Toyota Forklift 8FBC (H) U Service Manual CU347-1 Vol.2

Sec Index.
fm 1 ページ２０１１年１月２６日水曜日午後３時４９分
SECTION INDEX
NAME SECTION
GENERAL 0
BATTERY 1
CONTROL SYSTEM 2
MULTI-FUNCTION DISPLAY 3
TROUBLESHOOTING (~2010.9) 4
TROUBLESHOOTING (2010.10~) 4A
MOTOR 5
DRIVE UNIT 6
FRONT AXLE 7
REAR AXLE 8
STEERING 9
BRAKE 10
BODY 11
MATERIAL HANDLING SYSTEM 12
MAST 13
CYLINDER 14
OIL PUMP 15
OIL CONTROL VALVE 16
SAS FUNCTIONS 17
APPENDIX 18
Sections indicated by solid characters are included in this manual.
Sections indicated by half-tone characters: See vol. 1.
Sec Index.fm 2 ページ２０１１年１月２６日水曜日午後３時４９分
Service Manual Change History
Description Page# Date
1 Added Service Manual Change History 1 2/15/13
2 Added Information Bulletins list 2 2/15/13
3 Updated Information Bulletins list 2 2/15/14
4 Updated Information Bulletins list 2 8/15/2014
Service Information Bulletins
1 SIB CC11-004 Tuning No.1 Explained 347-1 Chapter 3
2 SIB CC12-003 Pre-charge Circuit Eplanation (Error Codes 31-1 and 31-3) 347-1 Chapter 4a
3 SIB CC13-002 Unlocking H Mode and Speed Limiting 347-1 Chapter 3
4 SIB CC13-003 D-LIM and P-LIM Mode Options Set Explained 347-1 Chapter 3
5 SIB CC14-001 Brake and Stop Lamp Switch Adjustments 346 Chapter 2
6 SIB CE10-004R Voltage Conversion 347-1 Chapter 2
7 SIB CE10-007 Height Selector Information 347-1 Chapter 3
8 SIB CE10-008 Shock Sensor Information 347-1 Chapter 3
9 SIB CE11-001R Clamp Release Interlock (Mini Lever Units 347-1 Chapter 4 & 4a
10 SIB CE11-002 Horn Wires Breaking 347-1 Chapter 4 & 4a
11 SIB CE11-003 Clamp Release Interlock (Standard Lever Units) 347-1 Chapter 4 & 4a
12 SIB CE14-005 Special Grounding strap 347-1 Chapter 4 & 4a
13 SIB HS12-001 Revision to Pump Motor Class Rating 346 Chapter 5
14 SIB HS12-002 Oil Control Valve update to Chapter 16 346 Chapter 16
15 SIB HS13-003 Mini Lever Reducing Valve Pressure Checks 346 Chapter 16
16 SIB MA10-002 Tuning Modes Explained 347-1 Chapter 3
17 SIB MA10-003 Auto Speed Control Information 347-1 Chapter 3
18 SIB MA10-004 Touch Pad Information 347-1 Chapter 3
19 SIB MA10-006 AC Motor Controller Change 347-1 chapter 2
20 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin 346 Chapter 0
21 SIB MA12-003 Lubrication of Horn Contact Rings 346 chapter 0
22 SIB MA12-004 R/M 347-1 Chapter 4A updates 347-1 Chapter 4a
23 SIB MA12-005 B-Type Option Explained 347-1 Chapter 3
24 SIB MA14-001 Hydraulic Pump Spline lubrication 346 Chapter 0
25 SIB RA13-002 Steering Troubleshooting Information 346 Chapter 9
26 SIB RA13-003 Priority Valve Operation 346 Chapter 9
27 SIB RA14-001 Rear Axle Hub Oil Sea 346 Chapter 8
27 SIB ST08-001 Recommended Special Service Tools Not inserted
28 SIB ST10-001 Measuring Parking Brake Force on Trucks 346 Chapter 10
Hotline Tech Tips

1 HTT-2010-06 Drive Motor Over Current Limit Checks
2 HTT-2010-07 Slow Travel Or Surging Hydraulics
3 HTT-2010-08 Display, Main CPU and Changing Voltage
4 HTT-2010-09 Measuring Parking Brake Force
5 HTT-2010-10 Important Service Information Bulletins
6 HTT-2010-11 Slow Attachment Speeds
7 HTT-2010-12 Travel Alarm
8 HTT-2011-01 Speed Limit Adjustment
9 HTT-2011-03 Slow Lowering With Standard Levers
10 HTT-2011-04 "H" Power Mode
11 HTT-2011-05 Adding Electrical Devices,
12 HTT-2011-06 Battery Option/Type selection
13 HTT-2011-08 Tuning Item 1 Explained
15 HTT-2011-10 Controller Software Change
16 HTT-2011-11 Adding Forward Travel Alarm
17 HTT-2011-12 C1-2 Error Codes
18 HTT-2012-01 Relief Valve Structure, Using DVOM to Check Voltage Drop
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0-1
GENERAL
Page
EXTERIOR VIEWS .................................................0-2
VEHICLE MODEL...................................................0-3
FRAME NUMBER...................................................0-3 0
OPERATIONAL TIPS .............................................0-4
ATTENTIVE POINTS ON SAS ...............................0-5
CIRCUIT TESTER ..................................................0-6
Note:
See Vol. 1 (Pub. No. CU346) for the GENERAL items not included in this manual
Service Information Bulletins affecting Models
(30-)7FBCU15-32, 7FBEU15-20, 7BNCU15-25 and 8FBCU20-32
Service Information Bulletin
1 SIB MA06-001 - 7FBCU Option Menu Changes
2 SIB CC06-001 - A5 Error Code Additional Information
3 SIB RA06-002 - Tie Rod Change
4 SIB FA06-003 - Front Axle Hub Change
5 SIB FA06-002 - Changes to Reamer Bolt Torque
6 SIB RA04-001 - New Tie Rod End Design
7 SIB MA05-009 7FBEU Option Set Menu Changes
8 SIB MA05-008 Repair Manual Correction (Front Axle Bearing Preload Specification)
9 SIB CE02-002R - 7FBCU 36 to 48 Volt Conversion
10 SIB CY04-001 - New V & FSV Lift Cyl. Sealsfor 1~3 Ton 7 Series Trucks
11 SIB BF04-003 - Battery Compartment Reinforcement Plate & Battery Stopper Adjust
12 SIB DU05-004 - Reduction Gear Change
13 SIB ST99-001R - Recommended Special Service Tools
14 SIB ST03-001 - 7FBEU SST's for Electrical Troubleshooting
15 SIB ST00-001 - 7FBCU & 7FBH SST for Troubleshooting
16 SIB CC05-002 - Inching While Braking Option (7FBC(H)U15-32)
17 SIB CC05-008 - TMPU Inspection Standards (7FBCU15-55)
18 SIB CC05-006 - MB Contactor Cover (7FBCU15-32)
19 SIB FA05-001 - Gear Case Change (7FBCU35-55)
20 SIB HS05-003 Mini Lever Pressure Relief (7FBEU15-20)
21 SIB MS03-001 Introduction of Optional Quad Mast for 7FBEU15~20
22 SIB CE05-001 Key Switch Change (All Models)
23 SIB CC05-003 Accelerator Pedal Response (Tuning 12) (7FBE(H)U15-20)
24 SIB CE05-008 7FBEU Voltage Conversion
25 SIB CC05-011 Low Battery Voltage / Performance Reduction
26 SIB CC05-007 MB Contactor Cover (7FBEU15-20)
27 SIB ST06-001 - Recommended Special Service Tools
28 SIB CE05-006 Pump Motor Cooling Fan
29 SIB CE05-002 Addiitonal Pump Motor Cooling Fan Kit
30 SIB MA07-005 - Maintenance Indicator Changes
31 SIB RA07-001 Rear Axle Flange Change
32 SIB HS07-001 Addition of Back-Tilt Lock Valve
33 SIB CE06-005R - Display Battery Replacement
34 SIB CE06-005R Display Battery Replacement
35 SIB FA07-001R Front Axle Shaft Change
36 SIB CC07-004 - Tuning No. 14 Information
37 SIB DM07-001 Modification of Drive Motor Rotation Sensor Bearing Section
38 SIB CC08-003R Inching While Braking Option (Tuning Level 13)
39 SIB DU08-001R 7BNCU Drive Unit Repair Correction
40 SIB ST08-001 Recommended Special Service Tools
41 SIB CE08-002R Battery Connector Bracket
42 SIB HS08-002 Addition of OPSS Back-tilt Lock Valve
43 SIB CC08-010 7FB10-J35 Programming Changes
44 SIB Option Setting and Tuning Modes (7FB Models)
45 SIB BR09-001 7FB Repair Manual Corrections
46 CC09-001 7FB Revision of Repair Manual
47 CC09-003 Error Codes 31-1, 31-2 and 31-3
48 DU09-003 Gear Case Bolt Torque Change
49 CC09-004 5F and 5G codes
50 DM09-001 Drive, Pump and Steer Motor through Bolt Torque
51 DM09-002 Pump Motor Cable Clearance
52 CC10-001 Flashware v4.2
53 HS10-001 7FBEU Steering Circuit Hydraulic Schematics
54 SIB CE10-004 8FBC(H)U Voltage Conversion
55 SIB ST10-001 Measuring Parking Brake Force on 8FBC(H)U Trucks
56 SIB BR10-001 Stainless Steel Deadman Switch Mounting Screws
57 SIB CC10-005 v3.1 Software Update for Auxiliary Functions
58 SIB MA10-002 8FBCU Tuning Modes Explained
59 SIB CE10-006 7FBEU Motor Sensor Bearing Change
60 SIB CE10-007 8FBCU Height Selector Information
61 SIB CE10-008 8FBCU Shock Sensor Information
62 SIB MA10-003 8FBCU Auto Speed Control Information
63 SIB MA10-004 8FBCU Touch Pad Information
64 SIB MA10-006 AC Motor Controller Change
65 SIB CE11-001 Clamp Release Interlock (Mini Lever Units)
66 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin
67 SIB FA11-001 7FBEU Front Axle Repair Kits
68 SIB CC11-004 8FBCU Tuning No.1 Explained
69 SIB CE11-002 8FBCU Horn Wires Breaking
70 SIB CE11-003 Clamp Release Interlock (Standard Lever Units)
71 SIB DM11-002 7BNCU New Auxiliary Motor and Pump
Technical News Brief

1 TNB - 2001-01 - Curtis Controllers, Reach Truck 24 v. Drive Motor Overheat, EZ Pedal
Option, Over Heating Diagnosis, and 7FBCU Voltage Specs
2 TNB - 2004-07 - Hydraulic oil change
3 TNB-2006-02 - 7FBEU 6 Bolt Rear Axle Flange
4 TNB - 2006-04 - Cast Iron Body Hydraulic Pump
5 TNB - 2006-05 - Plate to Prevent Chain Rollback
6 TNB - 2006-10 - 7FBCU15-32 Steer Motor Operates After Auto Shutdown Activates
7 TNB - 2006-12 - 7FBCU15-18 Excessive Hydraulic Return Circuit Back Pressure
8 TNB - 2006-13 - Hydraulic Fluid for Cold Storage
9 TNB - 2006-01R - 7FBCU/7FBEU 7-Series Electric Lift Truck Erratic Display
10 TNB - 2006-09 - 7-Series Electric ROM Write
11 TNB-2003-07 - Allowable Variance on Mast Shimming, 7FBEU Counterweight Retention
12 TNB-2006-03 - 7FBEU Counterweight Squeaking
13 TNB-2003-04 - 7FBEU Steer System – Air Purging Procedure
14 TNB-2008-10 7BNCU Steer Sensor Alignment Tool
15 TNB-2008-16 Dual Contactor (Units with Pump Chopper)
16 TNB-2009-04 7FBEU Static Strap Update
Hotline Tech Tips

1 HTT-2004-11 - 7FBCU CB-1 & CB-2; 7FBEU gradeability; 7BNCU tilt speed; Side panels
7FBCU
2 HTT-2004-12 - 7FBCU15-32 Power Steer Motor, Load Sensor, ST Card; 7FBEU
gradeability; 7FBCU CB1 and CB2
3 HTT-2005-01 - 7FBEU Motor Bearing/RPM Sensor; E3 Display on 7FBEU; Hour Meter on
7FBEU and 7FBCU
4 HTT-2005-03 - CB-2 Error codes; 7FBNCU Drive Tire Compounds; 7FBCU35-55 Differential
Oil Level
5 HTT-2005-05 - 7FBCU/7FBEU, Seat Switch Testing
6 HTT-2005-06 - Attachment Installation on 7BPUE, and 7BNCU; 7FBEU and 7FBEHU
Thicker Floor mat; 7FBCU, 7FBEU, and 7FB/H Battery Correction Mode and Lift Interrupt
Settings
7 HTT-2005-07 - 7FBCU15-32 CPU Card Installation, Computer Board Replacement
8 HTT-2005-08 - 7FBCU15-32, code 64-1, 54-1, and CB1 or 2
9 HTT-2005-09 - 7FBEU15-20 & 7FBEHU18 units with mini-levers
10 HTT-2005-10 - 7FBEU1E-20, 7FBEHU18 Wrench Icon
11
HTT-2005-11 - 7FBCU & 7FBEU/HU Load Sensor, Contactor Tip Replacement, Slow Travel
12 HTT-2005-12 - 7FBCU20-32: Differential Gear Noises and Gear Number Three Failures;
7FBCU15-32: A8 Error Codes that will not clear with F1 Fuse Replacement
13
HTT-2006-01 - 7 Series Electric Lift Truck Erratic Display; 7FBE Drive Unit Part Numbers
14 HTT-2006-02 - 7FBCU with CB-1 and CB-2 Error Codes
15 HTT-2006-03 - 7FBCU15-55, E2-2 and C2-2,-3
16 HTT-2006-04 - 7FBCU & 7FBEU OPSS R/M, 7FBCU & 7FBEU Board Replacement
17 HTT-2006-05 - 7FBCU, 7FBEU Travel Alarm
18 HTT-2006-06 - 7FBCU & 7FBEU Battery Consumption
19 HTT-2006-07 - 7FBEU Slow Motor Speed
20 HTT-2006-08 - 7FBEU E2-1 Error Code
21 HTT-2006-09 - FE-4 Error Codes, 72-4 Error Codes,7FBEU Drive Unit P/N
22 HTT-2006-10 - 7FBCU15-32 A5 Error Codes
23 HTT-2006-11 - 7FBCU Drive Transistors
24 HTT-2006-12 - 7FB 61-1 Error Codes, 7FB Load Sensor
25 HTT-2007-01 - Hydraulic Oil for Cold Storage; 7FBEU Motor Bearing Seal Install
26 HTT-2007-02 - 7FB String Cutters, OPSS Tilt Back Lock Valve added
27 HTT-2007-03 - CU322 update; Replacing Interface Card on 7BNCU
28 HTT-2007-04 - Class 1 gear case oil
29 HTT-2007-05 - 7FBCU Gear Case Sealing
30 HTT-2007-06 - Steer Cylinder change
31 HTT-2007-07 - Jerky Creep Speed, New Hydraulic Oil
32 HTT-2007-08 - Optional 12V Power Supply, DC/MD Card troubleshooting
33 HTT-2007-09 - Repair Manual 322
34 HTT-2007-10 - Class 1 OPSS II, Load Sensor , and P7 & P8 Current Sensors
35 HTT-2007-11 - CU322 Repair manual clarification, 7FBEU 31-1, 31-2, 31-3
36
HTT-2007-12 - Class 1 Alarm with OPSS
37 HTT-2008-01 - Class I Gear Noise
38 HTT-2008-02 - Drive Unit Part Numbers, EF-1 & EF-2 Error Codes, Flashware Cable for
39 HTT-2008-03 - 7FBE Error Codes 64-2 & H9-2, 7FBCU15-55 A8, A1 & C3 Error Codes,
40 HTT-2008-04 - No Display with EZ Pedal, (30)7FBCU15-32 Complaint of Low Top Speed
41 HTT-2008-05 - 7FBCU20-32 Battery Slide out Field Installation Kit, (30)7FBCU15-55 Drive
42 HTT-2008-06 - 7FBE Front Hub Induction Hardening and Drive Axle Clattering
43 HTT-2008-07 - 7FBCU15-25 Inspecting the EHPS Transistor
44 HTT-2008-08 - 7FBE Internal Gear Hardened
45 HTT-2008-09 - (30)7FBCU15-32 Error Code C0-(1-6)
46 HTT-2008-10 - 7FBE Drive Axle Connector Rod Adjustment
47 HTT-2008-11 - Using The SST Tools In Diagnosing Board Issues and UL Ratings
48 HTT-2008-12 - Diagnostic Tips
49 HTT-2009-01 - Slow Lowering or Incorrect Staging During Lowering
50 HTT-2009-02 - C2-2 or C2-3 Error Codes and Trouble Shooting Error Codes H9-1,2,3 Or 64-
1,2,3
51 HTT-2009-03 - Static Strap Mounting and Lift Interrupt Settings
52
HTT-2009-04 - Battery Voltage Setting On PDI, Parking Brake Warning and String Cutters
53 HTT-2009-05 - Error Codes After Card Replacement
54 HTT-2009-06 - Error Codes A6-1, A6-2, A6-3, A6-5 or A6-6 at Key-On
55 HTT-2009-07 - Slow Travel Speed
56 HTT-2009-08 - Occurrence of Error Code AO-4
57 HTT-2009-09 - Jerky Travel at Slow Speeds
58 HTT-2009-10 - Gear Case Bolt Torque Increase
59 HTT-2009-11 - A5 Error Code On 7FBE and 7FBC Forklifts With OPSS, 5F and 5G Codes
for the 7BNCU Model Forklifts
60 HTT-2009-12 - 7FBCU Transistor Test Procedure & Speed Sensor Check
61 HTT-2010-01 - FE-4, E2-2, E2-4 Error Codes
62 HTT-2010-02 - Switch Adjust, RF Interference on AC Trucks
63 HTT-2010-03 - Documenting 7FBCU Brake Inspection and Adjustment During PDI,
Flashware v4.2
64 HTT-2010-04 - Class I Brush Warning Option 14, 7BNCU Diode Replace Instructions
65 HTT-2010-05 - Class I 7FBEU Front Axle Repair Kits
66 HTT-2010-06 - Class I AC Drive Motor Over Current Limit Checks, SAS Manual Lowering
Valve
67 HTT-2010-07 - 8FBCU Slow Travel or Surging Hydraulics, Setting Time/Date
68 HTT-2010-08 - 8FBCU Display, Main CPU and Changing Voltage
69 HTT-2010-09 - 8FBCU Measuring Parking Brake Force, 7BNCU Software v3.1
70 HTT-2010-10 - 8FBCU Service Information Bulletins
71 HTT-2010-11 - 8FBCU Slow Attachment Speeds, Seat Switch Failures
72 HTT-2010-12 - 8FBCU Travel Alarm in Both Forward and Reverse
73 HTT-2011-01 - Speed Limit Adjustment on 8FBCU
74 HTT-2011-02 - Class I-VI Common Electrical Acronyms, 7FBEU Error Codes 72-1, 72-2 or
Missing Manager's Functions
75 HTT-2011-03 - Class I 8FBCU Slow Lowering w/Standard Levers
76 HTT-2011-04 - Class I 8FBCU H Power Mode, 7FBEU RPM Sensor Bearing Damage
77 HTT-2011-05 - Class I Adding Electrical Devices,
78 HTT-2011-06 - Class I Battery Option/Type
79 HTT-2011-07 - Class I 7FBCU35-55 Using SST3 On CN112
80 HTT-2011-08 - Class I 8FBCU Tuning No. 1, Back to Basics Troubleshooting
81 HTT-2011-09 - Class I Important SIBs
82 HTT-2011-10 - Class I 8FBC(H)U Controller Software Change
83 HTT-2011-11 - Class I Adding Forward Travel Alarm
84 HTT-2011-12 - Class I C1-2 Error Codes, Hyd Oil Maint and Diagnosing Intermittent
Complaints
85 HTT-2012-01 - Class I 8FBCU Relief Valve Structure, Using DVOM to Check Voltage Drop
0-2
EXTERIOR VIEWS
0
0-3
VEHICLE MODEL
Model
Load Capacity Vehicle Model Voltage Remarks
Code
20 4000 lbs 8FBCU20 36V/48V
8FBCU25 ¦
25 5000 lbs
8FBCHU25 ¦
28 5500lbs 8FBCU28 ¦ 0
30 6000 lbs 8FBCU30 ¦
32 6500 lbs 8FBCU32 ¦ USA·CANADA·MEXICO only
FRAME NUMBER
Frame No. Punching Position
Punching position
Vehicle Model Punching format

8FBCU20 8FBCU25-60011
8FBCU25 * 8FBCU25 60011
8FBCHU25 8FBCHU25-60011
8FBCU28-60011
8FBCU28
* 8FBCU28 60011
8FBCU30 8FBCU32-60011
8FBCU32 * 8FBCU32 60011
*: EEC spec.
0-4
OPERATIONAL TIPS
1 Safe operation
(1) After jacking up, always support with wooden blocks or rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.
2 Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to
prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate
in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packing and O-rings with new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(9) (Tighten to the center of the specified tightening torque range.)
(10) If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table.
3 Protection of functional parts
(1) Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery
plug after the end of vehicle inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers, especially, may damage
elements inside the controllers.
4 Confirming defect status
Do not start immediate disassembly or replacement, but first confirm if such disassembly or replacement is
actually needed.
5 Handling of waste fluid, etc.
When draining waste fluid from the vehicle, always receive it with an appropriate container.
Since careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other harmful
substance may cause adverse affect to people or environmental destruction, sort each waste and always ask an
authorized contractor for appropriate disposal.
6 Handling of electronic parts
(1) Never apply impacts to electronic parts such as a

microcomputer or relay.
(2) Never let electronic parts be exposed to a high
temperature or humidity.
(3) Do not touch connector pins since they may be deformed
or be damaged due to static electricity.
0-5
ATTENTIVE POINTS ON SAS

