speed
3. I/O TRAVELING
Drive motor rpm
3/5 SPDDM
Target rpm
Speed sensor 1 (Drive motor) voltage
SSD
4/5
CSDM
SPDPSL EPS controller input vehicle speed (left front)
5/5 SPDPSR EPS controller input vehicle speed (right front)
SPDPS EPS controller input vehicle speed (rear)
4-13
Screen Display
Analyzer menu screen Description
No. item
SRC Reach limit switch
SWLF Material handling lever switch
SWAT1 Attachment 1 switch
1/4
SDM Floor switch
SWT Tilt limit switch
SWAT2 Attachment 2 switch
4. I/O M.HANDLING SH Lifting height switch
2/4
SPLF Load sensor voltage
Pump motor rpm
3/4 SPDPM
Target rpm
SSP Pump AC driver rotation sensor voltage
4/4 Pump AC driver current sensor 1 voltage
CSPM
Pump AC driver current sensor 2 voltage
VRTRA Tire angle sensor voltage
5. I/O STEERING 1/1 SPDPS EPS controller input vehicle speed (rear)
SSTT Steering torque sensor voltage
CSBAT Battery current sensor voltage
1/2
DOPT Not used
6. I/O OTHERS
SPA Accumulator switch
2/2
VBBA Battery pull-out input
SWING
Swing lock solenoid forced operation
SOL
7. ACTIVE TEST 1/1 BRAKE L Brake valve solenoid (weak) forced operation
BRAKE H Brake valve solenoid (strong) forced operation
FAN Cooling fan forced operation
DISPLAY Multifunction display DX program version
1/2 MAIN C/R Main controller program version
PS EPS controller soft version
8. VERSION DM
Drive AC driver program version
DRIVER
2/2
PM
Pump AC driver program version
DRIVER
4-14
ANALYZER MENU screen

Operation Procedure
1. Display the ANALYZER MENU screen.
2. By default, the ANALYZER MENU screen is displayed
with the [ANL] tab selected. On this screen, press the
switch (2) and select the [Return] tab, move to the
END menu. Press switch (3) to select the [TUN] tab
and move to the TUNING MENU screen.
G42804ZZ010_
“1. DIAG MEMORY”

Switch (1): Switching selection to next item
Switch (2): To END menu
Switch (3): To TUNING menu
Switch (4): To DIAG MEMORY screen
“2. I/O TEMP/VOLT”
G42804ZZ010_ Switch (4): To I/O TEMP/VOLT screen
“3. I/O TRAVELING”

Switch (4): To I/O TRAVELING screen
“4. I/O M.HANDLING”
Switch (4): To I/O M.HANDLING screen
“5. I/O STEERING”
G42804ZZ011_ Switch (4): To I/O STEERING screen
“6. I/O OTHERS”
Switch (4): To I/O OTHERS screen
“7. ACTIVE TEST”

Switch (4): To ACTIVE TEST screen
“8. VERSION”
G42804ZZ012_ Switch (4): To VERSION screen
4-15
Diagnostic Memory Function (DIAG MEMORY)

The controller stores up to 10 latest errors. The DIAG MEMORY screen displays these diagnostic codes with their
detection hour information (in key on hour meter reading).
The most latest diagnostic code is displayed as 1, followed by 2, 3 and so on to 10.
Operation Procedure
2. Check the “1. DIAG MEMORY” is selected on the
screen, and press switch (4) to display “DIAG
MEMORY 1/2” screen.
3. Press switch (4) on “DIAG MEMORY 2/2” screen to
return to the ANALYZER MENU screen.
Note:
• When no diagnostic code is displayed on the screen
and the hour meter time is 0.0h, it indicates that no
G42804ZZ013_
errors occurred in the past after that row.
• It is impossible to directly jump from the DIAG
MEMORY screen to other function screen. Return to
the ANALYZER MENU screen.
• For details of diagnostic code, refer to section 5,
Diagnostic Code List.
“DIAG MEMORY 1/2”

Displays diagnostic codes 1 to 5.
Switch (4): To “DIAG MEMORY 2/2” screen
G42804ZZ014_
“DIAG MEMORY 2/2”

Displays diagnostic codes 6 to 10.
Switch (4): Returning to the ANALYZER MENU screen
G42804ZZ015_
4-16
In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage and the switch state of each of traveling, load handling, EPS, SAS
and OPS switches, sensors and actuators.
The circuit or their quality can be judged by monitoring the displayed value.
In/Out Monitor (1) (I/O TEMP/VOLT)

Displays the temperature of each electrical functional part and the analog input voltage detected by each controller.
Operation Procedure
2. Press the switch (1) to select the “2. I/O TEMP/VOLT”
and press the switch (4) to display “I/O TEMP/VOLT
1/6” screen.
3. From here on, the screen changes in sequence each
time switch (4) is pressed. On the “I/O TEMP/VOLT
6/6”, press switch (4) to return to the ANALYZER
MENU screen.
Note:
G42804ZZ016_
You cannot move directly from I/O TEMP/VOLT screen
to the screen of the other items. Return to ANALYZER
MENU screen once, then move to screen of each time.
“I/O TEMP/VOLT 1/6”

TDM: Drive motor temperature: °C
Temperature of drive motor is displayed.
TDMDH: Drive AC driver heat sink temperature: °C
Temperature of the drive AC driver heat sink is
displayed.
TDMDB: Drive AC driver board temperature: °C
Temperature of the drive AC driver board is
displayed.
TDMDC: Drive AC driver condenser temperature: °C
G42804ZZ017_
Temperature of the drive AC driver condenser is
displayed.
Switch (4): To “I/O TEMP/VOLT 2/6” screen
4-17

TMCB: Main controller board temperature: °C
Temperature of main controller board is displayed.
TPM: Pump motor temperature: °C
Temperature of pump motor is displayed.
TPMDH: Pump AC driver heat sink temperature: °C
Temperature of the pump AC driver heat sink is
displayed.
TPMDB: Pump AC driver board temperature: °C
Temperature of the pump AC driver board is
G42804ZZ018_
displayed.
TPMDC: Pump AC driver condenser temperature: °C
Temperature of the pump AC driver condenser is
displayed.
TMCB: Main controller board temperature: °C
Temperature of the main controller control board is
displayed.
TPSDB: EPS controller board temperature: °C
Temperature of the EPS controller control board is
displayed.
G42804ZZ019_

TSLLT: Battery electrolyte temperature: °C
Temperature of the battery electrolyte is displayed.
TDSP: Display board temperature: °C
Temperature of the display board is displayed.
G42804ZZ020_

B48V: Battery voltage: V
Displays the battery voltage.
VBKY: Voltage after key switch: V
Voltage after key switch is displayed.
VBMB: Voltage after MB contactor: V
Voltage after MB contactor is displayed.
G42804ZZ021_
4-18

VDMD: Drive AC driver main circuit voltage: V
Voltage of drive AC driver main circuit is displayed.
VPMD: Pump AC driver main circuit voltage: V
Voltage of pump AC driver main circuit is displayed.
VBBTS: Battery voltage (EPS controller input): V
Voltage of EPS circuit power is displayed.
G42804ZZ022_
4-19
In/Out Monitor (2) (I/O TRAVELING)

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
Operation Procedure
2. Check the “3. I/O TRAVELING” is selected on the
screen, and press switch (4) to display “I/O
TRAVELING 1/5” screen.
3. Press switch (4) on “I/O TRAVELING 5/5” screen to
Note:
It is impossible to directly jump from the I/O
TRAVELING screen to other function screen. Return to
G42804ZZ023_
“I/O TRAVELING 1/5”

SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
SPDPS: EPS controller input vehicle speed: km/h or mph
Displays EPS vehicle speed.
VRA: Accelerator sensor 1 / 2 voltage: V
Displays input voltage from the accelerator sensor to
the controller.
Accelerator sensor 1 standard voltage
G42804ZZ024_ In neutral position: 2.05 to 2.75 V
Tilting to the frontmost position (forward):
2.95 to 4.80 V
Tilting to the backmost position (backward):
0.10 to 1.85 V
Accelerator sensor 2 standard voltage
In neutral position: 1.90 to 2.90 V
Tilting to the frontmost position (forward):
0.10 to 1.85 V
Tilting to the backmost position (backward):
2.95 to 4.80 V
SWBK: Brake switch
Displays the status of the brake switch.
SWBK: 0
SWBK (in a state of brake being released): 1
Switch (4): To “I/O TRAVELING 2/5” screen
4-20

VRTRA: Tire angle sensor voltage :V
Voltage of the tire angle sensor is displayed.
Standard voltage when the tire operates straight:
2.20 V
SH: Lifting height switch
Displays the statuses of the lifting height switches.
G42804ZZ025_
MH1 MH2-1
0=OFF 1=ON
Judges the quality of the switch ON/OFF by raising and
lowering the fork.
For the combination between lifting height switches, see
the table below.
However, the display does not change in case of the FV
mast with a 3000 mm (118 in) or less lift height.
MH1 MH2-1
Height Display
Switch Switch
Low lifting height 10 1 = (ON) 0 = (OFF)
High lifting height 01 0 = (OFF) 1 = (ON)
* The height at which the lifting height switch is turned on
or off varies according to the lifting height set for the
mast.
SPLF: Load sensor voltage: V (MPa)
Displays input voltage from the load sensor to the
controller, and detected pressure.
Standard at no load: 0.5 to 4.5 V
Voltage increases as load increases.
Input vehicle speed of the EPS controller is
displayed.
4-21

SPDDM: Drive motor revolution: rpm
This screen indicates the measured and target
numbers of revolutions of the drive motor.
The rotation sensor is checked by actually running
the vehicle.
The number of revolutions of the drive motor
increases with an increase in the traveling speed.
G42804ZZ026_

SSD: Speed sensor 1/2 (Drive motor) voltage: V
This screen indicates the voltages of the drive motor
rotation sensors.
When motor is stopped:
0.3 to 0.7 V or 0.9 to 1.4 V
When motor is rotating:
Variable between approx. 0.3 and 1.4 V
CSDM: Drive motor current sensor 1/2 voltage: V
This screen indicates the voltages of the drive motor
G42804ZZ027_
current sensors.
Standard value when vehicle is stopped:
Approx. 2.50 V
Standard value when vehicle is running: 0.9 to 1.4 V

SPDPSL: EPS controller input vehicle speed (left front):
km/h or mph
Input vehicle speed (left front) of the EPS controller
is displayed.
SPDPSR: EPS controller input vehicle speed (right front):
km/h or mph
Input vehicle speed (right front) of the EPS controller
is displayed.
SPDPS: EPS controller input vehicle speed (rear):
G42804ZZ028_
km/h or mph
Input vehicle speed (rear) of the EPS controller is
displayed.
4-22
In/Out Monitor (3) (I/O M.HANDLING)

Displays the load handling and mast control switch ON/OFF states and analog input voltages from load handling
and mast control sensors.
Operation Procedure
2. Check the “4. I/O M.HANDLING” is selected on the
screen, and press the switch (4) to display “I/O
M.HANDLING 1/4” screen.
3. Press switch (4) on “I/O M.HANDLING 4/4” screen to
Note:
You cannot move directly from I/O M.HANDLING
screen to the screen of the other items. Return to
G42804ZZ029_
ANALYZER MENU screen once, then move to screen
of each time.
“I/O M.HANDLING 1/4”

SRC: Reach limit switch
Displays the reach limit switch ON/OFF state.
In neutral position: 0
During reach-out operation: 1
During reach-in operation: 1
SWLF: Material handling lever switch
Displays the material handling lever switch ON/OFF
state.
G42804ZZ030_
During lift-down operation: 01
During lift-up operation (1/2 stroke): 10
During lift-up operation (full stroke): 11
LSL1 LSL2
SWT: Tilt limit switch
Displays the tilt limit switch ON/OFF state.
When tilting forward: 1
When tilting backward: 1
SWAT1: Attachment 1 switch
Displays the attachment 1 switch ON/OFF state.
During PUSH operation of the lever: 1
During PULL operation of the lever: 1
SWAT2: Attachment 2 switch
Displays the attachment 2 switch ON/OFF state.
During PUSH operation of the lever: 1
During PULL operation of the lever: 1
SDM: Floor switch
Displays the floor switch ON/OFF state.
When getting off the floor: 0
When getting on the floor: 1
Switch (4): To “I/O M.HANDLING 2/4” screen
4-23

SH: Lifting height switch
See “I/O TRAVELING 2/5”
SPLF: Load sensor voltage: V (MPa)
See “I/O TRAVELING 2/5”
G42804ZZ031_

SPDPM: Pump motor revolution: rpm
This screen indicates the measured and target
numbers of revolutions of the pump motor.
The number of revolutions of the pump motor
increases with an increase in the load handling
speed.
G42804ZZ032_

SSP: Pump AC driver rotation sensor voltage: V
Displays the voltage from the pump AC driver
rotation sensor.
When motor is stopped:
Constant, either 0.3 to 0.7 V or 0.9 to 1.4 V
When motor is rotating:
Variable between approx. 0.3 and 1.4 V
CSPM: Pump motor current sensor 1/2 voltage: V
Voltage of pump AC driver current sensor 1/2 is
G42804ZZ033_
displayed.
Without operating the load handling lever, and with
completion of accumulating by the accumulator:
approx. 2.5 V
In case other than above: 0.9 to 4.1 V
4-24
In/Out Monitor (4) (I/O STEERING)

Displays the analog input voltages from respective sensors for EPS control.
Operation Procedure
2. Check the “5. I/O STEERING” is selected on the
screen, and press the switch (4) to display “I/O
STEERING 1/1” screen.
3. Press switch (4) on “I/O STEERING 1/1” screen to
Note:
You cannot move directly from I/O STEERING screen
to the screen of the other items. Return to ANALYZER
G42804ZZ034_
“I/O STEERING 1/1”

VRTRA: Tire angle sensor voltage: V
Voltage of the tire angle sensor is displayed.
Standard voltage when the tire operates straight:
2.20 V
Displays EPS vehicle speed.
SSTT: Steering torque sensor voltage: V
Without operation: 1.10 to 1.90 V
When turning the steering to the right:
G42804ZZ035_
Decreasing the input voltage
When turning the steering to the left:
Increasing the input voltage
4-25
In/Out Monitor (5) (I/O OTHERS)

Displays the analog input voltages from battery current sensor and shock sensor.
Operation Procedure
2. Check the “6. I/O OTHERS” is selected on the screen,
and press the switch (4) to display “I/O OTHERS 1/2”
screen.
3. Press switch (4) on “I/O OTHERS 2/2” screen to
Note:
You cannot move directly from I/O OTHERS screen to
the screen of the other items. Return to ANALYZER
G42804ZZ036_
“I/O OTHERS 1/2”

CSBAT: Battery current sensor voltage: V
Displays input voltage from the battery current
sensor to the controller.
Standard value when vehicle is stopped:
Approx. 2.50 V
(When material handling lever, steering wheel, and
forward/backward switch are in neutral)
Other than the above: 2.30 to 2.70 V
DOPT: Not used
G42804ZZ037_
Switch (4): To “I/O OTHER 2/2” screen
“I/O OTHERS 2/2”

SPA: Accumulator switch
Displays the accumulator switch ON/OFF state.
Need accumulating: 0
Not need accumulating: 1
VBBA: Battery pull-out input: V
Input voltage of battery pull-out input is displayed.
During normal operation: 40 to 55 V
During pull-out operation: 0 V
G42804ZZ038_ Switch (4): Returning to the ANALYZER MENU screen
4-26
Active Test (ACTIVE TEST)

In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in
order to permit operation check of that function.
Active Test Item List

Selection Item
Item Description Content of Content of
Signal Signal
operation operation
Swing lock cylinder solenoid forced
SWING SOL OFF Lock ON Unlock
operation
Brake valve solenoid (weak) forced
BRAKE L OFF Brake stops ON Brake activates
operation
Brake valve solenoid (strong) forced
BRAKE H OFF Brake stops ON Brake activates
operation
FAN Cooling fan forced operation OFF Fan stops ON Fan rotates
• The items on the ACTIVE TEST screen consist of both of which indicates or does not indicate states.
• If the selected item is forcibly turned off or on by pressing the switch (2) or (3) and it is switched over to another
item by pressing the switch (1), forced operation is cancelled (and switches over to normal operation).
• The operation guidance in connection with the switches (2) and (3) indicates whether an item is forcibly operated
or not. (Refer to below)
Operation guidance Condition
Selected item not forcibly operated

• SWING SOL and FAN do not indicate state.
G42804ZZ039_
• BRAKE L and BRAKE H do not indicate state.
Selected item forcibly turned ON

G42804ZZ040_
Selected items forcibly turned OFF

G42804ZZ041_
Applicable function not provided or its state signal not received

G42804ZZ042_
Operation Procedure
2. Check the “7. ACTIVE TEST” is selected on the
screen, and press the switch (4) to display “ACTIVE
TEST 1/1” screen.
3. Press switch (4) on “ACTIVE TEST 1/1” screen to
Note:
You cannot move directly from ACTIVE TEST screen to
the screen of the other items. Return to ANALYZER
G42804ZZ043_
4-27
“ACTIVE TEST 1/1”

SWING SOL: Swing lock solenoid forced operation
Jack up the vehicle and check if the drive unit
swings.
ON (solenoid ON): Unlocking
OFF (solenoid OFF): Locking
BRAKE L: Brake valve solenoid (weak) forced operation
Through ON/OFF operation, check operation and
stop of the brake (weak).
ON (solenoid ON): Brake (weak) activates
G42804ZZ044_
OFF (solenoid OFF): Brake (weak) stops
(This item does not indicate the state.)
BRAKE H: Brake valve solenoid (strong)
forced operation
Through ON/OFF operation, check operation and
stop of the brake (strong).
ON (solenoid ON): Brake (strong) activates
OFF (solenoid OFF): Brake (strong) stops
(This item does not indicate the state.)
Note:
The ON signal of this function will turn to OFF
automatically after 1 minute.
FAN: Cooling fan for controller
Used to check the operation state of the controller
cooling fan visually and through the display.
ON: Fan rotates
OFF: Fan stops
Switch (1): Selecting the next item on the “ACTIVE TEST
1/1” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
4-28
PROGRAM VERSION (VERSION)

Displays program version of each controller.
Operation Procedure
2. Check the “8. VERSION” is selected on the screen,
and press the switch (4) to display “VERSION 1/2”
screen.
3. Press switch (4) on “VERSION 2/2” screen to return to
Note:
You cannot move directly from VERSION screen to the
screen of the other items. Return to ANALYZER MENU
G42804ZZ045_
screen once, then move to screen of each time.
“VERSION 1/2”
DISPLAY: Program version of the multifunction display DX
MAIN C/R: Program version of the main controller
PS: Program version of the EPS controller
Switch (4): To “VERSION 2/2” screen
G42804ZZ046_
“VERSION 2/2”
DM DRIVER: Program version of the drive AC driver
PM DRIVER: Program version of the pump AC driver
G42804ZZ047_
4-29
TUNING
General
This feature performs fine adjustment of traveling and load handling controls.
When receiving requests from users, such as the request to weaken the acceleration off regenerative braking
force, various settings levels can be changed on the tuning screens.
Tuning functions has 85 items (included spare items)
Level (*: Initial setting value)

No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery
1 capacity warning and battery over- Fast * Slow Disabled
discharge warning.
Battery charge indicator calibration Slow Fast
2 *
No.1 decrease decrease
Battery charge indicator calibration
3 Sensitive * Insensitive
No.2
Motor torque when the battery Power Power
4 *
discharge has proceeded down keep
5 To be used *
6 Accelerator lever sensitivity Insensitive * Sensitive
7 Acceleration torque Weak * Strong
8 Acceleration soft-start Slow * Quick
Regenerative braking torque at
9 Weak * Strong
accelerator-off
Regenerative braking soft-start at
10 Slow * Quick
accelerator-off
11 Acceleration torque at switch-back Weak * Strong
Acceleration soft-start at switch-
12 Slow * Quick
back
Regenerative braking torque at
13 Weak * Strong
switch-back
Regenerative braking soft-start at
14 Slow * Quick
switch-back
Regenerative braking soft-stop at
15 Slow * Quick
switch-back
16 Accelerator traction torque Weak * Strong
17 To be used *
Slow
18 Slope regeneration speed Quick
*
19 To be used *
20 To be used *
21 Traveling output when turning Weak * Strong
Maximum speed limitation during Quick
22 Slow
backward traveling *
Low speed setting during backward Quick
23 Slow
traveling *
24 To be used *
25 To be used *
Pump motor output during lift up Quick
26 Slow
operation *
4-30

No. Item
1 2 3 4 5 6 7 8
Pump motor output during tilt Quick
27 Slow
forward and backward operation *
Pump motor output during reach Slow
28 Quick
operation *
29 Pump motor output during the Slow * Quick

attachment operation *
(To be used) Pump motor output
30 during the attachment 2 pull Slow * Quick
operation
31 To be used *
32 Load meter display time Short * Long
Temperature at which the battery
temperature protection function Low
33 High
limits the vehicle performance in the *
maximum
34 Traction control start level Low * High
Traction control start level during
35 Low * High
regeneration
*: The pump motor output of the attachment levers 1 and 2 are in common.
Low battery capacity warning and battery over-discharge warning
Amount of Normal tuning level [No.1]

discharge 1 2 3 4 5 6 7 8
[%] Default
50
60
Battery warning
Battery indicator blinks.
70
80
90
Over-discharge warning
Ten segments of the battery indicator blink.
100
No warning
G428ZZ026_
4-31

Menu No. Item
1 2 3 4 5 6 7 8
START Not used *
INCH Not used *
LIFT
MAX Not used *
DOWN
ACC Not used *
DEC Not used *
Play at the beginning of lift up
START Insensitive * Sensitive
operation
Inching speed during lift up
INCH Slow * Quick
operation
LIFT
MAX Not used *
UP
Acceleration speed during lift up
ACC Weak * Strong
operation
Deceleration speed during lift up
DEC Weak * Strong
operation
START Not used *
INCH Not used *
TILT
MAX Not used *
FWD
ACC Not used *
DEC Not used *
START Play at the beginning of tilt operation Insensitive * Sensitive
INCH Not used *
MAX Not used *
TILT
BWD Acceleration speed during tilt
ACC Weak * Strong
operation
Deceleration speed during tilt
DEC Weak * Strong
operation
START Not used *
INCH Not used *
REACH
MAX Not used *
OUT
ACC Not used *
DEC Not used *
Play at the beginning of reach
START Insensitive * Sensitive
operation
INCH Not used *
REACH MAX Not used *
IN Acceleration speed during reach
ACC Weak * Strong
operation
Deceleration speed during reach
DEC Weak * Strong
operation
4-32

Menu No. Item
1 2 3 4 5 6 7 8
START Not used *
INCH Not used *
ATT1
MAX Not used *
PUSH
ACC Not used *
DEC Not used *
Response at the start of the
START Small * Wide
INCH Not used *
ATT1 MAX Not used *
PULL Acceleration during the
ACC Weak * Strong
Deceleration during the
DEC Weak * Strong
START Not used *
INCH Not used *
ATT2
MAX Not used *
PUSH
ACC Not used *
DEC Not used *
(To be used) Play at the
START beginning of the attachment 2 Insensitive * Sensitive
lever pull operation
INCH Not used *
MAX Not used *
ATT2
PULL (To be used) Acceleration speed
ACC during the attachment 2 lever Weak * Strong
pull operation
(To be used) Deceleration speed
DEC during the attachment 2 lever Weak * Strong
pull operation
*: Adjustments for attachment levers 1 and 2 are in common.

4-33
TUNING MENU Screen

Operation Procedure
2. By default, the SERVICE MENU screen is displayed
switch (3) and select the [TUN] tab.
Press switch (2) to select the [ANL] tab and move to
Press switch (3) to select the [OPT] tab and move to
the OPTION SET MENU screen.
G42804ZZ048_
“1. GENERAL”
Normal tuning
Switch (2): To ANALYZER menu
Switch (3): To OPTION SET menu
Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER”
Lift lever tuning
G42804ZZ048_ Switch (1): Switching selection to next item

“3. TILT LEVER”
Tilt lever tuning
“4. REACH LEVER”

Reach lever tuning
“5. ATT1 LEVER”
G42804ZZ049_
“6. ATT2 LEVER”

4-34
GENERAL (TUNING GENERAL)

Used to fine adjust settings related to traveling, material handling, and so on (except for settings related to material
handling lever tuning).
Operation Procedure
1. Display the TUNING MENU screen.
2. Check the “1. GENERAL” is selected on the screen,
and press the switch (4) to display “TUNE GEN (01 to
05)” screen.
3. Press switch (4) on “TUNE GEN (31 to 35)” screen to
return to the TUNING MENU screen.
Note:
You cannot move directly from GENERAL screen to
the screen of the other items. Return to TUNING MENU
G42804ZZ050_
“TUNE GEN.”
Normal tuning screen
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Displaying the next 5 items.
When the “TUNE GEN. (31 - 35)” screen is
displayed, it will return to the TUNING MENU
screen.
G42804ZZ051_
4-35
LIFT LEVER (TUNING LIFT LEVER)

Sets tuning levels for the lift lever.
Operation Procedure
2. Check the “2. LIFT LEVER” is selected on the screen,
and press the switch (4) to display “LIFT DOWN”
screen.
3. Press switch (4) on “LIFT DOWN” screen to switch to
the “LIFT UP” screen. Press switch (4) again to return
to the TUNING MENU screen.
Note:
You cannot move directly from LIFT LEVER screen to
G42804ZZ052_
“LIFT DOWN”
Lift lever lift down operation tuning screen
Switch (4): Moving to the “LIFT UP” (lift lever lift up
operation tuning) screen
G42804ZZ053_
“LIFT UP”
Lift lever lift up operation tuning screen
Switch (4): Returning to TUNING MENU screen
G42804ZZ054_
4-36
TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever.
Operation Procedure
2. Check the “3. TILT LEVER” is selected on the screen,
and press the switch (4) to display “TILT FWD” screen.
3. Press switch (4) on “TILT FWD” screen to switch to
the “TILT BWD” screen. Press switch (4) again to
Note:
You cannot move directly from TILT LEVER screen to
G42804ZZ055_
“TILT FWD”
Tilt lever forward operation tuning screen
Switch (4): Moving to the “TILT BWD” (tilt lever backward
G42804ZZ056_
“TILT BWD”
Tilt lever backward operation tuning screen
G42804ZZ057_
4-37
REACH LEVER (TUNING REACH LEVER)

Sets tuning levels for the reach lever.
Operation Procedure
2. Check the “4. REACH LEVER” is selected on the
screen, and press the switch (4) (execution) to display
“RCH OUT” (reach lever out operation tuning) screen.
3. Press switch (4) on “RCH OUT” screen to switch to
the “RCH IN” (reach lever IN operation tuning) screen.
Press switch (4) again to return to the TUNING MENU
screen.
Note:
G42804ZZ058_
You cannot move directly from REACH LEVER tuning
TUNING MENU screen once, then move to screen of
each time.
“RCH OUT”
Reach lever OUT operation tuning screen
Switch (4): Moving to the “RCH IN” (reach lever IN
G42804ZZ059_
“RCH IN”
Reach lever IN operation tuning screen
G42804ZZ060_
4-38
ATT1 LEVER (TUNING ATT1 LEVER)

Sets tuning levels for the attachment 1 and 2 levers.
Operation Procedure
2. Check the “4. ATT1 LEVER” is selected on the screen,
and press the switch (4) to display “ATT1 PUSH”
screen.
3. Press switch (4) on “ATT1 PUSH” screen to switch to
the “ATT1 PULL” screen. Press switch (4) again to
Note:
You cannot move directly from ATT1 LEVER screen to
G42804ZZ061_
“ATT1 PUSH”
Attachment lever 1 tilt toward operation tuning screen
Switch (4): Moving to the “ATT1 PULL” (attachment lever 1
backward operation tuning) screen
G42804ZZ062_
“ATT1 PULL”
Attachment lever 1 tilt backward operation tuning screen
G42804ZZ063_
4-39
ATT2 LEVER (TUNING ATT2 LEVER)

(To be used) Sets tuning levels for the attachment 2 lever.
Operation Procedure
2. Check the “5. ATT2 LEVER” is selected on the screen,
and press the switch (4) to display “ATT2 PUSH”
screen.
3. Press switch (4) on “ATT2 PUSH” screen to switch to
the “ATT2 PULL” screen. Press switch (4) again to
Note:
You cannot move directly from ATT2 LEVER
G42804ZZ064_
TUNING MENU screen once, then move to screen
of each time.
“ATT2 PUSH”
Attachment lever 2 tilt toward operation tuning screen
Switch (4): Moving to the “ATT2 PULL” (attachment lever 2
backward operation tuning) screen
G42804ZZ065_
“ATT2 PULL”
Attachment lever 2 tilt backward operation tuning screen
G42804ZZ066_
4-40
OPTION SET
General
• The option set function is used to fit the specifications of the controller and the multifunction display DX to the
options actually equipped on the vehicle. The option set items are not functioning on the vehicle that doesn’t
actually mount them even if the OPTION SET enables them.
• When main controller or multifunction display DX is replaced, it is necessary to reset them according to the
vehicle specifications.
Option Set Item List
Switching settings
Indication Description Setting Setting
Indication Indication
content content
DISP MODE *1 Setting the display language J Japanese I English
Setting the traveling speed display
MPH *1 YES mph NO km/h
unit
DATE TYPE *1 Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
Adjust the battery capacity indicator A1: Not used / A2: Battery provided locally
B-TYPE *1
calculation B1: Models provided with battery / B2: Not used
A: Not provided
Battery electrolyte level and
B UNIT *1 B: Previous type (electrolyte level unit)
temperature unit
C: Electrolyte level and temperature unit
B LEVEL ALM *1 Battery electrolyte level warning YES Enabled NO Disabled
Setting to enable / disable H mode
H MODE LOCK *1 YES Enabled NO Disabled
lock
MENULOCK
Setting the display language YES Japanese NO English
SPEC
AFS, multi-lever,
AFS *1 YES Enabled NO Disabled
remote controller specifications
BUZZER SPEC Not used — / — / —
SPD ALM2 Not used YES Not used NO Not used
A: Not provided,
Setting to enable / disable wheel
WHEEL IND *1 B: Displayed when the vehicle speed is 0km,
indicator
C: Always displayed
POWER
*1 Power meter indicator YES Enabled NO Disabled
METER
LOAD METER *1 Load meter display YES Enabled NO Disabled
CHARGE REC *1 Integrating wattmeter display YES Enabled NO Disabled
RAMP CONT Slope control setting YES Enabled NO Disabled
TRC CONT Traction control setting YES Enabled NO Disabled
Brake valve (accumulator) auto
ACCUM CONT YES Enabled NO Disabled
accumulating setting
Traction Traction
Setting the traction limitation mode restrictions restrictions
D-LIM MODE *1 A B
at over-discharge warning regardless of according to
discharge level discharge level
B LEVEL LIM *1 Battery electrolyte level protection YES Enabled NO Disabled
B TEMP LIMIT *1 Battery electrolyte temp protection YES Enabled NO Disabled
POWER KEEP Power keep YES Enabled NO Disabled
CHARGER
*1 For models with on-vehicle charger YES Enabled NO Disabled
UNIT
ACCEL TYPE *1 Accelerator stage setting W Wide N Narrow
BACK BUZZER Not used — Not used — Not used
STOP LAMP Not used — Not used — Not used
*1: These items are set according to the type of each vehicle before shipment from the factory.
4-41
OPTION SET MENU Screen

On the OPTION SET MENU screen, selection can be made among with or without vehicle optional specification
settings.
Operation Procedure
switch (3) and select the [OPT] tab. Check that “1.
OPTION SET” is selected, and press switch (4) to
display OPTION SET screen.
3. The screen changes in sequence each time switch (4)
is pressed, and it returns to the OPTION SET screen
when switch (4) is pressed on the screen where
G42804ZZ067_
“STOP LAMP” is displayed.
Note:
You cannot move directly from OPTIONSET screen to
the screen of the other items. Return to OPTIONSET
“OPTION SET” Screen

Switch (2): Switching the selected option set item to the
option on the left
Switch (3): Switching the selected option set item to the
option on the right
Switch (4): Displaying the next 5 items.
When the “STOP LAMP” screen is displayed, it
will return to the OPTION SET MENU screen.
G42804ZZ068_
4-42
MATCHING
General
Each function is controlled by using the sensors and each signal voltage at standard vehicle condition stored in the
controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a sensor at standard
vehicle condition) is required when performing maintenance on a section or replacing parts related to the sensor.
For the accelerator sensor used for drive functions, the signal voltage values at accelerator fully released,
accelerator fully closed are stored, respectively, in the controller to control based on these values. When servicing
these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard
vehicle condition) is necessary.
For the load and tire angle sensors used for SAS-R functions, the signal voltage values at standard vehicle
condition are stored respectively, in the controller to control based on these values. When servicing or replacing
these sensors, matching (updating the sensor signal voltage value in the standard vehicle condition) is necessary.
Also, matching is needed for the tilt angle sensor when the vehicle posture has changed excessively, and for the
load sensor when the load under no load condition (no load on fork) is changed because of addition or removal of
any attachment or fork, replacement of mast or change of fork length. On the other hand, matching is needed for
the tire angle sensor when the tire angle sensor or related part is replaced.
Each lever angle sensor for material handling lever function is controlled based on the memory of signal voltage
values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or
replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is
necessary.
It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire
size or type is changed according to “TIRE DATA List”.
Matching Items and Prerequisite for Implementation
1. DRIVE
Prerequisite for
No. Indication Description
implementation
Accelerator sensor output value with fully opened accelerator
1 ACCEL OFF *1,*3
position to the controller.
Accelerator sensor output value with frontmost accelerator position
2 ACCEL FWD END *1,*3
to the controller.
Accelerator sensor output value with backmost accelerator position
3 ACCEL BWD END *1,*3
to the controller.
2. SAS-R
Prerequisite for
implementation
1 TIRE CENTER Tire angle sensor output value while the vehicle traveling straight *2,*4
2 TIRE RIGHT END Tire angle sensor output value in the right steering end state *2,*4
3 TIRE LEFT END Tire angle sensor output value in the left steering end state *2,*4
STEERING Steering torque sensor output value while the steering operation is
4 *2,*5
CENTER OFF
5 SPEED DATA Speed sensor output value *2,*6
For No.5, “SPEED DATA”, automatic matching is performed when the vehicle satisfies the given conditions (vehicle
standard state). You can check the matching results in the “SPEED DATA” screen.
4-43
3. LOAD METER
Prerequisite for
implementation
The mast type is stored.
1 MAST TYPE *7,*10
V J SV J FSV J FV J FSW J FW J QFV J “ — ” (N/A)
2 CYL. SIZE 1 Diameter of the lift cylinder is stored. *7,*10
3 CYL. SIZE 2 Diameter of the lift cylinder is stored. *7,*10
4 ZERO SET 1 Zero point of the load meter is stored. *7,*8,*9,*10
5 ZERO SET 2 Zero point of the load meter is stored. *7,*8,*9,*10
As requested
by user to
6 COMPENSATION The value of load meter compensation data is stored.
adjust the
accuracy
4. TIRE DATA
Prerequisite for
implementation
1 TIRE DATA The tire data according to the tire size is stored. *1,*6
Prerequisite content for implementation

*1: When main controller replacement
*2: When replacing EPS controller
*3: When removing / installing or replacing accelerator sensor
*4: When removing / installing or replacing tire angle sensor
*5: When removing / installing or replacing steering torque sensor
*6: When replacing load tire or drive tire
*7: When removing / installing or replacing mast
*8: When removing / installing or replacing load sensor
*9: When installing or changing attachment or fork
*10: When replacing the multifunction display DX
4-44
MATCHING MENU Screen

Operation Procedure
1. Enter the password on the status screen to display the
service function initial screen.
switch (3) and select the [MAT] tab. Press switch (2) to
select the [OPT] tab and move to the OPTION SET
screen. Press switch (3) to select the [etc.] tab and
move to the OTHER SERVICE FUNCTION MENU
screen.
G42804ZZ069_
“1. DRIVE”
Switch (3): To OTHERS menu
Switch (4): To “MATCHING DRIVE” screen
“2. SAS”
G42804ZZ069_ Switch (4): To “MATCHING SAS” screen
“3. LOAD METER”
Switch (4): To “MATCHING LOAD METER” screen
“4. TIRE DATA”
Switch (4): To “MATCHING TIRE DATA” screen
G42804ZZ070_
4-45
DRIVE (MATCHING DRIVE)

Matching is performed for drive function.
Operation Procedure
1. Display the MATCHING MENU screen.
2. Check the “1. DRIVE” is selected on the screen, and
press the switch (4) to display “ACCEL OFF” screen.
3. Press switch (4) on “BRAKE ACT” screen to return to
the MATCHING MENU screen.
Note:
• In standard vehicle condition, if the value in the
bracket ( ) and the value outside the bracket ( ) are
different, matching is required.
G42804ZZ071_
• Make sure that the diagnostic indicator on the
display is blinking. During matching (driving), the
blinking of the spanner indicator informs that the
vehicle cannot be driven even with the accelerator
lever operated.
• If matching is performed, “OK” is indicated on the
display.
• You cannot move directly from MATCHING screen
to the screen of the other items. Return to
MATCHING MENU screen once, then move to
screen of each time.
4-46
“ACCEL OFF” Screen

Accelerator lever potential neutral matching
Switch (1): Pressing this for more than 2 seconds will
perform matching
Switch (4): To the next matching screen
Vehicle condition:
(1) All parts related to the accelerator lever should be
formally mounted.
(2) The accelerator lever should be neutral position.
G42804ZZ072_
“ACCEL FWD END”

Accelerator lever potential frontmost matching
perform matching
Vehicle condition:
formally mounted.
(2) The accelerator lever should be maximum
G42804ZZ073_
forward tilting position.
Caution:
For safety, make sure that the spanner indicator on
display is flashing (twice blinks per a second) before
the accelerator lever operate.
The flashing of the spanner indicator informs that the
mode of main controller is being shifted to the driving
inhibition mode.
So this procedure can be done in condition that the
lever operated.
“ACCEL BWD END”

Accelerator lever potential backmost matching
perform matching
Vehicle condition:
formally mounted.
(2) The accelerator lever should be maximum
G42804ZZ074_
backward tilting position.
Caution:
For safety, make sure that the spanner indicator on
display is flashing (twice blinks per a second) before
the accelerator lever operate.
The flashing of the spanner indicator informs that the
mode of main controller is being shifted to the driving
inhibition mode.
So this procedure can be done in condition that the
lever operated.
4-47
SAS (MATCHING SAS)

Matching is performed for SAS function.
Operation Procedure
2. Check the “2. SAS” is selected on the screen, and
press the switch (4) to display “TIRE CENTER”
screen.
3. The screen changes in sequence each time switch (4)
is pressed, and it returns to the MATCHING MANU
screen when switch (4) is pressed on the “SPEED
DATA” (speed sensor matching) screen.
Note:
G42804ZZ075_
• In standard vehicle condition, if the value in the
bracket ( ) and the value outside the bracket ( ) are
different, matching is required.
• During SAS-R matching, the spanner indicator
blinks.
• If matching is performed, “OK” is indicated on the
display.
• You cannot move directly from MATCHING screen
to the screen of the other items. Return to
MATCHING MENU screen once, then move to
screen of each time.
“TIRE CENTER”
Tire angle sensor straight matching
perform matching
Vehicle condition:
(1) This procedure should be done in condition that
all equipments including forks or attachment are
mounted as specified.
G42804ZZ077_
(2) Vehicle should be with no load on the level
ground.
(3) Mast should be Reach-in.
(4) Forks or attachments should be lowered as low
as possible so that the vehicle direction can be
checked easily.
(5) The tire angle should be adjusted the straight
position.
“TIRE RIGHT END”

Tire angle sensor right end matching
perform matching
Vehicle condition:
G42804ZZ076_
ground.
(4) Hold the steering wheel at the clockwise turn end
position.
4-48
“TIRE LEFT END”

Tire angle sensor left end matching
perform matching
Vehicle condition:
G42804ZZ078_
ground.
(4) Hold the steering wheel at the counterclockwise
turn end position.
“STEERING CENTER”
Steering torque sensor center matching
perform matching
Vehicle condition:
(1) All parts related to the steering wheel should be
formally mounted.
(2) Disconnect the PS motor connector, turn the
G42804ZZ079_
steering wheel slightly clockwise and
counterclockwise and release it.
“SPEED DATA”
Speed sensor matching
The screen on the left shows the matching value for each
tire with the load tire LH as a fixed value (1 ton series:
255). The respective speed sensor values are shown on
the right.
When the given condition is satisfied as the vehicle travels,
the signal from each speed sensor is stored as the tire
G42804ZZ080_ diameter so as to compensate for any deviation resulting
from tire diameter variation.
Standard: Set the key switch to ON in no-load state,
and travel straight ahead (tire angle within ±2 ×) at a
constant speed of 4 km/h (2.5 mph) or more for at least
0.5 seconds.
(Select a flat surface unlikely to cause slipping.)
Note:
• Matching is performed automatically in the above standard state. This means that there is no need for matching
due to tire wear through vehicle use.
• Automatic matching is only enabled once each time the key switch is set to ON. So, to repeat matching for any
reason, briefly set the key switch to OFF beforehand.
• Use the procedure below to carry out matching after tire or EPS controller replacement.
(1) Display the OPTION SET screen, and set “TRC CONT” to NO (disable).
(2) Perform matching while driving with the “SPEED DADA” screen displayed in above standard vehicle
status.
(3) After carrying out matching, check that the values displayed when the vehicle is traveling at
approx. 5 km/h (3.1 mph) are within ±0.1 km/h across the respective speed sensors.
(4) After matching, set “TRC CONT” back to YES (enable).
4-49
LOAD METER (MATCHING LOAD METER)

Matching is performed for load meter functions.
Operation Procedure
2. Press switch (1) twice and check the “3. LOAD
METER” is selected on the screen, and press the
switch (4) (execution) to display “MAST TYPE”
screen.
3. From here on, the screen changes in sequence each
time switch (4) is pressed. On the COMPENSATION
screen, press switch (4) to return to the MATCHING
G42804ZZ081_ MENU screen.
LOAD METER LOAD METER LOAD METER

(V, SV) (FSV, FV, FSW, FW) (QFV, “ — ”)
G42804ZZ082_
4-50
“MAST TYPE” Screen

Mast type setting screen
Used to select the type of the mounted mast. Select “-” if the mast type is not specified. If “Unspecified” is selected,
the load meter function will be disabled.
Switch (2): Switching in the following sequence:
“—” (unspecified) J QFV J FW J FSW J FV J FSV J SV J V
Switch (3): Switching in the following sequence:
V J SV J FSV J FV J FSW J FW J QFV J “—” (unspecified)
“CYL. SIZE” “CYL. SIZE 1” Screen
Cylinder diameter No.1 setting screen (low lifting height)
Switch (2): Reducing the cylinder diameter No.1
Switch (3): Increasing the cylinder diameter No.1
“CYL. SIZE 2” Screen
Cylinder diameter No.2 setting screen (high lifting height)
Switch (2): Reducing the cylinder diameter No.2
Switch (3): Increasing the cylinder diameter No.2
Mast Type Cylinder Diameter No.1 *1 Cylinder Diameter No.2 *2

V 45 —
SV 45 —
FSV 70 45
FV 70 32
Caution:
*1: Lift cylinder bore (V, SV), front lift cylinder bore (FSV, FV)
*2: Rear lift cylinder bore (FSV), piston rod outside diameter of rear lift cylinder (FV)
“ZERO SET” “ZERO SET1” Screen
Load meter 0 point matching screen (low lift height)
The result is displayed if the matching operation (holding down switch (1) for more than 2 seconds) is performed.
OK: Matching completed
NG: The signal voltage is outside the matching range or a load is lifted high on the mast.
If “NG” is displayed, check the states of the vehicle and mast, as well as the load meter for malfunction and its
harness for break and short circuit.
Switch (1): Pressing this for more than 2 seconds will perform matching
Vehicle condition:
(1) This procedure should be done in condition that all equipments including forks or attachment are mounted
as specified. However, it is acceptable to do this procedure in condition of no forks only for the fork-less
specification.
(2) Vehicle should be with no load on the level ground should be with in 0.1 degrees.
(3) Raise forks or attachments at height of approximately 500 mm (19.69 in) form the ground. (The visual
observation is acceptable.)
(4) The vehicle should be in stationary state.
Caution:
Set the above height for all type of the mast.
4-51
“ZERO SET 2” Screen

Load meter 0 point matching screen (high lift height)
Caution:
Matching is not required for FV mast with a 3000 mm (118 in) or less lift height.
The result is displayed if the matching operation (holding down switch (1) for more than 2 seconds) is performed.
OK: Matching completed
NG: The signal voltage is outside the matching range or a load is lifted high on the mast.
If “NG” is displayed, check the states of the vehicle and mast, as well as the load meter for malfunction and its
harness for break and short circuit.
Switch (1): Pressing this for more than 2 seconds will perform matching
Vehicle condition:
FV·FSV (1) This procedure should be done in condition that
100 mm mounted as specified. However, it is acceptable
(3.93 in) to do this procedure in condition of no forks only
for the fork-less specification.
ground.
(3) Raise the rear lift cylinders to a height of
approximately 100 mm (3.93 in).
G42804ZZ109_
(The visual observation is acceptable.)
(4) The vehicle should be in stationary state.
Caution:
Set the above height only for FV and FSV mast with more than 3300 mm (130 in).
“COMPENSATION” Screen
Load meter compensation screen
To correct the value, place the mast in an upright position, put a load (whose weight is determined correctly) on the
fork, lift up the fork approximately 1000 mm (39.4 in) and under these conditions, adjust the value displayed at the
upper right part of the screen to the load weight.
Switch (2): Correcting the value to the negative side
Switch (3): Correcting the value to the positive side
Switch (4): To “MATCHING MENU” screen
4-52
TIRE DATA (MATCHING TIRE DATA)

Used to set the tire constant.
The tire constant is set according to the type of the mounted tires before shipment from the factory. However, if the
type or size of tire is changed, the tire constant should be set again according to the tire constant list.
Operation Procedure
2. Check the “6. TIRE DATA” is selected on the screen,
and press the switch (4) to display “TIRE DATA”
screen.
3. Press switch (4) again to return to the MATCHING
MENU screen.
G42804ZZ083_
“TIRE DATA” Screen

Switch (2): Reducing the tire constant
Switch (3): Increasing the tire constant
Switch (4): To “MATCHING MENU” screen
Tire constant 178
G42804ZZ084_
4-53
OTHERS MENU
Before hour meter start
G42804ZZ085_
After hour meter start
G42804ZZ086_
Operation Procedure
1. Enter the password on the status screen to display the service function initial screen.
2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the
switch (3) and select the [etc.] tab. Press switch (2) to select the [MAT] tab and move to the MATCHING menu
screen. Press switch (3) to select the [Return] tab and return to the status screen.
Note:
• After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be displayed
on the “DEMO MODE”.
• “CHARGER CNT CLR” is displayed only in case of models provided with an on-vehicle charger.
“1. METER START”
Switch (1): Switching selection to next screen
Switch (2): To MATCHING menu
Switch (4): To METER START setting screen
“2. DEMO MODE”
Switch (4): To DEMO MODE setting screen
“3. TO DEFAULT SET”
Switch (4): To TO DEFAULT SET setting screen
“4. MASK PASSWORD”
Switch (4): To MASK PASSWORD setting screen
“5. MANAGER PASS CLR”
Switch (4): To MANAGER PASS CLR setting screen
“6. CHARGER CNT CLR”
Switch (4): To CHARGER CNT CLR setting screen
4-54
“7. CONTRAST”
Switch (4): To CONTRAST setting screen
4-55
HOUR METER START

This menu item is used to make the following meters start counting: hour meters, odometer, trip meter and
maintenance hour meter.
With this menu option, you can also enable the following functions or operations regardless of whether the demo
mode is enabled or disabled.
• Enables the load handling operation during traveling.
• Enables all functions of the PIN code entry system (OPT).
Note:
Once the hour meter has started, it cannot be returned to the state where it was before it starts.
Operation Procedure
2. Check the “1.METER START” is selected on the
screen, and press the switch (4) to display “METER
START” screen.
G42804ZZ087_
“METER START” Screen

Hour meter start procedure
1. Press and hold down switch (2) for more than 2
seconds to additionally display a right arrow on the
screen.
2. Press switch (3) while holding down switch (2) to
complete the setting. On completion of the setting,
G428ZZ308_
“YES” is highlighted instead of “NO”.
Switch (4): To “OTHERS MENU” screen
G428ZZ309_
G428ZZ310_
Hour meter
Key ON hour meter before the start Key ON hour meter after the start
G42804ZZ089_ G42804ZZ090_
Note:
On completion of the hour meter start operation, the hourglass icon on the key ON hour meter blinks to
indicate that the hour meter has started to count up.
4-56
DEMO MODE
This menu item is used to enable or disable the demo mode.
Before starting the hour meter, you can enable the following functions temporarily in the demo mode.
Demo mode Yes (enabled) No (disabled)
Load handling during traveling Allowed Not allowed
Authentication
Authentication
possible only for
possible by simply
Authentication function registered
pressing the log-in
PIN code entry system (OPT) authentication
switch
numbers
Registration, change or deletion of
Enabled Disabled
authentication number
Note:
Even after the demo mode has been disabled, the data recorded and the settings made during the demo
mode are all retained.
Operation Procedure
switch (3) and select the [etc.] tab. Check the
“2.DEMO MODE” is selected on the screen, and press
the switch (4) to display “DEMO MODE” screen.
Note:
After the hour meter start operation completes,
G42804ZZ091_
“METER START” and “DEMO MODE” items of other
service function menus will not be displayed.
“DEMO MODE” Screen
Switch (2): Setting from YES
Switch (3): Setting from NO
Switch (4): Return to “OTHERS MENU” screen
G428ZZ311_
G428ZZ312_
Display in the key on hour meter screen Note:

during demo mode During demo mode, “DEMO” is displayed in the key on
hour meter screen.
G42804ZZ93_
4-57
TO DEFAULT SET
This menu item is used to initialize the tuning values or the settings of items with default values.
Setting items applied:
• Menu lock
• Power select mode (ESPH)
• Drive power control setting, load handling power control setting
• Low speed setting
• Maximum speed setting
• Over speed alarm setting
• Tuning level
Note:
This does not apply to data dependent on each individual vehicle, such as option set data, various
matching data, load meter setting data and tire constant data.
Before hour meter start After hour meter start
G42804ZZ094_ G42804ZZ095_
Operation Procedure
switch (3) and select the [etc.] tab.
Before hour meter start:
Press the switch (1) to check if “3. TO DEFAULT SET” is selected.
Press the switch (4) to display TO DEFAULT SET screen.
After hour meter start:
Display the OTHERS MENU screen and press the switch (1), select the “1. TO DEFAULT SET”.
Press the switch (4) to display TO DEFAULT SET screen.
4-58
“TO DEFAULT SET” Screen

DEFAULT SET operation procedure
1. Press the switch (2) and select the “YES”.
2. To initialize the settings, press and hold down the
switch (1) for more than 2 seconds.
3. When the settings are reset to the default values,
progress is displayed as a bar.
4. When reset is complete, “OK” is displayed.
Note:
• When the DEFAULT SET operation is in progress,
do not turn off the key switch or disconnect the
battery plug.
• You can return to another service function menu by
pressing the switch (4), except when the DEFAULT
SET operation is in progress.
G42804ZZ096_
4-59
SERVICE SECONDARY PASSWORD SETTING (MASK PASSWORD)

This menu item is used to set or clear a service secondary password.
You can enter any four-digit number as a service secondary password, using the 4 switches on the multifunction
display DX.
If you set a service secondary password, you will be prompted to enter the secondary password after you enter the
ordinary password necessary to display the SERVICE FUNCTION screen, and you can move to the SERVICE
FUNCTION screen only when the passwords you entered coincide with the registered ones.
No service secondary password has been set by default.
Note:
Do not forget the password you set. In the event you forget it, replace the multifunction display DX.
G42804ZZ097_ G42804ZZ098_
Operation Procedure
Press the switch (1) to check if “4. MASK PASSWORD” is selected.
Press the switch (4) to display MASK PASSWORD screen.
Display the OTHERS MENU screen and press the switch (1), select the “2. MASK PASSWORD”.
Press the switch (4) to display MASK PASSWORD screen.
Note:
“CHARGER CNT CLR” is displayed only in case of models provided with an on-vehicle charger.
4-60
Service secondary password clear

If you press and hold down the switch (1) for more than 2 seconds without entering any digit on the MASK
PASSWORD screen, the registered password is deleted and “OK” appears on the completion of its deletion.
Note:
The service secondary password can be cleared only when no digit has been entered
(when every box is [ ]).
G42804ZZ099_
Service secondary password set

1. When you enter a 4-digit number, “SET” appears in the lower left corner of the screen, informing that you are
ready to save it as a password.
2. Press and hold down the switch (1) for more than 2 seconds to save the password. After the password has
been saved, “OK” appears.
Note:
• A 4-digit number needs to be entered in order for it to be accepted as a password.
• If you press and hold down the switch (4) for more than 2 seconds, the number you entered becomes
invalid and the screen switches over to another service function menu screen.
4-61
ADMINISTRATOR’S SECONDARY PASSWORD CLEAR (MANAGER PASS CLR)

This menu item is used to clear the administrator’s secondary password.
If so requested by the user, you can clear the administrator’s secondary password on the service function screen.
G42804ZZ100_ G42804ZZ101_
Operation Procedure
Press the switch (1) to check if “5. MANAGER PASS CLR” is selected.
Press the switch (4) to display MANAGER PASS CLR screen.
Display the OTHERS MENU screen and press the switch (1), select the “3. MANAGER PASS CLR”.
Press the switch (4) to display MANAGER PASS CLR screen.
Note:
“MANAGER PASS CLR” Screen
Administrator’s secondary password deletion method
If you press and hold down the switch (1) for more than 2
seconds, the administrator’s secondary password is
deleted and “OK” appears on the completion of its deletion.
Switch (1): Clears the password if pressed and held down
for more than 2 seconds
Switch (4): Returning to OTHERS MENU screen
G42804ZZ102_
4-62
CHARGER COUNTER CLEAR (WITH ON-VEHICLE CHARGER ONLY)

This menu item is used to clear the charger counter.
You can clear the charger counter on the service function screen.
G42804ZZ103_ G42804ZZ104_
Operation Procedure
Press the switch (1) to check if “6. CHARGER CNT CLR” is selected.
Press the switch (4) to display CHARGER CNT CLR screen.
Display the OTHERS MENU screen and press the switch (1), select the “4. CHARGER CNT CLR”.
Press the switch (4) to display CHARGER CNT CLR screen.
“CHARGER CNT CLR” Screen

Charge counter deletion method
If you press and hold down the switch (1) for more than 2
seconds, the charger counter is deleted.
Switch (1): Clears the counter if pressed and held down for
more than 2 seconds
G42804ZZ105_
4-63
LCD CONTRAST ADJUSTMENT

This menu item is used to adjust the contrast of the multifunction LCD display.
G42804ZZ106_ G42804ZZ107_
Operation Procedure
Press the switch (1) to check if “7. CONTRAST” is selected.
Press the switch (4) to display CONTRAST screen.
Display the OTHERS MENU screen and press the switch (1), select the “5. CONTRAST”.
Press the switch (4) to display CONTRAST screen.
Note:
“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
G42804ZZ108_
sec05E_troubleshooting.book 1 ページ２０１２年７月１０日火曜日午前９時４９分
5-1
TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING ............................5-2
CONNECTOR HANDLING .........................................5-2 0
WIRE HARNESS AND CONNECTOR INSPECTION 2
PROCEDURE .......................................................5-2
SST Setting Methods.............................................5-4 2
EPS CONTROLLER CONNECTOR• 3
COMPONENT .....................................................5-5
4
DIAGNOSIS CODE LIST ........................................5-6
5
WHEN ERROR CODE IS DISPLAYED...................5-19
WHEN NO ERROR CODE IS DISPLAYED ............5-170 6
7
8
9
10
11
12
13
14
5-2
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at the
harness but hold the connector itself and pull it after
unlocking it.
To connect, push the connector fully until it is locked in
position.
3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness
side).
4. If insertion from the rear side is impossible, as in the
case of a waterproof connector, bring the tester probe
carefully into contact with the terminal so as not to
cause deformation of the connector terminal.
5. Do not touch connector terminals directly with your
hand.
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.
WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and
wire harness of the related circuit according to the
following procedure:
Continuity check
1. Disconnect the connectors at both ends of the
corresponding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Note:
Measure while lightly shaking the wire harness up and
down and sideways.
Open circuit at the wire harness occurs rarely partway
through a vehicle wiring but mostly at connectors.
Inspect especially the sensor connectors with
sufficient care.
5-3
Short circuit check

1. Disconnect the connectors at both ends of the
2. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or above
0
Measure while lightly shaking the wire harness up and
down and sideways.
2
2
3. Measure the resistance between a terminal
corresponding to the connector terminal and N1. 3
Always inspect the connectors at both ends.
Standard: 1 MΩ or above 4
The wiring may short-circuit due to pinching by the
body or defective clamping.
5
6
7
8
Visual and contact pressure checks 9
• Disconnect the connectors at both ends of the
• Visually inspect that there is neither rust nor foreign
10
matter trapped at connector terminals.
• Inspect that there is no loosening or damage at the 11
locked portion. Also, lightly pull the wire harness from
the connector to check that it does not come off. 12
13
14
• Insert a male terminal same as that of the terminal to a
female connector and check the extracting force.
Defective contact may exist at a terminal where the
extracting force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the
terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition
may be changed to normal by disconnecting and
reconnecting the connector. In that case, repeat
connector connection and disconnection several
times. If defect is perceived even once, terminal
contact may be defective.
5-4
SST SETTING METHODS

Use SSTs for quick, accurate troubleshooting of the 7FBR series electrical system.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect connection,
careful operation is necessary.
SST No. SST name remarks

IC check pin C4-1, -2, -3
09230-13700-71
(for B1 and Z4 connectors) F0-1
-
09230-13240-71 Main controller check harness
(for power source check)
C2-2
C4-1, -2, -3
Shorting harness C8-1, -2
09232-13130-71 (SST2)
(for A14, A15, A16, A17, A19, A32, B1 E2-2
(09230-13130-71)
and S1 connectors) E8-1, -2
FB-1, -2
G3-1
51-1, -3
56-1, -2
09234-13900-71 (SST13) Shorting harness
61-1
(09230-13900-71) (for A33 and A36 connectors)
71-1
72-1
09236-13900-71 (SST15) Front speed sensor check harness
51-1, -3
(09230-13900-71) (for H1 and H2 connectors)
09237-13900-71 (SST16) Front speed sensor check harness
51-1, -3
(09230-13900-71) (for HA1 and HA2 connectors)
09238-13900-71 (SST17) Load sensor check harness
61-1
(09230-13900-71) (for A22 connector)
09240-13241-71 For AC driver -
Caution:
• Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
connected, various boards may be damaged.
• Fix the mast with a cross beam against the frame such as by furnishing with a wooden block so as to
protect the service person from being trapped and compressed between them.
When connecting the battery plug, avoid to get in the space between them.
• The discharging of CO(condenser) may be deficient time to time due to the use of SST connection.
Thereby, when connecting to or disconnecting from the connector vs. every control board, the voltage
between P14 and N1 should be measured in advance. If the discharge has remained deficient, use the
resistance of approx. 100k ohms to discharge before starting the service.
Note:
When the sequence is started from the inspection by SST connection, when the key switch is turned again
after having been turned off, the error code “CB-2” may be displayed.
This symptom occurs due to the variation of CO(condenser) performance having been brought about by
the SST connection. This code display negligible in view of intended aim of the inspections to proceed.
SST13 setting method

Troubleshooting for “Error code 51-1, 51-3, 56-1, 56-2, 61-1, 71-1 or 72-1”
SST13 is a shorting harness to short-circuit between the corresponding connector pins.
Carefully connect it since the board may be damaged if it is connected to wrong pin Nos.
5-5
EPS CONTROLLER CONNECTOR•COMPONENT

Z27 [CN145] Z4 [CN144]
+
P21
-
P22
0
P24
2
2
P23
A
Gate connector
3
A
4
- 5
6
+
P22
7
Connect 09240-13241-71 to where shown with arrow.
8
9
10
11
12
13
14
1. Disconnect the SSD2 connector.
2. Connect the vehicle side harness and 09233-13900-
SSD2
71*.
(* mark shows the component part of 09230-13900-71)
SSD1
3. Connect 09233-13900-71 and the SSD1 connector.
DIAGNOSIS CODE LIST 5-6

Indication : Diagnosis code will be indicated on the display when vehicle trouble occurs.
Memory : Use this indicated diagnosis code that can be checked on the display when using the service function DIAG MEMORY.
Indicator : Diagnostic mode
Overheat warning (O/ H)
Battery overheat warning (BT O/ H)
UP LED on the charger operation panel (UP LED)
Indication Memory Lamp Error mode Page Related connectors Connector ref. page
O/H
DCR A0-1 Drive AC driver power-circuit overheating abnormality 5-19 A25, A27, A30 21-20
lighting
O/H
PCR A0-2 Pump AC driver power-circuit overheating abnormality 5-22 A25, A27, A30 21-20
lighting
Diagnostic
A1-2 A1-2 mode Drive AC driver high voltage 5-25 -
blinking
Diagnostic
A1-4 A1-4 mode Pump AC driver high voltage 5-26 -
blinking
O/H
C/R A2-1 Main controller circuit board overheating abnormality 5-27 -
lighting
O/H
DCR A2-2 Drive AC driver circuit board and capacitor overheating abnormality 5-28 A25, A27, A30 21-20
lighting
O/H
PCR A2-3 Pump AC driver circuit board and capacitor overheating abnormality 5-31 A25, A27, A30 21-20
lighting
O/H
PSCR A2-4 ECPU board overheating abnormality 5-34 -
lighting
Diagnostic
A3-1 A3-1 mode Battery connection incorrect 5-35 -
blinking
Diagnostic
A9 21-24
A5-1 A5-1 mode Floor switch GND short abnormality 5-36
A26, A27 21-20
blinking
Diagnostic
A24, A25 21-20
A6-1 A6-1 mode Lift lever switch No.1 GND short abnormality 5-38
AF1 21-24
blinking
Diagnostic
A24, A25 21-20
A6-2 A6-2 mode Lift lever switch No.2 GND short abnormality 5-38
AF1 21-24
blinking
Diagnostic
A6-3 A6-3 mode Tilt limit switch GND short abnormality 5-38 A24, A25, E2 21-20
blinking
Diagnostic
A6-4 A6-4 mode Reach limit switch GND short abnormality 5-38 A24, A25, E1 21-20
blinking
Diagnostic
A24, A25 21-20
A6-5 A6-5 mode Attachment lever switch GND short abnormality 5-38
Z2, Z3 -
blinking
Diagnostic
Attachment 2 lever switch GND short abnormality A24, A25 21-20
A6-6 A6-6 mode 5-38
(When attachment lever switch connected independently.) Z3 -
blinking
Diagnostic
A8-1 A8-1 mode F1 fuse open abnormality 5-45 -
blinking
Diagnostic
A8-2 A8-2 mode F6 fuse open abnormality 5-45 A27, A32 21-20
blinking
Diagnostic
AA-1 AA-1 mode Main controller temperature sensor open/ short abnormality 5-48 -
blinking
Diagnostic
AA-2 AA-2 mode Drive AC driver circuit board temperature sensor open/ short abnormality 5-49 -
blinking
Diagnostic
AA-4 AA-4 mode Pump AC driver circuit board temperature sensor open/ short abnormality 5-50 -
blinking
Diagnostic
AA-5 AA-5 mode EPS controller temperature sensor open/ short abnormality 5-51 -
blinking
Diagnostic
AB-1 AB-1 mode Cooling fan drive circuit abnormality 5-52 A25, A27, A30 21-20
blinking
Diagnostic
AC-1 AC-1 mode Semiconductor switch abnormality 5-54 A24, A26, A27, A28, A29 21-20
blinking
5-7
5-8
Diagnostic
AD-1 AD-1 mode Drive AC driver J Main controller communication abnormality 5-56 A26, A27, A28, A29 21-20
blinking
Diagnostic
AD-2 AD-2 mode Drive AC driver J Main controller communication abnormality (on start up) 5-56 A26, A27, A28, A29 21-20
blinking
Diagnostic
AD-5 AD-5 mode Pump AC driver J Main controller communication abnormality 5-56 A26, A27, A28, A29 21-20
blinking
Diagnostic
AD-6 AD-6 mode Pump AC driver J Main controller communication abnormality (on start up) 5-56 A26, A27, A28, A29 21-20
blinking
Diagnostic
AF-1 AF-1 mode Main controller CPU error 5-59 -
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
C0-2 C0-2 mode Drive AC driver power-circuit short 5-60 -
blinking
Diagnostic
C1-1 C1-1 mode Drive AC driver current sensor neutral voltage error 5-62 -
blinking
Diagnostic
C1-2 C1-2 mode Drive AC driver current sensor over current 5-63 -
blinking
O/H
DM C2-1 Drive motor overheating abnormality 5-65 -
lighting
Diagnostic
A14 21-24
C2-2 C2-2 mode Drive motor temperature sensor open/ short abnormality 5-66
A28 21-20
blinking
Diagnostic
C3-1 C3-1 mode Drive AC driver power-circuit temperature sensor open/ short abnormality 5-68 -
blinking
Diagnostic
C4-1 C4-1 mode Accelerator potentiometer open 5-69 A24, A25, B1 21-20
blinking
Diagnostic
C4-2 C4-2 mode Accelerator potentiometer short 5-69 A24, A25, B1 21-20
blinking
Diagnostic
C4-3 C4-3 mode Accelerator potentiometer output abnormality 5-69 A24, A25, B1 21-20
blinking
Diagnostic
C4-4 C4-4 mode Accelerator potentiometer neutral error 5-69 B1 21-20
blinking
Diagnostic
C4-5 C4-5 mode Accelerator potentiometer matching value error 5-69 -
blinking
Diagnostic
A15, S1, AS1 21-24
C8-1 C8-1 mode Drive motor speed sensor open 5-72
A28, A40 21-20
blinking
Diagnostic
A15, S1, AS1 21-24
C8-2 C8-2 mode Drive motor speed sensor short 5-74
A28, A40 21-20
blinking
Diagnostic
CB-1 CB-1 mode MB contactor open 5-76 A24, A27, A32 21-20
blinking
5-9
5-10
Diagnostic
CB-2 CB-2 mode MB contactor short 5-76 -
blinking
Diagnostic
CB-3 CB-3 mode MB contactor drive circuit open 5-76 A27, A32 21-20
blinking
Diagnostic
CB-4 CB-4 mode MB contactor drive circuit abnormality 5-76 A27, A32 21-20
blinking
Diagnostic
CB-5 CB-5 mode MB contactor drive circuit short 5-76 A27, A32 21-20
blinking
Diagnostic
CC-1 CC-1 mode Drive AC driver CPU error 5-81 -
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
E0-2 E0-2 mode Pump AC driver power-circuit abnormality 5-82 -
blinking
Diagnostic
E1-1 E1-1 mode Pump AC driver current sensor neutral voltage error 5-84 -
blinking
Diagnostic
E1-2 E1-2 mode Pump AC driver current sensor over current 5-85 -
blinking
O/H
PM E2-1 Pump motor overheating abnormality 5-87 -
lighting
Diagnostic
A16 21-24
E2-2 E2-2 mode Pump motor temperature sensor open/ short abnormality 5-88
A29 21-20
blinking
Diagnostic
E3-1 E3-1 mode Pump AC driver power-circuit temperature sensor open/ short abnormality 5-90 -
blinking
Diagnostic
A17 21-24
E8-1 E8-1 mode Pump motor speed sensor open 5-91
A29 21-20
blinking
Diagnostic
A17 21-24
E8-2 E8-2 mode Pump motor speed sensor short 5-93
A29 21-20
blinking
Diagnostic
EC-1 EC-1 mode Pump AC driver CPU error 5-95 -
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
5-11
5-12
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
EE-1 EE-1 mode Display J Main controller communication error 5-96 -
blinking
Diagnostic
EE-2 EE-2 mode Display J Main controller communication error (on start up) 5-96 -
blinking
Diagnostic
EF-1 EF-1 mode EPS controller CPU error 5-97 -
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
EF-7 EF-7 mode EPS controller EEP-ROM error 5-98 -
blinking
Diagnostic
EF-8 EF-8 mode EPS controller EEP-ROM error 5-98 -
blinking
Diagnostic
F0-1 F0-1 mode EPS controller main circuit abnormality 5-99 Z4 -
blinking
Diagnostic
F0-2 F0-2 mode EPS controller main circuit abnormality 5-99 Z4 -
blinking
Diagnostic
F0-3 F0-3 mode EPS controller main circuit abnormality 5-99 A24, A25, A33, A35 21-20
blinking
Diagnostic
A26 21-20
F1-1 F1-1 mode Main controller J Display communication error 5-103
M3 21-26
blinking
Diagnostic
A26 21-20
F1-2 F1-2 mode Main controller J Display communication error (on start up) 5-103
M3 21-26
blinking
Diagnostic
F4-1 F4-1 mode Display CPU error 5-104 -
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
M3 21-26
F5-1 F5-1 mode Battery electrolyte level/ temperature sensor harness open 5-105
N1 21-20
blinking
Diagnostic
M3 21-26
F5-2 F5-2 mode Battery electrolyte level/ temperature sensor harness short 5-107
N1 21-20
blinking
Diagnostic
F5-3 F5-3 mode Battery electrolyte temperature sensor open 5-110 -
blinking
5-13
5-14
Diagnostic
F5-4 F5-4 mode Battery electrolyte temperature sensor overheating abnormality 5-112 -
blinking
Diagnostic
mode and
F6-1 F6-1 Charging abnormality (Safety timer activated) 5-114 M2, M3 21-26
UP LED
blinking
Diagnostic
M2, M3 21-26
F7-1 F7-1 mode Charging start abnormality 5-118
Z1 -
blinking
Diagnostic
mode and M2, M3 21-26
F8-1 F8-1 Charging completion abnormality 5-122
UP LED Z1 -
blinking
Diagnostic
FB-1 FB-1 mode Battery current sensor neutral voltage error 5-125 A25, A27, A32 21-20
blinking
Diagnostic
FB-2 FB-2 mode Battery current sensor over current 5-125 A25, A27, A32 21-20
blinking
BT O/H
- FC-1 Battery electrolyte overheating abnormality 5-127 -
lighting
Diagnostic
FE-1 FE-1 mode EPS controller J Main controller communication error 5-128 A26, A35, A36 21-20
blinking
Diagnostic
FE-2 FE-2 mode EPS controller J Main controller communication error 5-128 A26, A36 21-20
blinking
Diagnostic
FE-4 FE-4 mode Main controller J EPS controller communication error 5-130 A26, A36 21-20
blinking
Diagnostic
FE-5 FE-5 mode Main controller J EPS controller communication error 5-130 A26, A36 21-20
blinking
Diagnostic
A36 21-20
FE-6 FE-6 mode AFS controller J EPS controller communication error 5-131
Z5, Z6 -
blinking
Diagnostic
A36 21-20
FE-7 FE-7 mode AFS controller J EPS controller communication error 5-131
Z5, Z6 -
blinking
Diagnostic
A26 21-20
FF-1 FF-1 mode Power supply circuit for display over current 5-133
M3 21-26
blinking
Diagnostic
A21 21-24
G1-1 G1-1 mode Brake shut-off solenoid open 5-135
A35 21-20
blinking
Diagnostic
A21 21-24
G1-2 G1-2 mode Brake shut-off solenoid short 5-135
A35 21-20
blinking
Diagnostic
A21 21-24
G1-3 G1-3 mode Brake shut-off solenoid drive circuit abnormality 5-135
A35 21-20
blinking
Diagnostic
A20 21-24
G2-1 G2-1 mode Brake proportional valve solenoid open 5-137
A35 21-20
blinking
Diagnostic
A20 21-24
G2-2 G2-2 mode Brake proportional valve solenoid short 5-137
A35 21-20
blinking
Diagnostic
A20 21-24
G2-3 G2-3 mode Brake proportional valve solenoid drive circuit abnormality 5-137
A35 21-20
blinking
Diagnostic
A19 21-24
G3-1 G3-1 mode Accumulator pressure switch open 5-139
A27 21-20
blinking
Diagnostic
32-1 32-1 mode Drive AC driver ID abnormality 5-142 A28 21-20
blinking
Diagnostic
32-3 32-3 mode Pump AC driver ID abnormality 5-143 A29 21-20
blinking
Diagnostic
33-1 33-1 mode Main controller J Drive AC driver CAN communication abnormality 5-144 A26, A27, A28 21-20
blinking
Diagnostic
33-3 33-3 mode Main controller J Pump AC driver CAN communication abnormality 5-146 A26, A27, A29 21-20
blinking
5-15
5-16
Diagnostic
A36 21-20
51-1 51-1 mode Front speed sensor LH open 5-148
H2, HA2 21-24
blinking
Diagnostic
A36 21-20
51-2 51-2 mode Front speed sensor LH short 5-148
H2, HA2 21-24
blinking
Diagnostic
A36 21-20
51-3 51-3 mode Front speed sensor RH open 5-148
H1, HA1 21-24
blinking
Diagnostic
A36 21-20
51-4 51-4 mode Front speed sensor RH short 5-148
H1, HA1 21-24
blinking
Diagnostic
51-5 51-5 mode Rear speed sensor signal abnormality 5-151 A24, A27, A36, A37 21-20
blinking
Diagnostic
A23 21-24
54-1 54-1 mode Swing lock solenoid open 5-152
A35 21-20
blinking
Diagnostic
A23 21-24
54-2 54-2 mode Swing lock solenoid short 5-152
A35 21-20
blinking
Diagnostic
A23 21-24
54-3 54-3 mode Swing lock solenoid drive circuit abnormality 5-152
A35 21-20
blinking
Diagnostic
56-1 56-1 mode One of traction signal lines open 5-154 A25, A27, A33, A37 21-20
blinking
Diagnostic
56-2 56-2 mode Both of traction signal lines open 5-156 A25, A27, A33, A37 21-20
blinking
Diagnostic
61-1 61-1 mode Load sensor open 5-159 A22, A36 21-20
blinking
Diagnostic
61-2 61-2 mode Load sensor short 5-159 A22, A36 21-20
blinking
Diagnostic
64-1 64-1 mode Lift solenoid open 5-160 A18, A35 21-20
blinking
Diagnostic
64-2 64-2 mode Lift solenoid short 5-160 A18, A35 21-20
blinking
Diagnostic
64-3 64-3 mode Lift solenoid drive circuit abnormality 5-160 A18, A35 21-20
blinking
Diagnostic
A36, PA1 21-20
67-1 67-1 mode Lifting height switch open/ short abnormality 5-162
Q1 21-28, 30, 32, 34, 36
blinking
Diagnostic
A8 21-24
71-1 71-1 mode Tire angle sensor open 5-164
A36 21-20
blinking
Diagnostic
A8 21-24
71-2 71-2 mode Tire angle sensor short 5-164
A36 21-20
blinking
Diagnostic
A36 21-20
72-1 72-1 mode Steering torque sensor open 5-166
AX1, X1 21-26
blinking
Diagnostic
A36 21-20
72-2 72-2 mode Steering torque sensor short 5-166
AX1, X1 21-26
blinking
Diagnostic
74-1 74-1 mode Abnormal matching value for tire angle 5-168 -
blinking
Diagnostic
74-2 74-2 mode Abnormal matching value for tire angle 5-168 -
blinking
Diagnostic
75-1 75-1 mode Abnormal matching value for steering torque sensor 5-169 -
blinking
5-17
5-18
5-19
WHEN ERROR CODE IS DISPLAYED

z Error Code A0-1 (Drive AC driver power-circuit overheating abnormality)
Related portion
A25-2 (100, FNDC2) A30-2
Cooling fan
Main A27-3 (1, CBAT+) A30-1
controller
Drive AC driver
Temperature sensor
Probable cause:
(1) The power cable and motor cable tightening is defective (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive AC driver defect
(4) Cooling fin or cooling fan clogging (8) Main controller defect
Disconnect the battery plug, and confirm whether there is looseness in the conclusion part of the power
cable and motor cable.
Do not leave the vehicle standing in a hot place.
5-20
Error code A0-1
If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Forcibly turn on the cooling fans, using Active Test in
the Analyzer menu, and check the rotation of the
cooling fan. The fan does not rotate.
1
[ANL] ACTIVE TEST 1/1 (FAN)
FAN OFF J ON
The fan rotates.
Turn on the key switch to check for errors.
“DCR” disappears. “DCR” is

displayed.
Inspection: Temperature check

Turn on the key switch and check the value of TDMDH
using the Analyzer menu.
[ANL] I/O TEMP/VOLT 1/6 (TDMDH)

Record the value of
TDMDH.
Turn off the key switch and leave the vehicle standing
for a while (about 15 minutes).
The TDMDH temperature has

lowered by 5°C or more
compared to the TDMDH
temperature previously
checked.
displayed.

Turn on the key switch and check the value of TDMDH
[ANL] I/O TEMP/VOLT 1/6 (TDMDH)

The TDMDH temperature has not
lowered by 5°C or more compared to the
TDMDH temperature previously checked.
Drive AC driver defect
The “DCR” warning indicator turns off when the temperature of the drive AC driver
gets lower, and the vehicle can still be used as it is.
However, the problem seems to be caused by continuous overload operation. So
check how the vehicle was operated and avoid a continuous overload operation.
5-21
Jp
Turn off the key switch and disconnect the battery plug and
the A30 connector, and visually check inside the connector
and the caulked portion of its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.)
1. Connect the A30 connector and the battery plug.
The fan rotates.
2. Turn on the key switch and forcibly turn on the cooling Connector contact defect
fan. And check the rotation of the cooling fan, using
Active Test in the Analyzer menu.

FAN OFF J ON
The fan does not rotate.
Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the A25, A27 and A30 connectors, check the
harnesses for their continuities.
OK
Inspection: Cooling fan check

1. Disconnect the battery plug and connect the A25, A27 and
A30 connectors. Connect the battery plug and turn on the
key switch.
2. Forcibly turn on the cooling fans, using Active Test in the
Analyzer menu, and check the rotation of the cooling fan.

FAN OFF J ON
The fan does not The fan rotates.
rotate.
Cooling fan defect Connector contact defect
* If the fan does not rotate using the Active Test in the Analyzer menu after replacing the fan, there might be other defects, so
replace the main controller.

Check each harness for its continuity.
Disconnect the battery plug and the A25, A27 and A30 connectors, and visually check inside the connector
Note: Perform this check with SST disconnected.
Portions to be checked Standard
A27-3 to A30-1 Continuity
A25-2 to A27-3 No continuity
5-22
z Error Code A0-2 (Pump AC driver power-circuit overheating abnormality)

Related portion
A25-2 (100, FNDC2) A30-2
Cooling fan
Main A27-3 (1, CBAT+) A30-1
controller
Pump AC driver
Temperature sensor
Probable cause:
(3) Harness defect (7) Pump AC driver defect
5-23
Error code A0-2

1
FAN OFF J ON
The fan rotates.
“PCR” disappears. “PCR” is

displayed.

Turn on the key switch and check the value of TPMDH
[ANL] I/O TEMP/VOLT 2/6 (TPMDH)

Record the value of
TPMDH.
The TPMDH temperature has

compared to the TPMDH
checked.
displayed.

Turn on the key switch and check the value of TPMDH
[ANL] I/O TEMP/VOLT 2/6 (TPMDH)

The TPMDH temperature has not
lowered by 5°C or more compared to the
TPMDH temperature previously checked.
Pump AC driver defect
The “PCR” warning indicator turns off when the temperature of the pump AC driver
5-24
Jp
The fan rotates.

FAN OFF J ON

Harness defect
OK

key switch.

FAN OFF J ON
rotate.

5-25
z Error Code A1-2 (Drive AC driver high voltage)

Related portion
MB
P1 F1 P4
Drive
AC driver
Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Drive AC driver defect
(3) F1 fuse open
If CB-1, -3 or -5 is also displayed, perform troubleshooting with priority given to CB-1, -3 or -5.
Error code A1-2
Turn the key switch from OFF to ON to check for Inspection: Check of voltage of drive AC driver
A1-2
errors. Check the value of VDMD, using the Analyzer menu.
error
A1-2 error does not occurs
occur . [ANL] I/O TEMP/VOLT 6/6 (VDMD)
VDMD: Less than 65 V VDMD: 65 V or more
Inspection 1: Check of the battery voltage

1. Turn off the key switch and disconnect the battery plug.
2. Measure the voltage between both ends of the battery
plug with a circuit tester.
Inspection 2: Check of F1 fuse Less than 65 V 65 V or more
1. Turn off the key switch and disconnect the
battery plug.
2. Remove the F1 fuse and measure the NG Drive AC driver defect Battery defect
resistance between its both ends with a circuit (∞ Ω)
tester. F1 fuse open
OK (0 Ω)
Was the battery plug disconnected during YES Do not disconnect the battery plug during traveling except in case
traveling? of an emergency.
NO
* Check the battery plug.

* Check the battery electrolyte.
5-26
z Error Code A1-4 (Pump AC driver high voltage)

Related portion
MB
P1 F1 P4
Pump
AC driver
Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Pump AC driver defect
(3) F1 fuse open
If CB-1, -3 or -5 is also displayed, perform troubleshooting with priority given to CB-1, -3 or -5.
Error code A1-4
Turn the key switch from OFF to ON to check for Inspection: Check of voltage of pump AC driver
errors. A1-4
Check the value of VPMD, using the Analyzer menu.
error
A1-4 error does not occurs.
occur [ANL] I/O TEMP/VOLT 6/6 (VPMD)
VPMD: Less than 65 V VPMD: 65 V or more
Inspection 1: Check the battery voltage.

2. Measure the voltage between both ends of the battery
plug with a circuit tester.
Inspection 2: Check of F1 fuse Less than 65 V 65 V or more
battery plug.
2. Remove the F1 fuse and measure the Pump AC driver defect Battery defect
NG
resistance between its both ends with a circuit (∞ Ω)
tester. F1 fuse open
OK (0 Ω)
Was the battery plug disconnected during YES Do not disconnect the battery plug during traveling except in case
traveling? of an emergency.
NO
Check the battery plug.

Check the battery electrolyte.
5-27
z Error Code A2-1 (Main controller circuit board overheating abnormality)

Related portion
Main controller
Temperature sensor
Probable cause:
(1) The ambient temperature around the Main controller is high (3) Temperature sensor defect (Main controller
(2) Overheating (continuous overload operation) defect)

Error code A2-1
“C/R” disappears. “C/R” is

displayed.

Turn on the key switch and check the value of TMCB
[ANL] I/O TEMP/VOLT 3/6 (TMCB)

Record the value of TMCB.
The TMCB temperature has

compared to the TMCB
“C/R” disappears. “C/R” is
checked.
displayed.

Turn on the key switch and check the value of TMCB
[ANL] I/O TEMP/VOLT 3/6 (TMCB)

The TMCB temperature has not lowered
by 5°C or more compared to the TMCB
temperature previously checked.
Main controller defect
The “C/R” warning indicator turns off when the temperature of the main controller
5-28
z Error Code A2-2 (Drive AC driver circuit board and capacitor overheating
abnormality)
Related portion
A25-2 (100, FNDC2) A30-2
Cooling fan
Main A27-3 (1, CBAT+) A30-1
controller
Drive AC driver
Circuit board Capacitor
temperature sensor temperature sensor
Probable cause:
(3) Harness defect (7) Drive AC driver defect
5-29
Error code A2-2

1
FAN OFF J ON
The fan rotates.

displayed.

Turn on the key switch and check the value of TDMDB
and TDMDC using the Analyzer menu.
[ANL] I/O TEMP/VOLT 1/6 (TDMDB, TDMDC)

Record the value of
TDMDB and TDMDC.
The TDMDB and TDMDC

Turn on the key switch to check for errors. temperatures have lowered by
5°C or more compared to
“DCR” disappears. “DCR” is those previously checked.
displayed.

Turn on the key switch and check the value of TDMDB
and TDMDC using the Analyzer menu.
[ANL] I/O TEMP/VOLT 1/6 (TDMDB, TDMDC)

The TDMDB and TDMDC temperatures
have not lowered by 5°C or more
compared to those previously checked.
The “DCR” warning indicator turns off when the temperature of the drive AC driver
5-30
Jp
The fan rotates.

FAN OFF J ON

Harness defect
OK

key switch.

FAN OFF J ON
rotate.

5-31
z Error Code A2-3 (Pump AC driver circuit board and capacitor overheating
abnormality)
Related portion
A25-2 (100, FNDC2) A30-2
Cooling fan
Main A27-3 (1, CBAT+) A30-1
controller
Pump AC driver
Circuit board Capacitor
temperature sensor temperature sensor
Probable cause:
(3) Harness defect (7) Pump AC driver defect
5-32
Error code A2-3

1
FAN OFF J ON
The fan rotates.

displayed.

Turn on the key switch and check the value of TPMDB
and TPMDC using the Analyzer menu.
[ANL] I/O TEMP/VOLT 2/6 (TPMDB, TPMDC)

Record the value of
TPMDB and TPMDC.
The TPMDB and TPMDC

Turn on the key switch to check for errors. temperatures have lowered by
5°C or more compared to
“PCR” disappears. “PCR” is those previously checked.
displayed.