1 Reference should be made to separate manual “New Model Feature 8FBCU20 to 32 Pub. No.PU319” for the
explanations of SAS functions and operations.
2 Read Section 17 “SAS Precautions for Repair” on Page 17-9 in this repair manual in advance.
3 Whenever the repair or replacement is performed to the place where relative to SAS function, matching
procedure by which the SAS regain proper function must be performed. (See 17-18)
4 The warning on the SAS caution label must be confirmed when the modification or change is such as to change 0
the original specification.
If improper, change the label. (See Page 17-22)
5 Care should always be exercised for safety operation whenever you operate the truck.
Make distinction between the SAS featured trucks and those of none, because the control features are different.
6 The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil will
adversely affect the functions of these valves, always wash the parts clean at the time of installation after
disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the hydraulic oil
is very important.
7 Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults.
Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts,
etc.)
0-6
CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according to the
purpose of measurement.
Analog type: This type is convenient for observing movement during operation, but the measured value should only
be used for reference or rough judgement.
Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1 Difference in measurement results with the digital type and analog type
* The result may be different between measurements with the analog type and digital type.
Always use a circuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described below.
(1) Analog circuit tester
Forward direction Reverse direction Measurement result example
Tester range: kΩ range
Analog type
Continuity exists
Forward
11 kΩ
No continuity
Reverse
•
(2) Digital circuit tester
Forward direction Reverse direction

Measurement result example
Tester range: MΩ range
Digital type
No continuity
Forward
1
Continuity exists
Reverse
2 MΩ
0-7
2 Difference in result of measurement with circuit tester

The circuit tester power supply voltage depends on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a diode varies with the circuit tester power supply voltage.
The diode characteristics are shown in the figure below.
(mA) The resistance values of the same semiconductor measured
6
with two types of circuit testers having different power supply
5 voltages are different.
Forward current
4 Germanium This manual describes the results of measurement with a

3 diode circuit tester whose power supply voltage is 3.0 V.
2 Silicon
diode
1
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)
3 Difference in measurement result by measurement range (analog type)

In the analog type circuit tester, changing the measurement range switches over the internal circuit to vary the
circuit resistance. Even when the same diode is measured, the measurement result varies with the
measurement range.
Always use the range described in the repair manual for
measurement.
Resistor Meter
0Ω
Variable resistor
Current flow
Resistor
Range:×10 (SW1)
Resistor
Range:×1
Power source: 1.5V
Red Black
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sec02.book 1 ページ２０１３年１２月２４日火曜日午前１０時３７分
2-1
CONTROL SYSTEM
Page
GENERAL...............................................................2-2
SPECIFICATIONS ..................................................2-3
COMPONENTS ......................................................2-4
BEFORE REPAIR...................................................2-8
INSPECTION ...........................................................2-8
CONNECTOR INSPECTION ..................................2-9 2
TO USE SST............................................................2-9
INSPECTION ...........................................................2-9
CONTROLLER .....................................................2-31
REMOVAL·INSTALLATION .....................................2-31
CONTACTOR PANEL ASSY................................2-34
INSPECTION .........................................................2-35
OCL MEASUREMENT ............................................2-36
REASSEMBLY .......................................................2-39
DISPLAY ...............................................................2-40
LAMP SWITCH.....................................................2-41
DISASSEMBLY·INSPECTION·REASSEMBLY ...........2-43
ACCELERATOR SENSOR
(POTENTIOMETER) ...........................................2-44
BRAKE SWITCH ADJUSTMENT...................... 2-45A
MINI LEVER..........................................................2-46
JOYSTICK.............................................................2-48
COMPONENTS ....................................................2-50
Service Manual Changes
1 Changed connector CN104-9 (basic 2-14 1/31/12
4 Changed connector CN102-32 to CN101- 2-16 1/31/12
5 Changed connector CN102-32 to CN101- 2-17 1/31/12
6 Added CE10-004R 57 2/8/2013
7 Added MA10‐006 58 2/15/2013
8 Added CC14-001 60-61 2/15/2014
9 SIB CE11-001R Clamp Release Interlock (Mini Lever Units) 347-1 Chapter 4 & 4a
Hotline Tech Tips

sec02.book 2 ページ２０１１年１月２５日火曜日午前９時５４分
2-2
GENERAL
8FBC series models are equipped with traveling/load handling controllers that control traveling and load handling
system. They are multi-functional controllers equipped with micro computers.
The traveling/load handling controller provides high performance in a wide range by means of inverter control of AC
motor drive system.
The main controller has a self-diagnosis function that automatically detects any abnormality of the main drive/pump
circuits, accelerator, PS circuit, SAS/OPS function or any other sensor and displays the corresponding error code
together with a warning beep.
At the same time, an action such as disabling traveling, disabling load handling or restriction of traveling speed
automatically taken to ensure safety.
In addition, setting the display to the analyzer (fault analysis) mode can identify the faulty portion and inspect the
main diver/pump circuits, each operating system and sensors.
~2010.9
Contactor panel
Load handling AC driver
Traveling AC driver
Main controller
2-3
2010.10~
2
Contactor panel Load handling AC driver
Traveling AC driver
Main controller
SPECIFICATIONS
All models
F1 (for drive and pump circuit) 600A
F4 (for lights) 10A
Fuses F5 (for control circuit) 10A
F6 (for controller) 10A
F7 (for controller) 10A
Contactor MB (for power supply) CP304T-A32
2-4
COMPONENTS
2401
05
AR
AR
AR
AR
2400-234
2-5
2401
~2010.9
GK MO
ML AI
BL RJ
XH AI
LZ
BL PL AI
LU LZ
LZ RJ
LZ LZ BL
BL
HW
BL LZ
LZ BL
LU
LZ RJ AA
LZ
XF LZ 20
LZ
LZ AA
AA
AA AA HI
TI HI
HI
BV
KP
HI
HI
AA 20 HI
HI
HI
2401-379
2-6
2401
2010.10~
XG GK BE
ML
AI CC MO
RJ
JX AA
XH RJ BE
BD BE
JN
SJ AI
PL
FT RJ
BL
LT
KY
LU
SH
UX
AA
30 AA ES
SJ
XF AA
BV
HI
KP
LN
AA
AA AJ
TI
20
20
2401-382
sec02.book
7 ページ
01
２０１１年１月２５日
EC
CJ
火曜日
CJ
午前９時５４分
CO BP
AZ
BW GR
BP
AZ
AK AZ
CZ
BP
CZ 22
FK
BP
61
GJ
FK CS CT
62 EN
CZ
AJ CZ
FK 44
44
AC 44
44
GJ
BX
2402-119
2402
2-7
2-8
BEFORE REPAIR
INSPECTION
1. Insulation resistance measurement

Note:
Always measure before inspecting the traveling/load handling
controller.
(1) Disconnect the battery plug and measure the resistance
between battery plug and body.
Measurement terminals Controller side of battery plug-body

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

• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tightening may
cause other failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When connecting
them again, be sure to confirm with the record and tags to prevent incorrect connection. Incorrect connection
may cause other failure.
• After installation, check that there is no interference of the bar and harness connection with other portion.
2-9
CONNECTOR INSPECTION
TO USE SST
Use SSTs for quick and accurate measure on the 8FBCU20~32, 8FBCHU25. The check will fail if the connection
method is wrong. Since boards may be damaged by incorrect connection, the operation is needed to be careful.
Caution:
Always unplug the battery plug before SST connection and disconnection. If the battery plug is still
connected, various boards may be damaged.
Part No. Purpose Remarks
Measure the voltage or resistance for
09230-13240-71 For use CN101 to CN104
main controller.
09240-13241-71
Measure the voltage for AC driver For use CN110 and CN111
(2010.10~)
INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board but check
the following items.
• Abnormality in related harnesses
• Looseness of the related connectors
• Bending or damage of connector pin and defective contact of any related connector pin.
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be
damaged.
Always replace the board after careful inspection.
Measurement method and standard list

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

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

2-10
MAIN CONTROLLER
CPU board
CN101 CN102 CN103 CN104
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
Conventional Lever
CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ⇔ Connector No. Conditions Standard Remarks
CN101-1 CN102-16 Lift lock solenoid ON Approx. 11V
(3, SOLLU+) (4, SLLL-) Lift lock solenoid OFF Approx. 0V
CN101-2 CN102-19 Tilt forward solenoid ON Approx. 11V
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid OFF Approx. 0V
CN101-3 CN102-1 Fan stop Approx. 1V
(97, FAN+) (98, FNDC1) Fan rotate Battery voltage
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
CN101-5 - Unused -
CN101-6 - Unused -
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
CN101-10 - Unused -
CN101-11 - Unused −
2-11

CN101-18 CN101-32
- Approx. 1V to 4V
(308, STCB) (51, POT-)
CN101-19 CN104-4 Key switch OFF Approx. 0V
(47, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN101-32
- Approx. 5V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN101-32
- Approx. 5V
(316, VRTRA+) (51, POT-)
CN101-24 - Unused -
CN101-25 CN101-32
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN101-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)
CN101-27 CN101-32
- Approx. 4.8V
(53, VRA1+) (51, POT-)
CN101-28 - Unused -
CN101-29 CN101-32
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN101-32
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 - Unused -
CN101-34 - Unused -
*1: W/ ATT1
*2: W/ ATT2
CN102-1 CN104-4 Fan stop Battery voltage
(98, FNDC1) (N2, N2) Fan rotate Approx. 0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-5 - Unused -
CN102-6 - Unused -
Knob position correcting solenoid ON Approx. 11V
CN102-7 CN102-14
Knob position correcting solenoid Approx. 0V
(329, SLS+) (330, SLS-)
OFF
CN102-8 - Unused -
CN102-9 CN104-4 EZ pedal neutral position Approx. 14V
*1
(332, OACC2) (N2, N2) EZ pedal backward position Approx. 0V
2-12

CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
CN102-13 - Unused -
CN102-14 CN102-7 Resistance measurement with battery
Approx. 10Ω
(330, SLS-) (329, SLS+) plug disconnected
CN102-15 - Unused -
Approx. 10Ω
(4, SLLL-) (3, SOLLU+) plug disconnected
Approx. 10Ω
(5, SLUL-) (3, SOLLU+) plug disconnected
CN102-18 - Unused -
Approx. 10Ω
(7, SLTFL-) (6, SLTFB+) plug disconnected
Attachment 1 lever in the neutral Approx. 2.3V
CN102-20 CN102-26 position
*2
(25, VRA12) (51, POT-) Attachment 1 lever in the forward or Approx. 0.5V to 4V
backward position
*2
backward position
Key switch OFF, tilt lever in the Approx. 0V
CN102-22 CN102-10 backward position
(62, SWTR) (51, LS-) Key switch OFF, tilt lever in the Approx. 5V
neutral position
Key switch OFF, tilt lever in the Approx. 0V
CN102-23 CN102-10 forward position
(61, SWTF) (51, LS-) Key switch OFF, tilt lever in the Approx. 5V
neutral position
CN102-24 - Unused -
CN102-25 - Unused -
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
*3
backward position
*3
backward position
CN102-30 CN102-26 Key switch OFF, accelerator pedal
Approx. 0.5V to 3.8V
(52, VRA1) (51, POT-) fully depressed
CN102-31 CN102-26
Tire position is neutral Approx. 2V
(317, VRTRA) (51, POT-)
Approx. 09V to 4.1V
2-13

Key switch OFF, brake pedal is free Approx. 0V
CN102-33 CN102-10
Key switch OFF, brake pedal is Approx. 5V
(65, SWBK) (51, LS-)
depressed
CN102-34 - Unused -
CN102-35 - Unused -
*1: W/ EZ pedal
*2: W/ ATT1
*3: W/ ATT2
CN103-1 CN103-2 Swing lock solenoid ON Approx. 9V
(327, SLSW+) (328, SLSW-) Switch lock solenoid OFF Approx. 0V
Approx. 6Ω
(328, SLSW-) (327, SLSW+) plug disconnected
CN103-3
- - -
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 CN102-26
- Approx. 5V
(307, STCB+) (51, POT-)
CN103-8 CN102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9
- Immeasurable -
(147, CAN2H)
CN103-10
- Immeasurable -
(148, CAN2L)
CN103-11
- Immeasurable -
(145, CAN1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
CN103-17 CN102-26 Variation upon changeover from
Approx. 1V to 4V
(56, VRTA) (51, POT-) forward to backward tilting
Lift lever in the neutral position Approx. 2.3V
CN103-18 CN102-26
Lift lever in the forward or backward Approx. 0.5 to 4V
(21, VRL2) (51, POT-)
position
CN103-19 CN102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20 - Unused -
CN103-21 - Unused -
CN103-22 - Unused -
2-14

CN103-23 - Unused -
Key switch OFF, mast height switch Approx. 0V
CN103-24 CN103-6 ON
(91, SH2-1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN103-25 - Unused -
CN103-26 CN102-26
(20, VRA1) (51, POT-)
position
CN103-27 CN104-11
- Approx. 2.5V
(322, SYR) (323, SYR-)
CN103-28 - Unused -
Forks on the ground Approx. 1V or less
CN103-29 CN102-26
Amount of change between raising Approx. 0.5V to 4.5V
(59, SPLF) (51, POT-)
and lowering on the lift with a load
CN103-30 CN102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
Key switch OFF, automatic fork Approx. 0V
CN103-32 CN103-6 leveling switch ON
(70, STK) (51, LS-) Key switch OFF, automatic fork Approx. 5V
leveling switch OFF
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)
(44, VBMB) (N2, N2) Key switch ON Battery voltage
CN104-3 CN104-9 Key switch ON Approx. 11V
(1, CBAT+) (2, CBAT-) Key switch OFF Approx. 0V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)
CN104-7 - Unused -
CN104-8 - Unused -

Approx. 28Ω
(2, CBAT-) (1, CBAT+) plug disconnected
CN104-10 - Unused -
CN104-11
- - -
(323, SYR-)
Revised January 31, 2012

2-15

CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 CN104-11
- Approx. 5V
(321, SYR+) (323, SYR-)
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 - Unused -
CN104-16 - Unused -
CN104-17 - Unused -
CN104-18 CN103-6 Key switch OFF, seat switch ON Approx. 0V

(67, SDM) (51, LS-) Key switch OFF, seat switch OFF Approx. 5V
Key switch OFF, direction switch Approx. 0V

CN104-19 CN103-6 backward
(46, DSR) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
Key switch OFF, parking brake switch Approx. 0V

CN104-20 CN103-6 release
(66, SPB) (51, LS-) Key switch OFF, parking brake switch Approx. 5V
lock
CN104-21 - Unused -

CN104-22 CN103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN104-23 - Unused -
CN104-24 CN103-6
Steering operation Approx. 0V to 5V
(314, SSTRC) (51, LS-)
CN104-25 - Unused -

CN104-26 CN103-6 forward
(45, DSF) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
CN104-27 - Unused -
CN104-28 - Unused -
CN104-29 - Unused -
CN104-30 CN103-6
(312, SSTR1) (51, LS-)
CN104-31 CN103-6
(313, SSTR2) (51, LS-)

2-16
Mini lever/Joystick lever

CN101-1 CN102-16 Lift lock solenoid ON Approx. 11V
(3, SOLLU+) (4, SLLL-) Lift lock solenoid OFF Approx. 0V
CN101-2 CN102-19 Tilt forward solenoid ON Approx. 11V
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid OFF Approx. 0V
CN101-3 CN102-1 Fan stop Approx. 1V
(97, FAN+) (98, FNDC1) Fan rotate Battery voltage
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
Approx. 0V to 10V
(9, SLLA2+) (11, SLPS-) forward to backward lifting
Approx. 0V to 10V
(32, SLTA1+) (33, STPL-) forward to backward tilting
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
Approx. 7Ω *1
(36, SA1PL-) (32, SLTA1+) plug disconnected
Approx. 7Ω *1
(37, SA1PS-) (32, SLTA1+) plug disconnected
Approx. 7Ω
(33, STPL-) (32, SLTA1+) plug disconnected
Approx. 7Ω
(34, STPS-) (32, SLTA1+) plug disconnected
Approx. 7Ω *2
(39, SA2PL-) (9, SLLA2+) plug disconnected
Approx. 7Ω *2
(40, SA2PS-) (9, SLLA2+) plug disconnected
Approx. 7Ω
(11, SLPS-) (9, SLLA2+) plug disconnected
Approx. 7Ω
(10, SLPL-) (9, SLLA2+) plug disconnected
CN101-18 CN101-32
- Approx. 1V to 4V
(308, STCB) (51, POT-)
(43, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN101-32
- Approx. 5V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN101-32
- Approx. 5V
(316, VRTRA+) (51, POT-)
CN101-24 CN101-32
- Approx. 5V
(219, VRH+) (51, POT-)
CN101-25 CN101-32
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN101-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)

2-17

CN101-27 CN101-32
- Approx. 4.8V
(53, VRA1+) (51, POT-)
CN101-28 CN101-32
- Approx. 4.6V
(29, VRT+) (51, POT-)
CN101-29 CN101-32
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN101-32
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 - - -
CN101-34 - - -
*1: W/ ATT1, *2: W/ ATT2

Note: Due to various options CN102-26 may not be present so use CN101-32.

2-18
(17, SOLCOM) (N2, N2) Key switch ON Battery voltage
(17, SOLCOM) (N2, N2) Key switch ON Battery voltage
Knob position correcting solenoid ON Approx. 11V
CN102-7 CN102-14
Knob position correcting solenoid Approx. 0V
(329, SLS+) (330, SLS-)
OFF
CN102-8 - Unused -
CN102-9 CN104-4 EZ pedal in the neutral position Approx. 14V
*1
(332, OACC2) (N2, N2) EZ pedal in the backward position Approx. 0V
CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
Key switch OFF Battery voltage
CN102-13 CN104-4
Key switch ON (Battery voltage -
(335, RY1-) (N2, N2)
Approx. 12V)
Approx. 10Ω
(330, SLS-) (329, SLS+) plug disconnected
CN102-15 - Unused -
Approx. 10Ω
(4, SLLL-) (3, SOLLU+) plug disconnected
CN102-17 - Unused -
CN102-18 - Unused -
Approx. 10Ω
(7, SLTFL-) (6, SLTFB+) plug disconnected
ATT1 lever in the neutral position Approx. 2.3V
CN102-20 CN102-26
ATT1 lever in the forward or Approx. 0.5 to 4V *2
(25, VRA12) (51, POT-)
backward position
CN102-21 CN102-26
(24, VRA11) (51, POT-)
backward position
Tilt lever in the neutral position Approx. 2.3V
CN102-22 CN102-26
Tilt lever in the forward or backward Approx. 0.5 to 4V
(23, VRT2) (51, POT-)
position
Tilt lever in the neutral position Approx. 2.3V
CN102-23 CN102-26
Tilt lever in the forward or backward Approx. 0.5 to 4V
(22, VRT1) (51, POT-)
position
*1: W/ EZ pedal
*2: W/ ATT1
2-19

CN102-24 - Unused -
CN102-25 - Unused -
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
CN102-28 CN102-26
(27, VRA22) (51, POT-)
backward position
CN102-29 CN102-26
(26, VRA21) (51, POT-)
backward position
Approx. 0.5 to 3.8V
CN102-31 CN102-26
Tire position is neutral Approx. 2V
(317, VRTRA) (51, POT-)
Approx. 0.9 to 4.1V
Key switch OFF, brake pedal is free Approx. 0V
CN102-33 CN102-10
Key switch OFF, brake pedal is Approx. 5V
(65, SWBK) (51, LS-)
depressed
CN102-34 - Unused -
CN102-35 - Unused -
*3: W/ ATT2
CN103-1 CN103-2 Swing SOL ON Approx. 9V
(327, SLSW+) (328, SLSW-) Swing SOL OFF Approx. 0V
Approx. 6Ω
(328, SLSW-) (327, SLSW+) plug disconnected
CN103-3
- - -
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 CN102-26
- Approx. 5V
(307, STCBT) (51, POT-)
CN103-8 CN102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9
- Immeasurable -
(147, CAN2H)
CN103-10
- Immeasurable -
(148, CAN2L)
2-20

CN103-11
- Immeasurable -
(145, CAN1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
Approx. 1 to 4V
(56, VRTA) (51, POT-) forward to backward tilting
CN103-18 CN102-26
(21, VRL2) (51, POT-)
position
CN103-19 CN102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20 - Unused -
CN103-21 - Unused -
CN103-22 - Unused -
CN103-23 - Unused -
CN103-24 CN103-6 ON
(91, SH2-1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN103-25 - Unused -
CN103-26 CN102-26
(20, VRL1) (51, POT-)
position
CN103-27 CN104-11
- Approx. 2.5V
(322, SYR) (323, SYR-)
Approx. 0.5V to 4.3V
(220, VRH) (51, POT-) upward to downward lifting
Forks on the ground Approx. 1V or less
CN103-29 CN102-26
Amount of change between raising Approx. 0.5V to 4.5V
(59, SPLF) (51, POT-)
and lowering of the lift with a load
CN103-30 CN102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
Key switch OFF, automatic lift leveling Approx. 0V
CN103-32 CN103-6 switch ON
(70, STK) (51, LS-) Key switch OFF, automatic lift leveling Approx. 5V
switch OFF
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
2-21
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)
(44, VBMB) (N2, N2) Key switch ON Battery voltage
(1, CBAT+) (2, CBAT-) Key switch ON Approx. 11V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)
CN104-7 - Unused -
CN104-8 - Unused -
Approx. 28Ω
(2, CBAT-) (1, CBAT+) plug disconnected
CN104-10 - Unused -
CN104-11
- - -
(323, SYR-)
CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 CN104-11
- Approx. 5V
(321, SYR+) (323, SYR-)
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 CN104-4
- Approx. 14V
(60, PSSW+) (N2, N2)
CN104-16 - Unused -
CN104-17 - Unused -
CN104-18 CN103-6 Key switch OFF, seat switch ON Approx. 0V
(67, SDM) (51, LS-) Key switch OFF, seat switch OFF Approx. 5V
CN104-19 CN103-6 backward
(46, DSR) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
Key switch OFF, parking brake switch Approx. 0V
CN104-20 CN103-6 release
(66, SPB) (51, LS-) Key switch OFF, parking brake switch Approx. 5V
lock
CN104-21 - Unused -
CN104-22 CN103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast height switch Approx. 5V
OFF
CN104-23 - Unused -
CN104-24 CN103-6
(314, SSTRC) (51, LS-)
CN104-25 - Unused -

2-22

CN104-26 CN103-6 forward
(45, DSF) (51, LS-) Key switch OFF, direction switch Approx. 5V
neutral
CN104-27 - Unused -
CN104-28 CN103-6 Key switch OFF, load switch ON Approx. 0V
(68, SLM) (51, LS-) Key switch OFF, load switch OFF Approx. 5V
CN104-29 - Unused -
CN104-30 CN103-6
(312, SSTR1) (51, LS-)
CN104-31 CN103-6
(313, SSTR2) (51, LS-)
TRAVELING AC DRIVER (~2010.9)
CN110 and CN111
5 4 3 2 1
12 11 10 9 8 7 6
CN110-1 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN110-2 N1
- Approx. 15V
(78, SSD+) (N1, N1)
CN110-3 - Unused -
CN110-4 N1
- Approx. 5V
(88, STDM+) (N1, N1)
CN110-5 N1
- Approx. 1V to 4V
(87, STDM) (N1, N1)
CN110-6 N1 L: Approx. 0.5V or
-
(79, SSD1) (N1, N1) H: Approx. 1.5V
2-23

-
(80, SSD2) (N1, N1) H: Approx. 1.5V
CN110-8 N1
- Approx. 5V
(151, OSETD) (N1, N1)
CN110-9 - Unused -
CN110-10 N1
- Approx. 5V
(151, SETD2) (N1, N1)
CN110-11
- Immeasurable -
(145, CAN1H)
CN110-12
- Immeasurable -
(146, CAN1L)
LOAD HANDLING AC DRIVER (~2010.9)

CN111-1 N1
- Approx. 48V
(42, KYSAT) (N1, N1)
CN111-2 N1
- Approx. 15V
(81, SSP+) (N1, N1)
CN111-3 - Unused -
CN111-4 N1
- Approx. 5V
(88, STPM+) (N1, N1)
CN111-5 N1
- Approx. 1V to 4V
(89, STPM) (N1, N1)
-
(82, SSP1) (N1, N1) H: Approx. 1.5V
CN111-7 - Unused -
CN111-8 N1
- Approx. 5V
(152, OSETP) (N1, N1)
CN111-9 N1
- Approx. 5V
(152, SETP) (N1, N1)
CN111-10
- Unused -
(151, SETD2)
CN111-11
- Immeasurable -
(145, CAN1H)
CN111-12
- Immeasurable -
(146, CAN1L)
2-24
TRAVELING AC DRIVER (2010.10~)
CN110 and CN111
㪏㪎㪍㪌㪋㪊㪉㪈
㪈㪌㪈㪋㪈㪊㪈㪉㪈㪈㪈㪇㪐
㪉㪊㪉㪉㪉㪈㪉㪇㪈㪐㪈㪏㪈㪎㪈㪍
CN110-1 - - -
CN110-2
( N1) - Approx. 0V
(14, CANGND)
CN110-3 L: Approx. 0.5V or
(N1, N1) -
(80, SSD2) H: Approx. 1.5V
(N1, N1) -
(79, SSD1) H: Approx. 1.5V
CN110-5 - - -
CN110-6
(N1, N1) - Approx. 12V
(78, SSD+)
CN110-7 - - -
CN110-8
(42, KYSAT)
CN110-9 - - -
CN110-10
- Immeasurable -
(146, CAN1L)
CN110-11 - - -
CN110-12 - - -
CN110-13 - - -
CN110-14 - - -
CN110-15 - - -
CN110-16 - - -
CN110-17
- Immeasurable -
(145, CAN1H)
2-25

CN110-18 - - -
CN110-19 - - -
CN110-20 - - -
CN110-21 - - -
CN110-22
(87, STDM)
CN110-23
(N1, N1) - Approx. 0.2 to 3.0V
(86, STDM+)
LOAD HANDLING AC DRIVER (2010.10~)

CN111-1 - - -
CN111-2
(N1) - Approx. 0V
(14, CANGND)
CN111-3 - - -
(N1, N1) -
(82, SSP1) H: Approx. 1.5V
CN111-5 - - -
CN111-6
(81, SSP+)
CN111-7 - - -
CN111-8
(42, KYSAT)
CN111-9 - - -
CN111-10
- Immeasurable -
(146, CAN1L)
CN111-11
(N1, N1) Approx. 0V
(152, OSETP)
CN111-12
(152, SETP)
CN111-13 - - -
CN111-14 - - -
CN111-15 - - -
CN111-16 - - -
CN111-17
- Immeasurable -
(145, CAN1H)
CN111-18 - - -
CN111-19 - - -
CN111-20 - - -
CN111-21 - - -
CN111-22
(89, STPM)
CN111-23
(N1, N1) - Approx. 0.2 to 3.0V
(88, STPM+)
2-26
CONTACTOR PANEL ASSY
CN134
2 1
CN131
2 1
CN130
1 2 3
4 5 6
CN130-1 CN130-2 Battery plug disconnected, and
Approx. 28Ω
(2, CBAT-) (1, CBAT+) CN130 disconnection
Apply the negative probe to the
CN130-2 CN130-1
CN130-1 terminal to measure Approx. 12V
(1, CBAT+) (2, CBAT-)
voltage.
CN130-3 P1 Battery plug disconnected, and
Approx. 0Ω
(101, FLP) (P1, P1) CN130 disconnection
Approx. 0Ω
(41, VBMB) (P1, P1) CN130 disconnection
Approx. 0Ω
(44, VBMB) (P4, P4) CN130 disconnection
Approx. 0Ω
(19, VBMBSL) (P4, P4) CN130 disconnection
CN131-1 N1 Apply the negative probe to the N1
Approx. 5V
(307, STCB+) (N1, N1) terminal to measure voltage.
CN131-2 N1 Apply the negative probe to the N1
0.5 V to 4.5V
(308, STCB) (N1, N1) terminal to measure voltage.
CN134 connector basic conditions (battery plug connected, key switch OFF)
Battery plug disconnected, and
CN134-1 CN134-2 Approx. 28Ω
CN134 disconnection
2-27
BACK RELAY (W/ EZ pedal)
CN28
3 2 1
6 5 4
CN28-1 CN28-3 EZ pedal in the neutral Approx. 0V
(334, PSACC+) (332, OACC2) EZ pedal in the backward Approx. 14V
CN28-2 - Unused -
CN28-3
- - -
(332, OACC2)
CN28-4 - Unused -
CN28-5
- - -
(103, LBU+)
CN28-6 CN28-5 EZ pedal in the neutral Battery voltage
(105, B48V) (103, LBU+) EZ pedal in the backward Approx. 0V
MULTI-FUNCTION DISPLAY
CN27
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
CN27-1 - Unused -
CN27-2 - Unused -
CN27-3
- - -
(169, TGND)
CN27-4
- - -
(14, DGND)
CN27-5 CN27-4
- Approx. 6.3V
(16, D7V) (14, DGND)
2-28

CN27-6 CN27-3
- Approx. 5V *1
(162, ITKY3) (169, TGND)
CN27-7 - Unused -
CN27-8 CN27-3
- Approx. 5V *1
(160, ITKY1) (169, TGND)
CN27-9
- Immeasurable -
(166, OTKY3)
CN27-10
- Immeasurable -
(165, OTKY2)
CN27-11
- Immeasurable -
(164, OTKY1)
CN27-12 CN27-3
- Approx. 0V *1
(167, LEDTKY1) (169, TGND)
CN27-13 - Unused -
CN27-14 - Unused -
CN27-15
- Immeasurable -
(146, CAN1L)
CN27-16
- Immeasurable -
(145, CAN1H)
CN27-17 - Unused -
CN27-18 - Unused -
CN27-19 CN27-3
- Approx. 3V *1
(168, LEDTKY2) (169, TGND)
CN27-20 CN27-3
- Approx. 5V *1
(161, ITKY2) (169, TGND)
CN27-21 CN27-3
- Approx. 5V *1
(163, IPSTKY1) (169, TGND)
CN27-22 - Unused -
CN27-23 - Unused -
CN27-24 - Unused -
CN27-25 - Unused -
CN27-26 - Unused -
CN27-27 - Unused -
CN27-28 - Unused -
CN27-29 - Unused -
CN27-30 - Unused -
*1: W/ PIN code entry system

2-29
TEN-KEY (W/ PIN code entry system)
CN18
5 4 3 2 1
10 9 8 7 6
CN18-1 CN18-7
- Approx. 5V
(160, ITKY1) (169, TGND)
CN18-2 CN18-7
- Approx. 5V
(161, ITKY2) (169, TGND)
CN18-3 CN18-7
- Approx. 5V
(162, ITKY3) (169, TGND)
CN18-4
- Immeasurable -
(165, OTKY2)
CN18-5 CN18-7
- Approx. 0V
(167, LEDTKY1) (169, TGND)
CN18-6 CN18-7
- Approx. 5V
(163, IPSTKY1) (169, TGND)
CN18-7
- - -
(169, TGND)
CN18-8
- Immeasurable -
(164, OTKY1)
CN18-9
- Immeasurable -
(166, OTKY3)
CN18-10 CN18-7
- Approx. 3V
(168, LEDTKY2) (169, TGND)
2-30
SOLENOID RELAY (Mini lever/Joystick lever)
CN132
3 2 1
8 7 6 5 4
CN132-1 - Unused -
CN132-2 CN132-4
- Approx. 12V
(97, FAN+) (335, RY1-)
CN132-3 - Unused -
CN132-4 Battery plug disconnected and
Approx. 180Ω
(335, RY1-) CN132 disconnection
CN132-5 - Unused -
CN132-6 N1
- Battery voltage
(19, VBMBSL) (N1, N1)
CN132-7 - Unused -
CN132-8 N1
- Battery voltage
(17, SOLCOM) (N1, N1)
2-31
CONTROLLER
REMOVAL·INSTALLATION
Main Controller Assy
Caution:
Before starting the job, disconnect the battery plug and measure the voltage between + and GND; if there is
any voltage, insert a resistor at approx. 100Ω between P4 and GND to discharge the capacitor.
N·m (kgf·cm) [ft·lbf]
T=10~15 (102~153) [7.38~11.07]
Removal Procedure
1. Disconnect the battery plug.
2. Remove the step RH.
3. Disconnect the wiring of the main controller.
4. Remove the main controller ASSY.
Installation Procedure
The reassembly procedure is the reverse of the disassembly procedure.
2-32
Traveling, Load Handling AC Driver (~2010.9)

Caution:
6 T=9.2~13.8 (94~141)
5 [6.79~10.18]
Click here for SIB on

Controller change
T=11.2~16.8 (114~171)
[8.26~12.39]
Removal Procedure
2. Remove the cover LH.
3. Disconnect the power cables.
4. Remove the copper bar.
5. Remove the traveling AC driver.
6. Remove the load handling AC driver.
Note:
Before connecting the connectors or the cables, check the connector No. or the cable tags to ensure correct
connection.
2-33
Traveling, Load Handling AC Driver (2010.10~)

Caution:
T=20~30 (204~306)
6 [14.74~22.10]
T=11.2~16.8 (114~171)
3 [8.26~12.39]
Removal Procedure
3. Disconnect the power cables.
4. Remove the copper bar.
5. Remove the traveling AC driver.
6. Remove the load handling AC driver.
Note:
connection.
2-34
CONTACTOR PANEL ASSY

Caution:
Removal Procedure
3. Remove the contactor cover.
4. Disconnect the power cable.
5. Disconnect the connector.
6. Remove the contactor.
2-35
Note:
connection.
INSPECTION
1. MB (power supply contactor)
Inspection method
CN134 Disconnect CN134 connector, and measure the resistance of
the MB coil.
Portion to be Measurement Tester
Standard
inspected terminals range
2 1 Both terminals
of Approx. 28Ω
MB coil Ωx1
CN134-1 (at 20°C)
CN134-2
2. FUSES
Inspection method
Disconnect the fuse and measure the insulation resistance.
Portion to be Measurement Tester
Standard
inspected terminals range
Both terminals of
FUSES 0Ω Ωx1
fuse
2-36
OCL MEASUREMENT
[For drive circuit]
1. Preparation before measurement
(1) Load the forklift so that it is within the rated capacity, and
position it so that the fork tip is facing a wall or steel pole.
Be sure to place a piece of wood between the fork tip and
the wall.
(2) Turn on the SST by pressing the POWER key on the unit.
SST 09140-13130-71
(3) Press the MODE key twice to switch to the AC+DC A

measurement mode.
2-37
(4) After pressing the SHIFT key, press the SAMPL key to set
the display update rate to “SLOW”.
(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.)
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.
2-38
(2) Turn on the key switch and set the direction switch to
“Forward”. Gradually depress the accelerator pedal to full
throttle and hold there. The SST will start 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.
• If the measurement value is not stable after 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:

[8FBCU20, 25, 8FBCHU25]
48 V: 450 ~ 575 A
36 V: 445 ~ 570 A
[8FBCU28, 30 32]
48 V: 460 ~ 590 A
36 V: 445 ~ 580 A
[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 valve, the OCL valve cannot be
measured.
2-39
REASSEMBLY
Contactor Panel ASSY Reassembly Drawing
T=N·m (kgf·cm) [ft·lbf]
T=11.2~16.8 (114.2~171.3)
[8.26~12.39]
T=2.0~3.0 (20~30)
[1.48~2.17]
T=11~15 (112.2~153.0)
[8.1~11.1]
T=1.3~1.7 (13.3~17.3)
[0.96~1.25]
T=11~15 (112.2~153.0)
[8.1~11.1]
T=2.9~3.9 (29.6~39.8)
[2.14~2.88] T=11~15 (112.2~153.0)
[8.1~11.1]
Assembly Procedure
1. Install the top cover so that the 㧗 sticker is on the harness
side.
Note:
㧗 A magnet is attached to the back of the top cover, allowing
arcs from the contacts to escape to the outside. If the top
cover is installed the wrong way round, the arcs will scatter on
Harness T=1.3~1.7 the inside, causing a faulty connection.
(13.26~17.34)
[0.96~1.25]
Copper bar 2. Install the copper bars so that the +0

ψ marks are on the inside.
+0
Note:
If the copper bars are installed the wrong way round, the
+0 +0
ψ
ψ
+0 +0
contacts on the movable side and the contacts on the fixed
side will be misaligned, resulting in overheating or adhesion.
Caution:
Contact wear tolerance
Movable side: 1 mm (0.039 in)
Fixed side: 1 mm (0.039 in)
2-40
DISPLAY
If the cause of trouble is judged to exist in the display, measure the voltage at the connector to which voltage is
applied.
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
CN27 connector basic condition (Battery plug connected)

Connector No. ⇔ Connector No. Conditions Standard: Remarks
CN27-5 CN27-4
- Approx. 6.3V
(16, D7V) (14, DGND)
2-41
LAMP SWITCH
T=24.5~45.5
(250~464) 4
[18.1~33.6]
Removal Procedure
2. Remove the steering wheel. [Point 1]
3. Remove the instrument panel.
4. Remove the direction cover.
5. Remove the column cover.
6. Disconnect the wiring of the lamp switch and remove it.
The installation procedure is the reverse of the removal procedure.
2-42
Point Operations
SST
[Point 1]
Disassembly:
Use the SST to remove the steering wheel.
SST 09950-76003-71
(09950-50012)
2-43
DISASSEMBLY·INSPECTION·REASSEMBLY
2
3
1. Remove the cam.
2. Remove the horn contact.
3. Remove the steering angle sensor.
4. Remove the light switch ASSY.
Reassembly Procedure
2-44
ACCELERATOR SENSOR
(POTENTIOMETER)
6 5 4 3 2 1
1. Remove the accelerator potentiometer.
2. Check that the resistance between terminals.
Terminal 5 - 6 1.8 to 3.4 kΩ
When the potentiometer is
rotated, the resistance must
Terminal 4 - 6
increase in proportion to its
number of rotations.
Terminal 1 - 2 1.8 to 3.4 kΩ
When the potentiometer is
rotated, the resistance must
Terminal 2 - 3
increase in proportion to its
number of rotations.
3. Temporarily install the accelerator potentiometer.

Note:
10 degrees The accelerator potentiometer turns it for an installation hole
in about 10 degrees clockwise direction and install it.
4. Display the matching menu and check the output voltage of

the accelerator potentiometer.
VRA1 Currently stored value
Standard: VRA1 0.75 ± 0.1 V
If the voltage is within the standard range:
Press and hold down the switch (1) for more than 2 seconds to
perform matching.
If the voltage is outside the standard range:
(1) Loose the screw and adjust the voltage to the standard
value while checking the display and rotating the
accelerator potentiometer.
(2) Tighten the screw.
(3) Press and hold down the switch (1) for more than 2
seconds to perform matching.
5. Fully depress the accelerator pedal and check the voltage at

VRA1 Currently stored value that time.
Standard: VRA1 2.30 to 4.80 V
VRA2 2.75 to 4.80 V
Caution:
Before depressing the accelerator pedal, make sure that the
Spanner indicator on the display is blinking.
If the voltage is within the standard range:
Press and hold down the switch (1) for more than 2 seconds to
VRA2 perform matching.
If the voltage is outside the standard range:
Replace the accelerator potentiometer or accelerator pedal.
2-45
Note:
For EZ pedal, take the pedal that has the lower output voltages
with the pedal fully stepped on, because them of the forward
pedal and reverse pedal may differ respectively.
6. Tighten the screw after adjustment and spread “I” mark by
yellow paint on the screw head.
Note:
• After performing the ACCEL OFF matching, be sure to
perform ACCEL ON matching.
• While the DRIVE is selected on the matching menu, the
spanner lamp blinks and driving is disabled.
• After entering and exiting the DRIVE on the matching
menu, Drive return to neutral is activated. Put the
direction lever in neutral and release the accelerator pedal
to cancel it.
2-46
MINI LEVER
Armrest
Lift lever
Tilt lever
Direction switch
Lever for fixing rotation

of lever box
Automatic fork leveling switch
Lift Lever-Attachment Lever
22.5 to 26° 22.5 to 26°
5 V (1)
PS1 (2)
GND (3)
PS2 (4)
2-47
Tilt Lever
22.5 to 26° 22.5 to 26°
5V
(1)
PS1
(2)
GND
(3)
PS2
(4)
Connector pin arrangement

(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green
Direction Switch
P T VBKY DSF DSR DSFo DSBu LS-
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
2-48
JOYSTICK
Armrest
Automatic fork
leveling switch
Direction switch
Lever for fixing rotation

of lever box
Joystick for lift and tilt
operation
Joystick for Lift and Tilt Operation
22.5 to 26° 22.5 to 26° 22.5 to 26° 22.5 to 26°
5V
(1)
PS1
(2)
GND
(3)
PS2
(4)
1 2 4 3
3 4 2 1
Connector pin arrangement