Turn on the key switch and check the value of TPMDB
and TPMDC using the Analyzer menu.
[ANL] I/O TEMP/VOLT 2/6 (TPMDB, TPMDC)

The TPMDB and TPMDC temperatures
have not lowered by 5°C or more
compared to those previously checked.
The “PCR” warning indicator turns off when the temperature of the pump AC driver
5-33
Jp
The fan rotates.

FAN OFF J ON

Harness defect
OK

key switch.

FAN OFF J ON
rotate.

5-34
z Error Code A2-4 (ECPU board overheating abnormality)

Related portion
ECPU board
Temperature sensor
Probable cause:
(1) The ambient temperature around the ECPU board is high (3) Temperature sensor defect (ECPU board
(2) Overheating (continuous overload operation) defect)

Error code A2-1
“PSCR” “PSCR” is
disappears. displayed.

Turn on the key switch and check the value of TPSDB
[ANL] I/O TEMP/VOLT 3/6 (TPSDB)

Record the value of
TPSDB.
The TPSDB temperature has

compared to the TPSDB
“PSCR” “PSCR” is
checked.
disappears. displayed.

Turn on the key switch and check the value of TPSDB
[ANL] I/O TEMP/VOLT 3/6 (TPSDB)

The TPSDB temperature has not lowered
by 5°C or more compared to the TPSDB
ECPU board defect
The “PSCR” warning indicator turns off when the temperature of the ECPU board
5-35
z Error Code A3-1 (Battery connection incorrect )

Related portion
F5
P1 A27-1 (41, B48V)
Main
controller
Battery
N1
Probable cause:
(1) Charger contact defect
(2) Set voltage defect
(3) The voltage in the B48V line after the F5 fuse is above the set voltage
(4) Main controller defect
Error code A3-1
Turn off the key switch and disconnect the battery plug.
A3-1 error does not occur. Plug contact defect or incorrect
Then, connect the battery plug correctly, turn back on
connection of battery
the key switch to check for errors.
A3-1 error occurs.
Inspection: Check of battery voltage

Less than 65 V
[ANL] I/O TEMP/VOLT 5/6 (B48V)
65 V or more
Check of battery voltage Less than 65 V

P1[+] - N1[-]
65 V or more
Check the battery, and replace it with a regular battery if necessary.

5-36
z Error Code A5-1 (Floor switch GND short abnormality)

Related portion
A26-6 (51, LS-) A9-1
Main
Floor switch
controller
A27-18 (67, LSD) A9-2
Probable cause:
(1) Connector contact defect (3) Harness defect
(2) Floor switch defect (4) Main controller defect
Error code A5-1
1. Disconnect the battery plug, disconnect the A9

connector, and visually check inside the connector
2. Connect the A9 connector, connect the battery plug,
and then turn on the key switch without standing on
the floor.
Inspection: Check of floor switch condition

SDM: 0
Check the value of SDM, using the Analyzer menu. Connector contact defect
[ANL] I/O TRAVELING 1/4 (SDM)
SDM: 1
Inspection: Check of floor switch condition

1. Turn off the key switch and disconnect the battery
plug.
2. Disconnect the A9 connector, connect the battery SDM: 0
Floor switch defect
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 1/4 (SDM)
SDM: 1

1. Turn off the key switch and disconnect the battery NG
plug. Harness defect
2. Disconnect the A26, A27 and A9 connectors and
check the harnesses for their continuities.
OK

5-37
Inspection 1: Check each harness for its continuity.

Before this check, turn off the key switch and disconnect the battery plug, disconnect the A26, A27 and A9
connectors, visually check inside each connector and the caulked portion of each wire for defects.

5-38
z Error Code A6-1, -2, -3, -4, -5, -6 (Material handling lever switch
abnormality)
Related portion
E1-1, 3
AE1
E1-2, 4 Reach lever switch
A26-35 (62, LSR) 2
E2-1, 3
E2-2, 4 Tilt lever switch
A25-23 (61, LST) 3
Z2-1, 3
Attachment 1
Z2-2, 4 lever switch
A25-21 (63, LSAT1) 4
5 *2
Main A25-29 (69, LSAT2) Z3-1, 3

controller Attachment 2
*1 Z3-2, 4 lever switch
A25-20 (60, LSL1)
AF1-1
Lift lever switch
A25-28 (68, LSL2) AF1-2 No.1
AF1-3
Lift lever switch
A24-32 (51, POT-) AF1-2 No.2
*1: Z3-1, 3 and A25-29 connectors are connected when the attachment lever switch is
connected independently.
*2: Z3-1, 3 and Z2-1, 3 connectors are not connected when the attachment lever switch is
connected independently.
Probable cause:
(1) The battery plug is connected while the material handling lever is being operated
(2) Connector contact defect
(3) Material handling lever switch defect
(4) Material handling lever switch installation portion defect
(5) Material handling lever switch harness defect
5-39
Error code A6-1
The A6-1 error may occur if the battery plug is connected and the key switch is turned on while the lift lever
is being operated. Stop operating the lever, and it will return to a normal state if the error disappears.
1. Disconnect the battery plug, disconnect the AF1
connector, and visually check inside the connector A6-1 error does not
and the caulked portion of its wire for defects. occur.
Connector contact defect
2. Connect the AF1 connector, connect the battery plug,
and turn on the key switch to check for errors.
A6-1 error occurs.
1. Disconnect the AF1 connector. A6-1 error does not

2. Connect the battery plug and turn on the key switch occur. • Lift lever switch No.1 defect
to check for errors. • Lift lever switch No.1 installation
defect
A6-1 error occurs.

2. Disconnect the A24 and A25 connectors and check
the harnesses for their continuities.
OK

Disconnect the battery plug and the AF1, A24 and A25 connectors, and visually check inside the connector

A25-20 to AF1-1 Continuity
5-40
Error code A6-2
The A6-2 error may occur if the battery plug is connected and the key switch is turned on while the lift lever
1. Disconnect the battery plug, disconnect the AF1
2. Connect the AF1 connector, connect the battery plug,
A6-2 error occurs.
1. Disconnect the AF1 connector. A6-2 error does not

2. Connect the battery plug and turn on the key switch occur. • Lift lever switch No.2 defect
to check for errors. • Lift lever switch No.2 installation
defect
A6-2 error occurs.

OK

Disconnect the battery plug and the AF1, A24 and A25 connectors, and visually check inside the connector

5-41
Error code A6-3
The A6-3 error may occur if the battery plug is connected and the key switch is turned on while the tilt lever
1. Disconnect the battery plug, disconnect the E2
2. Connect the E2 connector, connect the battery plug,
A6-3 error occurs.
1. Disconnect the E2 connector. A6-3 error does not

2. Connect the battery plug and turn on the key switch occur. • Tilt lever switch defect
to check for errors. • Tilt lever switch installation
defect
A6-3 error occurs.

OK

Disconnect the battery plug and the E2, A24 and A25 connectors, and visually check inside the connector and
the caulked portion of its wire for defects.

A25-23 to E2-1, 3 Continuity
5-42
Error code A6-4
The A6-4 error may occur if the battery plug is connected and the key switch is turned on while the reach
lever is being operated. Stop operating the lever, and it will return to a normal state if the error disappears.
A6-4 error occurs.
1. Disconnect the E1 connector. A6-4 error does not

2. Connect the battery plug and turn on the key switch occur. • Reach lever switch defect
to check for errors. • Reach lever switch installation
defect
A6-4 error occurs.

OK


5-43
Error code A6-5
The A6-5 error may occur if the battery plug is connected and the key switch is turned on while the
attachment 1 or attachment 2 lever is being operated. Stop operating the lever, and it will return to a normal
state if the error disappears.
1. Disconnect the battery plug, disconnect the E3 and
E4 connectors, and visually check inside the
connector and the caulked portion of its wire for A6-5 error does not
defects. occur.
2. Connect the E3 and E4 connectors, connect the
battery plug, and turn on the key switch to check for
errors.
A6-5 error occurs.
1. Disconnect the E3 and E4 connectors. A6-5 error does not

2. Connect the battery plug and turn on the key switch occur. • Attachment 1 or attachment 2
to check for errors. lever switch defect
• Attachment 1 or attachment 2
lever switch installation defect
A6-5 error occurs.

OK

Disconnect the battery plug and the E3, E4, A24 and A25 connectors, and visually check inside the connector

5-44
Error code A6-6
The A6-6 error may occur if the battery plug is connected and the key switch is turned on while the
attachment 2 lever is being operated. Stop operating the lever, and it will return to a normal state if the
error disappears.
A6-6 error occurs.
A6-6 error does not

1. Disconnect the E4 connector. • Attachment 2 lever switch defect
occur.
2. Connect the battery plug and turn on the key switch • Attachment 2 lever switch
to check for errors. installation defect
A6-6 error occurs.

OK


5-45
z Error Code A8-1, -2 (F1 or F6 fuse open abnormality)

Related portion
MB F1 P4
P3
Battery A27-2 (44, VBMB)

A32-7
F6
N1 Main
controller
Drive AC driver
Pump AC driver
Probable cause:
(1) Cable or connector contact defect
(2) Improper installation of F1 or F6 fuse
(3) F1 or F6 fuse open
(4) F6 fuse holder defect
(5) Harness or cable defect
(6) Drive AC driver defect
(7) Pump AC driver defect
5-46
Error code A8-1
If CB-1, -3, -5 or A8-2 is also displayed, perform troubleshooting with priority given to CB-1, -3, -5 or A8-2.
plug. Visually check the following terminals for loose
bolts:drive AC driver positive terminal, pump AC
driver positive terminal, contactor panel P3 and P4
terminals, drive AC driver negative terminal, pump
AC driver negative terminal and N1 terminal. A8-1 error does not
Caution: Before starting the job, measure the occur. Improper fastening of terminals
voltage between positive terminal and GND; if
there is any voltage, insert a resistor at approx.
100 Ω between [+] and GND to discharge the
capacitor.
2. Connect the battery plug and turn on the key switch
to check for errors.
A8-1 error occurs.
Inspection: Check of supply voltages to drive AC driver.

Approx. 48 V
1. Measure the voltage between the positive and Drive AC driver defect
negative terminals of each AC driver.
0V
Inspection: Check of supply voltages to pump AC

driver. Approx. 48 V
1. Measure the voltage between the positive and
negative terminals of each AC driver.
0V
Inspection: Check of installation of F1 fuse

A8-1 error does not
occur.
plug.
F1 fuse installation defect
2. Visually check if the F1 fuse is installed properly.
3. Connect the power cable, connect the battery plug,
and then turn on the key switch.
A8-1 error occurs.
Inspection: Check of F1 fuse

1. Turn off the key switch and disconnect the battery F1 fuse open or
NG (∞ Ω)
plug. AC driver defect (*) or
2. Remove the F1 fuse and measure the resistance Cable between P4 and N1 short
between its both ends with a circuit tester.
OK (0 Ω)
AC driver defect (*) or

Cable between P4 and AC driver defect positive terminal breakage
Cable between N1 and AC driver defect negative terminal breakage
AC driver defect (*)

Turn off the key switch and disconnect the battery plug, remove the copper bar for connection to the
AC driver positive terminal.
Measure the resistance between the positive and negative terminals of the AC driver.
When using an analog tester:
Positive terminal: [-] probe
Negative terminal: [+] probe

} AC drivers are defective if their resistance measured is 10 Ω or less.
5-47
Error code A8-2
If CB-1, -3 or -5 occurs, Perform troubleshooting with priority given to CB-1, -3 or -5.

1. Before this check, disconnect the battery plug,
disconnect the A32 connector, and visually check
inside the connector and the caulked portion of its A8-2 error does not occur.
wire for defects. (Refer to BEFORE Connector contact defect
TROUBLESHOOTING.)
and then turn on the key switch to check for errors.
A8-2 error occurs.
Inspection: Check of installation of F6 fuse

plug. A8-2 error does not occur.
F6 fuse installation defect
2. Visually check if the F6 fuse is installed properly.
3. Connect the F6 fuse and turn on the key switch to
check for errors.
A8-2 error occurs.

1. Turn off the key switch and disconnect the battery NG (∞ Ω)
plug. F6 fuse open
2. Remove the F6 fuse and measure the resistance
between its both ends with a circuit tester.
OK (0 Ω)
Inspection: Check of F6 fuse holder

1. Connect the F6 fuse, disconnect the connector of the
NG (∞ Ω)
F6 fuse holder.
F6 fuse holder defect
2. Measure the resistance of the connector of the F6
fuse holder between its both ends with a circuit
tester.
OK (0 Ω)
Inspection 1: Harness check NG

1. Connect the connector of the F6 fuse holder. Harness defect
2. Disconnect the A27 and A32 connectors.
OK

Perform this check with the battery plug and the A32, A27 connectors and P3 terminal disconnected, visually
check inside each connector and the caulked portion of each wire for defects.

A32-7 (fuse side) to P3 terminal Continuity
A27-2 to N1 No continuity
A32-7 (fuse side) to N1 No continuity
5-48
z Error Code AA-1 (Main controller temperature sensor open/ short

abnormality)
Related portion
Main controller
Temperature sensor
Probable cause:
Error code AA-1
If AA-1 is displayed, the main controller is defective, so replace it.

5-49
z Error Code AA-2 (Drive AC driver circuit board temperature sensor open/
short abnormality)
Related portion
Drive AC driver
Circuit board
temperature sensor
Probable cause:
Error code AA-2
If AA-2 is displayed, the drive AC driver is defective, so replace it.

5-50
z Error Code AA-4 (Pump AC driver circuit board temperature sensor open/
short abnormality)
Related portion
Pump AC driver
Circuit board
temperature sensor
Probable cause:
Error code AA-4
If AA-4 is displayed, the pump AC driver is defective, so replace it.

5-51
z Error Code AA-5 (EPS controller temperature sensor open/ short

abnormality)
Related portion
ECPU board
temperature sensor
Probable cause:
ECPU board defect
Error code AA-5
If AA-5 is displayed, the ECPU board is defective, so replace it.

5-52
z Error Code AB-1 (Cooling fan drive circuit abnormality)

Related portion
A25-2 (100, FNDC2) A30-2
Cooling fan
Main A27-3 (1, CBAT+) A30-1

controller
Probable cause:
(2) Cooling fan defect
(3) Harness defect
Error code AB-1

plug, disconnect the A30 connector, and visually
check inside the connector and the caulked portion of
its wire for defects.
(Refer to BEFORE TROUBLESHOOTING.) AB-1 error does not
2. Connect the A30 connector, connect the battery plug, occur.
turn on the key switch, forcibly turn on the power to
the cooling fan, using Active Test in the Analyzer
menu, and check if any error occurs.

FAN OFF J ON
AB-1 error occurs.
Inspection: Check of cooling fan drive circuit

plug, disconnect the A30 connector, and then
connect the battery plug and turn on the key switch. AB-1 error does not
2. Forcibly turn on the power to the cooling fan, using occur.
Cooling fan defect
Active Test in the Analyzer menu, and check if any
error occurs.

FAN OFF J ON
AB-1 error occurs.

2. Disconnect the A25, A27 and A30 connectors and
OK

5-53
Inspection 1:Check each harness for its continuity.

Perform this check with the battery plug and the A25, A27 and A30 connectors disconnected, visually check
inside each connector and the caulked portion of each wire for defects.

5-54
z Error Code AC-1 (Semiconductor switch abnormality)

Related portion
MB
F1 P4
P2 P3 +
Drive
A28-8
AC driver
+
Pump
A29-8 AC driver
N1
A26-4 (42, KYSAT)
Main
A27-1 (41, B48V) controller
A24-4 (41, VBBT)
F5
Probable cause:
(1) Drive AC driver harness defect
(2) Pump AC driver harness defect
5-55
Error code AC-1
Inspection1: Harness check

plug. NG
2. Disconnect the A24, A26, A27, A28 and A29 Harness defect
connectors and positive terminals of the drive AC
driver and the pump AC driver. Check the harnesses
for their continuities.
OK
Inspection: Check of Main controller

plug. AC-1 error occurs.
2. Disconnect the A28 and A29 connectors, connect the Main controller defect
A24, A26 and A27 connectors.
3 Connect the battery plug, and then turn on the key
switch to check for errors.
AC-1 error does not occur.
Inspection: Check of drive AC driver

plug.
2. Disconnect the A29 connector, connect the A24,
3. Connect the battery plug, and then turn on the key
Inspection: Check of pump AC driver

plug.
2. Disconnect the A28 connector, connect the A24,
3. Connect the battery plug, and then turn on the key
Defect in sections where AC-1 error occurs during drive

AC driver check and pump AC driver check.

Perform this check with the battery plug and the A24, A26, A27, A28 and A29 connectors and the positive
terminals of the drive AC driver and the pump AC driver disconnected, visually check inside each connector
and the caulked portion of each wire for defects.
Then, check the continuities between the A26 connector and the positive terminal of the AC driver.
Also, check the continuities between the harnesses and N1.
Note: Tighten the positive terminals of the AC driver surely.
A26-4 to N1 No continuity
5-56
z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication

abnormality)
Related portion
A26-4 (42, KYSAT) A28-8
A26-11 (145, CAN1H) A28-17
A26-12 (146, CAN1L) A28-16
Main A27-5 (N2, N2) Drive AC driver

controller
A27-4 (N2, N2)
A27-5 (N2, N2)
A27-6 (N2, N2)
A29-8
A29-17
A29-16
Pump
AC driver
A29-6
A29-23
Probable cause:
(1) Wrong AC driver type
(3) Harness defect
(4) AC driver defect
If AC-1 occurs, perform troubleshooting with priority given to AC-1.

5-57
Error code AD-1, -2, -5, -6
Disconnect the battery plug and check if the part

number of the AC driver is correct. Especially if an AC Wrong part number
Wrong AC driver type
driver has just been replaced, check that a different
model AC driver hasn’t been installed.
Correct part number

plug and visually check inside the A28 and A29
connectors and the caulked portions of their wires for
defects. AD-1, AD-2,
(Refer to BEFORE TROUBLESHOOTING.) AD-5, AD-6
2. Connect all connectors and the battery plug, and None of the error codes
then turn on the key switch to check for errors. above are displayed.
Especially if an AC driver has just been replaced
before the error occurred, check if the connector is
connected correctly.
Either AD-2 or AD-6 is displayed.
(*1: Record the error code that has been displayed.)
NG
2. Disconnect the A26, A27, A28 and A29 connectors
and check the harnesses for their continuities.
OK
Inspection: Battery voltage check

1. Turn off the key switch, and then connect the A26
and A27 connectors. At the same time, leave the A28 Less than 15 V
and A29 connectors disconnected.
2. Turn on the key switch and measure the voltage
between A29-8 and N2.
15 V or more
AC driver defect
Error that was recorded in *1

AD-2: Drive AC driver defect
AD-6: Pump AC driver defect
5-58

Perform this check with the battery plug and the A26, A27, A28 and A29 connectors disconnected, visually
Portions to be checked Standard Point

A26-4 to A28-8 Continuity AD-1, 2
A28-8 to A28-17 No continuity AD-1, 2
5-59
z Error Code AF-1, -2, -3, -4, -5, -6, -7, -8 (Main controller CPU error)
Related portion
Main controller
Probable cause:
Error code AF-1, -2, -3, -4, -5, -6, -7, -8
If AF is displayed, the Main controller is defective, so replace it.

5-60
z Error Code C0-2 (Drive AC driver power-circuit short)

Related portion
P7
U
Drive P8
AC V Drive motor
driver
P9
W
Probable cause:
(1) Improper fastening of motor cable (3) Motor cable defect
(2) Drive motor defect (4) Drive AC driver defect
If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
Error code C0-2
1. Turn off the key switch and disconnect the battery plug and visually
C0-2 error
check the fastened or caulked portions of the motor cables for
does not occur.
defects. (Refer to BEFORE TROUBLESHOOTING.) Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and then turn on the
key switch to check for errors.
C0-2 error occurs.

1. Turn off the key switch and disconnect the battery plug. C0-2 error
2. Disconnect the three motor cables from the drive AC driver and occurs.
insulate the terminals of the cables disconnected.
3. Connect the battery plug and turn on the key switch.
4. Check if the C0-2 error occurs.
C0-2 error does not occur.
Inspection 1: Check of motor cables

NG
2. Disconnect the motor cables from both the motor and the drive AC Motor cable defect
driver.
3. Check each motor cable for its continuity.
OK
Inspection: Check of drive AC driver *1

C0-2 error
1. Replace the drive AC driver with the pump AC driver.
occurs.
2. Connect the battery plug and turn on the key switch. Drive motor defect
3. Operate the tilt lever while standing on the floor, and check for
errors. (Ignore the error codes 32-1, 32-3.)
E0-2 error
occurs.
(Note: AC driver that is originally the drive AC driver before replacement.)
5-61
*1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the
drive AC driver.
Inspection: Motor check
NG
1. Turn off the key switch and disconnect the battery plug. Drive motor defect
2. Check the drive motor.
OK
Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each
terminal and the caulked portion and coating of each cable for defects, and then check the P7, P8 and P9
cables.

Both ends of P7 cable Continuity
P7 cable and P8 cable No continuity
5-62
z Error Code C1-1 (Drive AC driver current sensor neutral voltage error)
Related portion
Drive AC driver
Current sensor
Probable cause:
Error code C1-1
If C1-1 is displayed, the drive AC driver is defective, so replace it.

5-63
z Error Code C1-2 (Drive AC driver current sensor over current)

Related portion
P7
U
Drive P8 Drive
AC V
motor
driver
P9
W
Probable cause:
(1) Improper fastening of motor cable (4) Drive AC driver defect
(2) Drive motor defect (5) Drive motor speed sensor defect
(3) Motor cable defect
If C8-1, -2 is also displayed, perform troubleshooting with priority given to C8-1, -2.
Error code C1-2
Turn the key switch from OFF to ON, to check for C0-2 error occurs.
Proceed to identify the cause of C0-2.
errors.

plug and visually check the fastened or caulked
portions of the motor cables for defects. (Refer to C1-2 error does not
BEFORE TROUBLESHOOTING.) occur.
Improper fastening of motor cable
2. Connect the cables and the battery plug, turn on the
key switch, and then operate the accelerator lever
while standing on the floor and depressing the brake
pedal (releasing the brake) to check for errors.
C1-2 error occurs.

plug. NG
Drive motor cable defect
2. Disconnect the motor cables from both the motor and
the drive AC driver.
3. Check the motor cables for its continuity.
OK
Inspection: Check drive AC driver *1

plug.
C1-2 error occurs.
2. Replace the drive AC driver with the pump AC driver. Drive motor defect
3. Connect the battery plug, and turn on the key switch.
4. Check for errors. (Ignore the error codes 32-1 and
32-3.)
E1-2 error occurs.

5-64
*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
drive AC driver.
Inspection: (Motor check)
Drive motor defect
plug.
2. Check the drive motor.
OK

Check each cable for its continuity.
cables.
Refer to BEFORE TROUBLESHOOTING.

5-65
z Error Code C2-1 (Drive motor overheating abnormality)

Related portion
A28-9 (86, STDM+) A14-2
Drive motor
Drive AC driver Temperature
A28-10 (87, STDM) A14-1 sensor
Probable cause:
Overheating (continuous overload operation)

Error code C2-1
“DM” disappears. “DM” is

displayed.

Turn on the key switch and check the value of TDM
[ANL] I/O TEMP/VOLT 1/6 (TDM)

Record the value of TDM.
The TDM temperature has

compared to the TDM
“DM” disappears. “DM” is
checked.
displayed.

Turn on the key switch and check the value of TDM
[ANL] I/O TEMP/VOLT 1/6 (TDM)

The TDM temperature has not lowered
by 5°C or more compared to the TDM
Proceed to identify the cause of C2-2.
The “DM” warning indicator turns off when the temperature of the drive motor gets
lower, and the vehicle can still be used as it is.
5-66
z Error Code C2-2 (Drive motor temperature sensor open/ short

abnormality)
Related portion
A28-9 (86, STDM+) A14-2

Drive motor
Drive AC driver Temperature
A28-10 (87, STDM) A14-1 sensor
Probable cause:
(1) Connector contact defect (3) Drive motor temperature sensor harness defect
(2) Drive motor temperature sensor defect (4) Drive AC driver defect
Error code C2-2

plug and visually check inside the A14 connector and C2-2 error
the caulked portions of their wires for defects. (Refer does not occur.
to BEFORE TROUBLESHOOTING.)
C2-2 error occurs.
Inspection 1: (Check of temperature sensor unit)

NG
plug. Temperature sensor defect
2. Disconnect the A14 connector and check the
temperature sensor as a single unit.
OK
Inspection 2: (Harness check)

NG
OK

5-67
Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: A14-2 and A14-1)
Standard value: Approx. 245 Ω to 600 kΩ
Resistance value varies depending on temperature (Use the following values as a standard).
Resistance
Temperature
(A14-2 - A14-1)
20° C Approx. 13 kΩ
80° C Approx. 1.75 kΩ
100° C Approx. 1 kΩ
Inspection 2: Harness continuity/shorts

Turn off the key switch and disconnect the battery plug, disconnect the A28 and A14 connectors, and visually
Note:Perform this check with SST disconnected.

A28-9 to A14-2 Continuity *1
*1: Connect A14-1 and A14-2 on the harness side through 09232-13130-71 and check if there is continuity
between A28-9 and A28-10.
5-68
z Error Code C3-1 (Drive AC driver power-circuit temperature sensor open/

short abnormality)
Related portion
Drive AC driver
Temperature sensor
Probable cause:
Error code C3-1
If C3-1 is displayed, the drive AC driver is defective, so replace it.

5-69
z Error Code C4-1, -2, -3, -4, -5 (Accelerator potentiometer abnormality)

Related portion
A24-27 (53, POTA+) B1-4
A25-30 (52, POTA1) B1-3

Main Accelerator
controller A25-32 (54, POAT2) B1-2 potentiometer
A24-22 (50, POTA-) B1-1
Probable cause:
(1) Connector contact defect (3) Accelerator potentiometer defect
(2) Accelerator potentiometer harness defect (4) Main controller defect
If the lever was removed for a check, be sure to perform matching after installing it.
The C4-4 error may occur if the key switch is turned on while the accelerator lever is being operated.
Error code C4-1, -2, -3
1. Turn off the key switch and disconnect the battery plug, disconnect
the B1 connector, and visually check inside the connector and the C4-1, -2 or -3 error
caulked portion of its wire for defects. (Refer to BEFORE does not occur.
TROUBLESHOOTING.)
2. Connect the B1 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
C4-1, -2 or -3 errors
One of these errors occurs.
C4-1 error occurs and
Inspection: Check of accelerator potentiometer
C4-2 or C4-3 error
does not occur.
2. Disconnect the accelerator potentiometer connector (B1). 1
Check the error code.
C4-2 or -3 errors
One of these errors occurs.
Harness defect
2. Disconnect the A24, A25 and B1 connectors and check the
OK

5-70

C4-2 error
does not
plug.
occur.
2. Connect the B1-3 to B1-4 on the harness side
through SST2.
C4-2 error occurs.

plug.
2. Disconnect the B1 connector. C4-2 error occurs. Accelerator potentiometer
3. Connect the B1-2 to B1-4 on the harness side defect
through SST2.

NG
2. Disconnect the A24, A25 and B1 connectors and
OK
Error code C4-4
the B1 connector, and visually check inside the connector and the C4-4 error does not
caulked portion of its wire for defects. (Refer to BEFORE occur.
TROUBLESHOOTING.)
2. Connect the B1 connector, connect the battery plug, and turn on the
key switch to see if an error occurs.
C4-4 error occurs.

2. Check if the accelerator potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the accelerator potentiometer.
Refer to MULTIFUNCTION DISPLAY /SERVICE FUNCTION /
MATCHING.
NG
Accelerator potentiometer defect

5-71
Error code C4-5
After the completion of matching,

Matching of the accelerator potentiometer
C4-5 error does not occur. Matching has been made
Refer to MULTIFUNCTION DISPLAY /SERVICE
correctly.
FUNCTION / MATCHING.
Use the device as it is.
After the completion of
matching, C4-5 error
occurs.
Perform this check with the battery plug and the B1, A24 and A25 connectors disconnected. visually check
inside each connector and the caulked portion of each wire for defects.
.
{: Item to be checked
C4
1 2 3 4 5
A24-27 to B1-4 Continuity { − − − −
A24-22 to B1-1 Continuity − { − − −
B1-2 to B1-1 No continuity { − { − −
B1-2 to B1-4 No continuity − { { − −
B1-3 to B1-4 No continuity − { { − −
B1-2 to B1-3 No continuity − − { − −
5-72
z Error Code C8-1 (Drive motor speed sensor open)

Related portion
A28-15 (78, SSD+) A40-4 A15-2

P4 Drive motor
+ A40-3 A15-1 speed sensor 1
Drive A28-14 (79, SSD1)

AC driver
N1 AS1-2 S1-2
- Drive motor
A28-13 (80, SSD2) AS1-1 S1-1 speed sensor 2
Probable cause:
(1) Connector contact defect (4) Drive motor speed sensor 2 defect
(2) Speed sensor harness defect (5) Drive AC driver defect
(3) Drive motor speed sensor 1 defect
Error code C8-1
Turn off the key switch and disconnect the battery plug, disconnect the S1, A15,
A28, A40 and AS1 connectors, visually check inside each connector and the C8-1 error does
caulked portion of each wire for defects. (Refer to BEFORE not occur.
TROUBLESHOOTING.)
Connect all connectors and the battery plug, and then turn on the key switch to
check for errors.
C8-1 error occurs.
Between A28 and S1 or
between A28 and A15
2. Disconnect the A28, S1 and A15 connectors and check the harnesses for
harness defect
their continuities.
OK
Other than
12 to 16 V
2. Disconnect the S1 and A15 connectors and connect the A28 connector.
4. Measure the voltage between S1-2 and N1 and that between A15-2 and N1.
12 to 16 V
Inspection: Check of error code
C8-1 error occurs
or no error
2. Disconnect the S1 and A15 connectors, and connect the A28 connector.
occurs.
3. Short-circuit the S1-2 and S1-1 connectors and the A15-2 and A15-1
connectors on the wire harness side with SST2.
5. Check the error code that appears.
C8-2 error occurs. Drive AC driver defect
1
5-73
Inspection: Check of drive AC driver At least one of the

1. Turn off the key switch and disconnect the battery plug. resistances is not
2. Disconnect the SST2, disconnect the S1 and A15 connectors and connect approx. 100 Ω. Drive AC driver
A28 connector. defect
3. Measure the resistance between S1-1 (wire harness side) and N1 and that
between A15-1 (wire harness side) and N1.
Both the resistances are approx. 100 Ω.
Inspection: Check of drive motor speed sensor

2. Connect the S1 and A15 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-1.
4. Check the value of SSD, using the Analyzer menu.
[ANL] I/O TRAVELING 4/5 (SSD)
SSD: 0.3 or less/0.4 to 1.9 SSD: 0.4 to 1.9/0.3 or less SSD: 0.3 or less/0.3 or less
Drive motor speed Drive motor speed Drive motor speed sensor
sensor 1 defect sensor 2 defect 1 and 2 defect

Turn off the key switch and disconnect the battery plug, disconnect A28, S1 and A15 connectors, visually
check inside each connector and the caulked portion of each wire for defects and then check each harness
between A28 and S1 and that between A28 and A15.

A28-15 to S1-2 Continuity *1
*1: Connect S1-1 to S1-2 through SST and check if there is continuity between A28-15 and A28-13.
*2: Connect A15-1 to A15-2 through SST and check if there is continuity between A28-15 and A28-14.
5-74
z Error Code C8-2 (Drive motor speed sensor short)

Related portion
A28-15 (78, SSD+) A40-4 A15-2

P4 Drive motor
+ A40-3 A15-1 speed sensor 1
Drive A28-14 (79, SSD1)

AC driver
N1 AS1-2 S1-2
- Drive motor
A28-13 (80, SSD2) AS1-1 S1-1 speed sensor 2
Probable cause:
(1) Connector contact defect (4) Drive motor speed sensor 2 defect
(2) Speed sensor harness defect (5) Drive AC driver defect
(3) Drive motor speed sensor 1 defect
Error code C8-2
Turn off the key switch and disconnect the battery plug, disconnect the S1, A15,
A28, A40 and AS1 connectors, visually check inside each connector and the C8-2 error does
caulked portion of each wire for defects. (Refer to BEFORE not occur.
TROUBLESHOOTING.)
Connect all connectors and the battery plug, and then turn on the key switch to
check for errors.
C8-2 error occurs.
Between A28 and S1 or
between A28 and A15
2. Disconnect the A28, S1 and A15 connectors and check the harnesses for
harness defect
their continuities.
OK
Other than
12 to 16 V
2. Disconnect the S1 and A15 connectors and connect the A28 connector.
4. Measure the voltage between S1-2 and N1 and that between A15-2 and N1.
12 to 16 V
C8-2 error occurs
or no error
occurs.
2. Disconnect the S1 and A15 connectors, and connect the A28 connector.
C8-1 error occurs. Drive AC driver defect
1
5-75
At least one of the

resistances is not
approx. 100 Ω. Drive AC driver
2. Disconnect the S1 and A15 connectors and connect A28 connector.
defect
3. Measure the resistance between S1-1 (wire harness side) and N1 and that
between A15-1 (wire harness side) and N1.
Both the resistances are approx. 100 Ω.
Inspection: Check of drive motor speed sensor

2. Connect the S1 and A15 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-1.
4. Check the value of SSD, using the Analyzer menu.
[ANL] I/O TRAVELING 4/5 (SSD)
SSD: 2.0 or more/0.4 to 1.9 SSD: 0.4 to 1.9/2.0 or more SSD: 2.0 or more/2.0 or more
Drive motor speed Speed sensor 2 Drive motor speed sensor

sensor 1 defect defect 1 and 2 defect

Turn off the key switch and disconnect the battery plug, disconnect A28, S1 and A15 connectors, visually
between A28 and S1 and that between A28 and A15.

*1: Connect S1-1 to S1-2 through SST2 and check if there is continuity between A28-15 and A28-13.
*2: Connect A15-1 to A15-2 through SST2 and check if there is continuity between A28-15 and A28-14.
5-76
z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion
MB
P2 P3 F1 P4
F6
A32-7 A27-2 (44, VBMB)
N1 Main
F5 controller
A2-4 A27-1 (41, B48V)
A24-4 (41, VBBT)
A32-1 A27-9 (2, CBAT-)

MB
contactor A32-4 A27-3 (1, CBAT+)
Probable cause:
(1) Connector contact defect (4) F6 fuse defect
(2) MB contactor defect (5) F6 fuse holder defect
(3) Harness defect (6) Main controller defect
5-77
Error code CB-1
If CB-3 or -5 is also displayed, perform troubleshooting with priority given to CB-3 or -5.
CB-1error does not
Disconnect and then connect the battery plug again, and turn on the occur.
key switch to check for errors. 1
CB-1 error occurs.
No actuation
Check if the MB contactor actuation sound is heard when the key sound
Identify the cause of CB-3.
switch is turned on.
Actuation sound
Inspection: Check of the F6 fuse

1. Turn off the key switch and disconnect the battery plug. ∞Ω
F6 fuse defect
2. Remove the F6 fuse and measure the resistance between their
both ends with a circuit tester.
0Ω
Inspection: Check of the F6 fuse holder

1. Install the F6 fuse and disconnect the connector from the fuse
∞Ω
holder. F6 fuse holder defect
2. Measure the resistance between both end of the connector side of
the F6 fuse holder.
0Ω
Inspection 1: Harness check NG

Harness defect
Disconnect the A24, A27, A32 connectors and P3 terminal.
OK
Inspection: Voltage check

1. Connect all the connectors, connect the battery plug, and then turn
on the key switch.
2. Measure the voltage between both ends on the contact side of the
contactor. (Refer to the figure)
P2
30 V or more
MB contactor defect
P3
Less than 30 V

5-78
Inspection: Check of error code CB-1 error occurs. Check the state of
After performing the load handling operation, check for errors. the battery.
CB-1 error does not occur.
Error code CB-2
If AD-5, -6, E1-1, -2, E0-2, E8-1, -2 or EC-1, -2, -3 is also displayed, perform troubleshooting with priority
given to AD-5, -6, E1-1, -2, E0-2, E8-1, -2 or EC-1, -2, -3.
If this error occurs, electric charge remains in the AC driver for a while after the battery plug is
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3
V.
CB-2 error does not
Disconnect and then connect the battery plug again, turn on the key (There are cases where the
occur.
switch and wait for 5 seconds. After that, turn off the key switch and residual charge cannot be
then back on the key switch to see if an error occurs. discharged for reasons of
another error.)
CB-2 error occurs.
The contactor
opens.
Check if the MB contactor opens when the key switch is turned off. 1
The contactor does not open.
Inspection: Check of MB contactor

The contacts
deposited.
2. Measure the voltage between P4 and N1 of the contactor to see MB contactor defect
that it is 3 V or less.
3. Visually check the conditions of the contacts of the MB contactor.
The contacts not deposited.
Identify the cause of CB-3.
Inspection: Check of voltage

1. Disconnect and then connect the battery plug again, turn on the
Less than 15 V
key switch. Main controller defect
2. Turn off the key switch and 5 seconds or more after that, measure
the voltage between P4 and N1 of the contactor.
15 V or more

5-79
Error code CB-3, -5
1. Disconnect the battery plug and visually check inside the A32
CB-3, -5 error does
connector and the caulked portions of their wires for defects. (Refer
not occur.
to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the A32 connector, connect the battery plug, and then turn
on the key switch to check for errors.
CB-3 or CB-5
error occurs.
Inspection: Check of MB contactor coil
NG
2. Disconnect the A32 connector and measure the resistance of the MB contactor defect
MB contactor coil (resistance between A32-1 and A32-4).
Standard value: 15 to 30 Ω (Approx. 20 Ω: 20°C)
OK

NG
Disconnect the A27 and the A32 connectors and check the harnesses Harness defect
OK
Error code CB-4
CB-4 error does not

Disconnect the battery plug and visually check inside the A32
occur.
connector and the caulked portions of their wires for defects. (Refer to Connector contact defect
BEFORE TROUBLESHOOTING.)
CB-4 error occurs.
Inspection: Check of MB contactor coil

NG
2. Disconnect the A32 connector and measure the resistance of the MB contactor defect
MB contactor coil (resistance between A32-1 and A32-4).
Standard value: 15 to 30 Ω (Approx. 20 Ω: 20°C)
OK

NG
Disconnect the A27 and A32 connectors and check the harnesses for Harness defect
their continuities.
OK

5-80
Perform this check with the battery plug and the A24, A27 and A32 connectors are disconnected, visually

A32-7 to P3 Continuity CB-1
A32-7 to A27-2 Continuity CB-1
A32-7 to N1 No continuity CB-1
Before this check, disconnect the battery plug, disconnect the A27 and A32 connectors,
visually check inside each connector and the caulked portion of each wire for defects.

A32-1 to A32-4 No continuity CB-4, 5
A32-1 to P2 No continuity CB-4
A32-1 to P4 No continuity CB-4
5-81
z Error Code CC-1, -2, -3, -4, -5, -6, -7, -8 (Drive AC driver CPU error)
Related portion
Drive AC driver
Probable cause:
Error code CC-1, -2, -3, -4, -5, -6, -7, -8
If CC is displayed, the drive AC driver is defective, so replace it.

5-82
z Error Code E0-2 (Pump AC driver power-circuit short)

Related portion
P4 P14
U
+
Pump AC P15 Pump

driver V motor
N1 P16
- W
Probable cause:
(1) Improper fastening of motor cable (3) Motor cable defect
(2) Pump motor defect (4) Pump AC driver defect
If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.
Error code E0-2
1. Disconnect the battery plug and visually check the fastened or

caulked portions of the motor cables for defects. E0-2 error
(Refer to BEFORE TROUBLESHOOTING.) does not occur.
2. Connect the cables and the battery plug, turn on the key switch,
and then operate the tilt lever while standing on the floor to check
for errors.
E0-2 error occurs.
E0-2 error
2. Disconnect the three motor cables from the pump AC driver and
occurs.
insulate the terminals of the cables disconnected. Pump AC driver defect
4. Operate the tilt lever while standing on the floor to check if the
E0-2 error occurs.
E0-2 error does not occur.
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
OK
Inspection: Check of pump AC driver *1
1. Turn off the key switch and disconnect the battery plug. E0-2 error
2. Replace the pump AC driver with the drive AC driver. occurs.
Pump motor defect
4. Operate the tilt lever while standing on the floor to check for errors.
(Ignore the error codes 32-1 and 32-3.)
C0-2 error
occurs.
(Note: AC driver that is originally the Pump AC driver before replacement)
5-83
*1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the pump AC
driver.
Inspection: Motor check
NG
1. Turn off the key switch and disconnect the battery plug. Pump motor defect
2. Check the pump motor.
OK

cables.

5-84
z Error Code E1-1 (Pump AC driver current sensor neutral voltage error)
Related portion
Pump AC driver
Current sensor
Probable cause:
Error code E1-1
If E1-1 is displayed, the pump AC driver is defective, so replace it.

5-85
z Error Code E1-2 (Pump AC driver current sensor over current)

Related portion
P4 P14
U
+
Pump AC P15 Pump

driver V motor
N1 P16
- W
Probable cause:
(1) Improper fastening of motor cable
(2) Pump motor defect
(3) Pump motor cable defect
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3V.
Error code E1-2
Turn the key switch from OFF to ON, and operate the tilt E0-2 error occur
Proceed to identify the cause of E0-2
lever while standing on the floor to check for E0-2 error.
E0-2 error does not occur
Turn off the key switch and disconnect the battery plug
and visually check the fastened or caulked portions of
the motor cables for defects. (Refer to BEFORE E1-2 error
TROUBLESHOOTING) does not occur
Connect the cables and the battery plug, turn on the
key switch, and then perform load handling operation
(lifting or tilting) while standing on the floor to check for
errors.
E1-2 error occur
Inspection 1: (Check of motor cables)

plug. NG
Motor cable defect
2. Disconnect the motor cables from both the motor and
the pump AC driver.
OK
1
5-86
Inspection: (Check of pump AC driver)*1

1. Replace the pump AC driver with the drive AC driver.
E1-2 error occur
2. Connect the battery plug and turn on the key switch. Pump motor defect
3. Check the error code that is displayed. (Ignore the
error codes 32-1 and 32-3)
C1-2 error occur

(Note: AC driver that is originally the pump AC driver before replacement.)
*1If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
pump AC driver.
Inspection: (Motor check)

Pump motor defect
plug.
2. Check the pump motor.
OK

cables.

5-87
z Error Code E2-1 (Pump motor overheating abnormality)

Related portion
A29-9 (88, STPM+) A16-2
Pump AC driver Pump motor

Temperature
A29-10 (89, STPM) A16-1 sensor
Probable cause:
Overheating (continuous overload operation)

Error code E2-1
“PM” disappears. “PM” is

displayed.

Turn on the key switch and check the value of TPM
[ANL] I/O TEMP/VOLT 2/6 (TPM)

Record the value of TPM.
The TPM temperature has

compared to the TPM
“PM” disappears. “PM” is
checked.
displayed.