(1) Power line: Red
(2) GND line: Black
(3) Signal line: Green
2-49
Joystick for Attachment Operation
22.5 to 26° 22.5 to 26° 22.5 to 26° 22.5 to 26°
5 V (1)
PS1 (2)
GND (3)
1 2 4 3
PS2 (4)
3 4 2 1
Direction Switch
P T VBKY DSF DSR DSFo DSBu LS-
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
MARK TERMINAL
1 -
2 DSBu
3 DSFo
4 DSR
5 DSF
6 LS-
7 VBKY
8 VBKY
2-50
COMPONENTS
6712
DA DK
BK BC
DK
DE
DF CS CU
BJ
CT
CP CL AT
CR
BM CN
CB CO CV
DD
BL
23 DJ
CX BB
BR DL DL
CW
DC
CQ DH
BA
AE
AE
AU
DK
BX
6712-052
2-51
Mini Lever
6712
(LH LEVER) 20
CH
(HEIGHT SELECTOR) AL
CJ 21 BI
22 BP
22 CJ
21
22 21
21
22
45 CK 10
CG
AM
AQ
AP
6712-055
Joystick
6712
20
(LH LEVER)
CH
AL
24
25
BI
BP 24
25
45
CK
CG
10
AM
AP AQ
6712-056
2-52
4
5
Removal Procedure
2. Remove the counterweight.
3. Disconnect the connectors.
4. Remove the cover.
5. Remove the mini lever ASSY from the operator’s seat.
Removal Procedure
2-53
4
T= 14 (143) [10.3]
1 T= 35~40
(357~408) 3
[26~30]
5
T= 2.0~4.0
(20.4~40.8)
2 3 [1.5~3.0]
3
T= 2.0~4.0
(20.4~40.8)
[1.5~3.0]
1. Remove the lever for setting rotation. [Point 1]
2. Remove the rotary damper ASSY.
3. Remove the knob for fixing height and the lower bracket.
4. Remove the lever for setting forward and backward. [Point 2]
5. Remove the upper bracket.
6. Remove the armrest ASSY.
2-54
Point Operations
[Point 1]
Installation:
Install the lever for setting rotation so that the dimension B
shown in the illustration on the left becomes 3 to 6 mm (0.118
to 0.236 in).
B The B part moves 3.6 mm (0.142 in) with 1 notch of the
serration.
[Point 2]
Installation:
Align the hole in the clamp bracket with the lever shaft
protrusion to install, then turn as shown in the illustration on
the left.
Installation:
Follow the procedure below to install the forward-backward
adjustment lever.
(1) Move the armrest to the rearmost part.
(2) Tighten the flange nut until the operating force at the top of
the lever becomes 65 to 100 N (6.6 to 10.2 kgf) [14.6 to
22.5 lbf].
(3) Press the armrest forward with the force of 100 N (10.2
kgf) [22.5 lbf], and check that it doesn’t move. If it moves,
100 N (10.2 kgf) [22.5 lbf] tighten the flange nut further.
(4) Tighten nut A to the specified torque.
T = 14 N·m (142.8 kgf·cm) [10.3 ft·lbf]
Nut A
2-55
Mini lever Joystick
1
1
3
3
4
4
1. Remove the lever cover.
2. Disconnect the connector. [Point 1]
3. Remove each lever ASSY and guide. [Point 2]
4. Remove the direction switch ASSY.
Point Operations
[Point 1]
Disassembly:
Always mark connectors with a tag etc. so that the connection
points can be found during reassembly.
Note:
Perform the matching when the mini lever/joystick is
disassembled.
Chassis Electrical
CE10-004R
June 15, 2012
8FBC(H)U Voltage Conversion
8FBCU20-32, 8FBCHU25
SERVICE INFORMATION BULLETIN
Subject: 8FBC(H)U Voltage Conversion Page 1 of 1
MODEL APPLICATION:
GENERAL INFORMATION:
Below are the steps required for voltage conversions.
Step 1) Change the battery voltage within the option set mode (repair manual CU347 page 3-60).
Change the voltage to the desired voltage level of 36 volt (set to yes) or 48 volt (set to no). If a
48 volt battery is installed before the option set has been completed over voltage codes may
appear (A1-1, A1-2 and A1-4). If codes appear simply enter the option set and change setting and
then end program and exit.
Note: If the units have Mini Levers with the Toyota Clamp Release Interlock Module you will
need to change the 2.5 amp 12 volt DC/DC convertor to the proper voltages (36 or 48 volt).
Step 2) Change the horn to the correct voltage. Please consult your parts department for the
correct part number as some units may have a Toyota Special Design Request (TSDR).
Step 3) Replace the headlamps. In some cases the headlamps may be LED type (light
emitting diode) or another type of lamp may have been installed.
The Speaker brand (factory option number J20C) is multi-voltage so no change is required.
Step 4) Replace the rear lamps if equipped. Please consult your parts department for the
correct part numbers as some units may have a Toyota Special Design Request (TSDR) LED
type lamp or another type of lamp design.
The Speaker LED rear combo lamps (factory option number J21D) are multi-voltage so no
change is required.
Step 5) If the unit is equipped with a compartment lamp or any other lamp, please check the
voltage and replace as needed.
Note: The customer may have added other items such as fans, power supplies and other
electrical devices that can be voltage sensitive. Always assure you have investigated the truck
thoroughly.
Maintenance
MA10-006
November 30, 2010
AC Motor Controller Change
SERVICE INFORMATION BULLETIN 8FBCU20-32, 8FBCHU25
Subject: AC Motor Controller Change Page 1 of 1
MODEL APPLICATION:
The AC motor controllers have been changed. The new controllers were placed into production in
October 2010 and a new repair manual supplement CU347-SUPP has been released. The supplement
provides new information for sections 2, 3, 4 and 18 for repair manual CU347 Vol. 2 and is available for
download on TIS.
REPAIR INFORMATION:
The serial number first for each model has been listed below. The new controllers are not backward
compatible with prior serial numbers. Use EPC to determine the correct part number for your
model/serial number.
Serial Number First

8FBCU20 60521
8FBCU25 60514
8FBCHU25 60128
8FBCU28 60020
8FBCU30 60194
8FBCU32 60196
The program version number of the main and motor controllers has changed too and is listed below:
Main Controller and AC Motor Controller Versions

Description Main Controller Version AC Motor Controller Version
Standard Hydraulic Lever 3.0 0.27
Mini Lever or Joystick Lever 2.0 0.27
Control Circuit
CC14-001
January 31, 2014
Brake and Stop Lamp Switch
Adjustment
Subject: 8FBCU Brake and Stop Lamp Switch Adjustments Page 1 of 1
MODEL APPLICATION:
8FBCU20-32 and 8FBCHU25
The brake switch and stop lamp switch adjustments have been added to repair manual CU346.
Please add page 2-45A to existing paper manuals. The updated repair manual CU346 is available for
download in the Service section on TIS. The updated repair manual pages have been included for your
convenience.
sec03.book 1 ページ２０１１年１月２５日火曜日午後６時２９分
3-1
MULTI-FUNCTION DISPLAY
3
Page
GENERAL...............................................................3-2
GENERAL FUNCTIONS.........................................3-3
GENERAL ...............................................................3-3
ADMINISTRATOR FUNCTIONS .................................3-6
MASK FUNCTIONS..............................................3-20
GENERAL .............................................................3-20
PASSWORD ..........................................................3-21
3
ANALYZER ...........................................................3-23
TUNING ................................................................3-48
OPTION SET .........................................................3-58
MATCHING............................................................3-62
OTHERS MENU .....................................................3-71
MULTI-FUNCTION DISPLAY ASSY.....................3-83
COMPONENTS ......................................................3-83
Click here for SIB on unlocking H Mode and Speed Limiting
Click here for SIB on Auto Speed Control Information
Click here for SIB on Touch Pad Information

Description Page # Date
1 Added Change history page 2 8/31/2011
2 Added SIB CC12‐003 92,93 8/31/2011
3 Added SIB CCE13‐002 94,95 1/31/2013
4 Added SIB CE13‐003 96 1/31/2013
5 Added links to table of Contents 1 2/15/2013
6 Added bookmark for passwords bookmark 2/15/2013
7 Added SIB CC11‐004 106‐108 2/15/2013
8 Added SIB CE10‐007 118‐132 2/15/2013
9 Added SIB CE10‐008 133‐142 2/15/2013
10 Added SIB MA10‐002 143‐145 2/15/2013
11 Added SIB MA10‐003 146‐151 2/15/2013
12 Added SIB MA10‐004 152‐174 2/15/2013
8 SIB CE11-001R Clamp Release Interlock (Mini Lever Units) 347-1 Chapter 4 & 4a
Hotline Tech Tips

3-2
GENERAL
The multi-function display has various functions that indicate/notify the vehicle’s information such as vehicle speed,
the battery discharge level and so on. And the operator or administrator can set the vehicle performance with this
display. Furthermore, it has functions to perform maintenance, feeling adjustments and specification setting as a
service function.
On this model, a graphic LCD (Liquid Crystal Display) has been adopted and this provides various information to be
easy-to-understand with expressive capability.
(6) (9)
(7) (10)
(8)
(5)
(1) (2) (3) (4)
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) OPSS indicator
(7) Parking brake indicator
(8) Low speed setting indicator
(9) Diagnostic mode indicator
(10) Overheat warning indicator
3-3
GENERAL FUNCTIONS
GENERAL
General Function List
{: Provided OPT: Option
Remarks
Calendar watch {
Indication that maximum speed limiter is in active setting. {
Indication that overspeed alarm is in active setting. {
Initial display after Indication that auto speed control is in active setting. OPT With Auto Speed Control
key-ON Indication that maximum lift-height limiter is in active setting. OPT With Height Selector
Indication that shock sensor is built in. OPT With Shock Sensor 3
Indication that active mast front tilt control is in inactive
{
setting.
OPSS indicator {
Parking brake indicator {
Low speed setting (turtle) indicator {
Diagnostic mode indicator {
Overheat warning indicator {
Battery capacity indicator {
Digital speedometer {
Status display
Power select (SPH) indicator {
Direction indicator {
Mast tilt indicator {
Maintenance indicator {
Auto speed control indicator OPT With Auto Speed Control
Menu lock indicator {
Date/Time {
Key switch on hour meter {
Lap time meter {
Traveling hour meter {
Load handling hour meter {
Integrating meter Traveling/Load handling hour meter {
Seat on hour meter {
Odometer {
Trip meter {
Planed maintenance hour meter {
3-4
Remarks
Battery over-discharge warning { {
Low battery level warning { {
Overheat warning { {
Parking brake ON warning { {
Parking brake OFF warning { {
Warning Return to neutral warning for travel OPS { {
Return to neutral warning for load handling OPS {* {
Return to neutral warning at starting { {
Diagnostic code display { {
Overspeed alarm { {
Shock detection alarm OPT With Shock Sensor
Clock set {
Power select (SPH) function {
Travel power control setting {
Load handling power setting {
Low speed setting {
Setting function Maximum speed limitation setting {
Overspeed alarm setting {
Planned maintenance hour setting {
Auto power off time setting {
Second password registration for administrator {
Menu lock setting {
Indication of target height memory OPT
Support function for
Automatic height control setting OPT With Height Selector
Height Selector
Maximum height limitation OPT
Indication of shock detection histories OPT
Support function for Cancellation of shock detection warning OPT
With Shock Sensor
Shock Sensor Shock detection level setting OPT
Measurement of shock OPT
Support function for PIN code entry and setting OPT
With PIN Code Entry
PIN code entry Profile setting OPT
*: For an explanation of each function, see “New Model Features section”.

3-5
Initial screen after key-on

This screen is displayed for 2 seconds after the ignition key switch
is turned on. However, if the vehicle speed is detected 1 second or
more after that, the screen switches over to the TRAVELING
screen.
Display Description
JAN/ 1/2010 (FRI) Calendar watch is displayed.

3
Indicate if the maximum speed limitation in active setting.
Indicate if the overspeed alarm is in active setting.
Indicate if the auto speed control is in active setting.
Indicate if the maximum height limitation is in active setting.
Indicate if the shock sensor is in operation.
Indicate if the active mast front tilt control is in inactive setting.

3-6
ADMINISTRATOR FUNCTIONS
Administrators can set the vehicle’s performance and each function.
Administrator functions are protected with password so that the general operators cannot change these settings.
W/O PIN code entry system

Setting menu Setting Screen
Power Mode Select*
Power Control Functions Setting of Travel Power Control Level*
Setting of Load Handling Power Control Level*
Speed Setting of Low Speed*
Travel Functions Speed Setting of Speed Limiter
Speed Setting of Overspeed Alarm*
Height Position Setting of Height Selector
Load Handling Functions
Height Position Clearing of Height Selector
(Height Selector)
Height Position Setting of Maximum Height Limiter
Setting of Maintenance Hour Meter
Setting of Auto Power Off
Vehicle Management Functions
Setting of Administrator’s Second Password
Switching of Menu-Lock
Checking Shock Memories
Shock Sensor Functions Reset of Shock Alarm
(Shock Sensor) Measurement and Setting of Shock
Clearing Shock Memories
*: When menu lock setting is released, the operator can set it.
W/ PIN code entry system

Setting menu Setting Screen
Registry of PINs
PIN Code Entry Functions Change of Profile assignment
PIN Code Entry Profile Data Setting
Change of Initial PIN
Height Position Setting of Height Selector*
Load Handling Functions
Height Position Clearing of Height Selector*
(Height Selector)
Height Position Setting of Maximum Height Limiter
Setting of Maintenance Hour Meter
Setting of Auto Power Off
Vehicle Management Functions Setting of Auto Log Off
Setting of Administrator’s Second Password
Switching of Menu-Lock
Checking Shock Memories
Shock Sensor Functions Reset of Shock Alarm
(Shock Sensor) Measurement and Setting of Shock
Clearing Shock Memories
*: When menu lock setting is released, the operator can set it.
3-7
Administrator Password
Note:
• Always operate switches displayed on the display 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.
Password Entry Procedure
Step Display Operation Vehicle response
When pressing the switches, a

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

2 A short beep sounds.
seconds.
Switch (3)

seconds.
Switch (3)

Within 10 seconds, press switch
4 (2) and switch (4) at the same
seconds repeated short beeps
time for more than 2 seconds.
sound.
When the second password has been set:

Second password screen is displayed. Enter the second
5 password.
Other:
This screen is skipped.
6 Administrator menu screen is displayed automatically.

3-8
Administrator MENU screen
W/O PIN code entry W/ PIN code entry
Icons
Icon Description Icon Description
This icon can set the shock sensor

This icon can set the drive and lift
function. (Models with shock sensor
power control function.
only)
This icon can set the PIN code entry

This icon can set the travel control
system function. (Models with PIN code
function.
entry system only)
This icon can set the load handling

control function. (Models with height Returning to status screen.
selector or multi-function deluxe only)
This icon can set the vehicle

management function.
3-9
Administrator Menu Screen (W/O PIN code entry)

Status screen
Operating Procedure
1. Input the password on the status screen to display the
Administrator Menu screen.
Switch (1) Switch (2) Switch (3) Switch (4)
2. Press switch (2) or switch (3) to select the desired menu tab.
The selected tab is emphatically displayed and items that can
be set are displayed below.
3. Press switch (1) to select the item, and press switch (4) (enter)
to display the menu or setting screen for each function.
Note:
Select the return tab on the Administrator Menu screen, and
press switch (4) (enter) to display the status screen.
3-10
Power control setting screen

• Power Mode Select
• Setting of Travel Power Control Level
• Setting of Load Handling Power Control Level
Setting screen for travel function

• Speed Setting of Low Speed
• Speed Setting of Speed Limiter
• Speed Setting of Overspeed Alarm
Setting screen for load handling functions (Height Selector)

• Height Position Setting of Height Selector
• Height Position Clearing of Height Selector
• Height Position Setting of Maximum Height Limiter
Vehicle management setting screen

• Setting of Planned Maintenance Hour Meter
• Setting of Auto Power Off
• Setting of Administrator’s Second Password
• Switching of Menu-Lock
3-11
Support screen for shock sensor

• Checking Shock Memories
• Reset of Shock Alarm
• Monitor and Setting of Shock Detection Level
• Clearing Shock Memories
Return to status screen

3-12
1. Power Control Setting Menu Screen

This menu screen can set the travel and load handling power
control function.
Note:
When the H mode lock setting is “YES”, H mode cannot be
selected. Please refer to a service function about the way to
release the H mode lock. Click here for info on unlocking
H-Mode
(1) Power select screen

The power select mode (S, P, H or Original) can be selected by
pressing switch (2) or switch (3) on the power select screen by
shifting to the corresponding indicator position.
This is the same as the one in the operator functions.
Switch (2): S -> SPH -> H -> P
Switch (3): S -> P -> H -> SPH
Switch (4): Returning to power control setting menu
screen.
When the original mode is selected, all of S, P, and H are
inverted.
(2) Travel power control level setting

The travel power of the original mode can be set in five steps.
Switch (2): Select the lower level.
Switch (3): Select the higher level.
screen.
(3) Load handling power control level setting

The load handling power of the original mode can be set in five
steps.
Switch (2): Select the lower level.
Switch (3): Select the higher level.
screen.
3-13
2. Travel Setting Menu Screen

This menu screen can set the travel control function.
(1) Low speed setting screen

The speed limit of the Low speed setting function can be
changed.
Switch (2): Setting speed limit down.
Switch (3): Setting speed limit up.
Switch (4): Returning to setting menu screen.
It is adjustable from 2 to 30 mph by 1 mph. When MPH setting
is “NO” in optionset, it is adjustable from 2 to 50 km/h by
1 km/h.
If the operator set the speed to more than 30mph (50km/h), the
low speed function is disabled. In that case “OFF” is displayed.
Click
(2) Maximum speed limiter setting screen
here for The speed limit of the Maximum speed limiter can be changed.
info on Switch (2): Setting traveling speed down.
Speed Switch (3): Setting traveling speed up.
Limiting Switch (4): Returning to setting menu screen
1 km/h.
(3) Overspeed alarm setting screen

The speed to activate the overspeed alarm function can be
changed.
Switch (2): Setting traveling speed down.
Switch (3): Setting traveling speed up.
Switch (4): Returning to setting menu screen
1 km/h.
3-14
3. Load Handling Setting Menu Screen

This menu screen can set the load handling control function.
Automatic height control setting screen (W/ Height Selector)
Clear all memories screen (W/ Height Selector)
Maximum height limiter setting screen (W/ Height Selector)

3-15
4. Vehicle Management Setting Menu Screen

This menu screen can set the vehicle management function.
(1) Planned maintenance hour meter setting screen

Time for planned maintenance hour meter can be set from 10
up to 2000 hours by 10 hour for 10 to 200 hours, and 50 hour
for 200 to 2000 hours.
Switch (2): Decreasing setting time
Switch (3): Increasing setting time
Switch (4): Returning to menu screen
Pressing switch (1) for more than 2 seconds will reset the
current hour meter value to 0.
Note:
This reset operation doesn’t reset the setting value and keeps
it with the same value.
Pressing the switch (2) to decrease the set time, next to 10h is
“OFF” setting of the maintenance hour meter function.
The current value is kept but the maintenance indicator and the
buzzer are deactivated with this “OFF” setting.
(2) Auto power off time setting

The time to activate the auto power off function can be
changed.
Switch (2): Decreasing set time
Switch (3): Increasing set time
It is adjustable from 2 to 60 minutes with a step of 1 minute.
Auto power off function is disabled by selecting “OFF” which is
next to “60 min”.
3-16
(3) Administrator’s second password setting screen

The administrator can register the second password.
The second password can be registered by continuing to press switch (1) for 2 seconds after entering the
password by using switch (1) to (4). If press the switch (4) for 2 seconds or more, the screen returns to the menu
screen.
Administrator should manage the second password so that it doesn’t get unknown.
Even if it has got unknown, the service technician can clear it on the masked menu.
(4) Delete of password

Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s second password
setting screen.
If press the switch (4) for 2 seconds or more, the screen returns to the menu screen.

3-17
(5) Menu lock screen

This function can limit the change of the vehicle setting by the
operator.
When menu lock setting is “YES”, the following items are
limited.
• Operator setting menu is NOT displayed.
• Power control setting menu is NOT displayed.
• Operator cannot change the power select mode.
Switch (2): Selecting “Yes”
Switch (3): Selecting “No”
Note:
• The lock release setting (“NO”) is effective till key-OFF. (It
means set “YES” automatically when the key is turned
off.)
• This is not available (NOT Locked) before “hour meter
start”.
5. Shock Sensor Setting Menu Screen (OPT)

This menu screen can set the Shock Sensor function.
6. End Menu Screen

Switch (4): Returning to status screen
3-18
Administrator Menu Screen (W/ PIN code entry)

Status screen
• Entering Administrator Password
1. PIN Code Entry System Setting Menu Screen

This menu screen can set the PIN Code Entry System function.
• Registry of PINs
• Change of Profile Assignment
• Delete of PINs for operators
• Profile Data Setting
• Change of Initial PIN
2. Load Handling Setting Menu Screen (W/ Height

Selector)
This menu screen can set the Load Handling control function.
For details, refer to “Load Handling Setting Menu Screen” (W/O
PIN code entry).
• Height Position Setting of Height Selector
• Height Position Clearing of Height Selector
• Height Position Setting of Maximum Height Limiter
3-19
3. Vehicle Management Setting Menu Screen

This menu screen can set the vehicle management function.
For details, refer to “Vehicle Management Setting Menu Screen”
(W/O PIN code entry).
• Setting of Planned Maintenance Hour Meter
• Setting of Auto Power Off
• Setting of Auto Log Off
• Setting of Administrator’s Second Password
• Switching of Menu-Lock
4. Shock Sensor Setting Menu Screen (W/ Shock

Sensor)
This menu screen can set the Shock Sensor function.
• Checking Shock Memories
• Reset of Shock Alarm
• Monitor and Setting of Shock Detection Level
• Clearing Shock Memories
5. End Menu Screen

Switch (4): Returning to status screen
3-20
MASK FUNCTIONS
GENERAL
In the multi-function display, aside from the general functions that an operator or an administrator normally use, the
following mask 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 wrong use of service functions by users by mistake.
Mask Function List

When used
Function Description Board
Vehicle delivery Others
replacement
Displays the electrical system
status and reads the error Upon vehicle
Analyzer - -
information detected by abnormality
controllers.
Makes fine adjustment of
{ As requested
Tuning traveling and load handling -
*2 by customer
functions.
Specification Sets each vehicle option and {
- -
setting other specifications. *1 *2,*3
Option setting Each control
Enables or disables each control {
function enable/ - -
function. *2,*3
disable
Drive Updates voltage values of
{
SAS sensor signals under the - -
*2,*3
Matching Mini lever standard vehicle condition.
Makes the speedometer reading { {
Tire data
appropriate. *2 *4
Starts counting the hour meter,
{
Meter start odometer, trip meter and { -
*3
maintenance hour meter.
Enables simultaneous operation
Before starting
Demo mode of traveling and load handling - -
the hour meter
before starting the hour meter.
Initialize a set value with the { When it is
To default set -
Others menu default value. *2,*3 necessary
Mask second { When it is
Sets the mask second password. -
password setting *3 necessary
Administrator’s
Delete the administrator’s { As requested
second password -
second password. *3 by customer
clear
Adjusts the contrast of the { As requested
Contrast -
display screen. *3 by customer
*1: The option set function is used to fit the specifications of the controller and the multi-function display for the
options actually equipped on the vehicle. Functions are not available for the vehicle where they are not mounted,
even if the OPTION SET enables them.
*2: Board: Main controller control board
*3: Board: Control board for the multi-function display
*4: When tire size is changed or tire is replaced
3-21
PASSWORD
Note:
• 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 MASK MENU cannot be displayed after several attempts, the system may be faulty.
Password Entry Procedure

Step Display Operation Vehicle response

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

seconds.
Switch (4)

seconds.
Switch (1)

Within 10 seconds, press switch
4 (2) and switch (3) at the same
seconds repeated short beeps
time for more than 2 seconds.
sound.
Switch (2)
Switch (3)
When the mask second password has been set:

Second password screen is displayed. Input the second
5 password.
Other:
This screen is skipped.
6 Mask function initial screen is displayed for 5 seconds.
7 ANALYZER MENU screen is automatically displayed.

3-22
MASK MENU Screen

Operating Procedure
1. Enter the password on the general screen (See page 3-21) to
display the MASK MENU screen.
2. Select a desired function using the switch (2) or (3). Then

press the switch (4) to display the function screen or setting
screen of the selected function.

Switch (3)
Reads out information about the error detected by a controller

ANALYZER MENU screen and indicates the operating state of the electric system of the
vehicle.
Fine adjusts the settings for traveling control, material handling

TUNING MENU screen
control, etc.
Adjusts the display and the controllers according to the

OPTION SET MENU screen
specifications of each vehicle or the control conditions set for it.
Updates the sensor output voltages and the set values stored
MATCHING MENU screen
in the memories of the display and each controller.
This allows you to:

• Start each meter*.
• Switch demo mode*.
OTHERS MENU screen • Initialize the settings.
• Set a mask second password.
• Clear the administrator second password.
• Adjust the contrast of the LCD display.
END of MASK MENU From this screen, you can move to a status screen.
*: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not displayed on the
OTHERS MENU screen.
3-23
ANALYZER
GENERAL
Analyzer function supports operations for inspection/investigating faulty section by displaying the condition of the
control system, using communication between each controller and the multi-function display.
By switching the multi-function display to analyzer mode, operative conditions of the sensors and actuators which are
used for traveling, load handling and SAS/OPS functions, or the error information detected by the controller can be
read.
This is very useful for checking operative condition of each function and saving time for repairing when there is a
detect. Full utilization of the analyzer functions helps quick, easy servicing.
The analyzer has the following functions:
1. Diagnostic memory function (DIAG MEMORY)
The controller stores up to 10 diagnostic codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these diagnostic codes and indicates them on the display.
Each diagnostic codes is displayed with its detection time as the key ON hour meter reading.
2. In/Out monitor function (I/O MONITOR)
This function displays switch ON/OFF state and the analog input values from individual sensors and switches in
the traveling, load handling, and SAS systems. The circuit or sensor quality can be judged by monitoring the
displayed value.
(1) I/O TEMP/VOLT
Displays the temperature of each electrical functional part and the analog input voltage detected by each
controller.
(2) I/O TRAVELING
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
(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.
(4) I/O STEERING
Displays the ON/OFF states of knob position correction control and the analog input voltages from
respective sensors.
(5) I/O OTHERS
Displays the analog input voltages from battery current sensor and shock sensor, and the ON/OFF state of
display’s optional switch.
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.
Note:
The diagnostic code indication:
One diagnostic code is displayed in the upper right-hand portion on the I/O MONITOR or
ACTIVE TEST screen, when an error is detected.
3-24
ANALYZER SCREEN ITEM LIST

Analyzer menu screen Screen No. Display item Description
1. DIAG MEMORY 1/2 1. ~ 5.
Indications of errors occurred
2/2 6. ~ 10.
2. I/O TEMP/VOLT TDM Drive motor temperature: °C
TDMDH Drive motor driver heat sink temperature: °C
1/4
TDMDB Drive motor driver board temperature: °C
TCMB MB contactor temperature: °C
TMCB Main controller board temperature: °C
TPM Pump motor temperature: °C
2/4
TPMDH Pump motor driver heat sink temperature: °C
TPMDB Pump motor driver board temperature: °C
B48V Battery voltage: V
VBKY Voltage after key switch: V
3/4
VBMBSL Solenoid power source voltage: V
VBMB Voltage after MB contactor: V
VDMD Drive motor driver main circuit voltage: V
4/4
VPMD Pump motor driver main circuit voltage: V
3. I/O TRAVELING SPEED Traveling speed: km/h or mph
Accelerator sensor1 voltage: V
1/5 VRA
Accelerator sensor2 voltage: V
SWBK Brake switch
SDM Seat switch
DSF Forward switch
2/5
DSR Reverse switch
SPB Parking brake switch
SYR Yaw rate sensor voltage: V
SLSW Swing lock solenoid
3/5 SH Lifting height switch
SPLF Load sensor voltage: V (MPa display)
SPEED Traveling speed: km/h or mph
Drive motor rpm: rpm
4/5 SPDDM
[Target rpm]: rpm
Drive motor rotation sensor 1 voltage: V
SSD
Drive motor rotation sensor 2 voltage: V
5/5
Drive motor current sensor 1 voltage: V
CSDM
Drive motor current sensor 2 voltage: V
4. I/O M.HANDLING SLUL Unload solenoid
SLLL Lift lowering lock solenoid
SLTFL Tilt lock solenoid
SLTBL (Not used)
1/8
SHS Height selector switch
STK Tilt knob switch
SDM Seat switch
SHL (Not used)
3-25

4. I/O M.HANDLING VRTA Tilt angle sensor voltage: V
SPLF Load sensor voltage: V (MPa display)
2/8
SH Lifting height switch
VRH Height reel sensor voltage: V
Pump motor rpm: rpm
3/8 SPDPM
[Target rpm]: rpm
SSP Pump motor driver rotation sensor voltage: V
4/8 Pump motor driver current sensor 1 voltage: V
CSPM
Pump motor driver current sensor 2 voltage: V
Conventional Lever models SLUL Unload solenoid
SLLL Lift lowering lock solenoid
5/8
Lift lever angle sensor 1 voltage: V
VRL
SLUL Unload solenoid
6/8 SLTBL (Not used)
SWTF Forward tilt switch
SWTR Backward tilt switch
7/8 Attachment (1) lever angle sensor 1 voltage: V
VRA1
Attachment (1) lever angle sensor 2 voltage: V
8/8 Attachment (2) lever angle sensor 1 voltage: V
VRA2
Mini Lever/Joystick Lever SLUL Unload solenoid
models SLLL Lift lowering lock solenoid
5/8 CSL Lift proportional valve solenoid current: A
VRL
6/8 CST Tilt proportional valve solenoid current: A
Tilt lever angle sensor 1 voltage: V
VRT
Tilt lever angle sensor 2 voltage: V
CSA1 Attachment (1) proportional valve solenoid current: A
7/8
VRA1
CSA2 Attachment (2) proportional valve solenoid current: A
8/8
VRA2
3-26

5. I/O STEERING VRTRA Tire angle sensor voltage: V
SPEED Traveling speed: km/h or mph
1/1 Steering angle knob position actual value (target
K-POS
value), Steering synchronizer solenoid
SSTR Steering angle sensor signal
6. I/O OTHERS Shock sensor 1 voltage: V
IPL
1/1 Shock sensor 2 voltage: V
DOPT (Not used)
7. ACTIVE TEST SWING SOL Swing lock solenoid forced operation
STEERING SOL Steering synchronizer solenoid forced operation
1/3
LIFT LWR SOL Lift lowering lock solenoid forced operation
TILT SOL Tilt solenoid forced operation
UNLOAD SOL Unload solenoid forced operation
FAN Cooling fan for controller forced operation
2/3
ACC OUT1 Accessory output1 forced operation
ACC OUT2 Accessory output2 forced operation
3/3 SWG TEST LMP Swing lock operation check
8. VERSION DISPLAY Display program version
1/2
MAIN C/R Main controller program version
DM DRIVER Drive motor driver program version
2/2
PM DRIVER Pump motor driver program version
3-27
ANALYZER MENU screen

Operating Procedure
Enter the password on the status screen (See page 3-21) to display
the mask function initial screen. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.
“1. DIAG MEMORY”

Switch (1): Switching selection to next item
Switch (2): Selecting MASK MENU
Switch (4): To “DIAG MEMORY” screen
“2. I/O TEMP/VOLT”
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”
Switch (4): To “I/O STEERING” screen
“6. I/O OTHERS”
Switch (4): To “I/O OTHERS” screen
3-28
“7. ACTIVE TEST”

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

The controller stores up to 10 most recent errors. The DIAG MEMORY screen displays these diagnostic codes with
their detection time information (in key ON hour meter reading).
The most recent diagnostic code is displayed as 1, followed by 2, 3 and so on to 10.
Operating Procedure
1. Enter the password on the status screen (See page 3-21) to
display the mask function initial screen. After 5 seconds, the
ANALYZER MENU screen is automatically displayed.
2. Check that “1. DIAG MEMORY” is selected on the screen, and

press switch (4) to display “DIAG MEMORY 1/2” screen.
3-29
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 errors
occurred in the past after that row.
Switch (4)
• 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 4,
Diagnostic Code List.
“DIAG MEMORY 1/2”

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

Displays diagnostic codes 6 to 10.
Switch (4) : Returning to the ANALYZER MENU screen.
3-30
In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage from each of traveling, load handling, 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.
Operating Procedure
1. Display the ANALYZER MENU screen. (See page 3-27)
2. Press the switch (1) to select the “2. I/O TEMP/VOLT” and
press the switch (4) to display “I/O TEMP/VOLT 1/4” screen.
3. After it, “I/O TEMP/VOLT 2/4” to “I/O TEMP/VOLT 4/4” is
displayed sequential every time switch (4) is pressed. Press
switch (4) on “I/O TEMP/VOLT 4/4” screen to return to the
ANALYZER MENU screen.
Note:
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 1/4”

TDM: Drive motor temperature: °C
Temperature of the drive motor is displayed.
TDMDH: Drive motor driver heat sink temperature: °C
Temperature of the drive motor driver heat sink is displayed.
TDMDB: Drive motor driver board temperature: °C
Temperature of the drive motor driver board is displayed.
TCMB: MB contactor temperature: °C
Temperature of the MB contactor is displayed.
Switch (4): To “I/O TEMP/VOLT 2/4” screen
3-31

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 motor driver heat sink temperature: °C
Temperature of the pump motor driver heat sink is displayed.
TPMDB: Pump motor driver board temperature: °C
Temperature of the pump motor driver board is displayed.

B48V: Battery voltage: V
Battery voltage is displayed.
VBKY: Voltage after key switch: V
Voltage after key switch is displayed.
VBMBSL: Solenoid power source voltage: V
Voltage of solenoid power source is displayed.
VBMB: Voltage after MB contactor: V
Voltage of after MB contactor is displayed.

VDMD: Drive motor driver main circuit voltage: V
Voltage of drive motor driver main circuit is displayed.
VPMD: Pump motor driver main circuit voltage: V
Voltage of pump motor driver main circuit is displayed.
Switch (4): Returning to the ANALYZER MENU screen
3-32
In/Out Monitor (2) (I/O TRAVELING)

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
Operating Procedure
2. Press the switch (1) to select the “3. I/O TRAVELING” and
press the switch (4) to display the “I/O TRAVELING 1/5”
screen.
Note:
You cannot move directly from I/O TRAVELING screen to the
screen of the other items. Return to ANALYZER MENU screen
once, then move to screen of each time.
“I/O TRAVELING 1/5”

SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
VRA: Accelerator sensor 1 / 2 voltage: V
Displays input voltage from the accelerator sensor to the
controller.
Standard:
Accelerator sensor 1
When accelerator is not operated: 0.40 to 1.25 V
When accelerator pedal is fully depressed: 2.00 to 4.80 V
Accelerator sensor 2
When accelerator is not operated: 0.65 to 2.32 V
When accelerator pedal is fully depressed: 2.42 to 4.80 V
SWBK: Brake switch
Switch ON/OFF quality judgment by operating the brake
switch.
SWBK: 0 = OFF (in a state of brake being operated)
SWBK: 1 = ON (in a state of brake being released)
Switch (4): To “I/O TRAVELING 2/5” screen
3-33

SDM: Seat switch
Switch ON/OFF quality judgment by sitting on and leaving the
operator’s seat
SDM: 1 = ON when sitting on the seat
SDM: 0 = OFF when leaving the seat
DSF: Forward switch
DSR: Reverse switch
Switch ON/OFF quality judgment by operating the direction
lever
Display
Direction lever
DSF: DSR:
Forward 1 (= ON) 0 (= OFF)
Neutral 0 (= OFF) 0 (= OFF)
Reverse 0 (= OFF) 1 (= ON)
SPB: Parking brake switch

Switch ON/OFF quality judgment by operating the parking
brake lever.
SPB: 0 = OFF (in a state of parking brake being operated)
SPB: 1 = ON (in a state of parking brake being released)

SYR: Yaw rate sensor voltage: V
Displays input voltage from the yaw rate sensor to the
controller.
Standard value when vehicle is stopped: 2.20 ~ 2.80 V
SLSW: Swing lock solenoid
Judges the quality of the switch ON/OFF by operating the
swing lock solenoid
SLSW: 1 = ON Energized (swing lock released) state
SLSW: 0 = OFF Non-energized (swing lock) state
SH: Lifting height switch
Judges the quality of the switch ON/OFF by raising and
lowering the fork.
SH2-2
SH1
SH2-1
SH1 SH2-1 SH2-2

Height Display
Switch Switch Switch
Low lifting
100 1 (=ON) 0 (=OFF) 0 (=OFF)
height
High lifting
010 0 (=OFF) 1 (=ON) 0 (=OFF)
height
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.
3-34

SPDDM: Drive motor revolution [target]: 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.

SSD: Drive motor rotation sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor rotation
sensors.
Standard:
When motor is stopped:
Constant, either approx. 0.60 V or approx. 1.40 V
When motor is rotating:
Variable between approx. 0.60 V and 1.40 V
CSDM: Drive motor current sensor 1/2 voltage: V
This screen indicates the voltages of the drive motor current
sensors.
Standard:
Standard value when vehicle is stopped: Approx. 2.50 V
Standard value when vehicle is traveling: 0.50 to 4.50 V
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.
Operating Procedure
3-35
2. Press the switch (1) to select the “4. I/O M. HANDLING” and
press the switch (4) to display the “I/O M.HANDLING 1/8”
screen.
“I/O M.HANDLING 1/8”

SLUL: Unload solenoid
Displays output signal to the unload solenoid.
SLLL: Lift lock solenoid
Displays output signal to the lift lock solenoid.
SLTFL: Tilt control solenoid
Displays output signal to the tilt control solenoid.
SLTBL: Not used
Seat condition Sitting on seat

Not Lift lever Tilt lever Leaving seat
Lever condition
operated Raising Lowering Forward tilt Backward tilt
SLUL 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON)
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
Conventional
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
Lever
SLTBL - - - - - -
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
SLUL - - - - - -
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
Mini Lever/
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
Joystick Lever
SLTBL - - - - - -
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
SHS: Height selector switch

Switch ON/OFF quality judgment by operating the height
selector switch.
SHS: 0 = OFF
SHS: 1 = ON
STK: Automatic fork leveling control switch
Switch ON/OFF quality judgment by operating the tilt knob
switch.
STK: 0 = OFF
STK: 1 = ON
SDM: Seat switch
See “I/O TRAVELING 2/5”
SHL: Not used
Switch (4): To “I/O M.HANDLING 2/8” screen
3-36

VRTA: Tilt angle sensor voltage: V
Displays input voltage from the tilt angle sensor to the
controller.
Standard with mast in the vertical position: 1.20 to 3.95 V
Mast vertical → forward tilt: Input voltage decreases
Mast vertical → backward tilt: Input voltage increases
SPLF: Load sensor voltage: V (MPa)
SH: Lifting height switch
VRH: Height reel sensor voltage: V
Displays input voltage from the height reel sensor to the
controller.
Standard: 0.20 to 4.80 V
Mast raising → Input voltage increases
Mast lowering → Input voltage decreases

SPDPM: Pump motor revolution [target]: 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 material handling speed.

SSP: Pump motor driver rotation sensor voltage: V
Displays the voltage from the pump motor driver rotation
sensor.
Standard:
When motor is stopped: Constant, either approx. 0.60 V or
approx. 1.40 V
When motor is rotating: Variable between approx. 0.60 V
and 1.40 V
CSPM: Pump motor driver current sensor 1 / 2 voltage: V
Displays the voltage from the pump motor driver current
sensor 1 / 2.
Standard:
Standard value when vehicle is traveling: 0.50 to 4.50 V
3-37
Conventional Lever “I/O M.HANDLING 5/8”

See “I/O M.HANDLING 1/8”
SLLL: Lift lock solenoid
CSL: Lift proportional solenoid current: A
(Mini Lever/Joystick Lever)
Displays the current from the lift proportional solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A
Lever neutral position: 0.00 A
The current increases according to the amount of operation of
the lift lever
VRL: Lift lever angle sensor 1 / 2 voltage: V
Mini Lever/Joystick Lever Displays input voltage from lift lever angle sensor 1 / 2 to the
controller.
Standard:
(Conventional Lever)
Lift lever angle sensor 1
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50 V
Lever neutral position: 1.50 to 3.00 V
Lever pull position: neutral voltage to 4.50 V
Lever push position: 0.30 to neutral voltage
The voltage increases during lever backward operation, while
it decreases during lever forward operation.
Standard:
Lift lever angle sensor 2
The voltage decreases during lever backward operation, while
it increases during lever forward operation.
3-38

SLTFL: Tilt control solenoid
SLTBL: Not used
SWTF: Forward tilt switch
Switch ON/OFF quality judgment by operating the forward tilt
switch.
SWTR: Backward tilt switch
Switch ON/OFF quality judgment by operating the backward
tilt switch.
Mini Lever/Joystick Lever Display

Tilt lever
SWTF: SWTR:
Forward 1 ( = ON) 0 ( = OFF)
Neutral 0 ( = OFF) 0 ( = OFF)
Backward 0 ( = OFF) 1 ( = ON)
CST: Tilt proportional valve solenoid current: A

Displays the current from the tilt proportional solenoid.
Standard:
the tilt lever.
VRT: Tilt lever angle sensor 1 / 2 voltage: V
Displays input voltage from tilt lever angle sensor 1/2 to the
controller.
Standard:
Tilt lever angle sensor 1 (Mini Lever/Joystick Lever)
Standard:
Tilt lever angle sensor 2 (Mini Lever/Joystick Lever)
The input voltage decreases during lever backward operation,
while it increases during lever forward operation.
3-39

CSA1: Attachment (1) proportional valve solenoid current: A
Displays the current from the attachment (1) proportional
solenoid.
Standard:
the attachment (1) lever.
VRA1: Attachment (1) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment 1 lever angle
Mini Lever/Joystick Lever sensor 1 / 2 to the controller.
Standard:
Attachment 1 lever angle sensor 1
Standard:
3-40

CSA2: Attachment (2) proportional valve solenoid current: A
Displays the current from the attachment (2) proportional
solenoid.
Standard:
the attachment (2) lever.
VRA2: Attachment (2) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment (2) lever angle
Mini Lever/Joystick Lever sensor 1 / 2 to the controller.
Standard:
Standard:
3-41
In/Out Monitor (4) (I/O STEERING)

Displays the ON/OFF states of knob position and the analog input voltages from respective sensors.
Operating Procedure
2. Press the switch (1) to select the “5. I/O STEERING” and press
the switch (4) to display the “I/O STEERING 1/1” screen.
“I/O STEERING 1/1”

VRTRA: Tire angle sensor voltage: V
Displays input voltage from the tire angle sensor to the
controller.
Standard when tires are in straight ahead position:
1.80 to 2.50 V
K-POS: Steering angle knob position actual value
This screen indicates the actual (target) position of the steering
knob and the ON/OFF status of the knob position
compensation solenoid.
Actual value:
The knob position calculated and recognized by the controller
from the steering angle sensor signal
Target value:
The knob position calculated and recognized by the controller
from the tire angle sensor signal
Steering synchronizer solenoid:
0 = OFF non-energized state (Position compensation
disabled)
1 = ON energized state (Position compensation enabled)
3-42
One rotation (360°) of the steering wheel is divided by 160, and the
value is set to “80” when the knob is in the position as indicated in
the illustration.
159 Clockwise turn of the steering wheel: Increase in value
0 Counterclockwise turn of the steering wheel: Decrease in value
1
SSTR: Steering angle sensor signal
80
Standard position
SS1 SSC
SS2
1 = ON
0 = OFF
When the steering wheel is rotated once, SS1 and SS2 repeat ON
and OFF. SSC only turns on when the knob is in the standard
position.
In/Out Monitor (5) (I/O OTHERS)

Displays the analog input voltages from battery current sensor and shock sensor.
Operating Procedure
2. Press the switch (1) to select the “6. I/O OTHERS” and press
the switch (4) to display the “I/O OTHERS 1/1” screen.
3-43
“I/O OTHERS 1/1”

IPL: Shock sensor voltage: V
Displays input voltage from the shock sensor to the controller.
DOPT: Not used
3-44
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
Signal Content of operation Signal Content of operation
SWING SOL Swing lock solenoid forced operation OFF Lock ON Unlock
STEERING SOL Knob position correcting solenoid forced By-pass close By-pass open
OFF ON
operation
LIFT LWR SOL Lift lock solenoid forced operation OFF Lowering not possible ON Lowering possible
TILT SOL Tilt control solenoid forced operation Forward tilt not Forward tilt possible
OFF ON
possible
UNLOAD SOL Unload solenoid forced operation (Conventional lever) (Conventional lever)
OFF Material handling ON Material handling not
possible possible*1
FAN Cooling fan for controller forced Fan stops Fan rotates
OFF ON
operation
ACC OUT1*2 Accessory output 1 (brake auxiliary Stop lamp does not Stop lamp operates
OFF ON
equipment output) forced operation operate
ACC OUT2*3 Accessory output 2 (back-up auxiliary Back buzzer and Back buzzer and
equipment output) forced operation OFF back-up lamp do not ON back-up lamp operate
operate
SWG TEST LMP Swing lock solenoid operation display OFF No indication ON Indication
*1: The lift may lower depending on the load.