Turn on the key switch and check the value of TPM
[ANL] I/O TEMP/VOLT 2/6 (TPM)

The TPM temperature has not lowered
by 5°C or more compared to the TPM
Proceed to identify the cause of E2-2.
The “PM” warning indicator turns off when the temperature of the pump motor gets
5-88
z Error Code E2-2 (Pump motor temperature sensor open/ short

abnormality)
Related portion
A29-9 (88, STPM+) A16-2

Temperature
A29-10 (89, STPM) A16-1 sensor
Probable cause:
(2) Pump motor temperature sensor defect
(3) Pump motor temperature sensor harness defect
Error code E2-2

plug and visually check inside the A16 connector and E2-2 error
the caulked portions of their wires for defects. (Refer does not occurs.
to BEFORE TROUBLESHOOTING)
E2-2 error occurs.
Inspection 1: (Check of temperature sensor unit)

NG
plug. Temperature sensor defect
2. Disconnect the A16 connector and check the
temperature sensor as a single unit.
OK
Inspection 2: (Harness check)

NG
OK

5-89
Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: A16-2 and A16-1)
Standard value Approx. 245 Ω to 600 kΩ
Resistance value varies by temperature (Use the following values as a standard).
Resistance
Temperature
(A16-2 - A16-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
100°C Approx. 1 kΩ

Turn off the key switch and disconnect the battery plug and the A29 and A16 connectors and with SST
disconnected, visually check inside each connector and the caulked portion of each wire for defects.
(Refer to BEFORE TROUBLESHOOTING)

*1: Connect A16-1 and A16-2 on the harness side through 09232-13130-71 and check if there is continuity
between A29-9 and A29-10.
5-90
z Error Code E3-1 (Pump AC driver power-circuit temperature sensor open/

short abnormality)
Related portion
Pump AC driver
Temperature sensor
Probable cause:
Error code E3-1
If E3-1 is displayed, the pump AC driver is defective, so replace it.

5-91
z Error Code E8-1 (Pump motor speed sensor open)

Related portion
P4 A29-15 (81, SSP+) A17-2

+
speed sensor
N2 A29-14 (82, SSP1) A17-1
-
Probable cause:
(1) Connector contact defect (3) Speed sensor defect
(2) Speed sensor harness defect (4) Pump AC driver defect
If this error occurs, electric charge remains in the pump AC driver for a while after the battery plug is
Error code E8-1
Turn off the key switch and disconnect the battery plug, disconnect the A17
E8-1 error does
and A29 connectors, visually check inside each connector and the caulked
not occur.
portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
Connect all connectors and the battery plug, and then turn on the key switch
E8-1 error occurs.
Harness defect
2. Disconnect the A29 and A17 connectors and check the harnesses for their
continuities.
OK
Other than
12 to 16 V
2. Disconnect the A17 connector and connect the A29 connector. Pump AC driver defect
4. Measure the voltage between A17-2 (harness side) and N2.
12 to 16 V
Inspection: Check of error code E8-1 error
1. Turn off the key switch and disconnect the battery plug. occurs or no
2. Disconnect the A17 connector. error occurs.
3. Using SST2, connect the A17-1 and A17-2 (harness side).
E8-2 error occurs.
Inspection: Check of pump AC driver Other than
1. Turn off the key switch and disconnect the battery plug. Approx. 100 Ω
2. Disconnect SST2 from the A17 connector (harness side).
3. Measure the resistance between A17-1 (harness side) and N2.
Approx. 100 Ω
Speed sensor defect
5-92

Turn off the key switch and disconnect the battery plug, disconnect A29 and A17 connectors, and visually
check inside each connector and the caulked portion of each wire for defects and then check each harness.

*1: Connect A17-1 and A17-2 on the wire harness side through SST2 and check if there is continuity between
A29-15 and A29-14.
5-93
z Error Code E8-2 (Pump motor speed sensor short)

Related portion
P4 A29-15 (81, SSP+) A17-2

+
speed sensor
N2 A29-14 (82, SSP1) A17-1
-
Probable cause:
(1) Connector contact defect (3) Speed sensor defect
(2) Speed sensor harness defect (4) Pump AC driver defect
If this error occurs, electric charge remains in the pump AC driver for a while after the battery plug is
Error code E8-2
Turn off the key switch and disconnect the battery plug, disconnect the A17
E8-2 error does
and A29 connectors, visually check inside each connector and the caulked
not occur.
portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
E8-2 error occurs.
Harness defect
2. Disconnect the A29 and A17 connectors and check the harnesses for their
continuities.
OK
Other than
12 to 16 V
2. Disconnect the A17 connector and connect the A29 connector. Pump AC driver defect
4. Measure the voltage between A17-2 (wire harness side) and N2.
12 to 16 V
E8-2 error
occurs or no
error occurs.
2. Disconnect the A17 connector. Pump AC driver defect
E8-2 error occurs.

Inspection: Check of pump AC driver Other than
1. Turn off the key switch and disconnect the battery plug. Approx. 100 Ω
2. Disconnect the A17 connector.
3. Measure the resistance between A17-1 (wire harness side) and N2.
Approx. 100 Ω
Speed sensor defect
5-94

Turn off the key switch and disconnect the battery plug, disconnect A29 and A17 connectors, and visually
check inside each connector and the caulked portion of each wire for defects and then check each harness.

*1: Connect A17-1 and A17-2 on the wire harness side through SST2 and check if there is continuity between
A29-15 and A29-14.
5-95
z Error Code EC-1, -2, -3, -4, -5, -6, -7, -8 (Pump AC driver CPU error)
Related portion
Pump AC driver
Probable cause:
Error code EC-1, -2, -3, -4, -5, -6, -7, -8
If CC is displayed, the pump AC driver is defective, so replace it.

5-96
z Error Code EE-1, -2 (Display J Main controller communication error)

Related portion
A26-3 (14, DGND) M3-4
A26-14 (16, D7V) M3-5

Main
Display
controller A26-11 (145, CAN1H) M3-16
A26-12 (146, CAN1L) M3-15
Probable cause:
(2) Harness defect
(3) Display defect
Error code EE-1, 2
Identify the cause of F1-1 or F1-2.

5-97
z Error Code EF-1, -2, -3, -4 (EPS controller CPU error)

Related portion
ECPU board
CPU
Probable cause:
ECPU board defect
Error code EF-1, 2, 3, 4
If EF-1, EF-2, EF-3 or EF-4 is displayed, the ECPU board is defective, so replace it.
5-98
z Error Code EF-7, -8 (EPS controller EEP-ROM error)

Related portion
ECPU board
EEP=ROM
Probable cause:
ECPU board defect
Error code EF-7, 8
If EF-7 or EF-8 is displayed, the ECPU board is defective, so replace it.

5-99
z Error Code F0-1, -2, -3 (EPS controller main circuit abnormality)

Related portion
A35-1 (338, B20V+) A33-1 A33-10 A24-29 (73, 48VON+)

A35-2 (11, S20V+) A33-2 A33-26 A25-11 (74, 48VON-)
A35-3 (339, B20V-) A33-17 DC/DC A33-3 A24-31 (75, 20VON+) Main
A35-10 (12, S20V-) A33-18 controller A33-19 A25-9 (76, 20VON-) controller
A33-32 A33-20 A25-10 (72, VERR-)
A33-13
A33-14
A33-30
A33-16
F5
MPS F7
MB
A34 F3 A32
P21
P3
Z4-11 (159, TMPS1E)

Z4-10 (158, TMPS1G)
ECPU
board DMPS
P1
Z4-6 (154, TMPS3G) A12
TMPS3 TMPS1
Z4-7 (155, TMPS3E) A13
Z4-9 (156, TMPS4G)

TMPS4 TMPS2
Z4-8 (157, TMPS4E)
Z4-3 (172, SH1+)
BATT
SH1 SH2
Z4-2 (173, SH1-) N22
Z4-4 (175, SH2-)
Z4-5 (174, SH2+)
Z4-12 (171, TMPS2E)
Z4-13 (170, TMPS2G)
N22
TB1
Probable cause:
(1) Connector contact defect (4) ECPU board defect
(2) Harness defect (5) DC/DC controller defect
(3) TMPS defect
5-100
Error code F0-1
Inspection 1: EPS gate signal check Inspection 2: Harness check Harness defect
NG NG
Check the EPS gate signal with circuit Check the EPS gate wiring harness for its between the ECPU
tester. continuity. board and the TMPS
OK OK
Inspection: Check of TMPS ECPU board defect
Check the TMPS as a single unit. NG
TMPS defect
(Refer to page 3-10 in repair manual Pub.
No. CE344.)
OK
Harness defect between TMPS, shunt and N22
Error code F0-2

NG Harness defect between the ECPU board
Check the EPS gate wiring harness for its
and the TMPS
continuity.
OK
Inspection: Check of TMPS
Check the TMPS as a single unit. NG
TMPS defect
(Refer to page 3-10 in repair manual Pub.
No. CE344.)
OK
ECPU board defect
Error code F0-3
Turn off the key switch and disconnect the battery plug, disconnect the A35,
A33, A24 and A25 connectors, visually check inside each connector and the F0-3 error does
caulked portion of each wire for defects. not occur.
F0-3 error occurs.
Inspection: Check a 20 V voltage of the EPS controller
2. Remove the F3 fuse and disconnect the TMPS connector, then connect
Approx. 20 V
the battery plug and turn on the key switch. ECPU board defect
3. Measure the voltage between each of the following connectors.
A35-1 (338) [+] to A35-3 (339) [-]
A35-2 (11) [+] to 35-10 (12) [-]
Other than approx. 20 V
Inspection3: Harness check
NG
Check the harness for its continuity between the main controller and the DC/ Harness defect
DC controller and that between the DC/DC controller and the EPS controller.
OK
DC/DC controller defect
5-101
Inspection 1: EPS gate signal check

Remove the F3 fuse, disconnect the gate connectors on the TMPS, connect the battery plug and turn on the
key switch.
(1) Operate the steering wheel to check the EPS gate signal without performing traveling operation.
Portions to be checked
Standard
[+] probe [-] probe
15 V upon steering wheel clockwise turn. 1 V or less upon counterclockwise turn or in
Z4-10 (1G) Z4-11 (1E)
neutral position
Smooth change between 0 and approx. 15 V upon steering wheel clockwise turn, and
Z4-13 (2G) N22 (TB1)
1 V or less upon counterclockwise turn or in stopped state
15 V upon turning steering wheel counterclockwise turn 1 V or less upon clockwise
Z4-6 (3G) Z4-7 (3E)
turn or in neutral position
Smooth change between 0 and approx. 15 V upon steering wheel clockwise turn, and
Z4-9 (4G) N22 (TB1)
1 V or less upon counterclockwise turn or in stopped state
(2) Harness continuity check

Check each harness for its continuity with SST: 09230-13700-71 connected to the Z4 connector.
Portions to be checked Tester range Standard

SH1- to Z4-2 (SH1-) Ω×1 Approx. 0 Ω
SH1- to N22 (TB1) Ω×1 Approx. 0 Ω
SH2- to Z4-4 (SH2-) Ω×1 Approx. 0 Ω
SH2- to N22 (TB1) Ω×1 Approx. 0 Ω
Inspection 2: Harness continuity check between the ECPU board and the TMPS
(1) Disconnect the battery plug, disconnect the Z4 and TMPS connectors, and then check the harness for
open circuit.

Z4-6 to TMPS connector 3 (O) Ω×1 Approx. 0 Ω
Z4-8 to TMPS connector 4 (BW) Ω×1 Approx. 0 Ω
Z4-10 to TMPS connector 1 (RY) Ω×1 Approx. 0 Ω
Z4-12 to TMPS connector 2 (Y) Ω×1 Approx. 0 Ω
Z4-7 to TMPS connector 3 (SL) Ω×1 Approx. 0 Ω
Z4-9 to TMPS connector 4 (BR) Ω×1 Approx. 0 Ω
Z4-11 to TMPS connector 1 (G) Ω×1 Approx. 0 Ω
Z4-13 to TMPS connector 2 (L) Ω×1 Approx. 0 Ω
(2) Disconnect the battery plug, disconnect the Z4 and TMPS connectors, and then check the harness for
short circuit between G and E.

Z4-6 to Z4-7 Ω×1 10 Ω or less
Z4-8 to Z4-9 Ω×1 10 Ω or less
Z4-10 to Z4-11 Ω×1 10 Ω or less
Z4-12 to Z4-13 Ω×1 10 Ω or less
5-102
Inspection 3: Harness continuity check

Turn off the key switch and disconnect the battery plug, disconnect A35, A33, A24 and A25 connectors, and
visually check inside each connector and the caulked portion of each wire for defects and then check each
harness. (Refer to BEFORE TROUBLESHOOTING.)

A33-16 to P1 Continuity
A33-13 to P3 Continuity
5-103
z Error Code F1-1, -2 (Main controller J Display communication error)

Related portion
A26-11 (145,CAN1H) M3-16 (145, CAN1H)
Main
Display
controller
A26-12 (146,CAN1L) M3-15 (146, CAN1L)
Probable cause:
(1) Connector contact defect (3) Main controller defect
(2) Harness defect (4) Display defect
Error code F1-1, -2
Turn off the key switch and disconnect the battery plug and visually
check inside A26 to M3 connectors and the caulked portion of each
wire for defects.
No error occurs.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
Connect the connector, connect the battery plug and turn on the key
switch, and check if any error occurs.
Error occurs. If the version of

at least one AC
Inspection: driver is
Check the version information on the I/O monitor. displayed
[ANL] VERSION 2/2
If the version of an AC driver is
not displayed:
Inspection 1:
NG Harness (between A26 and M3)
Disconnect the A26 and M3 connectors and check the harness for its
defect
continuities.
OK
Display defect (*1)
*1: If the symptom persists after replacement of the display, there should be any other problems, so replace the Main
controller.
Turn off the key switch and disconnect the battery plug, disconnect the A26 and M3 connectors and check
each harness for its continuity.

A26-11 to M3-16 Continuity (Approx. 0 Ω)
A26-12 to M3-15 Continuity (Approx. 0 Ω)
M3-15 to M3-16 No continuity (Not 0 Ω)
5-104
z Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error)

Related portion
Display
Probable cause:
Display defect
Error code F4-1, -2, -3, -4, -5, -6, -7, -8
If F4 is displayed, the display is defective, so replace it.

5-105
z Error Code F5-1 (Battery electrolyte level/ temperature sensor harness

open)
Related portion
P1
Electrolyte level connector
Electrolyte level detection G Sensor M3-26

output Y (140, SLLT)
Sensor power supply R Display
N1
Electrolyte
level/ temp.
sensor unit
Electrolyte temp. B
Electrolyte
temp. Electrolyte temp. W
sensor
Electrolyte temp. connector
N1
Battery
Probable cause:
(2) Wrong unit connected
(3) Harness defect
(4) Electrolyte level/ temperature sensor defect
(5) Display defect
5-106
Error code F5-1
Be sure to connect the battery plug after connecting the N1 connector, otherwise, an error may occur.
Normally, even if the error occurs when connecting the battery plug before connecting the N1 connector, it will
disappear after about 1 minute.
Not electrolyte
level/ temperature
Check that the unit mounted on the battery is the electrolyte level/ sensor unit Change the setting of the battery
temperature sensor unit. unit. ([OPT] B UNIT)
Electrolyte level/ temperature

sensor unit is mounted.
1. Turn off the key switch and disconnect the battery plug, and
F5-1 error does not
visually check if the N1 harness connector on the vehicle side and
occur.
the electrolyte level/ temperature sensor unit are connected. Connector contact defect
2. Connect the connector, connect the battery plug, and then turn on
the key switch to see if any error occurs.
F5-1 error occurs.

Harness defect
2. Disconnect the N1 and M3 connectors and check the harnesses
OK
Inspection 2: Output current of the electrolyte level/ temperature

sensor unit check
NG Electrolyte level/ temperature
1. Disconnect the N1 connector.
sensor unit defect
2. Connect the battery plug, turn off the key switch and then check
the output current of the electrolyte level/ temperature sensor unit.
OK
Display defect

Turn off the key switch and disconnect the battery plug, disconnect the N1 and M3 connectors, and visually
with SST disconnected.
N1connector to M3-26 Continuity
Inspection 2: Check the output current of the electrolyte level/ temperature sensor unit
Disconnect the N1 connector and connect the battery plug. Turn off the key switch and check the output
current of the electrolyte level/ temperature sensor between the N1 connector (sensor side) and N1 terminal.

N1 connector [+] to N1 terminal [-] Current H, Current L: approx. 2 mA to 15 mA
* [+], [-]: In case of analogue tester
5-107
z Error Code F5-2 (Battery electrolyte level/ temperature sensor harness

short)
Related portion
P1

N1
Sensor power supply R
Electrolyte M3-1 (128, CH7V)

level/ temp. M3-5 (16, D7V)
sensor unit M3-6 (162, ITKY3)
Electrolyte temp. B M3-8 (160, ITKY1)
Electrolyte
temp. M3-15 (146, CAN1L)
Electrolyte temp. W
sensor M3-16 (145, CAN1H) Display
M3-18 (43, VBKY)
Electrolyte temp. connector M3-20 (161, ITKY2)
M3-21 (163, IPSTKY1)
N1 M3-22 (123, SW1)
Battery M3-23 (122, SW2)
M3-24 (121, SW3)
M3-25 (129, CHAC)
M3-33 (132, CHMS)
Probable cause:
(2) Harness defect
(3) Electrolyte level/ temperature sensor defect
(4) Display defect
5-108
Error code F5-2
1.Turn off the key switch and disconnect the battery plug, and visually F5-2 error does
check inside the N1 and M3 connectors and the caulked portion of not occur.
each wire for defects.
F5-2 error occurs
Inspection 1: Display voltage check

1. Turn off the key switch and disconnect the battery plug. OK (0 V) Electrolyte level/ temperature
2. Disconnect the N1 connector, connect the battery plug, turn on the sensor unit defect
key switch and then check the voltage of the display.
NG (Other than 0 V)
Inspection 2: Harness voltage check NG

1. Turn off the key switch and disconnect the battery plug. (Other than 0 V)
Harness defect
2. Disconnect the N1 and M3 connectors, connect the battery plug,
turn on the key switch and then check the voltage of harness.
OK (0 V)

Harness defect
2. Disconnect the N1 and M3 connectors and check the harness for its
continuities.
OK
Display defect
Inspection 1: Display voltage check

Disconnect the N1 connector, connect the battery plug and then turn on the key switch to check the voltage
between N1 connector and N1 terminal.

N1 connector (main harness side) to N1 terminal 0V
Inspection 2: Harness voltage check

Disconnect the N1 and M3 connectors, connect the battery plug and then turn on the key switch to check the
voltage between N1 connector and N1 terminal.

N1 connector (main harness side) to N1 terminal 0V
5-109

Turn off the key switch and disconnect the battery plug, disconnect N1 and M3 connectors, and visually check
inside each connector and the caulked portion of each wire for defects and then check each harness with SST
disconnected.
M3-26 to M3-1 No continuity
5-110
z Error Code F5-3 (Battery electrolyte temperature sensor open)

Related portion
P1

N1
Electrolyte
level/ temp.
sensor unit
Electrolyte temp. B
Electrolyte
sensor
N1
Battery
Probable cause:
(2) Usage of the battery electrolyte under low temperature (less than -20 °C)
(3) Electrolyte temperature sensor defect
(4) Electrolyte level/ temperature sensor unit defect
5-111
Error code F5-3
An error may occur when leaving the vehicle standing under a low temperature (less than -20 °C). So park the
vehicle under a normal temperature.
The vehicle can be used even with an error occurs due to being left standing under a low temperature for a long
time.
Normally, the error will disappear when the battery electrolyte temperature is above -20 °C. (The battery electrolyte
temperature can be checked with [ANL] I/O TEMP/VOLT 4/6 TSLLT, and it will be displayed as -20 even if it gets
lower than -20 °C.)
Since the error may occur frequently when customers usually work under a low temperature, setting [OPT] B UNIT
to A can prevent it from occurring.
At that time, note that the battery electrolyte level and temperature sensing function is invalid.
1.Turn off the key switch and disconnect the battery plug, and visually
check inside the connector of the electrolyte temperature sensor F5-3 error does
and the caulked portion of each wire for defects. not occur.
F5-3 error occurs
Inspection 1: Check the electrolyte temperature sensor as a single

unit
NG Electrolyte temperature sensor
1.Turn off the key switch and disconnect the battery plug.
defect
2. Disconnect the electrolyte temperature sensor connector and
check the sensor as a single unit.
OK
Electrolyte level/ temperature sensor unit defect
Inspection 1: Check the electrolyte temperature sensor as a single unit

Check item
Resistance of the electrolyte temperature sensor (Electrolyte temperature sensor side: electrolyte temperature B to W)
Standard: Approx. 330 kΩ to 35 kΩ (When temperature of electrolyte is 0°C to 50 °C)
* Resistance value varies according to the temperature of electrolyte.
Resistance value of the electrolyte

Temperature of electrolyte
temperature sensor
0°C approx. 330 kΩ
5-112
z Error Code F5-4 (Battery electrolyte temperature sensor overheating

abnormality)
Related portion
P1

N1
Electrolyte
level/ temp.
sensor unit
Electrolyte temp. B
Electrolyte
sensor
N1
Battery
Probable cause:
(2) Incorrect connection of unit
(3) Electrolyte temperature sensor defect
(4) Electrolyte level/ temperature sensor unit defect
5-113
Error code F5-4
If F5-1 error is also displayed, perform troubleshooting with priority given to F5-1.
Be sure to connect the battery plug after connecting the N1 connector, otherwise, an error may occur.
Normally, even if the error occurs when connecting the battery plug before connecting the N1 connector, it will
disappear after about 1 minute.
Not electrolyte
level/ temperature
Check that the unit mounted on the battery is the electrolyte level/ sensor unit Change the setting of the battery
temperature sensor unit. unit. ([OPT] B UNIT)
Electrolyte level/ temperature

sensor unit is mounted.
1.Turn off the key switch and disconnect the battery plug, and
visually check inside the connector of the electrolyte temperature F5-4 error does not
sensor and the caulked portion of each wire for defects. occur.
F5-4 error occurs
Inspection 1: Check the electrolyte temperature sensor as a single

unit
NG Electrolyte temperature sensor
1.Turn off the key switch and disconnect the battery plug.
defect
2. Disconnect the electrolyte temperature sensor connector and
check the sensor as a single unit.
OK
Electrolyte level/ temperature sensor unit defect
Inspection 1: Check the electrolyte temperature sensor as a single unit.

Check item
Resistance of the electrolyte temperature sensor (Electrolyte temperature sensor side: electrolyte temperature B to W)
Standard: Abnormality when the resistance value is below approx. 6 kΩ.
5-114
z Error Code F6-1 (Charging abnormality (Safety timer activated))

Related portion
F5
A27-1 (41, B48V)
Main
A24-105 (41, VBBT) controller
FCH M3-4 (14, DGND)

P2 Transformer M3-3 (169, TGND)
ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)
M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)
Operation M2-6 M3-23 (122, SW2)

N1
panel M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) AC power supply voltage defect (5) Operation panel defect
(2) Power cable defect (6) Harness defect
(3) Magnet switch defect (7) Display defect
(4) FCH fuse defect
For causes other than listed above, refer to “Although the charging is complete, the battery is not fully charged” or
“The magnet switch is not closed when a START button is pressed”.
5-115
Error code F6-1
F6-1 error indication will disappear after disconnecting the AC power plug. Error code can be checked on DIAG
MEMORY of the mask function.
Before performing troubleshooting of F6-1 error, turn on the key switch and check if any other error code will be
indicated. If displayed, perform troubleshooting with priority given to that error.
*
NG (0 V or abnormal
voltage reduction, phase
Inspection 1: Voltage check on the AC power supply side interruption)
1.Turn off the key switch and disconnect the AC power plug. AC power supply defect
2. Check voltage of each AC power supply terminal.
OK (AC191 to 220 V)
NG (0 V or abnormal
voltage reduction, phase
Inspection 2: AC power plug terminal voltage check
interruption)
1.Turn off the key switch and disconnect the AC power plug. Power cable defect
2. Check voltage of each AC power plug terminal.
OK (AC191 to 220 V)
Not all 10 charging

progress indicator come
Inspection: Charger timer test on in 10 seconds after
(Refer to “TIMER TEST” on page 2-21 in repair manual Pub. No. starting the test
Display defect
CE351.)
Not starting Test complete

the timer
test Inspection: Magnet switch check
1. Turn off the key switch and connect the AC power
F7-1 error plug.
1 2. Press “START” button.
3. Check if the magnet switch is closed and held in
that position.
OK
NG
(Closed and held)
To “The magnet switch
is not closed when a
START button is pressed”
Inspection: Magnet switch check
1. Press “STOP” button.
2. Check magnet switch for its continuity.
OK (Open) NG (Not open)
Magnet switch defect
Inspection 3: FCH fuse check

1.Turn off the key switch and disconnect the AC power plug and the battery plug.
2. Remove the FCH fuse and check for its continuity.
OK (Continuity) NG (No continuity)
To “Although the charging is complete, FCH fuse defect

the battery is not fully charged”
5-116
Inspection 4: Operation button check

1. Turn off the key switch, and disconnect the AC power plug and the NG
Operation panel defect
battery plug.
2. Disconnect the M2 connector and check for its continuity.
OK

NG
Disconnect the M2 and M3 connectors and check for their Harness defect
continuities.
OK
Display defect
Inspection 1: Check AC power supply voltage

Each AC power supply terminal AC191 to 220 V
Inspection 2: Check AC power plug

Each power plug terminal AC191 to 220 V
Inspection 3: Check FCH fuse

Remove the FCH fuse and check for its continuity.

Both end of the FCH fuse Continuity
5-117
Inspection 4: Check operation button

Disconnect the M2 connector, and visually check inside the connector and the caulked portion of each wire for
defects. (Refer to BEFORE TROUBLESHOOTING.)
Operation Portions to be checked Standard

Hold down the “STOP” button M2-5 to M2-3 (operation panel side) Continuity
Hold down the “START” button M2-7 to M2-3 (operation panel side) Continuity
Release the “STOP” button M2-5 to M2-3 (operation panel side) No continuity
Release the “START” button M2-7 to M2-3 (operation panel side) No continuity
Inspection 5: Check harness

Disconnect the M2 and M3 connectors, and visually check inside the connector and the caulked portion of
each wire for defects. (Refer to BEFORE TROUBLESHOOTING.)

M2-7 to M3-22 Continuity
5-118
z Error Code F7-1 (Charging start abnormality)

Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

M2-6 M3-23 (122, SW2)
N1 Operation
panel M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) Main controller defect (6) Transformer ASSY defect
(2) Wire connection defect (7) Magnet switch defect
(3) Capacity unsuitable (8) Harness defect
(4) Tap adjustment defect (9) Operation panel defect
(5) FCH fuse defect (10) Display defect
5-119
Error code F7-1
If F6-1 error is also displayed, perform troubleshooting with priority given to F6-1.
*
NG (Displayed value is
outside the range of
Inspection: Voltage check of the battery power supply
±10% of actual
Compare the indicated value on the display and the actual
measured value)
measured value (between P2 and N1). Main controller defect
[ANL] I/O TEMP/ VOLT 5/6 (B48V)
OK (Displayed value is in the

range of ±10% of actual
measured value)
Inspection 1: Wire connection check
1. Turn off the key switch, and disconnect the AC power plug and NG
Wire connection defect
the battery plug.
2. Check the wire connection.
OK
Inspection: Check the power distribution of the transformer ASSY

1. Turn off the key switch, and connect the battery plug and the AC
power plug. NG (Not heard)
2. Press “START” button of the charger. 1
3. Check the transformer ASSY operating sound.
* After the check, press “STOP” button to stop charging.
OK (Heard)
Inspection: Check the compatibility of the capacity of the battery and

the transformer ASSY. NG
Capacity unsuitable
(Refer to “APPLICABLE CHARGER LIST” on page 2-2 in repair
manual Pub. No. CE351.)
OK
Inspection: Tap adjustment check

NG
(Refer to “BEFORE CHARGING” on page 2-7 in repair manual Pub. Tap adjustment defect
No. CE351.)
OK
Transformer ASSY defect

5-120
NG
Inspection: Transformer ASSY fuse check
(No continuity)
(Refer to “Inspection 3: FCH fuse check” of F6-1 error FCH fuse defect
troubleshooting on page 5-115.)
OK (Continuity)
Inspection 2: Primary voltage of transformer ASSY check

1. Turn off the key switch, and disconnect the AC power plug and the
battery plug. OK
Transformer ASSY defect
2. Disconnect the Z1 connector.
3. Connect the AC power plug and press “START” button to perform
the check.
NG
Inspection 3: Magnet switch voltage check

1. Turn off the key switch, and disconnect the AC power plug and the
battery plug. OK
2. Disconnect the Z1 connector.
3. Connect the AC power plug and press “START” button to perform
the check.
NG

1. Turn off the key switch and disconnect the AC power plug and the NG
Harness defect
battery plug.
2. Disconnect the M2 and M3 connectors.
OK
Operation panel defect (*1)
*1 If there is no improvement in symptom after replacing the operation panel, there

might be other defected part, so replace the display.
Inspection 1: Check wire connection
Check if the P2 and N charger cables are correctly connected and there is no looseness.
Check if the Z1, M2 and M3 connectors are correctly connected.
Check if there is no loose connection at the battery plug and the AC power plug. (Also check if terminal is in
good condition and there is no heat generation at the time of power distribution)
Check if there is no damage on the power cable.
Inspection 2: Check primary voltage of transformer ASSY

Disconnect the Z1 connector, connect the AC power plug and press “START” button.

Z1-1 (U) to Z1-2 (V) (REC side) AC191 to 220 V
Z1-2 (V) to Z1-4 (W) (REC side) AC191 to 220 V
Z1-4 (W) to Z1-1 (U) (REC side) AC191 to 220 V
5-121
Inspection 3: Check voltage of magnet switch

Disconnect the Z1 connector, connect the AC power plug and press “START” button.

A1 to 96 AC191 to 220 V
Press “STOP” button.

A1 to 96 AC 0 V
A1 FW-0/0S 96
FW-1S

Disconnect the M2 and M3 connectors, and visually check inside the connector and the caulked portion of

5-122
z Error Code F8-1 (Charging completion abnormality)

Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

M2-6 M3-23 (122, SW2)
N1 Operation
panel M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(2) Magnet switch defect
(3) Operation panel defect
(4) Harness defect
(5) Display defect
5-123
Error code F8-1

*
Turn off the breaker of the power distribution panel and stop power
supply of AC200V to the AC power plug, and then perform the
check.
NG (Displayed value is
Inspection: Voltage check of the battery power supply
±10% of actual
Compare the indicated value on the display and the actual
measured value)
measured value (between P2 and N1). Main controller defect
OK
(Displayed value is in the range
of ±10% of actual measured
value)
Inspection 1: Magnet switch check
1. Turn off the key switch, and disconnect the AC power plug and NG (Continuity)
the battery plug.
2. Disconnect the Z1 connector and check for its continuity.
OK (No continuity)
Inspection 2: Operation panel check

the battery plug.
2. Disconnect the M2 connector and perform the check.
OK

Harness defect
the battery plug.
2. Disconnect the M2 and M3 connectors and perform the check.
OK
Inspection 4: Magnet switch signal check

1. Turn off the key switch, and disconnect the AC power plug and NG (Continuity)
Display defect
the battery plug.
OK (No continuity)

5-124
Inspection 1: Check the magnet switch.

Disconnect the Z1 connector and make sure that the magnet switch is turned off.

Main input terminal (R) to main output terminal (R) No continuity
Main input terminal (S) to main output terminal (S) No continuity
Main input terminal (T) to main output terminal (T) No continuity
Main input Main input Main input Main input

Main input Main input
terminal (S) terminal (T) terminal (S) terminal (R)
terminal (T) terminal (R)
Main output Main output Main output

terminal (T) terminal (S) terminal (R) Main output Main output Main output
terminal (T) terminal (S) terminal (R)
FW-0/0S FW-1S
Inspection 2: Check the operation panel.

Disconnect the M2 connector, and visually check inside the connector and the caulked portion of each wire for
defects.

M2-1 to M2-3 (Operation panel side) No continuity

Disconnect the M2 and the M3 connectors, and visually check inside the connector and the caulked portion of

Inspection 4: Check magnet switch signal

Disconnect the M3 connector and perform the check.

M3-33 to M3-2 (Display side) No continuity
5-125
z Error Code FB-1, -2 (Battery current sensor neutral voltage error)

Related portion
A27-10 (303, CSBAT+) A32-3
Battery
A25-24 (304, CSBAT) A32-8
Main current
controller sensor
A25-35 (305, CSBAT-) A32-5
Probable cause:
(1) Connector contact defect (3) Battery current sensor defect
(2) Harness defect (4) Main controller defect
Error code FB-1, -2
Disconnect the battery plug, disconnect the A32 connector, and FB-1, FB-2
visually check inside each connector and the caulked portion of each error does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
Connect the connector, connect the battery plug, and then turn on the
key switch to check for errors.
FB-1 or FB-2 error
occurs.
Harness defect
2. Disconnect the A25 and A27 connectors and check the harnesses
OK
Inspection: Check of battery current sensor

1. Turn off the key switch and disconnect the battery plug. CSBAT: Other
2. Disconnect the A32. than 0.00
4. Check the value of CSBAT using the Analyzer menu.
[ANL] I/O OTHERS 1/2 (CSBAT)
CSBAT: Approx. 0.00
Inspection: Check of battery current sensor

CSBAT: Approx.
2. Disconnect A32 and connect A32-3 to A32-8 on the harness side
5.00 Battery current sensor defect
through SST2.
4. Check the value of CSBAT using the Analyzer menu.
[ANL] I/O OTHERS 1/2 (CSBAT)
CSBAT: Other than 5.00
*1 If the symptom persists after replacement of the current sensor, there should be any other problems, so replace the Main
controller.
5-126

Disconnect the battery plug, disconnect the A32, A25 and A27, and visually check inside each connector and
the caulked portion of each wire for defects.
*1: Connect A32-3 and A32-8 on the harness side through SST2 and check if there is continuity between A27-
10 and A25-24.
*2: Connect A32-5 and A32-8 on the harness side through SST2 and check if there is continuity between A25-
24 and A25-35.
5-127
z Error Code FC-1 (Battery electrolyte overheating abnormality)

Related portion
Electrolyte
M3-26 (140, SLLT) N1
Display level/ temp.
sensor unit
Probable cause:
(1) The ambient temperature around the battery is high.
(2) Overheating (continuous overload operation)
(3) Battery electrolyte level/ temperature sensor unit defect

Error code FC-1
Inspection: Check of error

Turn on the key switch and check the battery overheat
warning indicator of display.
disappears. is displayed.

Turn on the key switch and check the value of TSLLT
[ANL] I/O TEMP/VOLT 4/6 (TSLLT)

Record the value of TSLLT.
for over 12 hours.
The TSLLT temperature has

Inspection: Check of error lowered by 5°C or more
Turn on the key switch and check the battery overheat compared to the TSLLT
warning indicator of display. temperature previously
checked.
disappears. is displayed.

Turn on the key switch and check the value of TSLLT
[ANL] I/O TEMP/VOLT 4/6 (TSLLT)

The TSLLT temperature has not lowered
by 5°C or more compared to the TSLLT
Proceed to identify the cause of F5-3 and F5-4.
The warning indicator turns off when the battery electrolyte temperature gets
5-128
z Error code FE-1, -2 (EPS controller J Main controller communication

error)
Related portion
P1 P3
MB
F7
A35-6 (360, VBBTS)
A36-12 (307, SMTBA) A26-7 (SMTSA)
A36-25 (308, SMTBK) A26-21 (SMTSK)

Main
ECPU board controller
A36-13 (309, SBTMA) A26-20 (SSTMA)
A36-26 (310, SBTMK) A26-22 (SSTMK)
A35-17 (N2, N2)
N2
Probable cause:
(1) F7 fuse defect
(2) Main harness defect
(3) ECPU board defect
5-129
Error code FE-1
If CB-1, -3, -4, -5, A3-1 or AC-1 is also displayed, perform troubleshooting with priority given to CB-1, -3, -4,
-5, A3-1 or AC-1.
Inspection: Check of voltage
NG (0 V)
Turn on the key switch and measure the voltage
between A35-6 (360) and N2.
OK (Approx. 48 V)
Inspection: Check of F7 fuse installation

NG F7 fuse installation
battery plug.
defect
2. Visually check if the F7 fuse is installed
properly.
OK

battery plug. NG (∞ Ω)
F7 fuse defect
2. Remove the F7 fuse and measure the
resistance between its both ends with a circuit
tester.
OK (0 Ω)
Main harness defect
Inspection: Harness check

No
continuity
battery plug.
(∞ Ω)
2. Disconnect the A26 and A36 connectors and Main harness defect
check each harness for its continuity.
A36-13 (309) to A26-20 (309)
A36-26 (310) to A26-22 (310)
Continuity (0 Ω)
ECPU board defect

Error code FE-2
NG
Check if the A26 and A36 connectors are correctly connected. Connector contact defect
OK

ECPU board defect
5-130
z Error code FE-4, -5 (Main controller J EPS controller communication

error)
Related portion
A36-12 (307, SMTBA) A26-7 (SMTSA)
A36-25 (308, SMTBK) A26-21 (SMTSK)

Main
ECPU board
A36-13 (309, SBTMA) A26-20 (SSTMA) controller
A36-16 (310, SBTMK) A26-22 (SSTMK)
Probable cause:
(1) Main harness defect
Error code FE-4, -5
If AF-1, -2, -3 or -4 is also displayed, perform troubleshooting with priority given to AF-1, -2, -3 or -4.
Inspection: Harness continuity check (discontinuity)
2. Disconnect the A26 and A36 connectors and check each No continuity (∞ Ω)
Main harness defect (discontinuity)
harness for its continuity.
A26-7 (307) to A36-12 (307)
A26-21 (308) to A36-25 (308)
Continuity (Approx. 0 Ω)

ECPU board defect
5-131
z Error code FE-6, -7 (AFS controller J EPS controller communication

error)
Related portion
Standard vehicle
A36-10 (294, SATBA)
A36-9 (295, SATBK)
ECPU board
A36-11 (296, SBTAA)
A36-24 (297, SBTAK)
Vehicle equipped with AFS
P1 P3
MB F8
Z5-8 (201, B48V)
A36-10 (294, SATBA) Z6-2 (SATSA)
A36-9 (295, SATBK) Z6-15 (SATSK)

AFS board
ECPU board
A36-11 (296, SBTAA) Z6-1 (SSTAA)
A36-24 (297, SBTAK) Z6-14 (SSTAK)
Vehicle equipped with multifunction lever or remote control device
A36-10 (294, SATBA)
A36-9 (295, SATBK)
ECPU board
A36-11 (296, SBTAA)
A36-24 (297, SBTAK)
Probable cause:
(1) Harness defect (3) AFS board defect (Equipped with AFS only)
5-132
Error code FE-6, -7
Standard
Check if the vehicle is equipped with
vehicle Set the “AFS” option setting to disable
multifunction lever, AFS or remote control
(“NO”) using Option set.
device.
Equipped Equipped with multifunction lever or

with AFS remote control device
Inspection: Harness continuity check

(discontinuity) No
1. Turn off the key switch and disconnect continuity
the battery plug. (∞ Ω)
Harness defect
2. Disconnect the A36 connector and
check each harness for its continuity.
A36-10 (294) to A36-11 (296)
A36-9 (295) to A36-24 (297)
Continuity (0 Ω)
Inspection: Check of voltage ECPU board defect

1. Turn off the key switch and disconnect
the battery plug.
2. Disconnect the Z5 connector and turn
on the key switch to measure the
voltage between Z5-8 (201) and N2.
OK NG (0 V)
(Approx. 48 V)
Inspection: Check of F8 fuse installation
1. Turn off the key switch and disconnect F8 fuse
NG
the battery plug. installation
2. Visually check if the F8 fuse is installed defect
properly.
OK
Inspection: Harness continuity check Inspection: Check of F8 fuse

(discontinuity) 1. Turn off the key switch and disconnect
1. Turn off the key switch and disconnect the battery plug. NG (∞ Ω) F8 fuse defect
the battery plug. 2. Remove the F8 fuse and measure the (replace)
2. Disconnect the A36 and Z6 connectors resistance between its both ends with
and check each harness for its a circuit tester.
continuity.
A36-10 (294) to Z6-2 OK (0 Ω)
A36-9 (295) to Z6-15
Continuity No continuity Harness defect
(0 Ω) (∞ Ω)
ECPU board defect Harness defect
AFS board defect
(Equipped with ASF
only)
5-133
z Error Code FF-1 (Power supply circuit for display over current)
Related portion
A26-14 (16, D7V) M3-5
Display
A26-3 (14, DGND) M3-4
Main
controller
Probable cause:
(2) Display defect
(3) Harness defect
Error code FF-1
the M3 connector and visually check inside the connector and the Screen is
caulked portion of its wire for defects. displayed.
the key switch to see if a screen is displayed.
No screen is displayed.
Inspection: Check of display

2. Disconnect the M3 connector.
Approx. 7 V
3. Connect the battery plug and turn on the key switch. Display defect
4. Measurement of voltage
Measure the voltage between the M3-5 and M3-4 connectors on
the harness side.
0V

NG
Harness defect
2. Disconnect the A26 connector and check the harnesses for their
continuities.
OK

5-134

Disconnect the battery plug, disconnect the M3 and A26 connectors, and visually check inside each connector
and the caulked portion of each wire for defects.