• On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item.
• If the selected item is forcibly turned off or on by pressing the switch (2) or (3) and it is switched over to another
item by pressing the switch (1), forced operation is canceled (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.
*2: Shipped from the factory; OFF
*3: With EZ pedal only
(Refer to below)
Operation guidance Condition
Selected item not forcibly operated
Selected item forcibly turned ON
Selected items forcibly turned OFF
Applicable function not provided or its state signal not received

3-45
Operating procedure
2. Press the switch (1) to select the “7. ACTIVE TEST” and press
the switch (4) to display the “ACTIVE TEST” 1/3 screen.
“ACTIVE TEST 1/3”

SWING SOL: Swing lock solenoid
Jack up the rear axle, and check that the rear axle swings.
ON (Solenoid ON): Unlock
OFF (Solenoid OFF): Lock
STEERING SOL: Knob position correcting solenoid (OPT)
Slowly turn the steering wheel, and check the difference of the
rear tire movement.
ON (By-pass open): Tires do not move match
OFF (By-pass close): Tires move (normal operation)
LIFT LWR SOL: Lift lock solenoid
Check the quality of lowering action by lift lowering operation.
ON (Solenoid ON): Lowering possible (normal operation)
OFF (Solenoid OFF): Lowering not possible
TILT SOL: Tilt control solenoid
Check the quality of mast forward tilt operation by forward tilt
operation.
ON (Solenoid ON): Forward tilt possible
OFF (Solenoid OFF): Forward tilt not possible
Switch (1): Selecting the next item on the “ACTIVE TEST
1/3” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): To “ACTIVE TEST 2/3” screen
3-46

UNLOAD SOL: Unload valve solenoid (Conventional lever)
Check the quality by material handling operation.
ON (Solenoid ON):
Material handling operation not possible (Except lowering)
OFF (Solenoid OFF):
Material handling operation possible (It may slowly lower
according to load condition, but this is not a fault).
FAN: Cooling fan for controller
Forcibly output the ON/OFF signal to check the fan operation
ON: Fan rotates
OFF: Fan stops
*1 ACC OUT1: Accessory output 1 (brake auxiliary equipment
output) forced operation.
Used to check if the stop lamp works normally.
ON: Stop lamp operates
OFF: Stop lamp does not operate
*2 ACC OUT2: Accessory output 2 (back-up auxiliary equipment
output) forced operation.
Used to check if the backup buzzer and the backup lamp work
normally.
ON: Buzzer sound and back-up lamp operates
OFF: Buzzer stop and back-up lamp do not operate
Switch (1): Selecting the next item on the “ACTIVE TEST
2/3” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): To “ACTIVE TEST 3/3” screen
*1: Shipped from the factory; OFF
*2: With EZ pedal only

SWG TEST LMP:
Check the swing lock operation states by OPSS indicator.
ON (Indicated):
Operation situation is indicated with OPSS indicator
OPSS indicator ON: Swing lock operated
OPSS indicator OFF: Swing lock released
OFF (not indicated):
OPSS indicator operates as OPSS indicator (normal operation)
Switch (1): Not used
Switch (2): Check mode; OFF
Switch (3): Check mode; ON
3-47
VERSION (Program Version)

Operating Procedure
2. Press the switch (1) to select the “8. VERSION” and press the
switch (4) to display the “VERSION 1/2” screen.
3. Press the switch (4) to display the VERSION 2/2 screen, and
press switch (4) again to return from the VERSION 2/2 screen
to the ANALYZER MENU screen.
Note:
You cannot move directly from a VERSION screen to another
screen. To do so, first return to the ANALYZER MENU screen,
and then move from it to the screen where the desired items is
displayed.
“VERSION 1/2”
DISPLAY: Program version of the multi-function display
MAIN C/R: Program version of the main controller
Switch (4): To “VERSION 2/2” screen
“VERSION 2/2”
DM DRIVER: Program version of the drive motor driver
PM DRIVER: Program version of the pump motor driver
3-48
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 75 items (included spare items) Click here for an explanation of
how the tuning mode works
Tuning Item List
Level (●: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
Click here for Activation timing of low battery capacity

Fast
1 warning and battery over-discharge Slow Disabled
Tuning 1 Info ●
warning. See page 3-51a.
Slow Fast
2 Battery charge indicator calibration No.1 ●
decrease decrease
3 Not used — ● —
Motor torque when the battery discharge Power Power
4 ●
has proceeded. Down Keep
6 Accelerator pedal sensitivity Insensitive ● Sensitive
7 Accelerator pedal torque Weak ● Strong
8 Accelerator soft-start Slow ● Quick
Regenerative braking torque at
9 Weak ● Strong
accelerator-off
Regenerative braking soft-start at
10 Slow ● Quick
accelerator-off
TUNE 11 Acceleration torque at switch-back Weak ● Strong

GEN 12 Acceleration soft-start at switch-back Slow ● Quick
Regenerative braking torque at switch-
13 Weak ● Strong
back
14 Slow ● Quick
switch-back
Regenerative braking soft-stop at
15 Slow ● Quick
switch-back
16 Accelerator traction torque Weak ● Strong
Strong
17 Accelerator and brake traction torque Weak
●
Rollback speed when the traveling
Slow
18 direction is opposite to the direction Fast
●
lever.
Slow
19 direction is the same as the direction Fast
●
lever.
The time of simultaneously operable
20 Short ● Long
accelerator and brake (OPT)
3-49

Menu No. Item
1 2 3 4 5 6 7 8
Maximum speed limitation during Fast
22 Slow
backward traveling ●
Low speed setting during backward Fast
23 Slow
traveling ●
Deceleration during accelerator-off
24 Weak ● Strong
when going up on a slope
25 Regenerative braking torque at brake on Weak ● Strong
Pump motor output during lift up Fast
26 Slow
operation ●
Pump motor output during tilt forward
27 Slow ● Fast
and backward operation
TUNE
Pump motor output during the
GEN
28 attachment (2) lever push and pull Slow ● Fast
operation
operation
Inching speed during Height Selector
31 Slow ● Fast
operation
O: Available
—: NOT available
Lever Level (●: Initial setting value)

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
Start at the beginning of lift
START
lever down operation
— O Small ● Wide
Inching speed during lift

INCH
— O Slow ● Fast
LIFT Maximum speed during lift

DOWN
MAX
— O Slow ● Fast
Acceleration speed during

ACC
lift lever down operation
— O Weak ● Strong
Deceleration speed during

DEC
3-50

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START
lever up operation

INCH
lever up operation
O O Slow ● Fast

UP
MAX
lever up operation
— O Slow ● Fast

ACC
lift lever up operation
O O Weak ● Strong

DEC
O O Weak ● Strong
Start at the beginning of tilt

START
lever forward operation
Inching speed during tilt

INCH
— O Slow ● Fast
TILT Maximum speed during tilt

FWD
MAX
— O Slow ● Fast

ACC
tilt lever forward operation
O O Weak ● Strong

DEC
O O Weak ● Strong

START
lever backward operation

INCH
— O Slow ● Fast
Maximum speed during tilt

TILT
MAX
— O Slow ● Fast
BWD Acceleration speed during
ACC tilt lever backward O O Weak ● Strong
operation
DEC tilt lever backward O O Weak ● Strong
operation
Start at the beginning of the
START attachment (1) lever push — O Small ● Wide
operation
Inching speed during the
INCH attachment (1) lever push O O Slow ● Fast
operation
Maximum speed during the
ATT1
PUSH
MAX attachment (1) lever push — O Slow ● Fast
operation
ACC the attachment (1) lever O O Weak ● Strong
push operation
DEC the attachment (1) lever O O Weak ● Strong
push operation
3-51

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START attachment (1) lever pull — O Small ● Wide
operation
INCH attachment (1) lever pull O O Slow ● Fast
operation
ATT1
PULL
MAX attachment (1) lever pull — O Slow ● Fast
operation
pull operation
pull operation
operation
operation
ATT2
PUSH
operation
push operation
push operation
operation
operation
ATT2
PULL
operation
pull operation
pull operation
*1: Mini Lever/Joystick Lever models

3-51a
Tuning No. 1 Information:
The default level of lift interrupt (Tuning #1) is level 1. This also affects the warning flashing as it will
warn at 5 flashing bars. Levels 1-3 are all 80% but the warning bar flashing is changed. Keep in mind
that Tuning No. 2 works hand in hand with Tuning No.1 so you must have No.2 set for the correct
battery.
Tuning No. 2 is the battery correction mode (Same as Tuning No. 4 on 7FBCU models).
This tuning sets the discharge curve starting point. This is based on voltage (battery
specific gravity and or A/Hr per positive plate) 1280 SG or 85 A/Hr per positive plate would
be set at level 3 setting and a 1310 SG or 100 A/Hr per positive plate would be level 6.
This is an example of the bar

flashing (warning) but lift interrupt will
still occur at 80% (2 volts per cell,
approx.) at 2 bars. Setting is default
level of 1.
3-51b
5 Bars
4 Bars
3 Bars
8FBCU= The chart above represent

bar flashing in reference to battery
discharge levels. So level 1 (50%)
will warn at 5 bars and interrupt at 2
bars remaining (all 10 will flash at
interrupt).
The above chart has 5 bars, 4 bars

and 3 bars (blinking) indicated. This
would indicate the warning level at
the setting of tuning #1. Do not
confuse warning with lift interrupt as
lift interrupt occurs at 2 bars
(switches to 10 bars flashing/blinking
when in lift interrupt).
3-51c
3-51d
(This page has been intentionally left blank.)

3-52
TUNING MENU Screen

Operating Procedure
2. By default, the MASK MENU screen is displayed with the

[ANL] tab selected. On this screen, press the switch (3) and
select the [TUN] tab.
Note:
The number of tuning menu items displayed varies according
to the number of spools of the mini-lever.
“1. GENERAL”
Switch (1): Switching selection to next item.
Switch (2): Selecting MASK MENU. (See page 3-22)
Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER”
“3. TILT LEVER”

“4. ATT1 LEVER”
“5. ATT2 LEVER”
3-53
GENERAL
Sets tuning levels for standard functions.
Operating Procedure
1. Display the TUNING MENU screen.
2. Check that “1. GENERAL” is selected, and press the switch (4)
to display TUNING LEVEL setting screen.
Switch (4)
“TUNE GEN.”
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to next screen

Switch (4): Returning TUNING MENU screen
3-54
LIFT LEVER (TUNING LIFT LEVER)

Sets tuning levels for the lift lever.
Operating Procedure
1. Display the TUNING MENU screen and press the switch (1),
select the “2. LIFT LEVER”.
2. Press the switch (4) to display TUNING LEVEL setting screen.
Switch (4)
“LIFT DOWN”
“LIFT UP”
Switch (4): Returning to TUNING MENU screen
3-55
TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever.
Operating Procedure
select the “3. TILT LEVER”.
Switch (4)
“TILT FWD”
“TILT BWD”
3-56
ATT1 LEVER (TUNING ATT1 LEVER)

Sets tuning levels for the ATT1 lever.
Operating Procedure
select the “4. ATT1 LEVER”.
Switch (4)
“ATT1 PUSH”
“ATT1 PULL”
3-57
ATT2 LEVER (TUNING ATT2 LEVER)

Sets tuning levels for the ATT2 lever.
Operating Procedure
select the “5. ATT2 LEVER”.
Switch (4)
“ATT2 PUSH”
“ATT2 PULL”
3-58
OPTION SET
Note:
• The option set function is used to fit the specifications of the controller and the multi-function display
for the options actually equipped on the vehicle. Functions are not available for the vehicle where they
are not mounted, even if the OPTION SET enables them.
• If main controller or multi-function display is replaced, it is necessary to reset it according to the vehicle
specification.
Option Set Item List

Switching settings
Indication Description Setting Setting
Indication Indication
content content
MPH* Setting the traveling speed display unit YES mph NO km/h
DATE TYPE* Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
Setting the battery voltage between 36V
36V* YES 36V NO 48V
and 48V
Click B-TYPE* Adjust the charge indicator calculation A1 / A2 / B1 / B2
here CLOSED Setting to enable/disable closed type
YES Enabled NO Disabled
for SIB MOTOR* (EE Type:) motor
on H MODE LOCK Setting to enable/disable H mode lock YES Enabled NO Disabled
setting Unlock (“NO”) Unlock (“NO”)
MENULOCK
Setting the mode of menu lock release A effective till B effective till set
B-Type SPEC*
key-OFF “YES”
Click Setting the traction limitation mode when
accelerator
here operating the accelerator and the brake A B brake priority
priority
simultaneously
for SIB
The motor
on H [YFS specification (E34A)only]
output
ACCEL & BRK* Both A/B are given priority to an The output of
Mode accelerator the drive motor
gradually stops
Lock by the anti-roll
Drive motor output setting after the A stops just after B
back control
accelerator and brakes simultaneous the restriction
after the
operation time progress set by tuning activates.
restriction
No. 20.
activates.
Setting the number of ways for oil control 2 / 3 / 4 / 5
OCV WAY*
valve ∗“5” is no used this model.
Setting the mode of buzzer sound when
BUZZER SPEC* A / B / C
OPS and Return-to-neutral operate
Setting to enable/disable buzzer sound
SEAT BUZZER* YES Enabled NO Disabled
when seat switch is off
Setting to enable/disable parking brake
PKB BUZZER YES Enabled NO Disabled
off warning
Setting to enable/disable overspeed
SPD ALM2 YES Enabled NO Disabled
alarm 2
Setting to enable/disable auto speed
ASC W/LOAD YES Enabled NO Disabled
control
Setting to enable/disable traveling speed
MODE S Enabled A Disabled
Click limit of auto speed control
here for Traction
Traction
SIB on Setting the traction limitation mode at
restrictions restrictions
D-LIM MODE A regardless of B
D-LIM over-discharge warning according to
Mode discharge discharge level
level
3-59
Click Switching settings

here for Indication Description Setting Setting
Indication Indication
content content
SIB on
P-LIM Setting the load handling limitation mode Lift interrupt
P-LIM MODE A Lift interrupt B
at over-discharge warning while travelling
Mode
Setting to enable/disable active mast
T FWD LIMIT YES Enabled NO Disabled
front tilt angle control
Setting to enable/disable backward tilt
T BWD LEVEL YES Enabled NO Disabled
automatic leveling control
Setting to enable/disable forward tilt
T F-SPD LIM YES Enabled NO Disabled
speed limit control
Setting to enable/disable the steering
KNOB CONT* YES Enabled NO Disabled
knob synchronizer
SHOCK
Setting to enable/disable shock-sensor YES Enabled NO Disabled
SENSOR*
H-SELECTOR* Setting to enable/disable height selector YES Enabled NO Disabled
Operate while
the vehicle
Operate while
moves to
Setting the mode of back up buzzer and operating the
BACK BUZZER A backward or B
back-up lamp operation direction lever
operating the
to backward
direction lever
to backward
Turn on while
regenerative Turn on while
STOP LAMP Setting the mode of stop lamp operation A braking or B brake pedal is
brake pedal is operated
operated
*: These are set according to the vehicle specification at the time of shipment.
OPTIONSET Screen
Operating Procedure

[ANL] tab selected. On this screen, press the switch (3) to
select the [OPT] tab.

3-60
3. Check that “1. OPTION SET” is selected, and press switch (4)
to display OPTION SET screen.
Note:
You cannot move directly from the OPTION SET screen to
another screen. To do so, first return to the OPTION SET
MENU screen, and then move from it to the screen where the
desired items are displayed.
Switch (4): To “OPTION SET” screen
“OPTION SET” Screen 1

Switch (2): Setting from NO to YES
Switch (3): Setting from YES to NO


3-61


Switch (4): Returning to OPTION SET MENU screen
3-62
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 tilt angle, load and tire angle sensors used for SAS 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 load-handling lever function is controlled based on the memory of signal voltage values
in the neutral position stored in the controller at the time of shipment. 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 released accelerator position
1 ACCEL OFF *1, *2
to the controller.
Accelerator sensor output value with fully stepped accelerator position to
2 ACCEL ON *1, *2
the controller.
2. SAS
Prerequisite for
implementation
Tilt angle sensor output value with fork in the horizontal position to the *1, *3, *4, *5, *7, *8,
1 TILT LEVEL
controller. *9
Tilt angle sensor output value at the forward tilt limit position and the load *1, *3, *4, *5, *7, *8,
2 TILT FWD LIMIT
sensor output value without load to the controller. *9
Tire angle sensor output value while the vehicle is traveling straight to
3 TIRE POSITION *1, *6
the controller.
3-63
3. LEVER
Prerequisite for
implementation
Lift lever angle sensor output value in the lift lever neutral position is
1 LEVER 1 *1, *10
stored in the controller.
Tilt lever angle sensor output value in the tilt lever neutral position is
2 LEVER 2 *1, *11
stored in the controller.
Attachment (1) lever angle sensor output value in the attachment (1)
3 LEVER 3 *1, *12
lever neutral position is stored in the controller.
Attachment (2) lever angle sensor output value in the attachment (2)
4 LEVER 4 *1, *13
lever neutral position is stored in the controller.
4. TIRE DATA
Prerequisite for
implementation
1 TIRE DATA The tire data according to the tire size is stored. *1, *15
Prerequisite content for implementation

*1: When replacing main controller
*2: When removing/installing or replacing accelerator sensor
*3: When removing/installing or replacement tilt angle sensor
*4: When length change or replacement of tilt angle sensor rod
*5: When removing/installing or replacing load sensor
*6: When removing/installing or replacing tire angle sensor or sensor cover
*7: When installing or changing attachment or fork
*8: When removing/installing or replacing mast
*9: When removing/installing or replacing tilt cylinder
*10: When replacing lift lever angle sensor
*11: When replacing tilt lever angle sensor
*12: When replacing attachment (1) lever angle sensor
*13: When replacing attachment (2) lever angle sensor
*14: When replacing multi-function display
*15: When the tire size or type is changed.
Before Starting Matching

Before performing matching, you must set the vehicle to “standard condition”. For “standard vehicle condition”, refer
to Section 17, “SAS/OPS”.
3-64
MATCHING MENU Screen

Operating Procedure

[ANL] tab selected. On this screen, press the switch (3) and
select the [MAT] tab.
“1. DRIVE”
Switch (4): To MATCHING DRIVE screen
“2. SAS”
Switch (4): To MATCHING SAS screen
“3. LEVER”
Switch (4): To MATCHING MINI LEVER screen
“4. TIRE DATA”
Switch (4): To TIRE DATA screen
3-65
DRIVE (MATCHING DRIVE)

Matching is performed for drive function.
Note:
After performing the ACCEL OFF matching, be sure to perform ACCEL ON matching.
Operating Procedure
1. Display the MATCHING MENU screen and press the switch
(1), select the “1. DRIVE”.
2. Press the switch (4) to display MATCHING screen.

Values in bracket ( ) are currently stored value.
Values outside bracket ( ) are current vehicle condition value.
Note:
In standard vehicle condition, if the value in the bracket ( ) and
the value outside the bracket ( ) are different, matching is
Switch (4) required.
3. Make sure that the Diagnostic indicator on the display is

blinking.
Caution:
During drive matching, the Diagnostic indicator blinks, inform-
ing that the vehicle does not run even if the accelerator pedal
depressed.
“ACCEL OFF” Screen

If matching is performed (press switch (1)), “OK” is indicated on the
display.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): To “ACCEL ON” screen
3-66
“ACCEL ON” Screen

display.
perform matching.
Switch (4): To “MATCHING MENU” screen
SAS (MATCHING SAS)

Matching is performed for SAS function.
Operating Procedure
(1), select the “2. SAS”.
2. Press the switch (4) to display MATCHING screen.

Note:
“TILT LEVEL” Screen

display
perform matching.
Switch (4): To “TILT FWD LIMIT” screen
3-67
“TILT FWD LIMIT” Screen

display
perform matching.
Switch (4): To “TIRE POSITION” screen
“TIRE POSITION” Screen

display
perform matching.
Switch (4): Returning to MATCHING MENU screen.
LEVER (MATCHING LEVER)

Matching is performed for mini lever or joystick functions.
Operating Procedure
(1), select the “3. LEVER” menu.
2. Press the switch (4) to display MATCHING SET screen.

Note:
3-68
“LEVER1” Screen
display
perform matching.
Switch (4): To “LEVER2” screen
Conventional Lever “LEVER2” Screen

display.
perform matching.
Mini Lever/Joystick Lever
“LEVER3” Screen
display
perform matching.
Note:
“Lever3” screen will be displayed according to the number of
ways being set.
“LEVER4” Screen
display
perform matching.
Switch (4): Returning to MATCHING MENU screen.
Note:
“Lever4” screen will be displayed according to the number of
ways being set.
3-69
TIRE DATA
It is necessary to input the tire data to the controller according to the tire radius, 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”.
Operating Procedure
1. Display the MATCHING MENU screen and select the “4. TIRE
DATA”.
2. Press the switch (4) to display “TIRE DATA” screen.
Switch (4)
“TIRE DATA” Screen

Switch (2): Setting tire data smaller
Switch (3): Setting tire data larger
Switch (4): Returning to MASK MENU screen.
3-70
Tire Data List

2 ton models
Vehicle model Tire size Tire type Tire constant
Smooth tire
Non-marking tire
8FBCU20 21 X 7 X 15 283
Smooth non-marking tire
Lug tire
Smooth tire
Non-marking tire
8FBCU25 21 X 7 X 15 283
Lug tire
Smooth tire
Non-marking tire
8FBCHU25 21 X 7 X 15 283
Lug tire
3 ton models
Vehicle model Tire size Tire type Tire constant
Smooth tire
Non-marking tire
8FBCU28 21 X 8 X 15 284
Lug tire
Smooth tire
Non-marking tire
8FBCU30 21 X 8 X 15 284
Lug tire
Smooth tire
Non-marking tire
8FBCU32 21 X 8 X 15 284
Lug tire
3-71
OTHERS MENU
Note:
After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be displayed on
the “OTHERS MENU”.
Before hour meter start After hour meter start
Operating Procedure
Enter the password on the status screen (See page 3-21) to display
the mask function initial screen. After 5 seconds, the ANALYZER
“1. METER START”

Switch (4): To “METER START” screen
“2. DEMO MODE”
Switch (4): To “DEMO MODE” screen
“3. TO DEFAULT SET”
Switch (4): To “TO DEFAULT SET” screen
3-72
“4. MASK PASSWORD”

Switch (4): To “MASK PASSWORD” screen
“5. MANAGER PASS CLR”
Switch (4): To “MANAGER PASS CLR” screen
“6. CONTRAST”
Switch (4): To “CONTRAST” screen
METER START (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 the parking brake reminder function.
• Enables the detection, warning and recording function, while clearing the data on shock detected by the
simplified shock sensor (option).
• Enables all functions of the PIN code entry system (option).
Note:
• This option does not the clear the PIN code authentication data or the simplified shock detection level
that was set when the demo mode was enabled.
• Once the hour meter has started, it cannot be returned to the state where it was before it starts.
Operating Procedure
2. Press the switch (2) or (3) to check the “OTHERS MENU” is

selected.

3-73
3. Press the switch (4) to display METER START screen.
“METER START” Screen

Hour meter start procedure
1. Press the switch (2) for more than 2 seconds to display the
right arrow (guidance) on the screen.
2. While pressing the switch (2), if you press the switch (3),
inverted NO on the screen turns to inverted YES, and the
setting is completed.
3. Press the switch (4) to return to MASK MENU screen.

3-74
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)
Material handling during traveling Allowed Not allowed
Parking brake OFF warning Enabled Disabled
Shock sensor (OPT) Detection, warning, recording Enabled Disabled
Authentication possible Authentication possible
Authentication function only for registered by simply pressing the
PIN code entry system (OPT) authentication numbers log-in switch
Registration, change or deletion
Enabled Disabled
of 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.
Operating Procedure

selected.
3. Display the OTHERS MENU screen and press the switch (1),
select the “2. DEMO MODE”.
4. Press the switch (4) to display DEMO MODE screen.
Note:
• After the hour meter start operation completes, “METER
START” and “DEMO MODE” items of other mask function
menus will not be displayed.
• When “YES” is selected, H mode lock becomes NO
automatically. The demo mode screen always displays H
mode lock condition.
3-75
“DEMO MODE” screen

Switch (2): Setting from YES
Switch (3): Setting from NO
Switch (4): Return to OTHERS MENU screen
Note:
After the start of the hour meter, no settings can be made in
the demo mode.
3-76
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 (SPH)
• Drive power control setting, material handling power control setting
• Low speed setting
• Maximum speed setting
• Over speed alarm setting
• Tuning level
• Auto power OFF time
Operating Procedure

selected.
Before hour meter start

3. Press the switch (1) to check if “3. TO DEFAULT SET” is
selected.
4. Press the switch (4) to display TO DEFAULT SET screen.
After hour meter start
select the “1. TO DEFAULT SET” .
4. Press the switch (4) to display TO DEFAULT SET screen.

3-77
“TO DEFAULT SET” Screen

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.
Note:
• When the Default Set operation is in progress, do not turn
off the ignition key switch or disconnect the battery plug.
• You can return to another mask function menu by
pressing the switch (4), except when the Default Set
operation is in progress.
3-78
MASK SECOND PASSWORD SETTING (MASK PASSWORD)

This menu item is used to set or clear a mask second password.
You can enter any four-digit number as a mask second password, using the 4 switches on the multi-function display.
If you set a mask second password, you will be prompted to enter the second password after you enter the ordinary
password necessary to display the MASK FUNCTION screen, and you can move to the MASK FUNCTION screen
only when the passwords you entered coincide with the registered ones.
No mask second password has been set by default.
Note:
Do not forget the password you set. In the event you forget it, consult your dealer.
Operating Procedure
display the mask function. After 5 seconds, the ANALYZER

selected.

3. Press the switch (1) to check that “4. MASK PASSWORD” is
selected.
4. Press the switch (4) to display MASK SECOND PASSWORD
screen.
select the “2. MASK PASSWORD” menu.
4. Press the switch (4) to display MASK SECOND PASSWORD
After hour meter start setting screen.
Note:
Once the meter starts, it cannot return to the condition of
shipment.
3-79
Mask second password set

1. When you enter a four-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 mask function menu
screen.
Mask second 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 mask second password can be cleared only when no digit
has been entered (when every box is [ ]).
3-80
ADMINISTRATOR SECOND PASSWORD CLEAR (MANAGER PASS CLR)

This menu item is used to clear the administrator second password.
If so requested by the customer, you can clear the administrator second password on the mask function screen.
Operating Procedure

selected.

3. Press the switch (1) to check that “5. MASK PASSWORD” is
selected.
4. Press the switch (4) to display MANAGER PASS CLR screen.
select the “3. MANAGER PASS CLR”.
4. Press the switch (4) to display MANAGER PASS CLR screen.

3-81
“ADMINISTRATOR SECOND PASSWORD CLEAR”

(MANAGER PASS CLR) Screen
If you press and hold down the switch (1) for more than 2 seconds,
the administrator second 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
LCD CONTRAST ADJUSTMENT

This menu item is used to adjust the contrast of the multi-function LCD display.
Operating Procedure

selected.

3-82

3. Press the switch (1) to check that “6. CONTRAST” is selected.
Press the switch (4) to display CONTRAST screen.
select the “4. CONTRAST”.
4. Press the switch (4) to display contrast setting screen.
“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
Switch (4): Returning to OTHERS MENU screen
3-83
MULTI-FUNCTION DISPLAY ASSY

COMPONENTS
5702
3-84
Removal Procedure
1. Remove the battery plug.
2. Remove the instrument panel RH.
3. Remove the multi-function display from the instrument panel RH.
3-85
1. Remove the rear cover.
2. Remove the circuit plate.
3. Remove the display ASSY.
4. Remove the switch plate.
Control Circuit
CC11-004R
January 31, 2017
8FBCU and 8FBE Tuning No.1 Explained
8FBCU20-32, 8FBCHU25,
SERVICE INFORMATION BULLETIN 8FBE(S)15-20U, 8FBEH18U
Subject: 8FBCU and 8FBE Tuning No.1 Explained Page 1 of 3
MODEL APPLICATION:
8FBCU20-32, 8FBCHU25, 8FBE15-20U, 8FBEH18U and 8FBES15U
The lift interrupt circuit/ battery warning is much different than the 7FBCU lift trucks. Below are
graphs and charts to help explain the difference. Also included with this information is the added
options of D-LIM Mode and P-LIM modes which affect how the unit performs when lift interrupt occurs.
REPAIR INFORMATION:
Please add this information to your repair manual CU-347-1 and CE206. The default level of lift
interrupt (Tuning #1) is level 1. This also affects the warning flashing as it will warn at 5 flashing bars.
Levels 1-3 are all 80% but the warning bar flashing is changed. Keep in mind that Tuning No. 2 works
hand in hand with Tuning No.1 so you must have No.2 set for the correct battery.

level of 1.
5 Bars
4 Bars
3 Bars
8FBCU and 8FBE = The chart above

represent bar flashing in reference to
battery discharge levels. So level 1
(50%) will warn at 5 bars and
interrupt at 2 bars remaining (all 10
will flash at interrupt).

Traction restrictions according to discharge level

Control Circuit
CC13-002R
January 31, 2017
8FBCU and 8FBE Unlocking H Mode
and Speed Limiting
Subject: 8FBCU and 8FBE Unlocking H Mode and Speed Limiting Page 1 of 2
MODEL APPLICATION:
REPAIR INFORMATION:
The following information is listed in the repair manual CU347-1 and CE206 but the sequence can
block the H mode from being set. The speed limit is now adjusted through the administrator menu.
H Mode Unlocking:
Step 1) First enter the option mode (Mask Function Menu) and switch H Mode Lock to NO. This
can be found on page 3-58 in repair manual CU347-1 and page 2-128 in repair manual CE206.
Step 2) Tune power mode to H mode. This can be found on page 3-12 in repair manual CU347-
1 and page 2-74 in repair manual CE206.
Subject: 8FBCU and 8FBE Unlocking H Mode and Speed Limiting Page 2 of 2
Setting Speed Limiting:

This can be found in repair manual CU347-1 page 3-13 and repair manual CE206 page 2-76.
If the customer requests a slower travel speed in the forward direction they can use Tuning
No. 22 to reduce reverse travel. This can be found on page 3-49 in repair manual CU347-1 and
page 2-115 in repair manual CE206.
Control Circuit
CC13-003R
January 31, 2017
8FBCU and 8FBE D-LIM and P-LIM
Mode Options Set Explained
Subject: 8FBCU and 8FBE D-LIM and P-LIM Mode Options Set Explained Page 1 of 1
MODEL APPLICATION:
8FBCU20-32 and 8FBCHU25, 8FBE15-20U, 8FBEH18U and 8FBES15U
D-LIM: If the option set is changed from the factory default of B to A the unit reduces the power from H
to S power mode if the battery drops below 2 volts per cell at any time and will not reset until the battery
is charged. If the operator uses the hydraulics while traveling and the voltage drops (2 volts per cell) the
power will be cut and top speed will be slower. Recommended setting is B.
The default mode of B will cutback power only momentary until the battery recovers (higher than 2
volts per cell) so it will clear if the operator releases the accelerator pedal or hydraulic lever.
Note: A bad cell in the battery could cause a constant power cutback condition.
P-LIM: The default setting is A which will cause lift interrupt when the battery reaches 2 volts per cell.
Adjusting to the B setting is only a warning and prohibits hydraulic and travel at the same time and
operators can over discharge the battery at times. Recommended setting is A.
This option information can be found in repair manual CU347-1 pages 3-58 and 3-59 and in
repair manual CE206 page 2-126.
Maintenance
MA12-005
September 14, 2012
B-Type Option Explained
Subject: B-Type Option Explained Page 1 of 1
MODEL APPLICATION:
The explanation for the battery type (B-Type) was omitted from the repair manual CU347-1. Please
add this information to page 3-58 of your repair manual. The different settings change the discharge
curve. For example; B2, “Sealed or Maintenance Free Battery” type has a quicker discharge level
because sealed batteries do not have the same depth as a flooded battery.
A1= USA Flooded

A2= EEC (European Battery)
B1= Japan Type Battery
B2= Sealed or Maintenance Free Battery
3-47

Operating Procedure
Note:
displayed.
“VERSION 1/2”
“VERSION 2/2”
3-48
TUNING
GENERAL
Tuning functions has 75 items (included spare items)
Tuning Item List

Menu No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery capacity
Fast
●
Slow Fast
decrease decrease
4 ●
9 Weak ● Strong
accelerator-off
10 Slow ● Quick
accelerator-off

13 Weak ● Strong
back
14 Slow ● Quick
switch-back
15 Slow ● Quick
switch-back
Strong
●
Slow
●
lever.
Slow
●
lever.
20 Short ● Long
3-49

Menu No. Item
1 2 3 4 5 6 7 8
22 Slow
23 Slow
traveling ●
24 Weak ● Strong
26 Slow
operation ●
27 Slow ● Fast
TUNE
GEN
operation
operation
31 Slow ● Fast
operation
O: Available
—: NOT available

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START

INCH
— O Slow ● Fast

DOWN
MAX
— O Slow ● Fast

ACC

DEC
3-50

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START
lever up operation

INCH
lever up operation
O O Slow ● Fast

UP
MAX
lever up operation
— O Slow ● Fast

ACC
O O Weak ● Strong

DEC
O O Weak ● Strong

START

INCH
— O Slow ● Fast

FWD
MAX
— O Slow ● Fast

ACC
O O Weak ● Strong

DEC
O O Weak ● Strong

START

INCH
— O Slow ● Fast

TILT
MAX
— O Slow ● Fast
operation
operation
operation
operation
ATT1
PUSH
operation
push operation
push operation
3-51

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
operation
operation
ATT1
PULL
operation
pull operation
pull operation
operation
operation
ATT2
PUSH
operation
push operation
push operation
operation
operation
ATT2
PULL
operation
pull operation
pull operation

3-51a
battery.

level of 1.
3-51b
5 Bars
4 Bars
3 Bars

interrupt).

3-51c
3-47

Operating Procedure
Note:
displayed.
“VERSION 1/2”
“VERSION 2/2”
3-48
TUNING
GENERAL
Tuning functions has 75 items (included spare items)
Tuning Item List

Menu No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery capacity
Fast
●
Slow Fast
decrease decrease
4 ●
9 Weak ● Strong
accelerator-off
10 Slow ● Quick
accelerator-off

13 Weak ● Strong
back
14 Slow ● Quick
switch-back
15 Slow ● Quick
switch-back
Strong
●
Slow
●
lever.
Slow
●
lever.
20 Short ● Long
3-49

Menu No. Item
1 2 3 4 5 6 7 8
22 Slow
23 Slow
traveling ●
24 Weak ● Strong
26 Slow
operation ●
27 Slow ● Fast
TUNE
GEN
operation
operation
31 Slow ● Fast
operation
O: Available
—: NOT available

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START

INCH
— O Slow ● Fast

DOWN
MAX
— O Slow ● Fast

ACC

DEC
3-50

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
START
lever up operation

INCH
lever up operation
O O Slow ● Fast

UP
MAX
lever up operation
— O Slow ● Fast

ACC
O O Weak ● Strong

DEC
O O Weak ● Strong

START

INCH
— O Slow ● Fast

FWD
MAX
— O Slow ● Fast

ACC
O O Weak ● Strong

DEC
O O Weak ● Strong

START

INCH
— O Slow ● Fast

TILT
MAX
— O Slow ● Fast
operation
operation
operation
operation
ATT1
PUSH
operation
push operation
push operation
3-51

Menu No. Item OPT
STD 1 2 3 4 5 6 7 8
*1
operation
operation
ATT1
PULL
operation
pull operation
pull operation
operation
operation
ATT2
PUSH
operation
push operation
push operation
operation
operation
ATT2
PULL
operation
pull operation
pull operation

3-51a
battery.

level of 1.
3-51b
5 Bars
4 Bars
3 Bars

interrupt).

3-51c
Chassis Electrical
CE10-007
September 30, 2010
8FBCU Height Selector
Information
Subject: 8FBCU Height Selector Information Page 1 of 15
MODEL APPLICATION:
The following pages have detailed information about the Height Selector Option that is not included in the
repair manual CU347.
Chassis Electrical
CE10-008
September 30, 2010
8FBCU Shock Sensor
Information
Subject: 8FBCU Shock Sensor Information Page 1 of 10
MODEL APPLICATION:
The following pages have detailed information about the Shock Sensor Option that is not included in
repair manual CU347.
Maintenance
MA10-003R
January 31, 2017
8FBCU and 8FBE Auto Speed Control
8FBC(H)U20-32, 8FBE(S)15-20U,
SERVICE INFORMATION BULLETIN 8FBEH18U
Subject: 8FBCU and 8FBE Auto Speed Control Information Page 1 of 6
MODEL APPLICATION:
8FBCU20-32, 8FBCHU25, 8FBE15-20U, 8FBEH18U, 8FBES15U
The following pages have detailed information about the Auto Speed Control (ASC) that is not in
repair manuals CU347 and CE206.
MAINTENANCE
MA10-004R
January 31, 2017
8FBCU and 8FBE Touch Pad Information
8FBCU20-32, 8FBCHU25, 8FBE(S)15-20U,
SERVICE INFORMATION BULLETIN 8FBEH18U,
Subject: 8FBCU and 8FBE Touch Pad Information Page 1 of 23
MODEL APPLICATION:
The following pages have detailed information about the Touch Pad Access that is not included in
repair manual CU347-1 and repair manual CE206.
Maintenance
MA10-002
August 31, 2010
8FBCU Tuning Modes
Explained
Subject: 8FBCU Tuning Modes Explained Page 1 of 3
MODEL APPLICATION:
The tuning modes in repair manual CU347 (starting on page 3-48) have limited details. Below are some
Additional information including graphs to help explain what the adjustments affect.
¾ Tuning No. 1 is lift interrupt and level 1 is 80% (Same as Tuning No. 3 on 7FBCU models)
¾ Tuning No. 2 is the battery correction mode (Same as Tuning No. 4 on 7FBCU models).
¾ Tuning No. 4 sets the torque/speed when the battery voltage/depth is low.
¾ Tuning No. 6 controls the initial response when the accelerator pedal is depressed
/released. You can think of this as a lag time before acceleration or deceleration starts.
¾ Tuning No. 7, 8, 9 and 10 (graph below).
TUNING No.10
Speed
Slow
TUNING No.7
Strong TUNING No.9
Quick Weak
Quick Weak
Strong
Accel ON Slow Accel OFF Time

TUNING No.8
¾ Tuning No. 11, 12, 13, 14 and 15 (graph below)

TUNING No.14
Speed Speed
Slow
TUNING No.13 TUNING No.11
Quick Weak Strong
Weak
Strong Slow Quick
Switchback Quick Time Switchback Slow Time

TUNING No.15 TUNING No.12
¾ Tuning No.16 (Accelerator traction torque). This setting changes the maximum
torque when the accelerator pedal is first depressed (not full pedal depression).
Level 1 would be much less torque (acceleration weaker) if the operator is
picking light loads or fragile loads. This tuning mode is not as noticeable with
heavy loads.
¾ Tuning No. 17 (Accelerator and brake traction torque). This tuning is only
effective if the Accel and BRK Option is set to A. This is not the normal setting
for USA functions as the brake is the priority. Europe has the accelerator as the
priority setting. So if you select A in the Option Accel and BRK this function will
be active. If enabled then this would be close to Tuning No. 16 but only when
the brake and accelerator are depressed at the same time.
¾ Tuning No.18 and No.19 (Anti-rollback on the slope)
To control downward traveling speed to roll-back on the slope when the accelerator
pedal is released.
Truck stops for a moment and moves downward at constant speed.
The speed can be adjusted from 0.5 km/h (0.3 mph) to 4.0 km/h (2.5 mph) using
multi-function display.
No anti-rollback control when the key switch is turned off.
¾ Tuning No. 26, 27, 28 and 29 (graph below).
¾ Mini Lever or Joystick control tuning (Lift Down, Lift Up, Tilt FWD, Tilt BWD, Att1Push/Pull
and Att2 Push/Pull) ( graph below).
sec04.book 1 ページ２０１１年１月２５日火曜日午前９時５２分
4-1
TROUBLESHOOTING (~2010.9)
Page
BEFORE TROUBLESHOOTING............................4-2
CONNECTOR HANDLING.........................................4-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ........................................................4-2
TROUBLESHOOTING METHOD ...........................4-4
TO USE SST...........................................................4-5
DIAGNOSIS CODE LIST........................................4-6
WHEN ERROR CODE IS DISPLAYED ................4-23 4
WHEN NO ERROR CODE IS DISPLAYED........4-179
Service Manual Changes
1 Added Bookmarks tab Bookmarks 2/15/13
2 Added Links to Table of Contents 1 2/15/13
3 Added SIB CE11-001R 207 2/15/13
4 Added SIB CE11-0-02 211 2/15/13
5 Added SIB CE11-003 212 2/15/13
6 Added SIB CE14-005 216-217 8/15/14
7
Hotline Tech Tips

4-2
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.
Standard:10 W or less
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.
4-3
Short circuit check

harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends.
Standard: 1 MΩ or above
ǡ

and sideways.
3. Measure the resistance between a terminal corresponding to

the connector terminal and N1. Always inspect the connectors
at both ends.
The wiring may short-circuit due to pinching by the body or

defective clamping.
4
ǡ ǡ
Visual and contact pressure checks

• Disconnect the connectors at both ends of the corresponding
harness.
• Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
• Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the connector to
check that it does not come off.
• 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.
Click here for information on Special

Grounding Strap to help eliminate
static electricity.
4-4
TROUBLESHOOTING METHOD
Inspection: Check of seat switch condition Defective portion
1. Turn off the key switch and disconnect the battery Repair or replacement
SDM: 0
plug.
2. Disconnect the CN43 connector, connect the battery Seat switch defect
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 2/5
SDM: 1 To the next step depending on the result.
Inspection 1:
1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN103, CN0104 and CN43
connectors and check the harnesses for their
continuities.
OK
Main controller defect
Explanation of Frames
1. Disconnect the battery plug, disconnect the CN43
connector, and visually check inside the connector
and the caulked portion of its wire for defects.
A single frame indicates measurement with a tester or an
(Refer to BEFORE TROUBLESHOOTING.)
ordinary step.
2. Connect the CN43 connector, connect the battery
plug, and then turn on the key switch without sitting in
the seat.
Inspection: Check of seat switch condition

A double frame indicates inspection by an analyzer
Check the value of SDM, using the Analyzer menu.
function.
Test item.
4-5
TO USE SST
Use SSTs for quick, accurate electrical troubleshooting on the 8FBCU series.
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

-
09230-13240-71 Main controller check harness
(for power source check)
09230-13700-71 CN76 short harness 61-1, 2
C2-2
C4-1 to 6
C5-1 to 6
C8-1, 2
CN7 IC check pin E2-2

09232-13130-71 Check harness E8-1, 2
Each short harness FB-1, 2
4
62-1, 2
71-1 to 3
72-1 to 4
G5-1 to 6
CN97 harness
09238-13130-71 68-1 to 3
CN99 check harness
Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
sec04.book
DIAGNOSIS CODE LIST
4-6
Indication : Information can be checked on the display when vehicle trouble occurs.
6 ページ
Memory : Use indication information that can be checked when the mask function DIAG MEMORY is used.
Indicator : Diagnostic mode
O/H
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

O/H
DCR A0-1 Drive motor drive power circuit overheating abnormality Traveling stop.
lighting
２０１１年１月２５日
O/H Load handling stop.