A26-14 to M3-5 Continuity
A26-3 to M3-4 Continuity
5-135
z Error code G1-1, -2, -3 (Brake shut-off solenoid abnormality)

Related portion
A21
A35-12 (331, SOLBS+) 1 1
ECPU Brake shut-off

board solenoid
A35-13 (332, SOLBS-) 2 2
Probable cause:
(1) Harness defect
(2) Solenoid defect
Error code G1-1
Inspection: Harness continuity check (open circuit) between

solenoid and ECPU board
NG (∞ Ω)
2. Disconnect the A35 and A21 connectors and check each Harness defect
harness for its continuity (open circuit).
A35-12 (331) to A21-1 (331)
A35-13 (332) to A21-2 (332)
OK (0 Ω)
Inspection: Check of the solenoid as a single unit

1. Turn off the key switch and disconnect the battery plug. NG (0 Ω or ∞ Ω)
Solenoid defect
2. Disconnect the A21 connector and measure the resistance
of the solenoid between A21-1 (331) and A21-2 (332).
OK (Approx. 10 Ω)
ECPU board defect

5-136
Error code G1-2
Inspection: Harness continuity check (short circuit) between

1. Turn off the key switch and disconnect the battery plug. NG (continuity)
Harness defect
2. Disconnect the A35 and A21 connectors and check each
harness for its continuity (short circuit).
A35-12 (331) to A35-13 (332)
OK ( ∞ Ω)

Solenoid defect
OK (Approx. 10 Ω)
ECPU board defect
Error code G1-3

NG (∞ Ω)
A35-12 (331) to A21-1 (331)
A35-13 (332) to A21-2 (332)
OK (0 Ω)

Harness defect
A35-12 (331) to A35-13 (332)
OK (∞ Ω)

Solenoid defect
OK (Approx. 10 Ω)
ECPU board defect

5-137
z Error code G2-1, -2, -3 (Brake proportional valve solenoid abnormality)

Related portion
A20
A35-5 (329, SOLBC+) 1 1
Brake
ECPU
proportional
board
valve solenoid
A35-16 (330, SOLBC-) 2 2
Probable cause:
(1) Harness defect
(2) Solenoid defect
Error code G2-1

NG (∞ Ω)
A35-5 (329) to A20-1 (329)
A35-16 (330) to A20-2 (330)
OK (0 Ω)

Solenoid defect
OK (Approx. 10 Ω)
ECPU board defect

5-138
Error code G2-2

Harness defect
A35-5 (329) to A35-16 (330)
OK ( ∞ Ω)

Solenoid defect
OK (Approx. 10 Ω)
ECPU board defect
Error code G2-3

NG (∞ Ω)
A35-5 (329) to A20-1 (329)
A35-16 (330) to A20-2 (330)
OK (0 Ω)

Harness defect
A35-5 (329) to A35-16 (330)
OK (0 Ω)

Solenoid defect
OK (Approx. 10 Ω)
ECPU board defect

5-139
z Error code G3-1 (Accumulator pressure switch open)

Related portion
A19
A27-20 (70, LSPA) 1
Main Accumulator
controller A26-6 (51, LS-) 2 pressure switch
Probable cause:
(1) Harness defect (5) Pressure reducing valve needs to washed
(2) Main controller defect (6) Battery overdischarged or end of life
(3) Relief valve needs to washed (7) Accumulator defect or end of life
(4) Pressure switch defect
Error code G3-1
Inspection: Check of SPA value

OK
Turn on the key switch and check the
(SPA: 0)
value of SPA using the Analyzer menu.
[ANL] I/O OTHERS 2/2 (SPA)
NG (SPA: 1)
Turn off the key switch and disconnect

Turn off the key switch and disconnect
the battery plug.
the battery plug.
Disconnect the A19 connector and
Disconnect the A19 connector.
connect SST2 to the harness.
Inspection: Check of SPA value Inspection: Check of SPA value

OK
Turn on the key switch and check the Turn on the key switch and check the
(SPA: 0)
value of SPA using the Analyzer menu. value of SPA using the Analyzer menu.
[ANL] I/O OTHERS 2/2 (SPA) [ANL] I/O OTHERS 2/2 (SPA)
NG 1 NG OK
(SPA: 1) (SPA: 1) (SPA: 0)
Inspection: Check of voltage 2 Inspection: Check of voltage
1. Turn off the key switch and disconnect 1. Turn off the key switch and disconnect
the battery plug. the battery plug.
2. Disconnect the A27 connector and turn 2. Disconnect the A27 connector and turn
on the key switch to measure the on the key switch to measure the
voltage between A27-20 (70) and N1. voltage between A27-20 (70) and N1.
Less than 3 V or more Less than 3 V or
3V 3V more
Main controller Harness defect Main controller defect Harness defect
defect
5-140
Disconnect the SST2 and connect the A19 connector.
Check the relief pressure of the oil control valve.

(Refer to page 17-12 in repair manual Pub. No. CE351.)
Inspection: Check of SPLF value
NG
Turn on the key switch and check the value of SPLF during lift Wash the relief valve.
(SPLF: Less than 7.5 MPa)
relief using the Analyzer menu. (Refer to page 17-10 in repair
[ANL] I/O M.HANDLING 2/4 (SPLF)
OK
(SPLF: 7.5 MPa or more)
Inspection: Check of pressure of the brake valve pressure
NG Wash the pressure reducing
reducing valve
(Less than 7.5 MPa valve.
Install the pressure gauge at the G2 port of the brake valve and
(Refer to page 10-12 in repair
perform the check of pressure.
OK
7.5 MPa or more
Pressure switch defect
5-141
Disconnect the SST2 and connect the A19 connector.
Check the relief pressure of the oil control valve.

Inspection: Check of SPLF value
NG
Turn on the key switch and check the value of SPLF during lift Wash the relief valve.
(SPLF: Less than 7.5 MPa)
relief using the Analyzer menu. (Refer to page 17-10 in repair
[ANL] I/O M.HANDLING 2/4 (SPLF)
OK
(SPLF: 7.5 MPa or more)
Inspection: Check of pressure of the brake valve pressure
NG Wash the pressure reducing
reducing valve
(Less than 7.5 MPa) valve.
Install the pressure gauge at the G2 port of the brake valve and
(Refer to page 10-12 in repair
perform the check of pressure.
OK
(7.5 MPa or more)
Inspection: Check of pressure switch
Turn on the brake valve solenoid, using Active Test in the
Analyzer menu, and check the pressure during pump motor NG
operation. (Other than standard)
Pressure switch defect
Standard: 4.5 to 5.5 MPa
[ANL] ACTIVE TEST 1/1 (BRAKE L)

BRAKE L OFF → ON
OK
(Within standard)
Set the automatic pressure accumulation (“ACCUM CONT”) to
disable (“NO”) using Option set.
Inspection: Check of accumulator

Turn on the brake valve solenoid, using Active Test in the
NG
Analyzer menu, and check the pressure at which that drops
(0.4 MPa or more) Accumulator defect or end of
quickly.
life
[ANL] ACTIVE TEST 1/1 (BRAKE L)
BRAKE L OFF → ON
OK
(0.4 MPa or less)
Battery overdischarged or end of life
Check that the battery is not being used in an overdischarged condition.
5-142
z Error Code 32-1 (Drive AC driver ID abnormality)

Related portion
Drive AC driver
Probable cause:
(2) Harness defect
* When a pump AC driver is installed as a drive AC driver, the 32-1 error always occurs (which does not mean that
the new AC driver is defective).
Turn off and then back on the key switch.
If AD-5 or -6 is also displayed, perform troubleshooting with priority given to AD-5 or -6.
Error code 32-1
1. Disconnect the battery plug, disconnect the A28 connector, and

32-1
visually check inside the connector and the caulked portion of its
error does not occur. Drive AC driver connector
wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
contact defect
2. Connect the A28 connector, connect the battery plug, and then
turn on the key switch to check for errors.
32-1
error occurs.
5-143
z Error Code 32-3 (Pump AC driver ID abnormality)

Related portion
A29-6 (152, STEP)
Pump AC driver A29-23 (152, STEP-)
Probable cause:
(2) Harness defect
* When a new AC driver is installed on the vehicle, the 32-3 error always occurs (which does not mean that the
new AC driver is defective).
Turn off and then back on the key switch.
Error code 32-3
1. Disconnect the battery plug, disconnect the A29 connector, and

32-3
visually check inside the connector and the caulked portion of its
error does not occur. Pump AC driver connector
wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
contact defect
2. Connect the A29 connector, connect the battery plug, and then turn
on the key switch to check for errors.
32-3 error occurs.
5-144
z Error code 33-1 (Main controller J Drive AC driver CAN communication

abnormality)
Related portion
A26-4 (42, KYSAT) A28-8

A26-11 (145, CAN1H) A28-17
Drive AC
A26-12 (145, CAN1L) A28-10
driver
Main
controller A26-5 (N2, N2)
A27-4 (N2, N2)
A27-5 (N2, N2)
A27-6 (N2, N2)
Probable cause:
(2) Harness defect
5-145
Error code 33-1
Disconnect the battery plug and A26, A27 and A28 connectors, and
visually check inside the connector and the caulked portion of its wire
33-1 error does not
for defect. (Refer to BEFORE TROUBLESHOOTING.)
occur.
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the AC driver, should be confirmed the
connection of each connector.
33-1 error
occurs.
Harness defect
2. Disconnect the A26, A27 and A28 connectors and check the
harness.
OK
33-1 error does not

Turn off the key switch and connect the A26, A27 and A28 occur.
connectors, then turn on the key switch.
33-1 error
occurs.
Inspection: Check of drive AC driver 33-1error does not
1. Replace the drive AC driver with the pump AC driver. occur.
3. Check the error code. (Ignore the error codes 32-1, 32-3.)
33-3 error
occurs.

Check each harness for its continuity and short
Turn off the key switch and disconnect the battery plug, disconnect the A26, A27 and A28 connectors and
visually check inside each connector and caulked portion. Then check the continuity and short of each
Portion to be checked Standard
5-146
z Error code 33-3 (Main controller J Pump AC driver CAN communication

abnormality)
Related portion
A26-4 (42, KYSAT) A29-8

A26-11 (145, CAN1H) A29-17
Pump AC
A26-12 (145, CAN1L) A29-10 driver
Main
controller A26-5 (N2, N2)
A27-4 (N2, N2)
A27-5 (N2, N2)
A27-6 (N2, N2)
Probable cause:
(2) Harness defect
(3) Pump AC driver
5-147
Error code 33-3
Disconnect the battery plug and A26, A27, A29 connectors, and
visually check inside the connector and the caulked portion of its wire
33-3 error does not
for defect. (Refer to BEFORE TROUBLESHOOTING.)
occur.
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the AC driver, should be confirmed the
connection of each connector.
33-3 error
occurs.
Harness defect
2. Disconnect the A26, A27 and A29 connectors and check the
harness.
OK
33-3 error does not

Turn off the key switch and connect the A26, A27 and A29 occur.
connectors, then turn on the key switch.
33-3 error
occurs.
Inspection: Check of pump AC driver 33-3 error does not
1. Replace the pump AC driver with the drive AC driver. occur.
3. Check the error code. (Ignore the error codes 32-1, 32-3.)
33-1 error
occurs.
(Note: AC driver that is originally the pump AC driver before replacement.)

Check each harness for its continuity and short
Turn off the key switch and disconnect the battery plug, disconnect the A26, A27 and A29 connectors and
visually check inside each connector and caulked portion. Then check the continuity and short of each
Portion to be checked Standard
5-148
z Error code 51-1, -2, -3, -4 (Front speed sensor abnormality)

Related portion
HA2 H2
1 1 2 2
Front speed
A36-2 (334, SSFL-) 2 2 1 1 sensor (LH)
ECPU A36-14 (333, SSF+)

board
HA1 H1
A36-15 (335, SSFR-) 2 2 1 1
Front speed
1 1 2 2 sensor (RH)
Probable cause:
(1) Harness defect
(2) Speed sensor defect
Error code 51-1
Short circuit between A36-14 and A36-2 connectors using 51-1 error occurs. ECPU board defect
SST13. Main harness defect (short circuit)
51-2 error occurs.
Disconnect the HA2 connector and short circuit between 51-1 error occurs.
Main harness defect (open circuit)
HA2-1 and HA2-2 connectors using SST16.
51-2 error occurs.
Disconnect the H2 connector and short circuit between H2-1 51-1 error occurs.
Sub-harness defect (open circuit)
and H2-2 connectors using SST15.
51-2 error occurs.
Front speed sensor (LH) defect (open circuit)

5-149
Error code 51-2
Disconnect the battery plug. disconnect the HA2

connector and connect the battery plug.
51-2 error occurs. 51-1 error occurs.

51-2
error
Disconnect the battery plug. Connect the HA2 occurs. Sub-harness
connector and disconnect the H2 connector, then defect
connect the battery plug. (short circuit)
51-1 error occurs.
Front speed sensor (LH) defect (short circuit)
Continuity
Disconnect the battery plug. Disconnect the A36 and
(Approx. 0Ω) Main harness defect
HA2 connectors and check the harness for its continuity
(Short circuit between A36-14 and A36-2)
between A36-14 (333) and A36-2 (334).
No continuity (∞ Ω)
ECPU board defect

Main harness defect (short circuit)
Error code 51-3
Short circuit between A36-14 and A36-15 connectors using 51-3 error occurs. ECPU board defect
SST13. Main harness defect (short circuit)
51-4 error occurs.
Disconnect the HA1 connector and short circuit between 51-3 error occurs.
Main harness defect (open circuit)
HA1-1 and HA1-2 connectors using SST16.
51-4 error occurs.
Disconnect the H1 connector and short circuit between H1-1 51-3 error occurs.
Sub-harness defect (open circuit)
and H1-2 connectors using SST15.
51-4 error occurs.
Front speed sensor (RH) defect (open circuit)

5-150
Error code 51-4
Disconnect the battery plug. disconnect the HA1


51-4
error
Disconnect the battery plug. Connect the HA1 occurs. Sub-harness
connector and disconnect the H1 connector, then defect
connect the battery plug. (short circuit)
51-3 error occurs.
Front speed sensor (RH) defect (short circuit)
Continuity
(Approx. 0Ω) Main harness defect
HA1 connectors and check the harness for its continuity
between A36-14 (333) and A36-15 (335).
ECPU board defect

Main harness defect (short circuit)
5-151
z Error code 51-5 (Rear speed sensor signal abnormality)

Related portion
A37-3 (324, SS+) A24-30 (SS+)
ECPU A37-11 (325, SS-) A27-17 (SS-) Main

board controller
A36-22 (330, BPOT-)
J18
Probable cause:
(1) Harness defect
* Perform inspection with the vehicle in stopped state (rear wheel in stopped state).
Error code 51-5
Inspection: Check of ECPU board voltage

A37-3: Approx. 1 V
Measure the voltage of ECPU board connector pin between
A37-11: 0 V
each of the following connectors. ECPU board defect
A37-3 (324) [+] - A36-22 (300) [-]
A37-11 (325) [+] - A36-22 (300) [-]
Other than
A37-3: Approx. 1 V
A37-11: 0 V
Inspection: Harness continuity check (open circuit)
Disconnect the battery plug and disconnect A24, A27 and A37
connectors, and check the harnesses for their continuities No continuity (∞ Ω)
Harness defect (open circuit)
between each of the following connectors.
A24-30 (324) - A37-3 (324)
A27-17 (325) - A37-11 (325)

ECPU board defect
5-152
z Error code 54-1, -2, -3 (Swing lock solenoid abnormality)

Related portion
A23
A35-14 (327, SOLS+) 1 1
ECPU Swing lock

board solenoid
A35-15 (328, SOLS-) 2 2
Probable cause:
(1) Harness defect
(2) Solenoid defect
Error code 54-1

77

the solenoid and the ECPU board
Disconnect the battery plug and disconnect A35 and A23
NG (∞ Ω)
connectors, and check the harnesses for their continuities Harness defect
A35-14 (327) - A23-1 (327)
A35-15 (328) - A23-2 (328)
OK (0 Ω)
Inspection: Check of solenoid

Disconnect the battery plug and disconnect A23 connector, NG (0 Ω or ∞ Ω)
Solenoid defect
and measure the resistance of the solenoid between
A23-1 (327) and A23-2 (328).
OK (Approx. 5.5 Ω)
ECPU board defect

5-153
Error code 54-2

Disconnect the battery plug and disconnect A35 and A23 NG (continuity)
Harness defect
connectors, and check the harnesses for their continuities
A35-14 (327) - A35-15 (328)
OK (∞ Ω)

Solenoid defect
A23-1 (327) and A23-2 (328).
OK (Approx. 5.5 Ω)
ECPU board defect
Error code 54-3

Disconnect the battery plug and disconnect A35 and A23
NG (∞ Ω)
A35-14 (327) - A23-1 (327)
A35-15 (328) - A23-2 (328)
OK (0 Ω)

Disconnect the battery plug and disconnect A35 and A23 NG (continuity)
Harness defect
A35-14 (327) - A35-15 (328)
OK (∞ Ω)

Solenoid defect
A23-1 (327) and A23-2 (328).
OK (Approx. 5.5 Ω)
ECPU board defect

5-154
z Error Code 56-1 (One of traction signal lines open)

Related portion
A27-30 (85, NS) A33-5 A33-9 A37-5 (83, NS+)
A33-25 A37-13 (84, NS-)
Main A27-31 (97, RS) A33-21 DC/DC A33-8 A37-4 (98, RS+) ECPU
controller controller board
A33-24 A37-12 (99, RS-)
A25-10 (72, VERR-) A33-20 A33-32 (N2, N2)
Probable cause:
(2) Harness defect
(4) DC/DC controller defect
5-155
Error code 56-1
Turn off the key switch and disconnect the battery plug, disconnect
the A25, A27, A33 and A37 connectors, and visually check inside NG
each connector and the caulked portion of each wire for defects.
OK

Harness defect
2. Disconnect the A25, A27, A33 and A37 connectors and check the
OK
Disconnect the battery plug and connect the A25, A27, A33 and A37
connectors.
Connect A33-5 to A33-21 on the DC/DC controller side through
SST13.
56-1 error is
Connect the battery plug and turn on the key switch to check if the displayed.
56-1 error disappears.
Disconnect the battery plug and connect A33-25 to A33-24 on the

DC/DC controller side through SST13.
56-1 error is
Connect the battery plug and turn on the key switch to check if the displayed.
ECPU board defect

Turn off the key switch and disconnect the battery plug, disconnect the A25, A27, A33 and A37 connectors and

5-156
z Error Code 56-2 (Both of traction signal lines open)

Related portion
A27-30 (85, NS) A33-5 A33-9 A37-5 (83, NS+)
A33-25 A37-13 (84, NS-)
Main A27-31 (97, RS) A33-21 DC/DC A33-8 A37-4 (98, RS+) ECPU
controller controller board
A33-24 A37-12 (99, RS-)
A25-10 (72, VERR-) A33-20 A33-32 (N2, N2)
Probable cause:
(2) Harness defect
(4) DC/DC controller defect
5-157
Error code 56-2
Turn off the key switch and disconnect the battery plug, disconnect
the A25, A27, A33 and A37 connectors, and visually check inside NG
each connector and the caulked portion of each wire for defects.
OK

Harness defect
2. Disconnect the A25, A27, A33 and A37 connectors and check the
OK
Disconnect the battery plug and connect the A25, A27, A33 and A37
connectors. 56-1 error does not
Connect A33-5 to A33-20 on the DC/DC controller side through occur.
SST13.
Connect the battery plug and turn on the key switch to check if the
56-1 error occurs.
56-1 error occurs.
Disconnect the battery plug and connect A33-21 to A33-20 on the 56-1 error does not
DC/DC controller side through SST13. occur.
56-1 error occurs.
56-1 error occurs.
56-1 error occurs.
56-1 error occurs.
56-1 error occurs.
56-1 error occurs.
ECPU board defect

5-158

Turn off the key switch and disconnect the battery plug, disconnect the A25, A27, A33 and A37 connectors and

5-159
z Error Code 61-1,-2 (Load sensor open/ short abnormality)

Related portion
A36-1 (58, SPL+) A22

3 3
ECPU A36-18 (59, SPL) 2 2
Load sensor
board 1 1
A36-22 (300, BOPT-)
Probable cause:
(1) Load sensor defect
(2) Harness defect
Error code 61-1
Disconnect the A22 connector and short circuit between A22-2 61-2 error occurs.
Load sensor defect (open circuit)
and A22-3 connectors using SST17.
61-1 error is displayed.
Short circuit between A36-1 and A36-18 connectors using 61-2 error occurs.
Harness defect (open circuit)
SST13.
ECPU board defect

Harness defect (short circuit)
Error code 61-2
61-1 error
Disconnect the battery plug, disconnect the A22 occurs.
A22 connectors and check the harness for its
continuity between A22-1 (300) and A36-22 (300).
Continuity No continuity
(Approx. 0 Ω) (∞ Ω)
Load sensor defect Harness defect
(short circuit) (open circuit)
Disconnect the battery plug. Disconnect the A36 and Continuity
A22 connectors and check the harness for its (Approx. 0 Ω) Harness defect
continuity (short circuit) between A36-1 (58) and (Short circuit between A36-1 and A36-18)
A36-18 (59).
ECPU board defect

5-160
z Error code 64-1, -2, -3 (Lift solenoid abnormality)

Related portion
A18
A35-4 (3, SOLL+) 1 1
ECPU Lift
board solenoid
A35-11 (4, SOLL-) 2 2
Probable cause:
(1) Lift solenoid defect
(2) Harness defect
Error code 64-1

Disconnect the battery plug and disconnect the A35 and A18
NG (∞ Ω)
A35-4 (3) - A18-1 (3)
A35-11 (4) - A18-2 (4)
OK (0 Ω)
Inspection: Check of solenoid as a single unit

Disconnect the battery plug and disconnect the A18 connector, NG (0 Ω or ∞ Ω)
Solenoid defect
A18-1 (3) and A18-2 (4).
OK (Approx. 10 Ω)
ECPU board defect

5-161
Error code 64-2

Disconnect the battery plug and disconnect the A35 and A18 NG (continuity)
Harness defect
A35-4 (3) - A35-11 (4)
OK (∞ Ω)

Solenoid defect
A18-1 (3) and A18-2 (4).
OK (Approx. 10 Ω)
ECPU board defect
Error code 64-3

Disconnect the battery plug and disconnect the A35 and A18
NG (∞ Ω)
A35-4 (3) - A18-1 (3)
A35-11 (4) - A18-2 (4)
OK (0 Ω)

Disconnect the battery plug and disconnect the A35 and A18 NG (continuity)
Harness defect
A35-4 (3) - A35-11 (4)
OK (∞ Ω)

Solenoid defect
A18-1 (3) and A18-2 (4).
OK (Approx. 10 Ω)
ECPU board defect

5-162
z Error Code 67-1 (Lifting height switch open/short abnormality)

Related portion
PA1 QP1 Q1
A36-5 (90, MH1) 2 2 2 2 2 2
ECPU A36-6 (91, MH2-1) 3 3 3 3 3 3

board
A36-21 (301, BLS-) 1 1 1 1 1 1
Lifting height switch
Probable cause:
(1) Harness defect (3) ECPU board defect
(2) Lifting height switch defect
5-163
Error code 67-1
Inspection: Check of lifting height switch input value

Check the value of SH at a low lifting height using
SH: 11 SH: 00
the Analyzer menu.
[ANL] I/O M.HANDLING 2/4 (SH)
SH: 10 SH: 01
Inspection: Check of lifting height switch input value

Check the value of SH at a high lifting height using
the Analyzer menu.
[ANL] I/O M.HANDLING 2/4 (SH)
SH: 11 SH: 01 SH: 00
Inspection 1: Check of lifting height switch as a ECPU board Inspection 1: Check of lifting height switch as a
single unit defect single unit
Disconnect the battery plug and disconnect the Q1 Disconnect the battery plug and disconnect the Q1
connector, and check the continuity of the lifting connector, and check the continuity of the lifting
height switch. height switch.
OK NG OK NG
Lifting height switch defect Lifting height switch

(short circuit) defect
(open circuit)
Inspection: Check of lifting height switch input value Inspection: Harness continuity check
Compare the values of SH before and after Disconnect the battery plug and disconnect the Q1
disconnecting the PA1 connector. and A36 connectors, and check the harnesses for
their continuities between each of the following
[ANL] I/O M.HANDLING 2/4 (SH) connectors.
A36-5 (90) - Q1-2 (90)
The value does The value A36-6 (91) - Q1-3 (91)
not change. changes. A36-21 (301) - Q1-1 (301)
Sub-harness defect Continuity No continuity
(short circuit) (0 Ω) (∞ Ω)
Inspection: Harness continuity check ECPU board defect Harness defect
Disconnect the battery plug and disconnect the PA1 (open circuit)
and A36 connectors, and check the harnesses for
their continuities between each of the following
connectors.
When “10” is displayed.
A36-5 (90) - A36-21 (301)
A36-6 (91) - A36-21 (301)
A36-5 (90) - A36-21 (301)
A36-6 (91) - A36-21 (301)
No continuity Continuity
(∞ Ω) (0 Ω)
ECPU board defect Harness defect
(short circuit)
Inspection 1: Check of lifting height switch as a single unit

Disconnect the battery plug and disconnect the Q1 connector, and check the continuity of the lifting height
switch.
Portions to be checked Low lifting height High lifting height

Q1-2 (90) to Q1-1 (301) Approx. 0 Ω ∞Ω
Q1-3 (91) to Q1-1 (301) ∞Ω Approx. 0 Ω
5-164
z Error Code 71-1, -2 (Tire angle sensor open/ short abnormality)

Related portion
A36-16 (316, VRAH+) A8

2 2
ECPU A36-20 (317, VRAH) 3 3 Tire angle
board 1 1 sensor
A36-22 (300, BOPT-)
Probable cause:
(1) Tire angle sensor defect
(2) Harness defect
Error code 71-1
Inspection 1: Check of tire angle sensor as a single unit

NG
Disconnect the battery plug and disconnect the A8 connector, Tire angle sensor defect
and measure the resistance of the tire angle sensor.
OK
Disconnect the A8 connector and keep A36 connector

71-2 error occurs.
connected, and short circuit between A36-16 and A36-20 Harness defect (open circuit)
connectors using SST13.
71-1 error occurs.
ECPU board defect

5-165
Error code 71-2
Disconnect the battery plug, disconnect the A8


Tire angle
Disconnect the battery plug and disconnect the A8 NG
sensor
connector, and measure the resistance of the tire angle
defect
sensor.
OK
No
Inspection: Harness continuity check (open circuit)
continuity
Disconnect the battery plug and disconnect the A36
(∞ Ω) Harness
and A8 connectors, and check the harnesses for their
defect
continuities between each of the following connectors.
(open circuit)
A36-22 (300) - A8-1 (300)
Continuity
(Approx. 0 Ω)
ECPU board defect
Inspection: Harness continuity check (short circuit)

Continuity
(Approx. 0Ω) Harness defect
and A8 connectors, and check the harnesses for their
A36-16 (316) - A36-20 (317)
ECPU board defect


Set the drive wheel in straight traveling position, then disconnect the battery plug and disconnect the A8
connector, and measure the resistance of the tire angle sensor with setting the tire.

A8-1 to A8-2 2.5 kΩ to 6 kΩ
A8-1 to A8-3 1 kΩ to 15 kΩ
A8-2 to A8-3 1 kΩ to 15 kΩ
5-166
z Error Code 72-1,-2 (Steering torque sensor open/ short abnormality)

Related portion
AX1 X1
A36-17 (176, SST+) 1
1 1 1
ECPU A36-19 (177, SST) 3 3 3 3 Steering torque
SPIRAL sensor
board 2 2 2
A36-23 (178, SST-) 2
Probable cause:
(1) Spiral defect
(2) Steering torque sensor defect
Error code 72-1
Inspection 1: Check of steering torque sensor as a

single unit
Disconnect the battery plug and disconnect the AX1
connector, and measure the resistance of the steering
torque sensor.
NG OK
72-2 error
Harness
Short circuit between A36-17 and A36-19 connectors occurs.
defect
using SST13.
(open circuit)
72-1 error occurs.
ECPU board defect

No continuity
Disconnect the battery plug and disconnect the X1 and
(∞ Ω)
AX1 connectors, and check the harnesses for their
Spiral defect (open circuit)
X1-1 (176) - AX1-1 (176)
X1-3 (177) - AX1-3 (177)
Continuity (Approx. 0Ω)

Disconnect the battery plug and disconnect the X1 and Continuity
AX1 connectors, and check the harnesses for their (Approx. 0Ω)
Spiral defect (short circuit)
AX1-1 (176) - AX1-2 (178)
AX1-3 (177) - AX1-2 (178)
Steering torque sensor defect

5-167
Error code 72-2
Disconnect the battery plug. disconnect the AX1


Continuity
Disconnect the battery plug and disconnect the A36 Harness defect
(Approx. 0 Ω)
and AX1 connectors, and check the harnesses for their (short circuit
continuities between each of the following connectors. between A36-17
A36-17 (176) - A36-19 (177) and A36-19)
ECPU board defect

No continuity
(∞ Ω)
and AX1 connectors, and check the harnesses for their Harness defect (open circuit)
A36-23 (178) - AX1-2 (178)

Continuity
(Approx. 0 Ω)
AX1 connectors, and check the harnesses for their Spiral defect (short circuit)
AX1-1 (176) - AX1-3 (177)

No continuity
(∞ Ω)
AX1 connectors, and check the harnesses for their Spiral defect (open circuit)
X1-2 (178) - AX1-2 (178)
Inspection 1: Check of steering torque sensor as a

single unit
NG
Disconnect the battery plug and disconnect the X1 Steering torque sensor defect
connector, and measure the resistance of the steering
torque sensor.
OK
ECPU board defect
Inspection 1: Check of steering torque sensor as a single unit

Disconnect the battery plug and disconnect the A8 connector, and measure the resistance of the tire angle
sensor.

AX1-1 to AX1-2 2.5 kΩ to 6 kΩ 72-1
AX1-1 to AX1-3 1.5 kΩ to 6 kΩ 72-1
AX1-2 to AX1-3 0.5 kΩ to 3 kΩ 72-1
X1-1 to X1-2 2.5 kΩ to 6 kΩ 72-2
X1-1 to X1-3 1.5 kΩ to 6 kΩ 72-2
X1-2 to X1-3 0.5 kΩ to 3 kΩ 72-2
5-168
z Error Code 74-1, -2 (Abnormal matching value for tire angle)

Related portion
ECPU board
Probable cause:
(1) The stored matching value of tire angle sensor in neutral, right end or left end is outside the specified
matching range.
If 71-1 or -2 is also displayed, perform troubleshooting with priority given to 71-1 or -2.
Error code 74-1, -2

matching, 74-1 or 74-2
error does not occur. Matching has been made
Perform matching of tire angle.
correctly.
Refer to “MATCHING” on page 4-42.
74-1 or 74-2 error occurs.
ECPU board defect
5-169
z Error Code 75-1 (Abnormal matching value for steering torque sensor)
Related portion
ECPU board
Probable cause:
(1) The stored matching value of steering torque sensor in neutral is outside the specified matching range.
If 71-1 or -2 is also displayed, perform troubleshooting with priority given to 71-1 or -2.
Error code 75-1

matching, 75-1 error does
not occur. Matching has been made
Perform matching of steering torque sensor.
correctly.
Refer to “MATCHING” on page 4-42.
75-1 error occurs.
ECPU board defect
WHEN NO ERROR CODE IS DISPLAYED 5-170

Probable causes of problems for which no error code is displayed.
If an error code is displayed or the spanner indicator blinks, be sure to perform checks with priority given to it.
Control systems Phenomena on the vehicle Failed portions and failure modes How to check Action and remedies
Power-supply Although the key switch or ten- Battery Check the battery voltage. • Charge the Battery
key operation is turned on, power : Low voltage : Battery plug is disconnected.
is not supplied. Check the battery voltage.
(The display screen does not Key switch main body - • Check the switch, and replace it if
appear, and the vehicle does not : Open failure necessary.
move.) Key switch harness • Check the harness, and repair or
: Wire breakage, short circuit or leakage replace it if necessary.
(harness, connector or F5 and F6 fuses) • Replace the F5 fuse
• Replace the F6 fuse.
Numeric keypad harness (with PIN code - • Check the harness, and repair or
entry) replace it if necessary.
: Open failure
Numeric keypad main body (with PIN code Check the operation of each switch. • Replace the numeric keypad main
entry) : Check if a response (lighting of LED or body.
: Switch failure sounding of buzzer) is given only to a
particular switch.
If there are two types of switches:
switch to which a response is given
and switch to which no response is
given in the combination of (1, 2 and
3), (4, 5 and 6), (7, 8 and 9) or (OFF, 0
and ON), it is certain that there is a
defective switch.
Display (with PIN code entry) Log on with the initial registration • Register PIN using the Administrator
: PIN not registered number, using the Administrator menu, menu.
check if PIN has been registered.
Display power supply and ground harness - • Check the harness, and repair or
(with PIN code entry) replace it if necessary.
: Wire breakage, short circuit, leakage • Replace the display.
(harness or connector)
Display (with PIN code entry)
: Internal failure
Main controller Check the voltage of display power • Replace the main controller.
: Internal failure supply.
: Check the voltage between D7V and
DGND
Less than 7 V J Main controller defect
Power-supply The display screen does not Display power supply or ground harness - • Check the harness, and repair or
appear. : Wire breakage, short circuit, leakage replace it if necessary.
(The vehicle runs normally.) (harness or connector) • Replace the display.
Display • Replace the main controller.
: Internal failure
Main controller
: Internal failure
Traveling The vehicle does not run, or does Warm-up function is activated. Check the warning indicator on the * It is not an error.
not run uphill suddenly. display and check the warning sound. The warm-up function is activated for
* Due to the usage by customers (leaving several seconds when the key switch is
the vehicle standing under -35 °C or turned on to protect the controller.
lower temperature for a long time),
when the warm-up function is activated, The traveling and load handling
the warning indicator on the display will operation cannot be performed during
turn on along with a warining sound. warming up, so restart to use the
vehicle after the warning sound goes
off.
Accelerator potentiometer main body Check the accelerator potentiometer • Check the sensor, and replace it if
: Internal failure voltage, using Analyzer. necessary.
Accelerator potentiometer installation portion : Seated off seat • Check the harness, and repair or
: The link or the installation portion is broken Operate the accelerator lever from replace it if necessary.
or damaged. forward to backward to check the
Accelerator potentiometer harness change in voltage.
: Wire breakage, short circuit, leakage
Accelerator potentiometer neutral/forward tilt Check the matching value on the • Perform matching again with a correct
limit/backward tilt limit matching value Matching screen. vehicle state.
: No agreement with the vehicle state
Brake switch main body Check the operation of the brake switch, • Check the switch, and replace it if
: Internal failure using Analyzer. necessary.
Brake switch installation portion : Accelerator lever in neutral position • Check the harness, and repair or
: The link or the installation portion is broken Release then depress the brake pedal replace it if necessary.
or damaged. to check the change in the input
Brake switch harness signal.
Battery pull-out switch main body Check the operation of the pull-out • Check the switch, and replace it if
: Internal failure switch, using Analyzer. necessary.
Battery pull-out switch harness : Accelerator lever in neutral position • Check the harness, and repair or
: Wire breakage, short circuit, leakage Perform the battery pull-out operation replace it if necessary.
(harness or connector) to check the change in the input
signal.
5-171
Traveling The vehicle does not run, or does Brake Check the operation of the brake and the • Check the brake, and repair or replace
5-172
not run uphill suddenly. : Dragging drive motor. it if necessary
Drive motor : With the battery plug disconnected, • Check the drive motor, and repair or
: Seizure or dragging of drive motor the brake released and the front replace it if necessary.
wheels off the ground, rotate each tire
manually to see if it rotates smoothly.
Front brake Check the front brake • Check the front brake, and repair or
: Dragging Forcibly turn off the brake solenoid to replace it if necessary.
check the front brake, using Active Test.
: Forcibly turn off the brake solenoid to
check if the front brake can be
released.
Drive motor speed sensor main body Check the voltage of the drive motor • Check the drive motor speed sensor,
: Internal failure speed sensor, using Analyzer. and adjust or replace it if necessary.
Drive motor speed sensor installation portion : Seated in seat, brake released • Check the harness, and repair or
: Gap improperly adjusted Operate the accelerator lever and replace it if necessary.
Drive motor harness check the change in the speed sensor
: Wire breakage, short circuit, leakage (cable voltage.
or terminal board)
Drive AC driver Check the voltage of the drive motor • Check the cable, and repair or replace
: Internal failure current sensor, using Analyzer. it if necessary.
Motor cables : Seated in seat, brake released • Replace the drive AC driver.
: Wire breakage, short circuit, leakage (cable Operate the accelerator lever and
or terminal board) check the change in the current
sensor voltage.
Main controller - • Replace the main controller.
: Internal failure
Load handling Load handling cannot be Warm-up function is activated. Check the warning indicator on the * It is not an error.
performed. display and check the warning sound. The warm-up function is activated for
(The pump motor does not run several seconds when the key switch
and accumulate pressure * Due to the usage by customers (leaving turns on to protect the controller.
automatically even when the vehicle standing under -35 °C or
performing the load handling lower temperature for a long time), The traveling and load handling
operation.) when the warm-up function is activated, operation cannot be performed during
the warning indicator on the display will warming up, so restart to use the
turn on along with a warining sound. vehicle after the warning sound goes
off.
Load handling Load handling cannot be Pump motor speed sensor main body Check the voltage of the pump motor • Check the pump motor speed sensor,
performed. : Internal failure speed sensor, using Analyzer. and adjust or replace it if necessary.
(The pump motor does not run Pump motor speed sensor instrallation portion : Seated in the seat • Check the harness, and repair or
and accumulate pressure : Gap improperly adjusted Operate the material handling lever replace it if necessary.
automatically even when Pump motor harness and check the change in the motor
performing the load handling : Wire breakage, short circuit or leakage speed sensor voltage.
operation.) (cable or terminal board)
Pump AC driver Check the voltage of the pump motor • Check the motor cable, and repair or
: Internal failure current sensor, using Analyzer. replace it if necessary.
Motor cable : Seated in the seat • Replace the pump AC driver.
: Wire breakage, short circuit or leakage Operate the material handling lever
(cable or terminal board) and check the change in the current
sensor voltage.
Oil pump - • Check the oil pump, and repair or
: Seizure replace it if necessary.
Pump motor • Check the pump motor, and repair or
: Seizure replace it if necessary.
: Internal failure
Only load handling cannot be Material handling switch main body Check the material handling switch, • Check the material handling switch,
performed. : Internal failure using Analyzer. and replace it if necessary.
(The pump motor operates with Install the material handling switch : Seated off seat • Check the harness, and repair or
automatic pressure : Installation portion is broken or damaged. Operate the material handling lever replace it if necessary.
accumulation.) Material handling switch harness from forward to backward to check if
: Wire breakage, short circuit, leakage the switch turns on and off normally.
Floor switch main body Check the floor switch, using Analyzer. • Check the floor, and replace it if
: Open failure : Material handling lever in neutral necessary.
Floor switch harness position • Check the harness, and repair or
: Wire breakage (harness or connector) Seat in then off the seat to check if the replace it if necessary.
switch turns on and off normally.
Battery pull-out switch main body Check the pull-out operation of the • Check the switch, and replace it if
: Internal failure battery, using Analyzer. necessary.
Battery pull-out switch harness : Accelerator lever in neutral position • Check the harness, and repair or
: Wire breakage, short circuit, leakage Perform the battery pull-out operation replace it if necessary.
(harness or connector) to check the change in the input
signal.
Oil pump - • Check the oil pump, and repair or
: Leak replace it if necessary.
Priority valve • Check the priority valve, and repair or
: Leak, seizure replace it if necessary.
5-173
Load handling Only load handling cannot be Main controller - • Replace the main controller.
5-174
performed. : Internal failure
(The pump motor operates with
automatic pressure
accumulation.)
Only lowering is impossible. Lowering lock valve - • Check the lowering lock valve, and
(Other load handling operations, : Seizure repair or replace it if necessary.
including raising, are possible.)
PS Steering is heavy. (Power assist is Harness between the MB and MPS contactors - • Check the harness, and repair or
impossible.) : Wire breakage (harness, connector or F3 replace it if necessary.
fuse) • Replace the F3 fuse.
MPS contactor Check the applied voltage of the MPS • Repair or replace the MPS contactor.
: Contactor contact defect, contactor coil contactor coil.
breakage : MPS contactor contact defect if a 13 V
voltage between + side and - side of
the MPS contactor coil is detected.
Check the resistance of the MPS
contactor coil.
: Approx. 68 Ω at normal times
Harness between the MPS contactor and the • Check the harness, and repair or
ECPU board replace it if necessary.
: Wire breakage, short circuit, leakage • Replace the ECPU board.
-
ECPU board
: Internal failure
PS motor harness • Check the harness, and repair or
: Wire breakage, short circuit, leakage - replace it if necessary.
PS motor Check the continuity of the PS motor • Repair or replace the PS motor.
: Motor defect : Approx. 0 Ω at normal times
Harness between the ECPU board and the PS Check the EPS gate signal • Check the harness, and repair or
transistor : Refer to inspection 1 for the EPS replace it if necessary.
: Wire breakage, short circuit, leakage controller main circuit error (F0-1,2,3). • Replace the ECPU board.
ECPU board
: Internal failure
PS transistor (TMPS) Check the single unit of the PS transistor • Repair or replace the PS transistor
: PS defect (TMPS) (TMPS).
: Refer to the information of the TMPS
single unit check.
PS Steering is heavy. (Power assist is Shunt (SH1/SH2) Check the single unit of the shunt (SH1/ • Repair or replace the shunt (SH1/SH2).
impossible.) : Shunt defect SH2)
: Refer to the information of the SH1/
SH2 single unit check.
Harness between the PS transistor (TMPS) - • Check the harness, and repair or
and the N2 shunt replace it if necessary.
ECPU board - • Replace the ECPU board.
: Internal failure
OPS Material handling OPS does not Floor switch main body Check the floor switch, using Analyzer. • Check the switch, and replace it if
operate. : Short circuit : Material handling lever in neutral necessary.
Floor switch harness position • Check the harness, and repair or
: Short circuit (harness or connector) Seat in then off the seat to check if the replace it if necessary.
switch turns on and off normally.
Oil control valve - • Check the oil control valve, and repair
: Seizure or leakage of the lowering lock or replace it if necessary.
valve • Check the solenoid, and replace it if
Lift solenoid harness necessary.
: Short circuit, leakage (harness or • Check the harness, and repair or
connector) replace it if necessary.
ECPU board • Replace the ECPU board.
: Internal failure
: Internal failure
Multifunction display [Spanner indicator] One of the following matching operations is Check the matching value on the • Perform matching again with a correct
DX Although no error code is not performed. Matching screen. vehicle state.
displayed, the spanner indicator • Accelerator potentiometer neutral voltage * When performing matching with the
is left on. matching accelerator lever in neutral position, the
• Accelerator potentiometer forward tilt limit matching value of forward tilt limit/
voltage matching backward tilt limit will be cleared. Be
• Accelerator potentiometer backward tilt limit sure to perform matching again.
voltage matching
• Tire angle sensor straight angle matching
• Tire angle sensor left end angle matching
• Tire angle sensor right end angle matching
• PS torque sensor neutral voltage matching
• Tire diameter data
5-175
Multifunction display [Speedometer] Display setting Check the set value on the Option Set • Change the setting correctly.
5-176
DX Speed is not displayed. : Wheel indicator is set to C mode (always screen.
displayed).
(Option Set WHEEL IND)
[Wheel indicator] Display setting Check the set value on the Option Set • Change the setting correctly.
Although the vehicle is stopped, : Wheel indicator is set to A mode (not screen.
the wheel indicator is not displayed).
displayed. (Option Set WHEEL IND)
[Wheel indicator] Tire main body • Check the tire, and replace it if
-
After the vehicle run straight, the : Type, diameter necessary.
wheel indicator does not show Tire angle sensor main body Check the sensor voltage, using • Check the sensor, and replace it if
that wheel is in straight position. : Internal failure Analyzer. necessary.
Install the tire angle sensor : Accelerator lever in neutral position • Check the harness, and repair or
: The installation portion is broken or Turn a steering to check the change in replace it if necessary.
damaged. voltage.
Tire angle sensor harness
Tire angle sensor straight angle, left end or Check the matching value on the • Perform matching again with a correct
right end matching value Matching screen. vehicle state.
[Power meter] Display setting Check the set value on the Option Set • Change the setting correctly.
Power meter is not displayed. : Power meter indicator setting screen.
(Option Set POWER METER)
[Menu lock] Display setting Check the setting value on the Option • Change the setting correctly.
Although the menu lock function : Menu lock specification Set screen.
setting is disabled, the lock can (Option Set MENULOCK SPEC)
still be performed through key
OFF to ON operation.
[Load meter] Lift lever is not in neutral position. • Load is not displayed when operating
Load meter is not displayed. - the lift lever. Put the lift lever in neutral
position.
Traveling • Load is not displayed when traveling.
-
Stop traveling.
Display setting Check the setting value on the Option • Change the setting correctly.
: Load meter display setting Set screen.
(Option Set LOAD METER)
Display setting On the service function setting screen, • Change the setting correctly.
: Cylinder diameter, mast type, zeropoint check if each setting is correct.
adjustment
Multifunction display [Load meter] Main controller - • Replace the main controller.
DX The load is always displayed : Internal failure
during vehicle is standing. Main controller - • Replace the main controller.
: Internal failure
[Load meter] Load sensor main body Check the load sensor voltage, using • Check the sensor, and replace it if
The correct load is not displayed. : Internal breakage Analyzer. necessary.
Load sensor harness : In NL • Check the harness, and repair or
: Wire breakage, short circuit, leakage Lower and raise the lift to its replace it if necessary.
(harness or connector) lowermost and uppermost (relief)
positions to check the change in the
voltage.
Display setting On the service function setting screen, • Make each setting correctly.
: Cylinder diameter, mast type, zeropoint check if each setting is correct.
adjustment, calibration * To improve the accuracy, perform
adjustment on the LOAD
COMPENSATION screen of the load
meter matching.
Cannot be measured under the recommended - • To measure the load correctly, perform
condition. a measurement with the load lifted to a
height of approx. 500 mm, the mast
raised to a vertical position and both
load handling and traveling operations
stopped.
* This load meter measures and

calculates pressure on the lift cylinder.
So, even if measuring the same load,
the measured value may vary
depending on the mast height, tilt level,
temperature of the hydraulic oil, way to
stop load handling, mechanical loss of
the mast, leakage from the oil control
valve, etc.
Use this load meter as a guide, because
the accuracy same as a scale is not
guaranteed.
: Internal failure
: Internal failure
5-177
TBC Insufficient braking force of front Hydraulic oil Check if the hydraulic oil other than the • Replace with the specified hydraulic oil.
5-178
brake : The specified oil is not used. specified one is used.
Lifting height switch main body Check the operation of the lifting height • Check the switch, and replace it if
: Internal failure switch necessary.
Lifting height switch harness : Perform load handling operation to • Check the harness, and repair or
: Wire breakage (harness or connector) check the change in the input signal. replace it if necessary.
Brake hydraulic circuit Forcibly turn on the brake solenoid to • Repair or replace the leakage part.
: Leak check for leakage, using Active Test.
: Check the leakage with the brake
solenoid forcibly turned on.
Brake shut-off solenoid Forcibly turn on the brake solenoid to • Repair or replace the brake solenoid.
Brake proportional valve solenoid check the pressure, using Active Test.
: Solenoid defect : Refer to the information of the on-
vehicle check of the brake valve.
Front brake ASSY Check the front brake ASSY • Repair or replace the defective part.
: IASSY assembly defect : Refer to the information of
disassembly, inspection and assembly
of the front brake.
: Internal failure
Dragging of front brake ECPU board Check for dragging in key-off state. • Replace the ECPU board.
: Internal failure J The ECPU board is defective if the
dragging is resolved.
Brake shut-off solenoid Check the brake for dragging with the • Repair or replace the brake solenoid.
Brake proportional valve solenoid pressure relief valve of the brake valve
: Solenoid defect opened.
J Solenoid is defective if the dragging is
resolved.
Brake proportional valve solenoid Open the bleeder plug of the wheel • Repair or replace the brake solenoid.
: Solenoid defect cylinder to check the residual pressure. • Repair of replace the front brake.
Front brake J The brake proportional valve solenoid
: Solenoid defect is defective if there is residual
pressure.
The front brake is defective if the
dragging is still remained.
The vehicle speed does not rise Vehicle speed sensor installation portion Check the gap between the vehicle • Check the installation of the vehicle
up. (TRC is displayed.) : Gap improperly adjusted speed sensor and the load wheel. speed sensor, and adjust or replace it if
: Refer to the information of necessary.
disassembly, inspection and assembly
of the front brake.
TBC The vehicle speed does not rise Load wheel installation portion Check the load wheel for looseness • Check the installation of the load
up. (TRC is displayed.) : Installation defect : Refer to the information of removal wheel, and adjust or replace it if
and installation of the front axel. necessary.
Tire angle sensor straight angle matching Check the matching value on the • Perform matching again with a correct
value Matching screen. vehicle state.
: Internal failure
: Internal failure
Braking force when switch back Tire angle sensor straight angle matching Check the matching value on the • Perform matching again with a correct
comes off. value Matching screen. vehicle state.
Rear brake Check the rear brake for dragging. • Check the rear brake, and adjust or
: Improper adjustment replace it if necessary.
: Internal failure
: Internal failure
Automatic pressure accumulation Brake hydraulic circuit After performing air bleeding of the brake • Repair or replace the leakage part if
is activated frequently. : Leak line, forcibly turn on the brake solenoid to necessary.
check for leakage, using Active Test.
: To perform air bleeding, refer to the
information of air bleeding of the front
brake.
Pressure switch Check the operation pressure of the • Repair or replace the pressure switch.
: Pressure switch defect pressure switch.
: Refer to information of disassembly,
inspection and assembly of the front
brake.
Accumulator Check the opertation of the accumulator. • Repair or replace the accumulator.
: Leak : Refer to information of the on-vehicle
check of the brake valve
The vehicle is unstable when the Swing lock cylinder main body Forcibly turn on and off the swing lock • Repair or replace the swing lock
swing lock indicator is displayed. : The link or lock is impossible. solenoid to check the lock. cylinder.
(Internal damage)
5-179
TBC The vehicle is unstable when the Installation state of the swing lock cylinder Check the installation of the swing lock • Check the swing lock cylinder, and
5-180
swing lock indicator is displayed. : No agreement with the vehicle state cylinder. adjust or replace it if necessary
: Refer to information of the removal
and installation of the swing lock
cylinder.
The vehicle is unstable when Tire angle sensor straight angle matching Check the matching value on the • Perform matching again with a correct
turning to the left/right. value Matching screen. vehicle state.
Suspension Check the suspension. • Repair or replace the part related to the
: Installation defect : Refer to the information of the suspension if necessary.
suspension.
On-vehicle charger Although the AC power plug is Display setting Check the set value on the Option Set • Change the setting correctly.
(OPT) connected, charging screen does : Charger unit is invalid screen.
not appear on the display. (Option Set CHARGER UNIT)
Power charger Check the power voltage. • Check the power, and repair or replace
: Power supply defect, electricity failure : Turn off the key switch, disconnect the it if necessary.
AC power plug, and check if the
voltage of each power terminal is
between 191 and 220 V.
Power cable Check the voltage of the AC power plug • Check the power cable, and repair or
: Wire breakage, short circuit, leakage terminal. replace it if necessary.
: Check if the voltage of each AC power
plug terminal is between 191 and 220
V.
Charger wire connection Check wire connection • Check the wire, and repair or replace it
: Wire connection defect : Turn off the key switch, disconnect the if necessary.
AC power plug, and check the wire
between the R terminal (wire color:
white) and the S terminal (wire color:
red) on the back of the insertion point
of the AC power plug.
Harness between the operation panel and the - • Check the harness, and repair or
display replace it if necessary.
On-vehicle charger Although the AC power plug is Operation panel Short-circuit the CHGGND and CHGAC • Replace the charge panel.
(OPT) connected, charging screen does : Internal failure connectors of the display with the • Replace the display.
not appear on the display. Display harness between the operation panel
: Internal failure and display disconnected, and check if
the charging screen is displayed.
J If it is displayed, the operation panel is
defective.
Although the AC power plug is Harness between the operation panel and the - • Check the harness, and repair or
disconnected, charging screen display replace it if necessary.
appears on the display. : Wire breakage, short circuit, leakage
Operation panel Check if the charging screen is displayed • Replace the charge panel.
: Internal failure with the harness between the operation • Replace the display.
Display panel and display disconnected.
: Internal failure J If it is displayed, the operation panel is
defective.
Although the charging Display setting Check the set value on the Option Set • Change the setting correctly.
(reservation) button is pressed, : Display indicator setting screen. J: with charging reservation function
charging does not start. (Option Set DISP. MODE) I: without charging reservation function
(Charging screen appears on the Harness between the operation panel and the - • Check the harness, and repair or
display.) display replace it if necessary.
Operation panel Check the operation button. • Replace the charge panel.
: Internal failure : Disconnect the harness between the
operation panel and the display to
check each button of the SW1
(charge), SW2 (reservation) and SW3
(stop) on the operation panel, that if
the terminal of the button being
pressed and the CHGGND connector
are connected while the button being
pressed, and if disconnected while
being released.
5-181
On-vehicle charger Although the charging Display Check the MS excitation signal output • Replace the display.
5-182
(OPT) (reservation) button is pressed, : Internal failure : Short-circuit CHGGND and CHGAC
charging does not start. with the harness between the
(Charging screen appears on the operation panel and the display
display.) disconnected, and check if the voltage
between CHGMS and CHGGND
connectors is 7 V.
After that, start charging with short-
circuit of the CHGGND and CHGAC
connectors, and Charging screen
being displayed, then check if the
voltage between the CHGMS and
CHGGND connectors is 0 V.
Magnet switch Check the magnet switch. • Replace the magnet switch.
: Internal failure : Connect the AC power plug, press the
charging button, and check if the
voltage between A1 and 96 is between
191 and 220 V.
After that, press "STOP" button, and
check if the voltage between A1 and
96 is 0 V.
Although "STOP" button is Harness of the operation panel - • Check the harness, and repair or
pressed, charging does not : Wire breakage, short circuit, leakage replace it if necessary
complete. (harness or connector)
(Able to start charging)
* Press "STOP" button, although Operation panel Check the operation button. • Replace the charge panel.
the display shows that charging is : Internal failure : Disconnect the harness between the • Replace the display.
complete, the magnet switch Display operation panel and the display, and
does not turn off. Perform : Internal failure check if the SW3 and CHFFND
troubleshooting for error "F8-1: connectors are connected when
Charging completion pressing "STOP" button on the
abnormality". operation panel, and disconnected
when release the button.
J If it is abnormal, the operation panel is
defective.
If it is normal, the display is defective.
Charging completes normally, but Transformer ASSY setting - • Use the battery that the capacity is
not fully charged. : Incompatible capacity compatible with the transformer ASSY.
: Tap adjusment defect • Adjust the tap.
Transformer ASSY main body • Replace the transformer ASSY.
: Internal failure
On-vehicle charger Charging completes normally, but Battery - • Perform equalizing charge.
(OPT) not fully charged. : Uneven voltage between cells • Replace the battery (in the end of the
: Capacity decline (low electrolyte operating life).
temperature)
: Capacity decline (operating life)
Main controller Measure the battery voltage and • Replace the main controller.
: Internal failure compare it to that of the Analyzer.
LED of the operation panel does Harness between the operation panel and the - • Check the harness, and repair or
not turn on. display replace it if necessary
(Able to start charging) : Wire breakage, short circuit, leakage
Operation panel Check the applied voltage to each LED. • Replace the charge panel.
: Internal failure : Short-circuit the CHGGND and • Replace the display.
Display CHGAC display connectors with the
: Internal failure harness between the operation panel
and the display disconnected, and
within 2 seconds from short-circuit
check each voltage between LED1
and CHGGND connectors, LED2 and
CHGGND connectors, LED3 and
CHGGND connectors, and LED4 and
CHGGND connectors is 5 V.
J If the voltage is normal, the charge
panel is defective.
If the voltage is abnormal, the display
is defective
Although the charging Harness between the operation panel and the - • Check the harness, and repair or
(reservation) button is not display replace it if necessary
pressed, the magnet switch turns : Wire breakage, short circuit, leakage
on. (harness or connector)
Operation panel Check the magnet switch signal. • Replace the charge panel.
: Internal failure : Disconnect the harness between the • Replace the display.
Display operation panel and the display, and
: Internal failure check that the display connectors
between CHGGND and CHGMS are
disconnected.
J If connected, the display is defective.
If disconnected, the operation panel is
defective.
5-183
On-vehicle charger Although the charging Magnet switch Check the magnet switch. • Replace the magnet switch.
5-184
(OPT) (reservation) button is not : Internal failure : Disconnect the AC power plug, and
pressed, the magnet switch turns check that each terminal between the
on. input side and output side of each R,
S, and T for the magnet switch is
disconnected.
Although the AC power plug is Charging is complete (no error occurs). Check the charging status. Press "STOP" button, turn off the display,
disconnected, the LED of the : Check if the "Charging completion" and use as usual.
operation panel turns on or blinks. screen appears. * It is not an error.
After charging completion, if the AC
power plug is disconnected without
pressing any button, the "UP" LED will
be left on.
An error occurs. Check for error. (Only when the "UP" • Perform troubleshooting for
LED blinks) corresponding error code.
: Turn off the key switch, connect the
AC power plug, and check the error
code appears on the display.
Harness between the operation panel and the - • Check the harness, and repair or
display replace it if necessary
Operation panel Check the magnet switch signal. • Replace the charge panel.
: Internal failure : Disconnect the harness between the • Replace the display.
Display operation panel and the display, and
: Internal failure check if each voltage between LED1
and CHGGND connectors, LED2 and
CHGGND connectors, LED3 and
CHGGND connectors, and LED4 and
CHGGND connectors is 0V.
J If the voltage is normal, the charge
panel is defective.
If the voltage is abnormal, the display
is defective.
Charging does not start or Display setting Check if the reservation mode (start/ • Change the setting correctly.
complete as reserved with clock : Clock setting for charging reservation complete), day and time are set correctly
setting. on the charging reservation screen.
Display setting Check if the year, month, day and time • Change the setting correctly.
: Clock setting are set correctly on the clock set screen.
On-vehicle charger Charging does not start or Electricity failure occurs - Please use as usual.
(OPT) complete as reserved with clock * It is not an error.
setting. If an electricity failure occurs after
starting charging, it cannot operate as
set with clock setting.
Insufficient charging time Please use as usual.
(Only for completion reservation of charging) * It is not an error.
If the time from charging start to clock
- set for charging completion is shorter
than that required for full charging, the
charging will be continued even when
the set clock is exceeded.
Although operation days setting Display setting Check the setting on the administrator - Change the setting correctly.
has been made, equalizing : Operation days setting menu.
charge is activated on operation (Administrator menu OPERATION DAYS)
day.
* Equalizing charge may be Display setting Check if the year, month, day and time - Change the setting correctly.
activated automatically on : Clock setting are set correctly on the clock set screen.
operation day due to charging
frequency by customers.
Battery protection Battery electrolyte level warning Display setting Check the set value on the Option Set • Change the setting correctly.
function (OPT) indicator does not turn off. : The battery unit is wrongly set. (B UNIT) screen. Set according to the provided battery
(The battery electrolyte has been unit.
supplied.) Electrolyte level temperature unit harness - • Check the connection of the CN35
: The connector is disconnected. connector. (Connect it if it is
disconnected.)
Battery electrolyte level temperature unit - • Replace the electrolyte level
: Internal failure (Internal electrolyte level temperature unit.
harness breakage, electrolyte level sensor
failure)
5-185
Battery protection Integrating wattmeter is not The integrating wattmeter is only displayed on - -
5-186
function (OPT) displayed. models provided with on-vehicle charger.
It is not displayed correctly in cases other than
above.
Display setting Check the set value on the Option Set • Change the setting correctly.
: Power meter indicator setting screen.
(Option Set CHARGE REC)
The CO2 exhaust amount is not Display setting Check if the setting is made using the • Change the setting correctly.
displayed. : CO2 unit set Adminitrator menu.
(Administrator menu CO2 unit/CO2 UNIT
SET)
PIN code entry Although the ten-key operation is Display Log on with the initial registration • Register PIN using the Administrator
(OPT) performed, PIN cannot be : PIN is not registered. number, using the Administrator menu, menu.
certificated. check if PIN has been registered.
(Although the numeric keypad
operation sound can be heard,
the log-in cannot be performed.)
Although PIN is not pressed, Display Check if the meter is started with the • Perform the meter start.
certification can be performed. : Meter start is not set. service function.
Display - • Replace the display.
: Internal failure
5-187
5-188
z Error Code - (Although the AC power plug is connected, the charging

screen does not appear on the display)
Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

N1 panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) Wrong setting of charger unit (5) Operation panel defect
(2) AC power supply defect or electricity failure (6) Harness defect
(3) Power cable defect (7) Display defect
(4) Wire connection defect
5-189
Inspection: Check of the charger unit setting

NO Wrong setting of the charger unit
(Set “YES”)
[OPT] CHARGER UNIT
YES
Inspection 1: Check of AC power supply voltage

1. Turn off the key switch and disconnect the AC power NG AC power supply defect
plug. Electricity failure
2. Check each power supply terminal.
OK
Inspection 2: Check of AC power plug terminal voltage

1. Turn off the key switch and disconnect the AC power NG
Power cable defect
plug.
2. Check each power plug terminal
OK
Inspection 3: Check of wire connection

plug and the battery plug.
2. Perform check of the wire connection
OK

1. Turn off the key switch and disconnect the AC power
NG
plug and the battery plug. Harness defect
2. Disconnect the M2 and M3 connectors and perform
the check.
OK
OK
Inspection 5: Check of display function of the charging
(The charging screen
screen
appears.)
1. Turn off the key switch and disconnect the AC power Operation panel defect
2. Disconnect the M2 connector and perform the check
NG
(The charging screen does
not appear.)
Display defect
Inspection 1: Check the voltage of the AC power supply

Each AC power supply terminal AC191 to 220V
5-190
Inspection 2: Check the AC power plug

Each AC power plug terminal AC191 to 220V
Inspection 3: Check the wire connection

Check if the M2 and M3 connectors are connected correctly and check the wire connection of the terminal R and
S on the back of the insert point of the AC power plug.
Back of the insert point of the AC power plug
Terminal S
Terminal R
Inspection 4: Check the harness.

Disconnect the M2 and M3 connectors and visually check inside each connector and the caulked portion of each
wire for defects and then check each harness.

Inspection 5: Check the display function of the charging screen

Disconnect the M2 connector and short-circuit the M2-2 and M2-3 connectors on the wire harness side. Check
if the charging screen appears on the display.
5-191
z Error Code - (Although the AC power plug is disconnected, the charging

screen appears on the display)
Related portion
M2-2 M3-25 (129, CHGAC)
Operation
panel Display
M2-3 M3-2 (130, CHGGND)
Probable cause:
(1) Wire connection defect (3) Harness defect
(2) Operation panel defect (4) Display defect
Inspection: Wire connection check

NG
plug. Wire connection defect
2. Check if the M2 and M3 connectors are connected
correctly.
OK
Inspection: Check of AC 200V detection

1. Turn off the key switch and disconnect the AC power Charging screen
plug and the battery plug. disappears.
2. Disconnect the M2 connector and connect the
battery plug.
3. Check the display screen.
Charging screen does not
disappear.
NG
the check.
OK
Display defect

Disconnect the M2 and M3 connectors and visually check inside each connector and the caulked portion of
each wire for defects and then check each harness.

5-192
z Error Code - (Charging does not start when the START button is pressed
(even though charging screen appears on the display))
Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

N1 panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) Wire connection defect (4) Magnet switch defect
(2) Harness defect (5) Operation panel defect
(3) Display defect
5-193

OK

OK

NG
the check.
OK
Inspection 4: Display check

Display defect
OK
Inspection 5: Check of the voltage of the magnet switch

NG
plug and the battery plug. Magnet switch defect
2. Disconnect the Z1 connector and connect the battery
plug and AC power plug to perform the check.
OK
Inspection 1: Check the wire connection.

Check if the M2 and M3 connectors are connected correctly.
Inspection 2: Check the operation button.

Disconnect the M2 connector and visually check inside the connector and the caulked portion of each wire for
defects.

Hold down the "STOP" button M2-5 to M2-3 (Operation panel side) Continuity
Hold down the "START" button M2-7 to M2-3 (Operation panel side) Continuity
Release the "STOP" button M2-5 to M2-3 (Operation panel side) No continuity
Release the "START" button M2-7 to M2-3 (Operation panel side) No continuity
5-194


Inspection 4: Check the display.

Disconnect the M2 connector, and measure the voltage between the M2-1 and M2-3 connectors 2 seconds or
more after short-circuit the M2-2 and M2-3 connectors on the harness side.

M2-1 to M2-3 (harness side) 7V
Start charging through operation on the display, and check the voltage between the M2-1 and M2-3 connectors
with the M2-2 and M2-3 connectors shorted-circuit on the harness side.

M2-1 to M2-3 (harness side) 0V
5-195
Inspection 5: Check the voltage of the magnet switch.

Disconnect the Z1 connector, connect the AC power plug and press the “START” button of the charger.

A1 to 96 AC 191 to 220V
Press the “STOP” button of the charger.

A1 to 96 AC 0V
A1 FW-0/0S 96
FW-1S
5-196
z Error Code - (Charging does not stop when the STOP button is pressed
(able to start charging))
Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

N1 panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) Wire connection defect (3) Harness defect
(2) Operation panel defect (4) Display defect
Press “STOP” button, if the magnet switch does not turn off even when the charging completion screen appears on
the display, perform troubleshooting described in “F8-1: Charging completion abnormality”.
5-197
Turn off the breaker of the power supply board, stop

applying an AC200V voltage to the AC power plug, and
then perform checks.
OK

OK

OK

NG
the check.
OK
Normal (*1)
*1 Perform charging again, if the charging does not complete even when pressing “STOP” button, there should be any
other problems, so replace the display.
Inspection 1: Check the wire connection.

Check if the M2 and M3 connectors are connected correctly.
Inspection 2: Check the operation button.

Disconnect the M2 connector and visually check inside the connector and the caulked portion of each wire for
defects.

Hold down the "STOP" button M2-5 to M2-3 (Operation panel side) Continuity
Release the "STOP" button M2-5 to M2-3 (Operation panel side) No continuity


5-198
z Error Code - (Although the charging is complete, the battery is not fully
charged)
Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

N1 panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(1) Incompatible capacity of the battery and the transformer
(2) Tap adjustment defect
(3) Transformer defect
(4) Decline of battery capacity due to a decrease in temperature of the electrolyte
(5) Decline of battery capacity due to battery wear-out
(6) Battery defect
5-199
Inspection : Check the compatibility of the capacity of

the battery and the transformer. NG Incompatible capacity of the
(Refer to section 2: CHARGER in Repair manual Pub. battery and the transformer
No. CE351.)
OK
Inspection : Tap changer check

NG
(Refer to section 2: CHARGER in Repair manual Pub. Tap adjustment defect
No. CE351.)
OK
Inspection : Check of the transformer as a single unit

NG
(Refer to section 2: CHARGER in Repair manual Pub. Transformer defect
No. CE351.)
OK
Displayed value is
Inspection: Voltage check of the battery
±10% of actual measured
Compare the indicated value on the display and the
value.
actual measured value (between P2 and N1). Main controller defect
Displayed value is in the

range of ±10% of actual
measured value.
Inspection: Check of the specific gravity and
temperature of battery electrolyte after charging Battery defect
NG
completes (Check if the battery revives by
(Refer to section 1: BATTERY in Repair manual Pub. equalization charging)
No. CE351.)
OK
Decline of battery capacity due to a decrease in temperature of the electrolyte.

Decline of battery capacity due to battery wear-out.
5-200
z Error Code - (LED lamp on operation panel does not light on (able to start
charging))
Related portion
F5
A27-1 (41, B48V)
Main
FCH M3-4 (14, DGND)

ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)

M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
Display
M2-3 M3-2 (130, CHGGND)
M2-4 M3-1 (128, CHG7V)
M2-5 M3-24 (121, SW3)

N1 panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)

Z1
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)

AC AC
Magnet M2-11 M3-31 (127, LED1)
Power Power
switch
supply plug
Power
(95, MSCH)
cable
Probable cause:
(2) Display defect
(3) Harness defect
5-201
Inspection 1 : Applied voltage check of LED

plug and the battery plug. OK
2. Disconnect the M2 connector.
3. Connect the battery plug and check the applied
voltage of LED.
NG
Inspection 2 : Harness check

1. Disconnect the battery plug and the AC power plug. OK
Display defect
2. Disconnect the M2 and M3 connectors and check the
harnesses for their contuinuities.
NG
Harness defect
Inspection 1: Check the applied voltage of LED.

Disconnect the M2 connector and perform check of the applied voltage to each LED within 2 seconds after
short-circuit the M2-2 and M2-3 connectors on the harness side.
(If checking the applied voltage of more than one LED, it is necessary to short-circuit the the M2-2 and M2-3
connectors each time.)

NORMAL LED M2-10 to M2-3 (harness side) 5V
EQUAL LED M2-9 to M2-3 (harness side) 5V
UP LED M2-8 to M2-3 (harness side) 5V
Inspection 2: Check the harness


NORMAL LED
EQUAL LED
UP LED
5-202
z Error Code - (Although the START button is not pressed, the magnet
switch closes)
Related portion
M3-4 (14, DGND)

Transformer
M3-3 (169, TGND)
ASSY
M3-5 (16, D7V)
M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)
M3-36 (N1, N1)
M2-1 M3-33 (132, CHGMS)

M2-2 M3-25 (129, CHGAC)
M2-3 M3-2 (130, CHGGND) Display
M2-4 M3-1 (128, CHG7V)

M2-5 M3-24 (121, SW3)
Operation M3-23 (122, SW2)
M2-6
panel
M2-7 M3-22 (123, SW1)
M2-8 M3-32 (124, LED4)
Z1
M2-9 M3-29 (125, LED3)

Magnet M2-10 M3-30 (126, LED2)
switch M2-11 M3-31 (127, LED1)
(95, MSCH)
Probable cause:
(2) Harness defect
(3) Magnet switch defect
(4) Display defect
Inspection 1: Magnet switch signal check

Display defect
plug and the AC power plug.
OK

NG
plug and the AC power plug. Harness defect
2. Disconnect the M2 and M3 connectors and check the
harnesses for their contuinuities.
OK
Inspection 3: Magnet switch check

plug and the AC power plug.
2. Disconnect the Z1 connector and perform the check.
OK

5-203
Inspection 1: Check the magnet switch signal.

Disconnect the M3 connector and perform the magnet switch signal check.

M3-33 to M3-2 (Display side) No continuity


Inspection 3: Check the magnet switch.

Disconnect the Z1 connector and make sure that the magnet switch is turned off.

Main input terminal (R) to main output terminal (R) No continuity
Main input terminal (S) to main output terminal (S) No continuity
Main input terminal (T) to main output terminal (T) No continuity
Main input Main input Main input Main input

Main input Main input
terminal (S) terminal (T) terminal (S) terminal (R)
terminal (T) terminal (R)
Main output Main output Main output

terminal (T) terminal (S) terminal (R) Main output Main output Main output
terminal (T) terminal (S) terminal (R)
FW-0/0S FW-1S
5-204
z Error Code - (Although the AC power plug is not connected, LED lamps
on operation panel light on/ blink)
Related portion
M3-5 (16 D7V)

M3-15 (146, CAN1L)
M3-16 (145, CAN1H)
M3-18 (43, VBKY)
M2-4 M3-1 (128, CHG7V)
Operation
M2-3 M3-2 (130, CHGGND) Display
panel
M2-8 M3-32 (124, LED4)
M2-9 M3-29 (125, LED3)
M2-10 M3-30 (126, LED2)
M2-11 M3-31 (127, LED1)
Probable cause:
(2) Harness defect
(3) Display defect
5-205
Inspection : Lighting/ blinking LED check

“UP” LED is Inspection :Check of display function of the
1. Turn off the key switch.
lighting. charging screen.
2. Check the LED whether it is lighting or blinking without
1. Check if the screen indicates that charging is
connecting the AC power plug and only with the battery
complete.
plug connected.
LED other than Charging complete
“UP” LED is Not charging
“UP” is lighting/ screen.
blinking. complete screenv
blinking.
Normal *
Inspection : Error check with the AC
power plug connected
* If the AC power plug is disconnected
1. With the key switch turned off,
without any button pressed after
connect the battery plug and the AC
charging completes, the “UP” LED
power plug with the breaker turnd on.
keeps lighting.
2. Check the error code indicated on the
This is not a defect, so press the
display.
“STOP” button to turn off the display
Check the error and use the devise as it is.
None of the
code. error codes
Perform troubleshooting of that above are
error. displayed.
Inspection 1: Applied voltage check of LED

battery plug and the AC power plug.
OK
2. Disconnect the M2 connector. Operation panel defect
3. Connect the battery plug and check the
applied voltage of LED without connecting
the AC power plug.
NG

NG
battery plug and the AC power plug. Harness defect
2. Disconnect the M2 and M3 connectors and
check harnesses for their continuities.
OK
Display defect
5-206
Inspection 1: Check the applied voltage of LED.

Disconnect the M2 connector without connecting the AC power plug, perform check of applied voltage to each
LED on the harness side.

NORMAL LED M2-10 to M2-3 (harness side) 0V
EQUAL LED M2-9 to M2-3 (harness side) 0V
UP LED M2-8 to M2-3 (harness side) 0V


NORMAL LED M3-30 to M3-15 No continuity
EQUAL LED M3-29 to M3-15 No continuity
UP LED M3-32 to M3-15 No continuity
5-207
z Error Code - (Although operation days setting has been made, equalizing
charging is activated on operation day)
Probable cause:
(1) Wrong setting of operation days
(2) Wrong setting of clock
Inspection: Check operation days setting

Check setting with “OPERATION DAYS SET” in the NG
Wrong setting of operation days
Vehicle management setting menu of the Administrator
function.
OK
Inspection: Check clock setting

NG
Check the year, month, day, time on the clock set Wrong setting of clock
screen.
OK
Normal *
* The follows can be thought of as the causes.

Equalizing charge may be activated automatically on operation day due to charging frequency by customers.
No error is found on the charger, so use it as usual.
全体 .book 1 ページ２０１２年７月１０日火曜日午後５時１５分
21-1
WIRING DIAGRAM
Page
INTRODUCTION .....................................................21-3 NMF
ELECTRICAL WIRING ROUTINGS 0
and RELAY LOCATIONS........................................21-19 1
SYSTEM CIRCUITS ................................................21-43
4
CONNECTOR LIST .................................................21-83
3
CONNECTING DIAGRAM ......................................21-89
4
WIRING DIAGRAM .................................................21-90
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
21-2
21-3
INTRODUCTION
CHAPTERS OF THIS SECTION ......................................................21-4
HOW TO READ CHAPTERS
ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS

ELECTRICAL WIRING ROUTINGS ......................................................21-5
RELAY LOCATIONS..............................................................................21-6
SYSTEM CIRCUITS
SYSTEM CIRCUITS ..............................................................................21-8
REFERENCE PAGE ..............................................................................21-12
GROUND POINTS
GROUND POINTS ................................................................................21-13
FUSES FOR POWER SUPPLY

FUSES FOR POWER SUPPLY.............................................................21-13
CONNECTOR LIST
CONNECTOR LIST ...............................................................................21-14
WIRE TO WIRE .....................................................................................21-15
ABBREVIATIONS....................................................................................21-16
GLOSSARY OF TERMS AND SYMBOLS ....................................21-17

21-4
INTRODUCTION
CHAPTERS OF THIS SECTION

This section consists of the following 6 chapters:
INTRODUCTION Gives brief explanation of each chapter, provides instruc-

tions on how to use this manual, and defines the abbrevia-
tions used in the electrical circuit diagrams.
ELECTRICAL WIRING ROUTINGS Electrical wiring routings show installation positions,

and RELAY LOCATIONS ground points, connector numbers, and part names
related to wire harnesses, connectors, relay blocks and
junction blocks used in the forklift, such as in the engine
room, instrument panel and mast area.
Relay locations show design drawings and internal circuit
diagrams related to relays, relay blocks (R/B), junction
blocks (J/B), fusible links (F/L) and junction connectors
(J/C).
SYSTEM CIRCUITS Show power supply circuit diagrams and wiring diagrams
for each system, such as the engine.
(Only wiring information for complete circuits is shown.)
GROUND POINTS Show related systems for each ground point.
FUSES FOR POWER Show power distribution from each power supply
SUPPLY (fuse or fusible link) to various systems.
CONNECTOR LIST Shows shapes and part numbers of connectors used in

electrical wiring routings and electrical wiring diagrams.
21-5
INTRODUCTION
HOW TO READ CHAPTERS

ELECTRICAL WIRING ROUTINGS and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS
Electrical wiring routings show installation positions, ground points, connector numbers, and part
names related to wire harnesses, connectors, relay blocks and junction blocks used in the forklift.
(Connector codes are the same as those used in the electrical wiring diagrams.)
21-10 21-11
ELECTRICAL WIRING ROUTINGS ELECTRICAL WIRING ROUTINGS
FRONT BODY
A24 FUSIBLE LINK BLOCK ASSY AA FRONT PLATE LEFT OUTSIDE EARTH
A25 DIAGNOSIS
A27 JUNCTION CONNECTOR AB FRONT PLATE LEFT OUTSIDE EARTH
A29 CAN JOINT CONNECTOR
A30 CAN JOINT CONNECTOR AC FRONT PLATE LEFT OUTSIDE EARTH
A32 CAN JOINT CONNECTOR AD TRANSMISSION UPPER
C SIDE RH A34 CAN JOINT CONNECTOR
WIRE
A37 LPG WARNING RELAY
G ENGINE WIRE
A38 LPG WARNING BUZZER
A40 BACK UP LAMP SWITCH
1 ENGINE ROOM RELAY BLOCK A42 TILT ANGLE SENSOR
A45 MATCHING CONNECTOR
A46 MATCHING CONNECTOR
A24
to E2-2 A47 SHIFT SOLENOID(2)
AC1 to E2-16
A48 SHIFT SOLENOID(2)
AA1 A54 SHIFT SOLENOID(1)

to E2-4 A57
A55 SHIFT SOLENOID(1)
A48
AC3 A37 A57 TO PUSH PULL RELAY
A40 to E2-14
A38 A65 JUNCTION CONNECTOR (A)
AG3
A46 A66 JUNCTION CONNECTOR (B)
A47 A25
AC2 D1 T/C OIL TEMPERATURE SENSOR
G27 ENGINE ECU
A42
A45 G28 ENGINE ECU
A54 D1
G29 JUNCTION CONNECTOR (B)
AD G73 JUNCTION CONNECTOR (A)
A55
to E2-8
DA1
1A
AC 1B BODY MAIN WIRE to J/B
AB O LH SIDE WIRE
1C
AA
1D ENGINE WIRE to J/B
1E LH SIDE WIRE to J/B
J/B
D TC HEAT GAUGE WIRE
A BODY MAIN WIRE AA1 BODY MAIN WIRE to BODY MAIN WIRE
1A
G29
AC1
A65 AG1 1B
A55 AC2 BODY MAIN WIRE to SIDE RH WIRE
1C
AC3
DA1 1D AG1
A27
BODY MAIN WIRE to ENGINE WIRE
G27 1E AG3
G28 AO1
AO2 BODY MAIN WIRE to LH SIDE WIRE
AO2
AO3
A29 A34
AO1 DA1 T/C HEAT GAUGE WIRE to BODY MAIN WIRE
A30
G73
A31
A33 A32 A66
AO3
[A] Title [G] Ground point code

Indicates a location on the forklift. Indicates a ground point code.
[B] Wire harness [H] Ground point name
Indicates a wire harness name. Indicates a ground point name.
[C] Reference page for electrical wiring routing [I] Wire harness to wire harness connector
Indicates a reference page showing a Indicates a connector code that joins two
wire harness location when the wire harness wire harnesses.
continues to the different electrical wiring [J] Wire harness names
routing. Indicate two wire harness names for a wire
[D] Junction block harness and wire harness connection.
Indicates a junction block name and a [K] Part connector
connector code to be connected. Indicates a connector code connected to a
[E] Junction block connector part.
Indicates a connector code connected to a [L] Part name
junction block. Indicates a part name connected to a
[F] Wire harness and junction block connection connector.
Indicates a junction block name and a wire
harness name to be connected.
21-6
INTRODUCTION
RELAY LOCATIONS
Relay locations show connectors connected to junction blocks (J/B), relays, fuses and internal circuit
diagrams.
21-20 21-21
RELAY LOCATIONS
JUNCTION BLOCK:LEFT STEP(INNER CIRCUIT SEE PAGE E2-24) 1 ENGINE ROOM R/B:ENGINE ROOM LEFT
1A
90980-12506 BLACK 1B
90980-12383 * 1:15A E-THRO (4Y-E)
18 1 7.5A ECU-B2 (1DZ, 2Z)
19 2 19 1 * 2:7.5A (1DZ, 2Z)
20 3 20 2 15A (4Y-E)
21 4 21 3 * 3:DPF RELAY (1DZ, 2Z)
22 4 SPARE 30A BLR 1 25A 2
22 5 15A (4Y-E)
23 6 23 5
7 24 6 * 3:DPF RELAY (1DZ, 2Z)
24 SPARE 7.5A STA 1 30A 2
25 8 25 7 EFI MAIN RELAY (4Y-E)
26 9 26 8 * 4:C/OPN RELAY (4Y-E)
27 10 27 9 ASC RELAY (1DZ, 2Z) HOUR MET 2 7.5A 1 RR WIP 1 20A 2
28 11 28 10 * 5:EFI (4Y-E)
29 12 29 11 DPF (1DZ, 2Z) 2 1
13 30 12 ST 7.5A FR WIP 1 20A 2
30
31 14 31 13
32 15 32 14 GAUGE 2
10A
33 16 T/C FR RELAY 33 15
1 1 2
34 17 34 16
3 1 19 35 17 *3 BACK LP 2 10A
1 18 1 18
2 20 36 18 40A AM1
5 2 19 2 19 1
3 21
3 20 3 20 SFT 2 7.5A 1
1 4 2 4 22 5 3
4 21 4 21 1C
5 23
5 22 5 22 2
6 24 90980-12320 2 7.5A 1
6 23 6 23 TURN
7 25
7 24 7 24
3 8 26 18 1
8 25 8 25 2
5 9 27 19 2 IGN 2 *2 1
9 26 9 26
10 28 20 3 3 5 HORN 1 15A 2
1 4 2 10 27 10 27
11 29 21 4
11 28 11 28 1 SPARE 15A
12 30 22 5
12 29 12 29
T/C RR RELAY 13 31 23 6 *4 CDS 1 15A 2
13 30 13 30
14 32 24 7
14 31 14 31
15 33 25 8
15 32 15 32 *5 1 15A 2
16 34 26 9
16 33 16 33 DOUBLE HORN RELAY SPARE
17 35 27 10 10A
17 34 17 34
18 36 28 11 ALT-S 1 7.5A 2
1
29 12 ECU-IG 2 10A 1
30 13 5 3
WORK LP RELAY BCON LP RELAY STOP 1 7.5A 2
31 14 2
32 16
32 15
31 15 3 3 33 16
30 14 5 5 ACC-B 1 7.5A 2
34 17
29 13 2
28 12 1 2 1 2 24 12 3 5 TAIL 1
1D 7.5A 2
27 11 23 11
26 10 22 10 90980-12308 1
25 9 1 21 9 ECU-B 1 7.5A 2
12 24 LPG MAIN RELAY
24 8 20 8
5 3 11 23
23 7 19 7
22 6 2 18 6 10 22 *1 1 2
21 5 17 5 9 21 AM2 RELAY
HORN RELAY 8 20
1E 20 4 16 4 1
19 3 2 15 3 7 19 HTR 1 15A 2
90980-12311 18 2 14 2 6 18 5 3
3 5 17
17 1 13 1 2 WORK LP 1 15A 2
16 32 4 16
1
15 31 3 15
14 30 FLASHER RELAY 2 14 HEAD 1 15A 2
13 29 1 13 2
12 28 3 5
11 27
10 26 1
1 2
9 25 ST RELAY
8 24
7 23 40A AM2
6 22
5 21
4 20
3 19
2 18
1 17
21-24
JUNCTION BLOCK (INNER CIRCUIT) (1/3)
13 1C 1 1D
31 1A 14 1D
33 1B BCON LP RELAY 15 1D
5 3
15 1E 32 1A
1 2 16 1E
15 1B
16 1B
23 1E
28 1B
25 1E
24 1E
13 1A WORK LP RELAY
5 3
15 1C 13 1E
9 1E 31 1B
1 2
19 1B 29 1B
36 1B 10 1E
19 1E
4 4 1A
3
5 1A
1 2
8 1B 7 1A
3 1B T/C FR RELAY 13 1D
17 1B 2 1E
22 1E
4 3 1A
18 1E 3
2 1A
34 1B
1 2 1 1B
18 1D
19 1A
11 1C T/C RR RELAY
11 1E
1 3
28 1C 35 1B
26 1B 2
7 1D
22 1B
FLASHER RELAY 8 1D
24 1A
21 1E
25 1B
33 1C
23 1B
29 1C
3 1C
12 1A
4 1C
30 1C
21 1A
2 1C
21-7
INTRODUCTION
[A] Junction block /relay block

Indicates a junction block or relay block name, its location and a reference page for an internal circuit
diagram.
[B] Connector code and color
Indicates the code and color of a connector connected to a junction block.
[C] Connector part number
Indicates the part number of a connector.
[D] Connector shape and terminal number
Indicates a connector shape on the junction block side.
Numbers indicate terminal numbers.
[E] Connector shape and terminal number
Indicates a connector shape on the wire harness side.
Numbers indicate terminal numbers.
[F] Fuse
Indicates a fuse name and capacity.
[G] Internal circuit diagram
Indicates an internal circuit diagram of a junction block.
[H] Connector code and terminal number
Indicates a connector code and a terminal number connected to a junction block.
全体 .book
21-8
21-12
(BAT)
*䇭1: GASOLINE
*䇭2: LPG
15A *䇭3: WITH GASOLINE INDICATOR LAMP
EFI *䇭4: CNG
B-Y B-Y
a
SYSTEM CIRCUITS
LG
b
SYSTEM CIRCUITS (1)
8 ページ２０１２年７月１０日
LG-R
c
O
d
火曜日
R-W *1 R-W
e
*1 *2 R-L
f
R-L
g
*2
*1
*1
R-B
R-W
R-W
A䇭65(A),G 73(B) A䇭65(A),G 73(B)
JUNCTION CONNECTOR (A) 2 A JUNCTION CONNECTOR (A) 7 A 12 B 10 B
R-L
R-L
R-W
午後５時１５分
(LPG)
6 A 2 B 1 B 6 B 5 B 1 A 8 A
9 8 7
Y
Y
Y
*1
*2
*1
R-B
R-W
R-B
R-B
7 GK1 *2 4 AC3 3 AC3 1 2 3 4 5 6
8 GK1 7 GK2 *4
(GASOLINE)
JUNCTION CONNECTOR
A 66
*1
*1
R-B
R-L
R-B
R-L
R-L
R-L
R-L
R-W
(GASOLINE)
12 1D
Y
Y
*2
*2
*4
1 TC2 2 TC2
Y-B
R-B
1 A *2
INTRODUCTION
ENGINE CONTROL (4Y-E)
1
4 1D 9 AC2
1 B *4
*3
R-B
R-B
R-W
䇭
䇭
6 3
LPG SOLENOID
(MAIN)
R-L
K 䇭1(A)
OIL PRESSURE SWITCH (*1)
K 䇭5(B)
GAS LPG
2 2 A *2
R-L
2 B *4
IG
LPG CHANGE SWITCH

T 䇭6 䇭
R-L
4 h
*2
*1
L-B
W-B
R-L *1 R-L
i
*1 R-L
2 GK1 6 GK1 *2 j
6 GK2 *4 *3
R-B
k
*2
*1
L-B
W-B
L-B
l
*1 R-L
m
W-B
n
A system diagram shows the connections from fuses to ground points of each system.
A power source circuit diagram shows the connections from the power source to fuses.
GG
A system circuit consists of a power source circuit diagram and respective system circuit diagrams.
21-9
INTRODUCTION
[A] Section page [G] Page-to-page connection code

Indicates the page number for the section. Indicates a wire harness continues onto the
[B] System title following page from the matching code.
Indicates a system name. [H] Harness to harness connector
[C] Part name and connector code Indicates a connector code that connects
Indicates a part name and connector code to two wire harnesses.
be connected. For connector shapes, refer to For the connector shape, refer to chapter
chapter "CONNECTOR LIST". "CONNECTOR LIST".
T 6 Part connector Harness to harness connector

9 Terminal number
The wire harness in which the connector is A C2
located. Wire harness to be connected

Example: "T" indicates a connector used in Example: "AC" means a connection of the
the T wire harness. female connector*1 of the "A" wire and the
For wire harness names, refer to Chapter male connector*2 of the "C" wire.
"ELECTRICALWIRING ROUTINGS and *1: A female connector has a female
RELAY LOCATIONS". 䇭 terminal.
Serial number allocated to the connector *2: A male connector has a male
䇭 terminal.
Serial number of a connector
A65 (A), G73 (B) Male terminal side
Connector number
Used to indicate different connectors when
multiple connectors are connected to a part,
or multiple types of connectors are used
according to specifications.
[D] Fuse
Indicates a fuse name and capacity.
For fuse installation positions, refer to chapter
"ELECTRICAL WIRING ROUTINGS and
RELAY LOCATIONS".
[E] Power supply information
Indicates the ignition key position when power
is supplied to a fuse.
[F] Specification information
Indicates that connectors or wire colors vary
depending on forklift models, engine types or
specifications.
全体 .book
21-10
21-12
(BAT)
*䇭1: GASOLINE
*䇭2: LPG
15A *䇭3: WITH GASOLINE INDICATOR LAMP
EFI *䇭4: CNG
B-Y B-Y
a
LG
b
SYSTEM CIRCUITS (2)
LG-R
10 ページ２０１２年７月１０日
O
d
*1
火曜日
R-W R-W
e
*1 *2 R-L
f
R-L
g
*2
*1
*1
R-B
R-W
R-W
A䇭65(A),G 73(B) A䇭65(A),G 73(B)
JUNCTION CONNECTOR (A) 2 A JUNCTION CONNECTOR (A) 7 A 12 B 10 B
R-L
R-L
R-W
(LPG)
6 A 2 B 1 B 6 B 5 B 1 A 8 A
9 8 7
Y
Y
Y
*1
*2
*1
R-B
R-W
R-B
R-B
7 GK1 *2 4 AC3 3 AC3 1 2 3 4 5 6
8 GK1 7 GK2 *4
(GASOLINE)
JUNCTION CONNECTOR
A 66
*1
*1
R-B
R-L
R-B
R-L
R-L
R-L
R-L
R-W
(GASOLINE)
12 1D
Y
Y
*2
*2
*4
1 TC2 2 TC2
Y-B
R-B
1 A *2
INTRODUCTION
ENGINE CONTROL (4Y-E)
1
4 1D 9 AC2
1 B *4
*3
R-B
R-B
R-W
䇭
䇭
6 3
LPG SOLENOID
(MAIN)
R-L
K 䇭1(A)
K 䇭5(B)
GAS LPG
2 2 A *2
R-L
2 B *4
IG
LPG CHANGE SWITCH
T 䇭6 䇭
R-L
4 h
*2
*1
L-B
W-B
R-L *1 R-L
i
*1 R-L
2 GK1 6 GK1 *2 j
6 GK2 *4 *3
R-B
k
*2
*1
L-B
W-B
L-B
l
*1 R-L
m
W-B
n
GG
21-11
INTRODUCTION
[I] Terminal number [L] Wire color

Indicates a terminal number of a connector to Indicates a wire harness color.
be connected. When two alphabetical codes are indicated, for
[J] Junction block connector example "W-B", the first letter indicates the
Indicates a connector code connected to a basic wire color and the second letter indicates
junction block. the color of the stripe.
For a connector shape, refer to chapter Code Wire Color Code Wire Color Code Wire Color
"ELECTRICAL WIRING ROUTINGS and B Black L Blue SB Sky Blue
RELAY LOCATIONS". BR Brown LG Light Green V Violet
Junction block connector DG Dark Gray O Orange W White
Inside of a junction block G Green P Pink Y Yellow
GR Gray R Red AM Amber
Junction block type
Serial number allocated to the connector.
Example: "1B" indicates connector B in the
center junction block.
Example : W-B W B
Terminal number
(White) (Black)
A number inside indicates a relay block or
fuse block. [M] Switch
For shapes, refer to chapter "ELECTRICAL Circuit diagrams are shown with the switches
WIRING ROUTINGS and RELAY LOCATIONS". in the OFF position.
For switch operation conditions, refer to the
[K] Ground point code repair manual.
Indicates a ground point code.
For ground point positions, refer to chapter
"ELECTORICAL WIRING ROUTINGS and
RELAY LOCATIONS".
Ground point code

Wire harness connected to the ground point
A ground point is indicated by an alphabetical
code.
Example: "MJ" indicates that the M wire
harness is grounded at point J.
21-12
INTRODUCTION
REFERENCE PAGE
PARTS
Code See Page Code See Page Code See Page Code See Page
A 20 E2-8 G 7 E2-2 G 21 E2-2 K 6 E2-2
A 25 E2-10 G 8 E2-2 G 25 E2-2 O 2 E2-14
A 27 E2-10 G 9 E2-2 G 26 E2-2 Q 1 E2-8
A 35 E2-10 G 10 E2-2 G 27 E2-10 S 12 E2-14
A 36 E2-10 G 11 E2-2 G 28 E2-10 T 6 E2-16
A 65 E2-10 G 12 E2-2 G 29 E2-10 a 1 E2-8
A 66 E2-10 G 13 E2-2 G 73 E2-10
C 1 E2-16 G 16 E2-2 K 1 E2-2
C 3 E2-16 G 18 E2-2 K 2 E2-2
G 6 E2-2 G 19 E2-2 K 3 E2-2
RELAY BLOCK , JUNCTION BLOCK

Code See Page Relay Blocks Name or Joining Wire Harness and J/B
1 E2-10 Engine Room R/B
1C E2-19 BODY MAIN WIRE to J/B
1D E2-18 ENGINE WIRE to J/B
1E E2-18 LH SIDE WIRE to J/B
WIRE TO WIRE
Code See Page Joining Wire Harness and Wire Harness
AC2 E2-10 BODY MAIN WIRE to SIDE RH WIRE
AC3 E2-10 BODY MAIN WIRE to SIDE RH WIRE
AG1 E2-10 BODY MAIN WIRE to ENGINE WIRE
AO1 E2-10 BODY MAIN WIRE to LH SIDE WIRE
Aa1 E2-8 BODY MAIN WIRE to SUB ACCEL WIRE
GK1 E2-2 ENGINE WIRE to ENGINE SUB WIRE
GK2 E2-2 ENGINE WIRE to ENGINE SUB WIRE
QA1 E2-8 INSTRUMENT PANEL WIRE to BODY MAIN WIRE
SO1 E2-14 REAR UPPER MAIN WIRE to LH SIDE WIRE
TC2 E2-16 REAR UPPER SUB RH WIRE to SIDE RH WIRE
TS1 E2-16 REAR UPPER SUB RH WIRE to REAR UPPER MAIN WIRE
EARTH
Code See Page Name
AB E2-10 FRONT PLATE LEFT OUTSIDE EARTH
GF E2-2 ENGINE UPPER EARTH
GG E2-2 ENGINE UPPER EARTH
OK E2-14 REAR PILLER LEFT UNDER EARTH
[A] Parts
Indicates pages showing electrical wiring routings for the parts.
[B] Relay blocks and junction blocks
Indicates titles and pages showing electrical wiring routings for the relay blocks or junction blocks.
[C] Connections of wire harness and wire harness
Indicates titles and pages showing electrical wiring routings for the connections of two wire
harnesses.
[D] Ground points
Indicates titles and pages showing electrical wiring routings for the ground points.
21-13
INTRODUCTION
GROUND POINTS
GROUND POINTS
These tables describe related systems for each ground point.
21-2
GROUND POINTS
CODE GROUND POINT LOCATION SYSTEM NAME PAGE

SAS/OPS SYSTEM E3-36
CLEARANCE LAMP E3-72
STOP LAMP E3-76
STROBE LIGHT E3-52
AA FRONT PLATE LEFT OUTSIDE
TURN SIGNAL LAMP E3-70
BACK UP LAMP BUZZER E3-74
HEAD LAMP E3-68
POWER SHIFT TRANSMISSIN E3-32
ENGINE CONTROL (4Y-E) E3-10
COOLER E3-80
AB FRONT PLATE LEFT OUTSIDE CLEARANCE LAMP E3-72
COMBINATION METER E3-54
WET BRAKE E3-34
DIAG E3-42
COOLER E3-80
STARTING E3-6
STROBE LIGHT E3-52
TURN SIGNAL LAMP E3-70
HEATER E3-78
AC FRONT PLATE LEFT OUTSIDE
FRONT WIPER AND WASHER E3-60
HEAD LAMP E3-68
HORN E3-64
REAR WIPER AND WASHER E3-62
REAR WORK E3-28

These tables describe power distribution from each power supply (fuse or fusible link) to various
systems.
21-3
FUSE FOR POWER SUPPLY
FUSIBLE LINK BLOCK ASSY

FUSE SYSTEM Page
GLOW E3-76
100A GLOW
INTAKE HEATER E3-84
120A ALT CHARGING E3-96
ENGINE ROOM R/B

FUSE SYSTEM Page
OPS SYSTEM E3-250
7.5A ACC-B
7.5A ALT-S CHARGING E3-194
7.5A ECU-B SAS/OPS SYSTEM E3-234
10A BACK LP REAR WORKING LAMP E3-204
STROBE LIGHT E3-182
GLOW E3-162
INTAKE HEATER E3-166
ENGINE CONTROL (4Y-E) E3-170
FUEL E3-278
GAUGE REAR WIPER E3-76
21-14
INTRODUCTION
CONNECTOR LIST
CONNECTOR LIST

[A] Connector shape and terminal number

Indicates the connector shape on the wire harness side, which is connected to a part.
Numbers indicate terminal numbers that are used in the circuit diagrams.
[B] Connector color
Indicates a connector color.
[C] Part connector
Indicates a connector number connected to a part.
The code is the same as that used in the electrical wiring routing.
(Y) : YAZAKI number
(S) : SUMITOMO number
(A) : AMP number
(J) : JAE number
[D] Connector part number
[E] Connector name
Indicates a connector name.
21-15
INTRODUCTION
WIRE TO WIRE

9+4'619+4'
=%?
=#?

1 2 3 4 4 3 2 1
1 2 3 4
5 6 7 8 9 10
4 3 2 1
10 9 8 7 6 5
='?
5 6 7 8 8 7 6 5 90980-10322 90980-10375
90980-10897
90980-10896 /CKPJCTPGUU#55;VQ+PUVTWOGPVRCPGNJCTPGUU =$?
/CKPJCTPGUU#55;VQ#EEGNJCTPGUU

=&?
1 2 3 3 2 1 1 2 3 3 2 1 1 2 3 3 2 1
4 5 6 6 5 4
4 5 6 6 5 4 4 5 6 6 5 4
(A)174262-2 -
90980-10367 (Y)7322-1460 90980-10367 (Y)7322-1460
/CKPJCTPGUU#55;VQ
/CKPJCTPGUU#55;VQ.CORJCTPGUU 4* /CKPJCTPGUU#55;VQ.CORJCTPGUU .* %QPVTQNXCNXGNKOKVUYKVEJJCTPGUU

[A] Connector shape and terminal number

Indicates the connector shape that connects two wire harnesses.
On left: Female connector *1 shape (This example indicates a connector for the A wire)
On right: Male connector*2 shape (This example indicates a connector for the B wire)
*1: A female connector has a female terminal.
*2: A male connector has a male terminal.
[B] Connector color
Indicates a connector color.
[C] Harness to harness connector
Indicates a connector code that connects two wire harnesses
The code is the same as that used in the electrical wiring routing and wiring diagram.
(Y) : YAZAKI number
(S) : SUMITOMO number
(A) : AMP number
(J) : JAE number
[D] Connector part number
[E] Connector name
Indicates a connector name.
21-16
INTRODUCTION
ABBREVIATIONS
The following abbreviations are used in this section.
Abbreviations Explanation
ASC Auto Speed Control
ASSY Assembly
CNG Compressed Natural Gas
DPF Diesel Particulate Filter
ECU Electronic Control Unit
EPS Electrical Power Steering
FR Front
J/B Junction Block
LH Left-Hand
LPG Liquefied Petroleum Gas
M/T Manual Transmission
OPS Operator Presence Sensing
PIN Personal Identification Number
PS Power Steering
R/B Relay Block
RH Right-Hand
RR Rear
SAS System of Active Stability
SAS-R System of Active Sagety for Reach
SOL Solenoid
T/C Torque Converter & Transmission
TBC Traction and Brake Control
W/ With
W/O Without
21-17
INTRODUCTION
GLOSSARY OF TERMS AND SYMBOLS
BATTERY GROUND RELAY SWITCH, MANUAL
1. NORMALLY 1. NORMALLY
CLOSED OPEN
CAPACITOR HEADLIGHTS
(Condenser)
2. NORMALLY 2. NORMALLY
1. SINGLE OPEN CLOSED
FILAMENT
CIGARETTE LIGHTER RELAY, DOUBLE THROW SWITCH, DOUBLE THROW
2. DOUBLE
FILAMENT
DIODE HORN RESISTOR, TAPPED SWITCH, IGNITION
DIODE, ZENER LIGHT SENSOR (Thermistor)
LED METER, ANALOG SENSOR SWITCH, WIPER PARK

(Light Emitting Diode)
PHOTODIODE METER, DIGITAL SHORT PIN WIRES
1. NOT
CONNECTED
MOTOR RESISTOR FUSE

2. SPLICED
SPEAKER RESISTOR, SOLENOID HIGH-TENSION WIRE

VALIABLE or RHEOSTAT
TRANSISTOR CONTACTOR
21-18
MEMO
21-19

and RELAY LOCATIONS
ELECTRICAL WIRING ROUTINGS RELAY LOCATIONS

FRONT BODY (No.1)............................................21-20 FRONT BODY.......................................................21-38
FRONT BODY (No.2)............................................21-22 REAR BODY .........................................................21-39
REAR BODY .........................................................21-24 CONTACTOR PANEL / AC DRIVER.....................21-40
INSTRUMENT PANEL ..........................................21-26 CAN J/C ................................................................21-41
MAST AREA [V MAST] .........................................21-28
MAST AREA [SV MAST - 7FBR(S)]......................21-30
MAST AREA [SV MAST - 7FBRK] ........................21-32
MAST AREA [FV MAST] .......................................21-34
MAST AREA [FSV MAST] ....................................21-36
SYMBOLS WIRE NAME SYMBOLS WIRE NAME
A Main harness ASSY M Display harness
B Accel harness N Battery sensor harness
C Instrument panel harness P Mast harness / Sub wire (Mast)
D Lamp harness Q Height switch wire
E Control valve limit switch harness R P4 wiring
F Lift limit switch harness S Motor sensor harness
G Brake limit switch harness T Laser marker harness
H FR speed wire U Cable (Laser marker cable No.2)
I Drive motor wiring V Harness (Laser marker harness)
J Pump motor wiring W Cable (Laser marker cable No.1)
K Transformer wiring No.1 X Spiral cable ASSY
L Control connector (Connector cable)

21-20
FRONT BODY (No.1)

A Main harness ASSY M Display harness
B Accel harness N Battery sensor harness
C Instrument panel harness P Mast harness / Sub wire (Mast)
D Lamp harness T Laser marker harness
E Control valve limit switch harness W Cable (Laser marker cable No.1)
D3 D2
D1
D4 D5 D6
AD1
B1
B2
to 21-26
to 21-24
AN1 A41
AC1 A27 A26 A24 A42

A32
A25 AD2
A22
AB1 A28
to 21-26
A29
AM1 A30
N1
E2 A33
E1 A39
AT1
A31
AE1 A18
A40
A13
A34 to 21-28 A37
PA1 to 21-30 A36

TW1 A35
to 21-32
[ L/Lifting height switch ]
to 21-34
to 21-36
PA1
21-21
A13 EPS controller AB1 Main harness ASSY to Accel harness

A18 Lift lock solenoid AC1 Main harness ASSY to Instrument panel harness
A22 Load sensor AD1 Main harness ASSY to Lamp harness (RH)
A24 Main controller AD2 Main harness ASSY to Lamp harness (LH)
A25 Main controller AE1 Main harness ASSY to Control valve limit switch harness
A26 Main controller AM1 Main harness ASSY to Display harness
A27 Main controller AN1 Main harness ASSY to Battery sensor harness
A28 Drive AC driver AT1 Main harness ASSY to Laser marker harness
A29 Pump AC driver PA1 Mast harness / Sub wire (Mast) to Main harness ASSY
A30 Cooling fan TW1 Laser marker harness to Cable (Laser marker cable No.1)
A31 Fuse block
A32 Contactor panel
A33 DC/DC controller
A34 EPS controller
A35 EPS controller
A36 EPS controller
A37 EPS controller
A39 CAN J/C
A40 CAN J/C
A41 Drive AC driver
A42 Option connector
B1 Accelerator sensor
B2 Direction switch
D1 Turn signal lamp (RH)
D2 Turn signal lamp (RH)
D3 Head lamp (RH)
D4 Turn signal lamp (LH)
D5 Turn signal lamp (LH)
D6 Head lamp (LH)
E1 Reach limit switch
E2 Tilt limit switch
N1 Battery electrolyte level / temperature sensor
21-22
FRONT BODY (No.2)

I Drive motor wiring L Control connector (Connector cable)
J Pump motor wiring R P4 wiring
K Transformer wiring No.1
K1 L2
L3
J5 J6
J4
J2
K2
L1
I5
R1
I4
I3 I2
I1
R2
J3
J1
I6
21-23
I1 Drive AC driver (U)

I2 Drive motor (U)
I3 Drive AC driver (V)
I4 Drive motor (V)
I5 Drive AC driver (W)
I6 Drive motor (W)
J1 Pump AC driver (PU)
J2 Pump motor (U)
J3 Pump AC driver (PV)
J4 Pump motor (V)
J5 Pump AC driver (PW)
J6 Pump motor (W)
K1 Contactor panel (P2)
K2 Transformer ASSY
L1 Battery
L2 Drive AC driver (N1)
L3 Contactor panel (P1)
R1 Contactor panel (P4)
R2 Drive AC driver (P4)
21-24
REAR BODY
A Main harness ASSY H FR speed wire
F Lift limit switch harness S Motor sensor harness
G Brake limit switch harness
F4 F3 F1 F2
AF1
to 21-20
G2
A2
A16 to 21-26
A4 G1
A1
A17
A6
A7 A5
A10
S1 b AG1
A15
a
AS1
A23
A12
A8 A14
A9
HA1
HA2 7FBR(S)
A9 A19
7FBRK
A20 A21
[ Front axle LH ] [ Front axle RH ]
H2 H1
a
b
21-25
A1 Flasher relay AF1 Main harness ASSY to Lift limit switch harness
A2 Fuse block AG1 Main harness ASSY to Brake limit switch harness
A4 Horn AS1 Main harness ASSY to Motor sensor harness
A5 Horn HA1 FR speed wire (RH) to Main harness ASSY
A6 Buzzer HA2 FR speed wire (LH) to Main harness ASSY
A7 Option connector (Chime)
A8 Tire angle sensor
A9 Floor switch (7FBR series)
A10 Battery switch
A12 PS motor
A14 Temperature sensor (Drive motor)
A15 Speed sensor 1 (Drive motor)
A16 Temperature sensor (Pump motor)
A17 Speed sensor (Pump motor)
A19 Pressure switch
A20 Brake proportional valve solenoid
A21 Brake shut-off solenoid
A23 Swing lock solenoid
F1 Material handling lever switch (Rear)
F2 Material handling lever switch (Rear)
F3 Material handling lever switch (Front)
F4 Material handling lever switch (Front)
G1 Brake limit switch
G2 Brake limit switch
H1 Front speed sensor (RH)
H2 Front speed sensor (LH)
S1 Speed sensor 2 (Drive motor)
21-26
INSTRUMENT PANEL
A Main harness ASSY T Laser marker harness
C Instrument panel harness X Spiral cable ASSY
M Display harness
[ 7FBRK ]
T1 C1 C3 C4 C5
C6
C7
C1
C6 C3
C4
C5
T1 C7
M3
M1
to 21-20
to 21-20
C2
to 21-24
M2
X1
AX1
21-27
C1 Lighting switch AX1 Main harness ASSY to Spiral cable ASSY

C2 Key switch
C3 Turn signal switch
C4 Horn switch
C5 Horn switch
C6 Surge absorber
C7 Surge absorber
M1 PIN cord entry system
M2 Charger panel
M3 Multifunction display DX
T1 Laser marker switch
X1 Steering torque sensor
21-28
MAST AREA [V MAST]

P Mast harness / Sub wire (Mast) U Cable (Laser marker cable No.2)
Q Height switch wire V Harness (Laser marker harness)
W Cable (Laser marker cable No.1)
Q1
WU1
to 21-20 QP1
UV1
V2
V1
21-29
Q1 Lifting height switch QP1 Height switch wire to Mast harness / Sub wire (Mast)
V1 Laser lamp UV1 Cable (Laser marker cable No.2) to
Harness (Laser marker harness)
V2 Laser lamp switch
WU1 Cable (Laser marker cable No.1) to
Cable (Laser marker cable No.2)
21-30
MAST AREA [SV MAST - 7FBR(S)]

Q1
WU1
to 21-20 QP1
V2
UV1
V1
21-31
21-32
MAST AREA [SV MAST - 7FBRK]

Q1
WU1
to 21-20 QP1
V1 UV1 V2
21-33
21-34
MAST AREA [FV MAST]

P Mast harness / Sub wire (Mast)
Q Height switch wire
Q1
QP1
to 21-20
21-35
21-36
MAST AREA [FSV MAST]

Q1
WU1
to 21-20
QP1
V1
UV1
V2
21-37
21-38
RELAY LOCATIONS
FRONT BODY
Drive AC driver
Contactor panel
DC/DC controller
Main controller Pump AC driver
Cooling fan
Fuse block
EPS Controller
F1 Fuse
Application
F3 Fuse 30A
0.9 ton 1.0 - 1.3 ton 1.4 - 1.8 ton

㪉
models
㪈
Outline
drawing 8 5 4
Fuse block
Purple Orange Yellow
10A 㪉
10A 㪈
Numeral 8 5 4
F6 Fuse
F7 Fuse
Color seal Purple Orange Yellow

Rated current
300 360 410
㪈
(A)
21-39
RELAY LOCATIONS
REAR BODY
Fuse block
㪈㪇㪘㪉
10A 㪈
F5 Fuse
F4 Fuse
㪈
Fch Fuse
Transformer
ASSY model TR4225E TR4312E TR4370E
Outline
drawing
Capacity 40A 250V 50A 250V 60A 250V
Flasher relay
Transformer ASSY
全体 .book
21-40
A L A Main harness ASSY J Pump motor wiring L Control connector (Connector cable)
I Drive motor wiring K Transformer wiring No.1 R P4 wiring
I NO.3 L2 A41
L3 K1 L I5 I3
CHG cable N
K A Short bar
40 ページ２０１２年７月１０日
[ N1 Installation ]
Short bar
火曜日
N1
N
W PW
Contactor P1
CONTACTOR PANEL / AC DRIVER
P2
J5
V PV
J NO.3
RELAY LOCATIONS
F1 Fuse
J3
U
PU
J NO.2
J1
P4(P) J NO.1
P4(D)
P4
R1 R I NO.2 I NO.1
R2 I1 Short bar
21-41
RELAY LOCATIONS
CAN J/C
$NCEM A39 CAN J/C $NCEM A40
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
90980-11661 90980-11661
090II-12 090II-12
21-42
MEMO
21-43
SYSTEM CIRCUITS
POWER SOURCE LIGHTING SYSTEM

POWER SUPPLY..................................................21-44 HEADLIGHT..........................................................21-72
CHARGER ............................................................21-48 TURN SIGNAL LIGHT...........................................21-74
TRAVELING & LOAD HANDLING OTHER

DRIVE & MATERIAL HANDLING CONTROL .......21-52 BACK BUZZER .....................................................21-76
OPS & TBC ...........................................................21-56 LASER MARKER ..................................................21-78
EPS .......................................................................21-62 GROUND POINT ..................................................21-80
INSTRUMENT PANEL
MULTIFUNCTION DISPLAY &
PIN CODE ENTRY SYSTEM ................................21-66
HORN....................................................................21-70
B-O B-O
a
全体 .book
L-O L-O
b
21-44
GR-L GR-L
c
Y
5 A 8 A 3 A d
CSB- CSBT CST+ G
1 e
Cable
B
R
W
C P1
A2
G
Fuse block
Current sensor
F5 Fuse (10A)
4 G-W G-W 1 G G
6
Y P2 Y AC1 f
A
44 ページ２０１２年７月１０日
F4 Fuse (10A)
Short bar
2 5
W-G P2 B B 2 1 R R
A AC1
火曜日
1
B P2
R
R
4
R MB+ R
P2 A
4 2
Contactor B A1 C1
(MB) Flasher relay Lighting switch
L E
1
P3 B MB- B 2 1
A
3 1
G-Y
W-B
Fuse block
R-B
R-G
F6 Fuse (10A)
7
Y-B L L R-B
A
F7 Fuse (10A)
9
Y-B GR L GR
POWER SUPPLY
Short bar
A31
Cable
Fuse block
F3 Fuse (30A)
10
W-Y P3 W 2 1 Y
P3 A
Cable
+ A
L1 (A)
F1 Fuse (*1)
Battery 1
P4 Cable
P3 D
R
g
- A A32 (A), K1 (B), L3 (C), R1 (D) B
Contactor panel ASSY h
R-B
i
K2 (A) GR
Cable
Fch Fuse (*2) Transformer ASSY j
1
Cable P2 Y
A k
1 E (*1) : 0.9ton=300A (*2) : TR4225E=40A
1.0~1.0ton=360A TR4312E=50A Cable
m
N1 L2 (E) 1.4~1.8ton=410A TR4370E=60A
Drive AC driver (N1)
全体 .book
B-O (*LASER) : with Laser marker

a
L-O
b
GR-L
c
Y Y
d a
G G
e
C2
Key switch
3
OFF B-Y
G 1 B
f B-Y 2 B-Y B-Y B-Y B-Y
1 M 4
45 ページ２０１２年７月１０日
AC1
2 10
ST 3 G-W G-W G-W G-W
AC1
火曜日
B-Y
B-Y
B-Y
B-Y
B-Y
G-W
B-Y 1
8 AB1 7 AB1 2 AM1 A10
Battery switch
1 A
C4 (A), C5 (B)
G
G
2
L-O
B-Y
B-Y
B-Y
B-Y
B-Y
B-O
G-W
GR-L
Horn switch
3 4 18
G-W
1 B VBKY 18 A 19 A 4 A 1 D 10 D 24 B 35 B 33 C 2 AT1
VBBA VBKY VBBT B48V CSBAT+ CSBAT CSBAT- OLM+
P
P
A24 (A), A25 (B), A26 (C), A27 (D)
B-Y
Main controller
B2
Direction switch
M3
Multifunction display DX
(*LASER)
1 2 FNDC2 CBAT+ CBAT- VBMB 1

2 B 3 D 9 D 2 D
POWER SUPPLY
Y-R
R-W
T1
Laser marker switch
B
B
2
R-B
2
V-G
A30
(*LASER)
Cooling fan
M
1
R
R R R
g
B
h
R-B
i
GR GR
j b
Y Y
k c
Cable Cable
m d
21-45
全体 .book
21-46
Y
a
GR GR GR
GR
GR
GR
GR
46 ページ２０１２年７月１０日
30 14 13 6 C 8 C
VBBTS VBBTS VBBTS VBBTS P1 A34 (B), A35 (C)
EPS controller
火曜日
A33
DC/DC controller
MPS COIL+
MPS COIL-
GR
W-R
Contactor
Y
(MPS)
P21
2 B
POWER SUPPLY
Y
R2 (F)
Drive AC driver Pump AC driver
Short bar
P4 P4
1 F
Cable
GR
b
Y
c
Cable
d
21-47
POWER SUPPLY
PARTS
A1 21-24 A30 21-20 C1 21-26 L2 21-22, 40
A2 21-24 A31 21-20 C2 21-26 L3 21-22, 40
A10 21-24 A32 21-20 C4 21-26 M3 21-26
A24 21-20 A33 21-20 C5 21-26 R1 21-22, 40
A25 21-20 A34 21-20 K1 21-22, 40 R2 21-22, 40
A26 21-20 A35 21-20 K2 21-22 T1 21-26
A27 21-20 B2 21-20 L1 21-22
: WIRE TO WIRE
AB1 21-20 Main harness ASSY to Accel harness
AC1 21-20 Main harness ASSY to Instrument panel harness
AM1 21-20 Main harness ASSY to Display harness
AT1 21-20 Main harness ASSY to Laser marker harness

B-O B-O
a
全体 .book
L-O L-O
b
21-48
GR-L GR-L
c
5 A 8 A 3 A
CSB- CSBT CST+
1
Cable
B
R
W
C P1
Current sensor
C2
Key switch
A2
Fuse block 3
48 ページ２０１２年７月１０日
F5 Fuse (10A) OFF B-Y

2
Short bar
W-G P2 B 2 4 G-W 1 G 1 B
A AC1 B-Y 2 B-Y B-Y
1 M 4
火曜日
1 AC1
B P2 2
ST 3 G-W
B-Y
P2
2 AM1
A32 (A), K1 (B), L3 (C)
Contactor panel ASSY
Cable
B-Y
18
48V
M3
CHARGER
SW1 SW2 SW3 LED1 LED2 LED3 LED4 CHG7V CHGGND CHGAC CHGMS
K2 (A) 22 23 24 31 30 29 32 1 2 25 33
Transformer ASSY
L
LG
Fch Fuse (*2)

Y-B
L-R
Y-G
G-B
G-R
R-G
W-R
R-W
G-W
1
P2 W
A
7 A 6 A 5 A 11 A 10 A 9 A 8 A 4 A 3 A 2 A 1 A
Cable
R SW1 SW2 SW3 LED1 LED2 LED3 LED4 CH7V CGND CHAC CHMS
+ A Charger switch box

L1 (A)
B
Battery
G
L
R
W
W U1 W W
R
- A
R V1 R R
S
B W1 B B
T
Cable
Cable
Thermal relay Magnet switch
AC plug
1 E (*2) : TR4225E=40A M2 (A)
TR4312E=50A Charger panel
N1 L2 (E) N Pump AC driver TR4370E=60A
全体 .book
B-O
a
L-O
b
GR-L
c
49 ページ２０１２年７月１０日
火曜日
L-R
W-L
11 A 8 A
A39 (A)
L-R
W-L
CAN J/C
12 A 9 A
4 AM1 3 AM1
P-B
L-O
B-O
GR-L
GR-R
L-R
W-L
16 15 11 C 12 C 10 D 24 B 35 B
CAN1H CAN1L CAN1H CAN1L CSBAT+ CSBAT CSBAT-
M3 A25 (B), A26 (C), A27 (D)

CHARGER
Multifunction display DX Main controller
N1 D7V DGND DGND D7V

36 5 4 3 C 14 C
R
BR
W-B
R
BR
6 AM1 8 AM1 7 AM1
R
BR
W-B
W-B
W-B
1 G
N1 A41 (G)
21-49
21-50
CHARGER
PARTS
A2 21-24 A32 21-20 K1 21-22, 40 L3 21-22, 40
A25 21-20 A39 21-20, 41 K2 21-22 M2 21-26
A26 21-20 A41 21-20, 40 L1 21-22 M3 21-26
A27 21-20 C2 21-26 L2 21-22, 40
: WIRE TO WIRE

21-51
MEMO
全体 .book
21-52
A32 (A), L3 (C) C2
Contactor panel ASSY Key switch
A2
1 Fuse block 3
Cable
C P1
2 1
W-G P2 B 2 4 G-W G-W G-W G 1 B
A AC1 B-Y 2 B-Y B-Y
1 M 4
AC1
2 10
Short bar
ST 3 G-W
G
AC1
B-Y
4
R MB+ R
A 1
P2
Contactor
52 ページ２０１２年７月１０日
(MB)
A10
Battery switch
G-W
R
1 2
P3 B MB- B
火曜日
A
G-W
1
Fuse block
G
G
F6 Fuse (10A) M
7
Short bar
Y-B L L
A
A30
Cooling fan
2
B-Y
G-W
B
B
R-B
2 D 9 D 3 D 2 B 4 A 1 D 18 A 19 A
VBMB CBAT- CBAT+ FNDC2 VBBT B48V VBBA VBKY
A24 (A), A25 (B), A26 (C), A27 (D) A24 (A), A25 (B), A26 (C), A27 (D)
Main controller Main controller
SMTSA SMTSK SSTMA SSTMK SS+ SS- VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L
7 C 21 C 20 C 22 C 30 A 17 D 25 C 10 B 29 A 11 B 31 A 9 B 30 D 31 D 24 D
Y
G
P-L
Y-R
G-B
L
Y
B
R
O
L-B
R-L
Y-R
G-R
Cable
12 D 25 D 13 D 26 D 3 E 11 E 4 20 10 26 3 19 5 21 6
SMTBA SMTBK SBTMA SBTMK SS+ SS- VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L
DRIVE & MATERIAL HANDLING CONTROL
+ A
L1 (A)
Battery A36 (D), A37 (E) A33
EPS controller DC/DC controller
- A
Cable
1 E
N1 L2 (E)
全体 .book
W-B W-B W-B W-B R-Y

a
W-B
W-B
W-B
W-B
W-B
W-B
2 4 4 2
1 B 1 A
G-Y
b
GR
E2
Tilt limit switch
E1
Reach limit switch
c
F1 (A), F2 (B)
Material handling lever switch
(Rear)
F3 (A), F4 (B)
Material handling lever switch
(Front)
1 3 3 1
1 A 1 B
GR
G-Y
G-Y
53 ページ２０１２年７月１０日
G-R
G-R
P-B
G-Y
GR-R
G-R
W-B
W-B
G-W
12 A 9 A 7 B 10 B
火曜日
A39 (A), A40 (B)
G-Y
G-R
CAN J/C
1 AF1 3 AF1 2 AF1 5 AE1 3 AE1 2 AE1 11 A 8 A 8 B 11 B

P
V
R-L
R-L
L-R
W-L
O
G-Y
G-R
G-W
4 AM1 3 AM1
P-B
R-Y
GR-R
R-L
L-R
W-L
20 B 28 B 32 A 23 B 35 C 4 C 11 C 12 C 16 15
LSL1 LSL2 POT- LST LSR KYSAT CAN1H CAN1L CAN1H CAN1L
POTA1 POTA- POTA2 POTA+ LSB LSPA LSD LS- N2 N2 N2 N2 DGND D7V
D7V DGND
M3
30 B 22 A 32 B 27 A 23 D 20 D 18 D 6 C 5 C 4 D 5 D 6 D 3 C 14 C
5 4
R
BR
G
G
GR
L-R
R-B
R
BR
W-B
W-B
W-B
W-B
8 AM1 7 AM1
R
5 AB1 1 AB1 2 AB1 6 AB1 2 AG1
G-Y
B-W
R
BR
G
G
GR
L-R
R-B
W-B
W-B
3 1 2 4
1 A 1 2
EP1
VPA1
VPA2
VCP1
G1 (A), G2 (B)
Brake limit switch
A19
Pressure switch
A9
Floor switch
P
1 B 2 1 d
V
B1 e
R
Accelerator sensor
R
R
1 AG1
R R R 1 G
N1 A41 (G)
21-53
R-Y R-Y
a
全体 .book
R1 (D)
(*1) : 0.9ton=300A
21-54
1.0~1.0ton=360A
1.4~1.8ton=410A
F1 Fuse (*1)
1
Short bar P4 Cable
P3 D
R-Y
G-Y
b
GR
Cable
c
BR
BR
R-Y
GR
G-Y
1 F
54 ページ２０１２年７月１０日
Short bar
17 A 16 A 8 A P4 P4 8 A 23 A 6 A
CAN1H CAN1L KYSAT KYSAT SETP1 SETP-
火曜日
A28 (A), I1 (B), I3 (C), I5 (D), L2 (E), R2 (F) A29 (A), J1 (B), J3 (C), J5 (D)
STDM+ STDM U V W SSD1 SSD+ SSD2 CAN1H CAN1L STPM+ STPM PU PV PW SSP1 SSP+
9 A 10 A 1 B 1 C 1 D 14 A 15 A 13 A Short bar 17 A 16 A 9 A 10 A 1 B 1 C 1 D 14 A 15 A
N1 N
1 E
P
V
R
G
L
B
GR
LG
R-W
GR
A15
R-W
Speed sensor 1
CABLE
CABLE
CABLE
CABLE
CABLE
CABLE
(Drive motor)
Cable
1
SSD1
1 A 1 B 1 C 1 A 1 B 1 C
U V W 4 3 A PU PV PW
2 Y
SSD+ B
3 B
A39 (A), A40 (B)

CAN J/C
B
R
I2 (A), I4 (B), I6(C) J2 (A), J4 (B), J6 (C)
Drive motor Pump motor
2 AS1 1 AS1
2 LG
1 SD2+ 1 1
TDM TPM SSP1
LG-R
1 LG-R
2 SSD2 2 2
TDM+ TPM+ SSP+
S1
A14 Speed sensor 2 A16 A17
Temperature sensor (Drive motor) Temperature sensor Speed sensor
(Drive motor) (Pump motor) (Pump motor)
P
d
V
e
Cable
- A
L1 (A)
Battery
21-55
PARTS
A2 21-24 A29 21-20 F1 21-24 J2 21-22
A9 21-24 A30 21-20 F2 21-24 J3 21-22, 40
A10 21-24 A32 21-20 F3 21-24 J4 21-22
A14 21-24 A33 21-20 F4 21-24 J5 21-22, 40
A15 21-24 A36 21-20 G1 21-24 J6 21-22
A16 21-24 A37 21-20 G2 21-24 K1 21-22, 40
A17 21-24 A39 21-20, 41 I1 21-22, 40 L1 21-22
A19 21-24 A40 21-20, 41 I2 21-22 L2 21-22, 40
A24 21-20 A41 21-20, 40 I3 21-22, 40 L3 21-22, 40
A25 21-20 B1 21-20 I4 21-22 M3 21-26
A26 21-20 C2 21-26 I5 21-22, 40 R1 21-22, 40
A27 21-20 E1 21-20 I6 21-22 R2 21-22, 40
A28 21-20 E2 21-20 J1 21-22, 40 S1 21-24
: WIRE TO WIRE
AE1 21-20 Main harness ASSY to Control valve limit switch harness
AF1 21-24 Main harness ASSY to Lift limit switch harness
AG1 21-24 Main harness ASSY to Brake limit switch harness
AS1 21-24 Main harness ASSY to Motor sensor harness

Y
a
全体 .book
A32 (A), L3 (C)

21-56
Contactor panel ASSY C2
Key switch
1 6 A2
Cable Y P2 Y
C P1 Fuse block 3
A
2 1
W-G P2 B 2 4 G-W G-W G 1 B
A AC1 B-Y 2 B-Y B-Y
1 M 4
AC1
Short bar
2 10
ST 3 G-W
R AC1
B-Y
P2 G G
Contactor
(MB) 1
56 ページ２０１２年７月１０日
P3 B
A10
Battery switch
G-W
2
Fuse block
火曜日
F6 Fuse (10A)
G-W
7
Y-B L L R-B
A
Short bar
Y-B
G
G
B-Y
R-B
G-W
2 D 4 A 1 D 18 A 19 A
VBMB VBBT B48V VBBA VBKY
A24 (A), A25 (B), A26 (C), A27 (D)

Main controller
LSD LS- LSPA LSB
18 D 6 C 20 D 23 D
OPS & TBC
2 AG1
G-Y
B-W
G
Cable
2 1 1 A
R
+ A A9 A19 G1 (A), G2 (B)

L1 (A) Floor switch Pressure switch Brake limit switch
Battery
1 2 1 B
R
R
R
- A
1 AG1
Cable
R R R
1 E
N1 L2 (E)
全体 .book
Y Y
a a
GR-R
b
W-B W-B W-B P-B
c
A32 (A)
W-B
W-B
W-B
W-B
2 4 4 2 Fuse block
E2 E1
Tilt limit switch Reach limit switch F7 Fuse (10A)
9
Y-B GR GR GR GR GR
A d
GR
GR
GR
1 3 3 1 G-B
57 ページ２０１２年７月１０日
e
G
G-Y
G-Y
G-R
G-R
f
Y-R
火曜日
W-B
Y
h
G-Y
G-R
W
i
5 AE1 3 AE1 2 AE1 P-L
j
P-B
W
P-L
R-L
Y-R
GR-R
G-Y
G-B
G-R
32 A 23 B 35 C 11 C 12 C 17 D 30 A 22 C 20 C 21 C 7 C
POT- LST LSR CAN1H CAN1L SS- SS+ SSTMK SSTMA SMTSK SMTSA
POTA1 POTA- POTA2 POTA+ N2 N2 N2 N2 VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L
30 B 22 A 32 B 27 A 5 C 4 D 5 D 6 D 25 C 10 B 29 A 11 B 31 A 9 B 30 D 31 D 24 D
OPS & TBC
L
B
Y
R
G
O
GR
GR
GR
GR
L-B
R-L
L-R
Y-R
R-B
G-R
W-B
W-B
W-B
W-B
4 20 10 26 3 19 5 21 6 30 14 13
5 AB1 1 AB1 2 AB1 6 AB1 VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L VBBTS VBBTS VBBTS
A33
DC/DC controller
GR
L-R
R-B
N2
3 1 2 4 32
W-B
W-B
EP1
VPA1
VPA2
VCP1
W-B
W-B
W-B W-B
k
B1
Accelerator sensor
W-B
W-B
1 G
N1 A41 (G)
21-57
Y
a
全体 .book
GR-R GR-R 21-58

b a
P-B P-B
c b
X1
Steering torque sensor
GR
d A8 A22
Tire angle sensor Load sensor
1 2 3
R
W
G-B
e B P E
58 ページ２０１２年７月１０日
G 2 3 1 3 2 1
f Spiral cable
Y-R
g
G-O
W-B
W-B
B-W
R-W
G-W
火曜日
R
W
h
W
i
P-L 1 AX1 2 AX1 3 AX1
j
G-O
W-B
B-W
R-W
G-W
Y
G
W
Y
P-L
Y-R
G-B
G-Y
G-B
G-R
GR
12 D 25 D 13 D 26 D 3 E 11 E 6 C 8 C 17 D 23 D 19 D 16 D 20 D 22 D 1 D 18 D
SMTBA SMTBK SBTMA SBTMK SS+ SS- VBBTS P1 SST+ SST- SST VRAH+ VRAH BPOT- SPL+ SPL
A35 (C), A36 (D), A37 (E) A35 (C), A36 (D), A37 (E)
EPS controller EPS controller
B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L- N2 SOLBC+ SOLBC- SOLBS+ SOLBS- SOLL+ SOLL- SOLS+ SOLS-
1 C 3 C 2 C 10 C 5 E 13 E 4 E 12 E 8 E 16 E 17 C 16 C 5 C 13 C 12 C 4 C 11 C 14 C 15 C
OPS & TBC
B-L
Y-G
B-R
R-B
P-G
W-L
R-G
W-B
B-W
W-G
1 17 2 18 9 25 8 24 7 23
R
GR
G-Y
W-B
B-W
R-W
W-G
G-W
B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L-
A33
DC/DC controller
2 1 2 1 1 2 1 2
A20 A21 A18 A23

Brake proportional valve Brake shut-off solenoid Lift lock solenoid Swing lock solenoid
solenoid
W-B
k
全体 .book
GR-R
a
P-B
b
R-L
1
Q1
Lifting height switch
GR
P-B
G-Y
GR-R
2 3 12 A 9 A 7 B 10 B
A39 (A), A40 (B)
O
59 ページ２０１２年７月１０日
CAN J/C
GR
R-L
11 A 8 A
1 QP1 2 QP1 3 QP1
火曜日
L-R
W-L
O
GR
R-L
1 PA1 2 PA1 3 PA1 4 AM1 3 AM1
O
GR
R-L
GR
L-R
G-Y
W-L
21 D 5 D 6 D 16 15 17 A 16 A
BLS- MH1 MH2-1 CAN1H CAN1L CAN1H CAN1L
A35 (C), A36 (D), A37 (E) A28 (A)

EPS controller Drive AC driver
SSF+ SSFR SSFL
SSD1 SSD+ SSD2
14 D 15 D 2 D M3
OPS & TBC
Multifunction display DX 14 A 15 A 13 A
B
B
G
LG
A39 (A), A40 (B)
CAN J/C 3 A
B
B
G
G
4 B 3 B
L
R
1 HA1 2 HA1 1 HA2 2 HA2
2 AS1 1 AS1
Y-L
Y-L
B-Y
B-Y
LG
LG-R
2 1 2 1
1 2 2 1
SSD1 SSD+ SD2+ SSD2
H1 H2
Front speed sensor Front speed sensor
(RH) (LH) A15 S1
Speed sensor 1 Speed sensor 2
(Drive motor) (Drive motor)
21-59
21-60
OPS & TBC
PARTS
A2 21-24 A23 21-24 A37 21-20 H1 21-24
A8 21-24 A24 21-20 A39 21-20, 41 H2 21-24
A9 21-24 A25 21-20 A40 21-20, 41 L1 21-22
A10 21-24 A26 21-20 A41 21-20, 40 L2 21-22, 40
A15 21-24 A27 21-20 B1 21-20 L3 21-22, 40
A18 21-20 A28 21-20 C2 21-26 M3 21-26
21-28, 30, 32,

A19 21-24 A32 21-20 E1 21-20 Q1
34, 36
A20 21-24 A33 21-20 E2 21-20 S1 21-24
A21 21-24 A35 21-20 G1 21-24 X1 21-26
A22 21-20 A36 21-20 G2 21-24
: WIRE TO WIRE
AE1 21-20 Main harness ASSY to Control valve limit switch harness
AG1 21-24 Main harness ASSY to Brake limit switch harness
AS1 21-24 Main harness ASSY to Motor sensor harness
AX1 21-26 Main harness ASSY to Spiral cable ASSY
HA1 21-24 FR speed wire (RH) to Main harness ASSY
HA2 21-24 FR speed wire (LH) to Main harness ASSY
PA1 21-20 Mast harness / Sub wire (Mast) to Main harness ASSY
21-28, 30, 32,

QP1 Height switch wire to Mast harness / Sub wire (Mast)
34, 36
21-61
MEMO
全体 .book
A32 (A), L3 (C) G

a
21-62
GR
b
6
1 Y P2 Y
Cable A
C P1
A2
G
Fuse block
F5 Fuse (10A)
2
W-G P2 B 2 4 G-W G-W
A
Short bar
62 ページ２０１２年７月１０日
R
P2
Y
Contactor
(MB)
火曜日
A13 (A), A34 (B), A35 (C), A36 (D), A37 (E)
P3 B 8 C EPS controller
P1
Fuse block
F7 Fuse (10A)
TMPS1E
TMPS1G
TMPS3G
TMPS3E
TMPS2G
MPS COIL+
MPS COIL-
SH2+
TMPS4G
TMPS4E
TMPS2E
SH2-
9 IGBT
Y-B GR L GR
A
Short bar
GR
W-R
A31
L
Y
V
R
G
O
B
SB
BR
Fuse block
R-Y
B-W
F3 Fuse (30A)
EPS
10
W-Y P3 W 2 1 Y
P3 A B SHORT BAR
Contactor
(MPS)
Cable
+ A
L1 (A) B R P
Battery
B
L
G
P21 P23 P24

- A 1 A 2 A
2 B
A12
PS motor
Y
R-B 1 2 R-W
Cable
M
1 E
N1 L2 (E)
全体 .book
G
a
GR GR GR GR
b
GR
GR
GR
30 14 13 16
A8 VBBTS VBBTS VBBTS B48V
Tire angle sensor
A33
DC/DC controller
GR
63 ページ２０１２年７月１０日
B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L- N2
2 3 1 1 17 2 18 9 25 8 24 7 23 32
B-L
Y-G
B-R
R-B
P-G
W-L
R-G
火曜日
W-B
B-W
B-W
R-W
W-G
W-B
A13 (A), A34 (B), A35 (C), A36 (D), A37 (E)
EPS controller 16 D 20 D 22 D 6 C 1 C 3 C 2 C 10 C 5 E 13 E 4 E 12 E 8 E 16 E
VRAH+ VRAH BPOT- VBBTS B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L-
SH1+
SH1-
TB1 N2 SST+ SST- SST SMTBA SMTBK SBTMA SBTMK SS+ SS-
17 C 17 D 23 D 19 D A13 (A), A34 (B), A35 (C), A36 (D), A37 (E) 12 D 25 D 13 D 26 D 3 E 11 E
EPS controller
P
W
W
Y
W-B
G
P-L
Y-R
G-B
G-B
G-Y
G-R
EPS
G-B
1 AX1 2 AX1 3 AX1 a
G
b
Y-R
c
R
W
Y
d
W
Spiral cable e
P-L
f
W-B
B
R
W
1 2 3
P
B
W-B
X1
Steering torque sensor
N2
1 B
W-B W-B
W-B
W-B W-B W-B
1 G
N1 A41 (G)
21-63
全体 .book
21-64
A33
DC/DC controller
VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L

64 ページ２０１２年７月１０日
4 20 10 26 3 19 5 21 6
Y
B
R
O
L-B
R-L
Y-R
G-R
火曜日
25 C 10 B 29 A 11 B 31 A 9 B 30 D 31 D 24 D
VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L
A24 (A), A25 (B), A26 (C), A27 (D)

Main controller
SS- SS+ SSTMK SSTMA SMTSK SMTSA CAN1H CAN1L

17 D 30 A 22 C 20 C 21 C 7 C 11 C 12 C
G
W
P-L
Y-R
G-B
P-B
GR-R
EPS
a
12 A 9 A
G
b A39 (A)
Y-R CAN J/C
c
Y 11 A 8 A
d
W
e
L-R
W-L
P-L
f
4 AM1 3 AM1
L-R
W-L
16 15
CAN1H CAN1L M3
21-65
EPS
PARTS
A2 21-24 A26 21-20 A35 21-20 L2 21-22, 40
A8 21-24 A27 21-20 A36 21-20 L3 21-22, 40
A12 21-24 A31 21-20 A37 21-20 M3 21-26
A13 21-20 A32 21-20 A39 21-20, 41 X1 21-26
A24 21-20 A33 21-20 A41 21-20, 40
A25 21-20 A34 21-20 L1 21-22
: WIRE TO WIRE
AX1 21-26 Main harness ASSY to Spiral cable ASSY

A32 (A), L3 (C) C2
Key switch
全体 .book
Contactor panel ASSY A2

Fuse block 3
21-66
1
Cable
C P1 F5 Fuse (10A) OFF B-Y
2 1
W-G P2 B 2 4 G-W G 1 B
A AC1 B-Y 2 B-Y B-Y
1 M 4
AC1
2
Short bar
ST 3 G-W
P2
B-Y
2 AM1
66 ページ２０１２年７月１０日
B-Y
火曜日
18
VBKY
M3 M3
Multifunction display DX Multifunction display DX
SLLT ITKY1 ITKY2 ITKY3 IPSTKY1 OTKY1 OTKY2 OTKY3 LEDTKY1 LEDTKY2 TGND SW1 SW2 SW3 LED1 LED2 LED3 LED4 CHG7V CHGGND CHGAC CHGMS N1
26 8 20 6 21 11 10 9 12 19 3 22 23 24 31 30 29 32 1 2 25 33 36
Y-R
W-B
L
L
B
Y
V
G
O
W
LG
BR
GR
Y-B
L-R
Y-G
G-B
G-R
R-G
W-R
R-W
G-W
1 AM1 6 AM1
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
(*TEN-KEY)
V-Y
1 2 3 6 8 4 9 5 10 7 7 A 6 A 5 A 11 A 10 A 9 A 8 A 4 A 3 A 2 A 1 A
ITKY1 ITKY2 ITKY3 IPSTKY1 OTKY1 OTKY2 OTKY3 LEDTKY1 LEDTKY2 TGND SW1 SW2 SW3 LED1 LED2 LED3 LED4 CH7V CGND CHAC CHMS
1 AN1
M1 M2 (A)
PIN code entry system Charger panel
W-B
Cable
V-Y
+ A
L1 (A)
Battery
MULTIFUNCTION DISPLAY & PIN CODE ENTRY SYSTEM
1
SLLT W-B
- A
N1
Battery electrolyte level / temperature sensor
W-B
Cable
1 E (*TEN-KEY) : with PIN cord entry 1 G
N1 L2 (E) A41 (G) N1
Drive AC driver (N1) Drive AC driver (N1)
全体 .book
A28 (A) A29 (A)

CAN1H CAN1L CAN1H CAN1L

17 A 16 A 17 A 16 A
P
V
L-R
W-L
GR
L-R
G-Y
W-L
67 ページ２０１２年７月１０日
4 AM1 3 AM1 11 A 8 A 7 B 10 B 8 B 11 B
火曜日
L-R
W-L
12 A 9 A A39 (A), A40 (B)
CAN J/C
16 15
CAN1H CAN1L
P-B
GR-R
M3
D7V DGND
5 4
R
BR
8 AM1 7 AM1
R
BR
P-B
Y
Y
G
G
W
W
GR-R
P-L
P-L
Y-R
Y-R
G-B
G-B
14 C 3 C 11 C 12 C 17 D 30 A 22 C 20 C 21 C 7 C 12 D 25 D 13 D 26 D 3 E 11 E
D7V DGND CAN1H CAN1L SS- SS+ SSTMK SSTMA SMTSK SMTSA SMTBA SMTBK SBTMA SBTMK SS+ SS-
A24 (A), A25 (B), A26 (C), A27 (D) A35 (C), A36 (D), A37 (E)
Main controller EPS controller
VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L-
25 C 10 B 29 A 11 B 31 A 9 B 30 D 31 D 24 D 1 C 3 C 2 C 10 C 5 E 13 E 4 E 12 E 8 E 16 E
L
B
P
Y
R
O
L-B
B-L
R-L
Y-R
Y-G
B-R
R-B
P-G
W-L
R-G
G-R
B-W
W-G
4 20 10 26 3 19 5 21 6 1 17 2 18 9 25 8 24 7 23
VERR+ VERR- 48VON+ 48VON- 20VON+ 20VON- NS RS TRC/L B20V+ B20V- S20V+ S20V- NS+ NS- RS+ RS- TRC/L+ TRC/L-
A33 A33
DC/DC controller DC/DC controller
21-67
21-68
PARTS
A2 21-24 A29 21-20 A39 21-20, 41 L3 21-22, 40
A24 21-20 A32 21-20 A40 21-20, 41 M1 21-26
A25 21-20 A33 21-20 A41 21-20, 40 M2 21-26
A26 21-20 A35 21-20 C2 21-26 M3 21-26
A27 21-20 A36 21-20 L1 21-22 N1 21-20
A28 21-20 A37 21-20 L2 21-22, 40
: WIRE TO WIRE
AN1 21-20 Main harness ASSY to Battery sensor harness

21-69
MEMO
C2
Key switch
全体 .book
A2
Fuse block 3
21-70
B 2 4 G-W 1 G 1 B
AC1 1 M 4 B-Y
2
ST 3 G-W
70 ページ２０１２年７月１０日
B-Y
B-Y
火曜日
1 A 1 A
C6 (A), C7 (B) C4 (A), C5 (B)
Surge absorber Horn switch
1 B 1 B
P
P
3 AC1
HORN
P
1 A
A4 (A), A5 (B)
Horn
1 B
W-B
W-B
W-B
1 G
N1 A41 (G)
21-71
HORN
PARTS
A2 21-24 A41 21-20, 40 C5 21-26
A4 21-24 C2 21-26 C6 21-26
A5 21-24 C4 21-26 C7 21-26
: WIRE TO WIRE

全体 .book
A2
Fuse block
21-72
F4 Fuse (10A)
B 2 1 R
5 AC1
R
2
C1
Lighting switch
72 ページ２０１２年７月１０日
3 1
火曜日
R-B
R-G
8 AC1
R-G
R-G
R-G
R-G
1 AD2 1 AD1
HEADLIGHT
R-G
R-G
2 2
D6 D3
Head lamp (LH) Head lamp (RH)
1 1
W-B
W-B
2 AD2 2 AD1
W-B
W-B
W-B
W-B
1 G
N1 A41 (G)
21-73
HEADLIGHT
PARTS
A2 21-24 C1 21-26 D6 21-20
A41 21-20, 40 D3 21-20
: WIRE TO WIRE
AD1 21-20 Main harness ASSY to Lamp harness (RH)
AD2 21-20 Main harness ASSY to Lamp harness (LH)

全体 .book
A2 21-74
Fuse block
G-Y
F4 Fuse (10A)
B 2 1 R R
9 AC1
R
G-Y
G-B
4 2 2
B L C3
Turn signal switch
E
1 A1
74 ページ２０１２年７月１０日
Flasher relay 3 1
W-B
R-Y
G-Y
火曜日
6 AC1 4 AC1
R-Y
G-Y
4 AD2 4 AD1
R-Y
R-Y
1 A 1 A
D4 (A), D5 (B) D1 (A), D2 (B)
Turn signal lamp (LH) Turn signal lamp (RH)
TURN SIGNAL LIGHT
1 B 1 B
GR
GR
5 AD2 5 AD1
W-B
W-B
W-B
W-B W-B W-B
W-B
1 G
N1 A41 (G)
21-75
TURN SIGNAL LIGHT
PARTS
A1 21-24 A41 21-20, 40 D1 21-20 D4 21-20
A2 21-24 C3 21-26 D2 21-20 D5 21-20
: WIRE TO WIRE

C2
Key switch
全体 .book
A2
Fuse block 3
21-76
B 2 4 G-W 1 G 1 B
AC1 B-Y 2
1 M 4
AC1
2
ST 3 G-W
B-Y
B-Y B-Y
76 ページ２０１２年７月１０日
B-Y
B-Y
火曜日
8 AB1 7 AB1
B-Y
B-Y
3 4
B2
Direction switch
1 2
Y-R
R-W
BACK BUZZER
4 AB1
R-W
1
B A6
Buzzer
E
2
W-B
W-B
W-B
1 G
N1 A41 (G)
21-77
BACK BUZZER
PARTS
A2 21-24 A41 21-20, 40 C2 21-26
A6 21-24 B2 21-20
: WIRE TO WIRE

A32 (A), L3 (C) C2 (*CAB) : Cab tire cable
Contactor panel ASSY Key switch
全体 .book
A2
1 Fuse block 3
21-78
Cable
C P1
2 1
W-G P2 B 2 4 G-W G-W G 1 B
A AC1 B-Y 2 B-Y
1 M 4
AC1
2 10
Short bar
ST 3 G-W
AC1
R
G
P2
Contactor
(MB) G
G-W
P3 B
78 ページ２０１２年７月１０日
Fuse block
F6 Fuse (10A)
火曜日
7 G-W
Short bar
Y-B L L R-B
A
G
G
B-Y
R-B
G-W
Y-L
2 D 4 A 1 D 18 A 19 A
2
VBMB VBBT B48V VBBA VBKY
V1
Laser lamp
A24 (A), A26 (C), A27 (D)
Main controller
1
1 UV1 OLM+ N2 N2 N2 N2
R
33 C 5 C 4 D 5 D 6 D
B
1
(*CAB)
V2
B-Y
Laser lamp switch

LASER MARKER
W-B
W-B
W-B
W-B
1 WU1
2 AT1
2
B
R-Y
(*CAB)
B-Y
1
1 TW1 2 UV1
Cable
T1
Laser marker switch
W
W-B
+ A
(*CAB)
L1 (A) 2
Battery
W-B
W-B
1 AT1
V-G
2 WU1
2 TW1
W
W-B
- A
(*CAB)
Cable
W-B W-B W-B
1 E 1 G
N1 L2 (E) N1 A41 (G)
Drive AC driver (N1) Drive AC driver (N1)
21-79
LASER MARKER
PARTS
A2 21-24 A32 21-20 L2 21-22, 40 V2 21-28, 30, 32, 36
A24 21-20 A41 21-20, 40 L3 21-22, 40
A26 21-20 C2 21-26 T1 21-26
A27 21-20 L1 21-22 V1 21-28, 30, 32, 36
: WIRE TO WIRE
TW1 21-20 Laser marker harness to Cable (Laser marker cable No.1)
UV1 21-28, 30, 32, 36 Cable (Laser marker cable No.2) to Harness (Laser marker harness)
WU1 21-28, 30, 32, 36 Cable (Laser marker cable No.1) to Cable (Laser marker cable No.2)
全体 .book
A26 (C), A27 (D)

21-80
Main controller
N2 N2 N2 N2
5 C 4 D 5 D 6 D
W-B
W-B
W-B
W-B
80 ページ２０１２年７月１０日
A33 A34 (B), A35 (C) M3
W-B
W-B
R
火曜日
DC/DC controller EPS controller Multifunction display DX
4
B
L E N2 N2 TB1 N1
A1
Flasher relay
2 1 32 17 C 36
G-Y
W-B
W-B
W
W-B
6 AM1
N2
1 B
R-Y
R-Y
R-G
R-G
GROUND POINT
2 2 1 A 1 A
D6
Head lamp (LH)
D4 (A), D5 (B)
Turn signal lamp (LH)
D1 (A), D2 (B)
Turn signal lamp (RH)
D3
Head lamp (RH)
W-B
W-B
W-B
W-B
1 1 1 B 1 B
W-B
W-B
GR
GR
Cable
+ A 2 AD2 2 AD1 5 AD2 5 AD1
L1 (A)
Battery
W-B W-B
a
W-B
W-B
W-B
W-B
W-B W-B W-B
b
- A
W-B W-B W-B
c
W-B W-B W-B W-B W-B W-B
d
Cable
Cable
e
全体 .book
(*LASER) : with Laser marker
Transformer ASSY
81 ページ２０１２年７月１０日
R
*LASER
1
火曜日
V1
Laser lamp
Y-L
(*LASER)
Cable
1 UV1
Pump AC driver
B
(*LASER)
N
1 WU1
B
GROUND POINT
(*LASER)
R-W
Short bar
P
1 TW1 1
B A6 L2 (E), A41 (G)
Buzzer 1 A Drive AC driver
A4 (A), A5 (B)
E Horn
W-B
1
G N1
(*LASER)
2 1 B
1 E
1 AT1
W-B
W-B
W-B
W-B
W-B
Cable
W-B W-B W-B
W-B
W-B
a
W-B
b
W-B
c
W-B
d
Cable
e
21-81
21-82
GROUND POINT
PARTS
A1 21-24 A33 21-20 D3 21-20 M3 21-26
A4 21-24 A34 21-20 D4 21-20 V1 21-28, 30, 32, 36
A5 21-24 A35 21-20 D5 21-20
A6 21-24 A41 21-20, 40 D6 21-20
A26 21-20 D1 21-20 L1 21-22
A27 21-20 D2 21-20 L2 21-22, 40
: WIRE TO WIRE
TW1 21-20 Laser marker harness to Cable (Laser marker cable No.1)
UV1 21-28, 30, 32, 36 Cable (Laser marker cable No.2) to Harness (Laser marker harness)
WU1 21-28, 30, 32, 36 Cable (Laser marker cable No.1) to Cable (Laser marker cable No.2)
21-83
CONNECTOR LIST
CONNECTOR LIST
CONNECTOR LIST...............................................21-84
WIRE TO WIRE
WIRE TO WIRE.....................................................21-87
21-84
CONNECTOR LIST
A1 A2 A4 A5 A6 A7 A8
Green Natural Natural Natural Natural Natural Black

1 1 1 1
1 2 1 2
2 2 1 2 3
3 4 3 4 90980-10786 90980-10786
90980-08081 90980-08081 Horn Horn 90980-10214 90980-10214 90980-11261
Flasher relay Fuse block Buzzer Option connector Tire angle sensor
(Chime)
A9 A10 A12 A13 A14 A15 A16
Gray Gray Natural Dark Gray Gray Black Gray
3 2 1 3 2 1 1 1 2 1 2 1 2 1 2
2
90980-11607 90980-11607 (S)6195-0057 90980-11156 90980-11156 90980-11156
90980-10123
Floor switch Battery switch EPS controller Temperature sensor Speed sensor 1 Temperature sensor
PS motor (Drive motor) (Drive motor) (Pump motor)
A17 A18 A19 A20 A21 A22 A23
Black Natural Natural Natural Black Black Natural
1 2 1 2 2 1 2 1 2
1 2 1 2 1 3
90980-11156 90980-10556 90980-11069 90980-11255
90980-11003 90980-11019 90080-98200
Speed sensor Pressure switch Brake shut-off Swing lock solenoid
(Pump motor) Lift lock solenoid Brake proportional solenoid Load sensor
valve solenoid
A24 A25 A26 A27
Natural Natural Natural Natural
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35 26 27 28 29 30 31
90980-12527 90980-12528 90980-12529 90980-12525

Main controller Main controller Main controller Main controller
A28 A29 A30 A31 A32
Black Black Black Black Gray
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 1 2
9 10 11 12 13 14 15 9 10 11 12 13 14 15 3 2 1
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23
(A)174352-2 5 4
57620-23560-71 6
(A)770680-1 (A)770680-1 Cooling fan 8 7
Fuse block
Drive AC driver Pump AC driver 10
11 9
90980-11239
Contactor panel
A33 A34 A35
Natural Natural Natural
1 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 9 10 11 12 13 14 15 16 17 18
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
90980-10123 90980-10656
90980-12153 EPS controller
EPS controller
DC/DC controller
A36 A37 A39 A40

Natural Natural Black Black
1 2 11 12 13 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 4 5 6
3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 7 8 9 10 11 12 7 8 9 10 11 12
14 15 24 25 26
16 17 18 19 20 21 22 23
90980-11391 90980-11661 90980-11661
90980-11390
EPS controller CAN J/C CAN J/C
EPS controller
21-85
CONNECTOR LIST
A41 A42 B1 B2 C1 C2
- Natural Black Natural Natural Natural
1 1 2 3 1 2
1 2 3 1 2 3 4 2 1
(A)174921-1 3 4
4 3
(Y)7323-1430 90980-11885 Lighting switch 90980-08081
90980-09799 Option connector Accelerator sensor
90980-10941 Key switch
Drive AC driver
Direction switch
C3 C4 C5 C6 C7 D1 D2
Natural - - - - - -
1 2 3 1 1 1 1 1 1
(A)174921-1 99144-12239 99144-12239
Surge absorber Surge absorber (Y)7315-1051 (Y)7315-1051
Turn signal switch
99141-11003 99141-11003 Turn signal lamp Turn signal lamp
(RH) (RH)
Horn switch Horn switch
D3 D4 D5 D6 E1 E2 F1
Natural - - Natural Natural Natural -
1 1 1
1 2 1 2
1 2 1 2
- (Y)7315-1051 (Y)7315-1051 - 3 4 3 4
Head lamp (RH) Turn signal lamp Turn signal lamp Head lamp (LH) (Y)7009-1326
(LH) (LH) (with Sleeve)
(Y)7283-1041 (Y)7283-1041
Material handling
Reach limit switch Tilt limit switch lever switch (Rear)
F2 F3 F4 G1 G2 H1
- - - - - Natural
1 1 1 1 1
1 2
(Y)7009-1326 (Y)7009-1326 (Y)7009-1326 99141-11004 99141-11004 (Y)7283-7023

(with Sleeve) (with Sleeve) (with Sleeve)
Brake limit switch Brake limit switch Front speed sensor
Material handling Material handling Material handling (RH)
lever switch (Rear) lever switch (Front) lever switch (Front)
H2 I1 I2 I3 I4 I5
Natural Red - Red - Red
1 1 1 1 1
1 2
(Y)7283-7023 90591-22005-71 90591-22005-71 90591-22005-71 90591-22005-71 90591-22005-71

Front speed sensor Drive AC driver Drive motor Drive AC driver Drive motor Drive AC driver
(LH)
I6 J1 J2 J3 J4 J5
- Red - Red - Red
1 1 1 1 1 1
90591-22005-71 90591-38009-71 90591-38009-71 90591-38009-71 90591-38009-71 90591-38009-71

Drive motor Pump AC driver Pump motor Pump AC driver Pump motor Pump AC driver
J6 K1 K2 L1 L2 L3
- Red Red - Black Red
1 1 1 1 1
+ -
90591-38009-71 90592-14003-71 90592-14003-71 90591-38009-71 90591-38009-71

Pump motor Contactor panel Transformer ASSY Drive AC driver Contactor panel
25122-13500-71
Battery
21-86
CONNECTOR LIST
M1 M2 M3 N1
Black Black Gray -
1 2 3 4 5 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1
7 8 9 10 11 12 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
6 7 8 9 10
(J)MX34036SF1 (SATOHPARTS)TJ-2-P
(A)174655-2 (A)174661-2
Multifunction display DX Battery electrolyte level /
PIN code entry system Charger panel temperature sensor
Q1 R1 R2 S1 T1 V1
Gray Red Red Black Natural Gray
3 2 1 1 1
1 2 1 2 1 2
90980-11607 90980-11156 (A)174463-1 -

Lifting height switch 90591-38009-71 90591-38009-71 Speed sensor 2 Laser marker switch Laser lamp
Contactor panel Drive AC driver (Drive motor)
V2 X1
Natural Black
1 2 1 2 3
- (Y)7283-1133-30
Laser lamp switch Steering torque
sensor
21-87
WIRE TO WIRE
Black 㪘㪙㪈 Black Natural 㪘㪚㪈 Natural
1 2 3 4 4 3 2 1
1 2 3 4 4 3 2 1 5 6 7 8 9 10 10 9 8 7 6 5
5 6 7 8 8 7 6 5 90980-10322 90980-10375
90980-10897 Main harness ASSY to Instrument panel harness

90980-10896
Main harness ASSY to Accel harness
Natural 㪘㪛㪈 Natural Natural 㪘㪛㪉 Natural Black 㪘㪜㪈 Black
1 2 3 3 2 1 1 2 3 3 2 1 1 2 3 3 2 1
4 5 6 6 5 4
4 5 6 6 5 4 4 5 6 6 5 4
(A)174262-2 -
90980-10367 (Y)7322-1460 90980-10367 (Y)7322-1460
Main harness ASSY to

Main harness ASSY to Lamp harness (RH) Main harness ASSY to Lamp harness (LH) Control valve limit switch harness
Natural 㪘㪝㪈 Natural Natural 㪘㪞㪈 Natural Gray 㪘㪤㪈 Gray
1 2 2 1 1 2 2 1
1 2 3 4 4 3 2 1
3 3
90980-11156 5 6 7 8 8 7 6 5
90980-11155
90980-10494 (Y)7322-1436
Main harness ASSY to 90980-10891
90980-10890
Main harness ASSY to Brake limit switch harness
Lift limit switch harness
Main harness ASSY to Display harness
Natural 㪘㪥㪈 Natural Black 㪘㪪㪈 Black Natural 㪘㪫㪈 Natural
1 1 1 2 2 1 1 2 2 1
90980-10871 90980-11156
90980-10870 90980-11155
90980-10556 90980-10555
Main harness ASSY to Main harness ASSY to

Battery sensor harness Motor sensor harness Main harness ASSY to
Laser marker harness
Gray 㪘㪯㪈 Black Natural 㪟㪘㪈 Natural Natural 㪟㪘㪉 Natural Natural 㪧㪘㪈 Natural
2 1 1 2 2 1 1 2 3 1 1 3
1 2 3 3 2 1 2 2
(S)6180-2321 90980-10555 (S)6180-2321 90980-10555
90980-11349 (S)6188-0283 (S)6180-3241 90980-10492
FR speed wire (RH) to FR speed wire (LH) to
Main harness ASSY to Main harness ASSY Main harness ASSY Mast harness /
Spiral cable ASSY Sub wire (Mast) to
Main harness ASSY
Gray 㪨㪧㪈 Gray Natural 㪫㪮㪈 Natural Natural 㪬㪭㪈 Natural Natural 㪮㪬㪈 Natural
1 2 3 3 2 1 1 2 2 1 1 2 2 1 1 2 2 1
(S)6189-0177 (S)6188-0328 3 4 4 3 3 4 4 3 3 4 4 3
90980-10476 (S)6189-4171 (S)6180-4181 (S)6189-4171 (S)6180-4181 (S)6189-4171

Height switch wire to
Mast harness / Sub wire (Mast)
Laser marker harness to Cable (Laser marker cable No.2) to Cable (Laser marker cable No.1) to
Cable (Laser marker cable No.1) Harness (Laser marker harness) Cable (Laser marker cable No.2)
21-88
MEMO
21-89
CONNECTING DIAGRAM
Z23 D2
AD1-6 [CN13-6]
LF-L
LR
LH-L
Cold storage vehicle LW LLM

AD1-2 [CN13-2]
AD1-3 [CN13-3]
D4 D5 D6 Z24 D1
[CN18] V1
AD2-4 [CN17-4]
LSL SWH
AD2-2 [CN17-2]
[CN306]
S MG N
Z10 [CN L] Z26 C4 C5 LF-R
SWLM2
[CN30] SWL SWF LH-R
LSR V2 [CN307]
Z11 [CN R] UV1
[CN305] C1 C3 SWK D3 D1 D2
LST MAST [CN3] [CN8]
C2 [CN4] [CN14]
AD1-4 [CN13-4]
AD1-5 [CN13-5]
Z12 [CN T]
FR
AE1 WU1 Z8
TEN KEY
<OPT>
Z9 ACC
[CN11] Z7 [CN31] [CN301] [CN73]
[CN74]
RR B1
M1 DISP LSAT2 E2 ATT1 [CN26]
Cold storage vehicle SWLM1
Z25 [CN29] [CN33] M3 [CN72]
TW1 [CN70] E1
T1 AC1
[CN300] LST [CN71] B2
AG1 [CN6] [CN304] [CN69] LSR SOLL
C6 [CN27]
LSB AM1 AB1
SA
[CN1] AE1 [CN25] AD1
A42 [CN28]
Z7-3 [CN31-3], Z26-1 [CN30-1]
AC1-3[CN69-3]
AT1 C7 [CN11] [CN13]
AF1 [CN39]
LSL2 [CN220]
A18
Z7-2 [CN31-2]
AD2 [CN17] [CN86]

F3 SPL
A10 [CN44]
A22[CN91]
LSL2
LSBATT
LSL
LSB A27 [CN104]
QP1 PA1 AG1 AF1
FORWARD/REVESE A24 [CN101] AN1[CN36] N1[CN35]
[CN93] [CN90] [CN6] [CN39] A26 [CN103]
CHIME A7 [CN24(F)] Z15 Z16 A25 [CN102] SLL
PBMAIN
A4
SWMH AC1-3[CN69-3]
A32[CN135] L1
LSBATT A34 [CN140] PBBTS PBDC/DC
H A11 A13 [CN51] A36 [CN142] A33
Q1 LBU A35 [CN141] A37 [CN143] [CN138] BATT
[CN47]
CHI-F&R [CN92] A5 A7 DIAG
[CN24(F)] A10[CN44]
Z25-2 [CN29-2]
Case L3 A19
Z25-1 [CN29-1]
A6 [CN23(R)] FORM LIGHT

CHI-F AX1 [CN87]
K1
Z25-2 [CN29-2]
*2 ADJUSTABLE [CN20]
*2 A12 A28 A30
VOL. BZ SPIRAL R1
[CN50] A29 [CN111] [CN110] [CN113]
MB
A39 A40 LSPA
Z13 Z14 [CN42] Z18
Z17 [CN232] [CN233] SSFR
[CN41] Z22 BZ-R A6
Z21
Cooling fan
Z19 Z20 [CN23(R)] SST
DMPS
X1
A6 LSP LS FRY [CN19] PW W
ACMDP
ACMDD
[CN23(R)] SWS J5 I5
A1 H1
PV V
[CN12] AC power plug J3 I3 SOLBC SOLBS [CN83]
SSFL PU U
J1 I1
MSCH N L2 N1
M2
VRAH [CN68] A20 [CN88]
H2 ACMP ACMD
STDM
STPM
F4
[CN84] F5 SW BOX U U
A2 J2 I2 S1 [CN53]
V A17 V
A21 [CN89]
[CN16] J4 I4 SSD2
A8
W SSP [CN56] W
[CN32] SOLS A23 K2 A15[CN54]
TF J6 I6 SSD1
[CN95]
A14 A9 LSD
Z1 [CN61] A16 [CN52] [CN43]
AS1
[CN55]
[CN49]
HA2
[CN82]
HA1 [CN81]
G42820DA001_
21-90
WIRING DIAGRAM
to PBCPU
*2
to PS
*1
to PBBTS
to PBBTS
to PBBTS
to PBBTS to PBBTS
to PBBTS to PBBTS
to PBBTS Pin code entry (OPT)
*2
CH CHARGER PBMAIN MAIN CONTROLLER LSB BRAKE LIMIT SWITCH
*1
TF TRANSFORMER ASSY PBDC/DC DC/DC CONTROLLER LSPA PRESURE SWITCH
MSCH CHARGER MAGNET SWITCH PBBTS PS CONTROLLER LST TILT LIMIT SWITCH
THR THERMAL RELAY ACMDD DRIVE AC DRIVER LSBATT BATTERY SWITCH
DCH CHARGER DIODE ACMDP MATERIAL HANDLING AC DRIVER LSD FLOOR SWITCH
FCH CHARGER FUSE SWK KEY SWITCH
Case FORM LIGHT
TMPS1 MAIN TRANSISTOR POWER STEERING NO.1 SWL LIGHTING SWITCH
BATT BATTERY TMPS2 MAIN TRANSISTOR POWER STEERING NO.2 SWF TURN SIGNAL SWITCH
F1 FUSE, DRIVE TMPS3 MAIN TRANSISTOR POWER STEERING NO.3 SWH HORE SWITCH
F3 FUSE, POWER STEERING TMPS4 MAIN TRANSISTOR POWER STEERING NO.4 SWMH LIFTING HEIGHT SWITCH
F4 FUSE, LAMP SH1 POWER STEERING SHANT SW SEARCH LIGHT SWITCH
F5 FUSE, CONTROL CIRCUIT SH2 POWER STEERING SHANT SWLM1 LASER MARKER SWITCH
F6 FUSE, BTS/PS & SOLENOID SWLM2 LASER LAMP SWITCH
F7 FUSE, PB BTS SPL LOAD SENSOR LH-L HEAD LAMP LH
DISP MULTIFUNCTION DISPLAY DX SSD SPEED SENSOR (DRIVE MOTOR) LH-R HEAD LAMP RH FORWARD/REVESE
DIAG DIAGNOSIS CONNECTOR SSP SPEED SENSOR (PUMP MOTOR) LF-L TURN SIGNAL LAMP (LH) CHIME
TEN KEY TEN-KEY STDM TEMPERATURE SENSOR (DRIVE MOTOR) LF-R TURN SIGNAL LAMP (RH)
BOXCHG CHARGER BOX STPM TEMPERATURE SENSOR (PUMP MOTOR) LWS WORKINGLAMP
ADJUSTABLE VOL. BZ
ACMD DRIVE MOTOR SSFL FRONT SPEED SENSOR (LEFT) LS SEARCH LAMP
ACMP PUMP MOTOR SSFR FRONT SPEED SENSOR (RIGHT) LR ROTALY LAMP
DMPS POWER STEERING MOTOR SST STEERING TORQUE SENSOR LBU BACK-UP LAMP
SLL BATTERY ELECTROLYTE LEVEL / TEMPERATURE SENSOR LSP SPOT LIGHT LAMP
SOLBC BRAKE PROPORTIONAL SOLENOID MB BATTERY CONTACTOR LLM LASER MARKER LAMP
SOLBS BRAKE CUT-OFF SOLENOID MPS POWER STEERING CONTACTOR BZ-R BUZZER REVERSE
SOLL LIFT LOCK SOLENOID CHIF FORWARD CHIME
SOLS SWING SOLENOID DSFO FORWARD OPTIONAL DIRECTION SWITCH CHIR REVERSE CHIME
FAN FAN DSBU BACK-UP DIRECTION SWITCH H HORN
LSL MATERIAL HANDLING LEVER SWITCH (FRONT) FRY FLASHER RELAY
VRAD DRIVE ACCEL VARI-OHM LSL2 MATERIAL HANDLING LEVER SWITCH (REAR) SA SURGE ABSORBER
LSATT1 ATTACHMENT 1 LIMIT SWITCH
VRAH TIRE VARI-OHM(HANDLE) LSATT2 ATTACHMENT 2 LIMIT SWITCH
LSR REACH LIMIT SWITCH G42820DA002_
copyright_E_vol2.fm 1 ページ２０１２年７月１０日火曜日午前８時４４分
Published by
1st Printing: July 2012
Pub. No. CE352
Printed in Japan
DA

7FBR RM Vol2 CE352

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foreword_vol2.

fm 1 ページ ２０１２年７月１０日 火曜日 午前８時４５分

TOYOTA INDUSTRIAL EQUIPMENT 7FBR10, 13, 15, 18

INSTRUCTION MANUAL NMF

ELECTRICAL COMPONENTS LAYOUT DRAWING

Cable Contactor panel

Installing sequence of cable N1 portion

To the battery plug

Caution for installation U U

To the transformer ASSY To the transformer ASSY

No. Parts name No. Parts name

A24 A25 A26 A27

Tester Probe (+)

Tester Probe (–)

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Key switch OFF, Attachment 1 lever in the

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

A32-2 P2 terminal Battery plug disconnected, and the A32

A32-4 A32-1 Apply the negative probe to the A32-4 to

M3 connector basic conditions (battery plug connected, key switch ON)

Connector No. ⇔ Connector No. Conditions Standard Remarks

Ten-Key (W/ PIN code entry system)

M1 connector basic conditions (battery plug connected, key switch ON)

Charger Switch Box (Option)

M2 connector basic conditions (battery plug connected, key switch ON)

Battery Electrolyte Level / Temperature Sensor

N1 connector basic conditions (battery plug connected, key switch ON)

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Steering wheel turned left Approx.

Z4-8 Z4-9 TMPS connector removed, Battery plug OFF,

Z4-9 Z4-8 Steering wheel turned right 0 V to 15 V

Z4-12 Z4-13 TMPS connector removed, Battery plug OFF,

Z4-13 Z4-12 Steering wheel turned left 0 V to 15 V

Connector pins layout

Connector No. ⇔ Connector No. Conditions Standard Remarks

4 Remove the EPS controller.

5 Follow the procedure below to remove the cooling fan.

6 Follow the procedure below to remove the main controller.

(3) Remove the main controller W/DC/DC controller.

Short bar G42803TA018_

2 Remove the drive / pump AC driver set bolt.

3 Remove the drive / pump AC driver.

CONTACTOR PANEL INSTALLATION PROCEDURE

2 How to use the F1 fuse separately

Application models 1.0 to 1.3 ton 1.5 to 1.8 ton

3 F1 fuse installing direction

4 Installing angle of P2 harness and P3 harness, and lapping sequence of P3 harness

CONTACTOR PANEL INSULATING RESISTANCE TEST PROCEDURE

Make sure to perform an insulating resistance test.

3 Disconnect the drive driver terminals from 4 points.

4 Disconnect the cable and the connector.

Contactor panel 5 Remove the contactor panel mounting bolt, and

No. Parts name No. Parts name

No. Parts name No. Parts name

2 Remove the pad.

3 Remove the knob, remove the accelerator lever

LIMIT SWITCH INSTALLATION PROCEDURE

Direction switch (LH) Direction switch (RH)

fm 1 ページ２０１２年７月１０日火曜日午前８時４５分