PCR A0-2 Pump motor drive power circuit overheating abnormality
lighting Steering become stiff.
火曜日
Diagnostic
Unable to traveling and load handling
A1-1 A1-1 mode Main controller high voltage
Steering become stiff.
blinking
Diagnostic
午前９時５２分
A1-2 A1-2 mode Drive motor drive circuit high voltage Traveling stop.
blinking
Diagnostic
Load handling stop.
A1-4 A1-4 mode Pump motor drive circuit high voltage
Steering become stiff
blinking
O/H Drive motor output restricted.
C/R A2-1 Main controller circuit board overheating abnormality
lighting Unable to load handling
O/H
DCR A2-2 Drive motor drive circuit board overheating abnormality Traveling stop.
lighting
PCR A2-3 Pump motor drive circuit board overheating abnormality
Diagnostic
Traveling and load handling stop.
A3-1 A3-1 mode Battery connection incorrect
blinking
Diagnostic
OPSS function invalidity
A5-1 A5-1 mode Seat switch GND short abnormality
Parking brake reminder alarm partially disable.
blinking
Diagnostic
A6-3 A6-1 mode Tilt switch GND short abnormality Tilt stop.
blinking
sec04.book
Diagnostic Traveling stop.
A8-1 A8-1 mode F1 fuse abnormality (Open) Load handling stop.
7 ページ
blinking Steering become stiff.

Diagnostic
Traveling stop.
A8-2 A8-2 mode F6 fuse abnormality (Open)
Load handling stop.
blinking
Diagnostic
２０１１年１月２５日
blinking
Diagnostic
Drive motor output restricted.
AA-1 AA-1 mode Main controller temperature sensor abnormality
火曜日
Load handling stop.

blinking
Diagnostic
AA-2 AA-2 mode Drive motor drive board temperature sensor abnormality Drive motor output restricted.
blinking
Diagnostic
AA-4 AA-4 mode Pump motor drive board temperature sensor abnormality Pump motor output restricted.
blinking
Diagnostic
Cooling fan stop.
AB-1 AB-1 mode Cooling fan drive circuit abnormality
blinking
AC-1 AC-1 mode Semiconductor switch abnormality Load handling stop.
Diagnostic
AD-1 AD-1 mode Drive motor driver → Main controller communication abnormality
blinking Traveling stop.
Diagnostic Knob position correcting stop.
Drive motor driver → Main controller communication abnormality (on
AD-2 AD-2 mode
start up)
blinking
Diagnostic
AD-5 AD-5 mode Pump motor driver → Main controller communication abnormality
blinking Load handling stop.
Diagnostic Steering become stiff.
Pump motor driver → Main controller communication abnormality (on
AD-6 AD-6 mode
start up)
blinking
4-7
sec04.book
4-8
Diagnostic
AF-1 AF-1 mode Main controller CPU error
8 ページ
blinking
Diagnostic
blinking Unable to traveling and load handling
２０１１年１月２５日
blinking
Diagnostic
火曜日
blinking
Diagnostic
blinking
Diagnostic
blinking
Some control operations not stable.
Diagnostic
blinking
Diagnostic
blinking
sec04.book
Diagnostic
C0-2 C0-2 mode Drive motor power-circuit short
9 ページ
blinking
Diagnostic
C1-1 C1-1 mode Drive motor current sensor neutral voltage error. Traveling stop.
blinking
Diagnostic
C1-2 C1-2 mode Drive motor current sensor over current.
２０１１年１月２５日
blinking
O/H
DM C2-1 Drive motor overheating abnormality.
lighting
火曜日
Diagnostic
C2-2 C2-2 mode Drive motor temperature sensor abnormality.
blinking Drive motor output restricted.
Diagnostic
C3-1 C3-1 mode Drive motor power circuit temperature sensor abnormality.
blinking
Diagnostic
C4-1 C4-1 mode Accelerator sensor POT1 open.
blinking
Diagnostic
blinking
Display only
Diagnostic
C4-3 C4-3 mode Accelerator sensor POT1 VCC short.
blinking
Diagnostic
blinking
Diagnostic
C4-5 C4-5 mode Accelerator sensor offset abnormality. Traveling stop.
blinking
4-9
sec04.book
4-10
Diagnostic
C4-6 C4-6 mode Accelerator sensor matching value error. Drive motor output restricted.
10 ページ
blinking
Diagnostic
C8-1 C8-1 mode Drive motor speed sensor open.
blinking
Traveling stop.
Diagnostic
C8-2 C8-2 mode Drive motor speed sensor short.
blinking
２０１１年１月２５日

CB-1 CB-1 mode MB contactor open. Load handling stop.
火曜日

Diagnostic
CB-2 CB-2 mode MB contactor short. Display only
blinking
Diagnostic
CB-3 CB-3 mode MB contactor drive circuit open.
blinking
CB-4 CB-4 mode MB contactor drive circuit short. Load handling stop.
Diagnostic
CB-5 CB-5 mode MB contactor drive circuit short.
blinking
O/H
C/P CB-6 MB contactor panel overheating abnormality.
lighting
Diagnostic Pump motor output restricted.
CB-7 CB-7 mode MB contactor panel temperature sensor abnormality.
blinking
sec04.book
Diagnostic
CC-1 CC-1 mode Drive motor drive CPU error.
11 ページ
blinking
Diagnostic
blinking
Traveling stop.
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
blinking
Diagnostic
blinking
Display only
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
E0-2 E0-2 mode Pump motor drive power circuit abnormality.
blinking
Diagnostic
Unable to load handling.
E1-1 E1-1 mode Pump motor current sensor neutral voltage error.
blinking
Diagnostic
E1-2 E1-2 mode Pump motor current sensor over current.
blinking
4-11
sec04.book
4-12
O/H
PM E2-1 Pump motor overheating abnormality.
lighting
12 ページ
Diagnostic
E2-2 E2-2 mode Pump motor temperature sensor abnormality.
Pump motor output restricted.
blinking
Diagnostic
E3-1 E3-1 mode Pump motor drive power circuit temperature sensor abnormality.
blinking
２０１１年１月２５日
Diagnostic
E8-1 E8-1 mode Pump motor speed sensor open.
blinking
火曜日
Diagnostic
E8-2 E8-2 mode Pump motor speed sensor short.
blinking
Diagnostic
EC-1 EC-1 mode Pump motor drive CPU error.

blinking Unable to load handling.
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Display only
Diagnostic
blinking
Diagnostic
blinking
sec04.book
Diagnostic
EE-1 EE-1 mode Display → Main controller communication error. Settings cannot be changed by display operation.
13 ページ
blinking
Diagnostic
EE-2 EE-2 mode Display → Main controller communication error. Unable to display operation
blinking
Diagnostic
F1-1 F1-1 mode Main controller → Display communication error.
blinking Vehicle settings cannot be changed by display
２０１１年１月２５日
Diagnostic operation.
火曜日
blinking
Diagnostic
F4-1 F4-1 mode Display CPU error.
blinking Traveling and load handling cannot be performed
Diagnostic simultaneously.
F4-2 F4-2 mode Display CPU error. Disable the traveling control function.
blinking W/ PIN Code Entry System:
Diagnostic PIN code entry system disable.
blinking
Diagnostic
F4-4 F4-4 mode Display CPU error. Display only
blinking
Diagnostic
F4-5 F4-5 mode Display CPU error. Display function not stable.
blinking
Diagnostic
blinking
Diagnostic
F4-7 F4-7 mode Display CPU error. Some control operations not stable.
blinking
Diagnostic
blinking
Diagnostic
FF-1 FF-1 mode D7V power supply circuit over current. Display turns OFF.
blinking
4-13
sec04.book
4-14
Diagnostic
Knob position correcting stop.
FF-2 FF-2 mode SSTR+ power supply circuit over current.
14 ページ
blinking
Diagnostic
32-1 32-1 mode Drive motor driver ID abnormality.
blinking
Display only
Diagnostic
32-3 32-3 mode Pump motor driver ID abnormality.
blinking
２０１１年１月２５日
Diagnostic
52-1 52-1 mode Yaw late sensor open.
火曜日
blinking
Diagnostic
52-2 52-2 mode Yaw late sensor short. Swing lock disable.
blinking
Diagnostic
52-3 52-3 mode Yaw late sensor neutral voltage error.
blinking
Diagnostic
54-1 54-1 mode Swing lock solenoid open.
blinking
Diagnostic
54-2 54-2 mode Swing lock solenoid short. Swing lock failed.
blinking
Diagnostic
54-3 54-3 mode Swing lock solenoid drive circuit abnormality.
blinking
Diagnostic
54-4 54-4 mode Swing lock solenoid abnormality. Partial limitation of rear wheel swing control function.
blinking
Diagnostic
61-1 61-1 mode Load sensor open.
blinking Partial limitation of mast control function.
Partial limitation of traveling control function.
Diagnostic Partial limitation of OPSS function.
61-2 61-2 mode Load sensor short.
blinking
sec04.book
Diagnostic
62-1 62-1 mode Tilt angle sensor open.
15 ページ
blinking
Diagnostic
62-2 62-2 mode Tilt angle sensor short.
blinking
Diagnostic
63-1 63-1 mode Tilt switch forward/backward simultaneous operation short. Partial limitation of mast control function.
blinking
２０１１年１月２５日
Diagnostic
63-2 63-2 mode Tilt switch forward position short.
火曜日
blinking
Diagnostic
63-3 63-3 mode Tilt switch backward position short.
blinking
Diagnostic
64-1 64-1 mode Lift lock solenoid open. Lift lower may stop.
blinking
Diagnostic
64-2 64-2 mode Lift lock solenoid short. Lift lower may stop.
blinking
(Conventional lever)
Diagnostic
Lift lower may operate while OPS is operating.
64-3 64-3 mode Lift lock solenoid drive circuit abnormality.
(Mini lever/Joystick lever)
blinking
Lift lower may not operate.
Diagnostic
64-4 64-4 mode Lift lock solenoid its continuity.
blinking
Diagnostic
65-1 65-1 mode Tilt control solenoid open. Tilt forward may stop.
blinking
Diagnostic
65-2 65-2 mode Tilt control solenoid short. Tilt forward may stop.
blinking
Diagnostic
Tilt forward may operate while OPS is operating.
65-3 65-3 mode Tilt control solenoid drive circuit abnormality.
blinking
Tilt forward may not operate.
4-15
sec04.book
4-16
Diagnostic
65-4 65-4 mode Tilt control solenoid its continuity.
16 ページ

blinking
Diagnostic
66-1 66-1 mode Outside matching value range for tilt angle sensor. Partial limitation of mast control function.
blinking
Partial limitation of mast control function.
Diagnostic
２０１１年１月２５日
67-1 67-1 mode Lifting height switch abnormality.

Height selector disable.
blinking
Partial limitation of OPSS function.
火曜日
Diagnostic
68-1 68-1 mode Lifting height sensor open.
blinking
Diagnostic
68-2 68-2 mode Lifting height sensor short.
Lift speed limited.

blinking
Diagnostic
68-3 68-3 mode Lifting height sensor abnormality.
blinking
Diagnostic
71-1 71-1 mode Tire angle sensor open.
blinking
Diagnostic
71-2 71-2 mode Tire angle sensor short.
blinking
Diagnostic
72-1 72-1 mode Steering angle sensor SS1 open.
blinking Knob position correcting stop.
blinking
Diagnostic
72-3 72-3 mode Steering angle sensor SSC open. Knob position correcting stop.
blinking
Diagnostic
72-4 72-4 mode Steering angle sensor power circuit open.
blinking
sec04.book
Diagnostic
73-1 73-1 mode Knob position synchronizer solenoid open.
17 ページ
blinking
Diagnostic
73-2 73-2 mode Knob position synchronizer solenoid short.
blinking
Diagnostic
73-3 73-3 mode Knob position synchronizer solenoid power circuit abnormality. Knob position correcting stop.
blinking
２０１１年１月２５日
Diagnostic
73-4 73-4 mode Knob position synchronizer solenoid abnormality.
火曜日
blinking
Diagnostic
74-1 74-1 mode Outside matching value range for tire angle error.
blinking
Diagnostic
H1-1 H1-1 mode Lift lever potentiometer open.
blinking
Diagnostic
H1-2 H1-2 mode Lift lever potentiometer short. Lift stop.
blinking
Diagnostic
H1-3 H1-3 mode Lift lever potentiometer output abnormality.
blinking
Diagnostic
Lift stop. (Conventional lever)
H1-4 H1-4 mode Lift lever potentiometer neutral error.
Load handling stop. (Mini lever/Joystick lever)
blinking
Diagnostic
H1-5 H1-5 mode Lift lever potentiometer matching value error. Lift stop.
blinking
Diagnostic
H2-1 H2-1 mode Tilt lever potentiometer open.
blinking
Diagnostic
H2-2 H2-2 mode Tilt lever potentiometer short. Tilt stop.
blinking
Diagnostic
H2-3 H2-3 mode Tilt lever potentiometer output abnormality.
blinking
4-17
sec04.book
4-18
Diagnostic
H2-4 H2-4 mode Tilt lever potentiometer neutral error. Load handling stop.
18 ページ
blinking
Diagnostic
H2-5 H2-5 mode Tilt lever potentiometer matching value error. Tilt stop.
blinking
Diagnostic
H3-1 H3-1 mode Attachment 1 lever potentiometer open.
blinking
２０１１年１月２５日
Diagnostic
H3-2 H3-2 mode Attachment 1 lever potentiometer short. Attachment 1 stop.
火曜日
blinking
Diagnostic
H3-3 H3-3 mode Attachment 1 lever potentiometer output abnormality.
blinking
Diagnostic
Attachment 1 stop. (Conventional lever)
H3-4 H3-4 mode Attachment 1 lever potentiometer neutral error.
blinking
Diagnostic
H3-5 H3-5 mode Attachment 1 lever potentiometer matching value error. Attachment 1 stop.
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
sec04.book
Diagnostic
H5-1 H5-1 mode Lift proportional solenoid open. (PULL)
19 ページ
blinking
Upward lift stop.
Diagnostic
H5-2 H5-2 mode Lift proportional solenoid short. (PULL)
blinking
Diagnostic
H5-3 H5-3 mode Lift proportional solenoid open. (PUSH)
blinking
２０１１年１月２５日
Downward lift stop.

Diagnostic
H5-4 H5-4 mode Lift proportional solenoid short. (PUSH)
火曜日
blinking
Diagnostic
H5-5 H5-5 mode Lift proportional solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H5-6 H5-6 mode Lift proportional solenoid (PULL/PUSH) abnormality.
blinking
Diagnostic
H6-1 H6-1 mode Tilt backward solenoid open.
blinking
Backward tilt stop.
Diagnostic
H6-2 H6-2 mode Tilt backward solenoid short.
blinking
Diagnostic
H6-3 H6-3 mode Tilt forward solenoid open.
blinking
Forward tilt stop.
Diagnostic
H6-4 H6-4 mode Tilt forward solenoid short.
blinking
Diagnostic
H6-5 H6-5 mode Tilt solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H6-6 H6-6 mode Tilt forward/backward solenoid abnormality.
blinking
4-19
sec04.book
4-20
Diagnostic
H7-1 H7-1 mode Attachment 1 PULL solenoid open.
20 ページ
blinking
Diagnostic
H7-2 H7-2 mode Attachment 1 PULL solenoid short.
blinking
Attachment 1 stop.
Diagnostic
H7-3 H7-3 mode Attachment 1 PUSH solenoid open.
blinking
２０１１年１月２５日
Diagnostic
H7-4 H7-4 mode Attachment 1 PUSH solenoid short.
火曜日
blinking
Diagnostic
H7-5 H7-5 mode Attachment 1 (PULL/PUSH) solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H7-6 H7-6 mode Attachment 1 PULL/PUSH solenoid abnormality.
blinking
Diagnostic
blinking
Diagnostic
blinking
Attachment 2 stop.
Diagnostic
blinking
Diagnostic
blinking
sec04.book
Diagnostic
21 ページ
blinking
Diagnostic
blinking
Diagnostic
HB-1 HB-1 mode Proportional solenoid power supply circuit (RY1) open. Load handling stop.
blinking
２０１１年１月２５日
Diagnostic
HB-2 HB-2 mode Proportional solenoid power supply circuit short.
火曜日
blinking
Diagnostic
HB-3 HB-3 mode Proportional solenoid power supply circuit over current.
blinking
Diagnostic
Lift upward or tilt backward may operate while OPS is
HC-1 HC-1 mode Unload solenoid open.
operating.
blinking
Diagnostic
HC-2 HC-2 mode Unload solenoid short.
operating.
blinking
Diagnostic
HC-3 HC-3 mode Unload solenoid drive circuit abnormality. Loading operations other than lower may not operate.
blinking
Diagnostic
HC-4 HC-4 mode Unload solenoid abnormality.
operating.
blinking
4-21
sec04.book
4-22
Diagnostic
G5-1 G5-1 mode Shock sensor 1 open.
22 ページ
blinking
Diagnostic
G5-2 G5-2 mode Shock sensor 1 short.
blinking
Diagnostic
G5-3 G5-3 mode Shock sensor 1 neutral voltage error.
blinking
２０１１年１月２５日
Shock sensor disabled.

Diagnostic
火曜日
blinking
Diagnostic
blinking
Diagnostic
blinking
4-23
WHEN ERROR CODE IS DISPLAYED

z Error Code A0-1 (Drive motor power-circuit overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2
Drive motor drive circuit

N1
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 motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect
If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-1
Operate check of three cooling fans, Please apply the

cooling fan compulsorily by using Active Test. The fans
do not rotate.
[ANL]ACTIVE TEST 2/3 FAN 1
FAN OFF → ON
The fans rotate.
Inspection: Temperature check

Turn on the key switch and check the value of TDMDH
using the Analyzer menu.
[ANL] I/O TEMP/VOLT 2/4
Record the value of

TDMDH.
2
4-24
Turn off the key switch and leave the vehicle standing
for a while (about 15 minutes).
The TDMDH temperature is 78°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TDMDH temperature previously
checked.

The TDMDH temperature is
TDMDH: 78°C or more and it has not
Less than lowered by 5°C or more compared
78°C to the TDMDH temperature
previously checked.
Drive motor drive circuit defect

Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions
Jp
Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN112, CN113 and CN114 connectors. Either
3. Connect the battery plug and turn on the key switch. 48V type: Excluding approx. 48V
4. Forcibly turn on the cooling fans, using Active Test. 36V type: Excluding approx. 36V
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
Inspection:
The fans do
2. Connect the CN112 and disconnect the CN113 and CN114.
not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.
3
4-25
Jp
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.
Inspection:
2. Connect the CN114 and disconnect the CN112 and CN113. The fans do
3. Turn on the key switch and connect the battery plug. not rotate.
FAN OFF → ON
The fans rotate.
Connector contact defect

Check each harness for its continuity.
Perform this check with the battery plug and the CN101, CN102, CN112, CN113 and CN114 connectors
disconnected, and visually check inside the connector and the caulked portion of its wire for defects.
Note:Perform this check with SST disconnected.
Portions to be checked Standard

CN101-3 to CN112-1 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No continuity
4-26
z Error Code A0-2 (Pump motor power-circuit overheating abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2
Pump motor drive circuit

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

do not rotate.
[ANL]ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.

Turn on the key switch and check the value of TPMDH
Record the value of

TPMDH.
2
4-27
The TPMDH temperature is 78°C or more for both
compared to the TPMDH temperature previously
checked.

The TPMDH temperature is
TPMDH:
78°C or more and it has not
Less than
lowered by 5°C or more compared
78°C
to the TPMDH temperature
previously checked.
Pump motor drive circuit defect

Jp

Harness defect
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug. Either
2. Disconnect the CN112, CN113 and CN114 connectors. 48V type: Excluding approx. 48V
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN112 and disconnect the CN113 and CN114. not rotate.
FAN OFF → ON
The fans rotate.
3
4-28
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.


4-29
z Error Code A1-1 (Main controller high voltage)

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6 (19, VBMBSL)
Main
controller
CN102-4 (19, VBMBSL)
Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Battery overvoltage
(3) F7 fuse open (6) The battery plug was disconnected during traveling.
(After the key switch is turned on and off,
A9-2 will be displayed.)
Error code A1-1
* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
A1-1
An error
occurs.
Turn off and back on the key switch. Inspection: Check of VBMBSL voltage
Check the VBMBSL voltage, using the Analyzer menu.
A1-1 No error occurs [ANL] I/O TEMP/VOLT 3/4
VBMBSL: Less than 65 V VBMBSL: More than 65 V
Inspection: Check of 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: Check of F7 fuse Approx. 48 V 65 V or more
battery plug. Main controller defect Replace the battery.
2. Remove the F7 fuse and measure the
resistance between its both ends with a circuit NG (∞ Ω)
F7 fuse open
tester.
OK (0 Ω)
Was the battery plug disconnected during YES Do not disconnect the battery plug during traveling except
traveling? in case of an emergency.
NO
Check the battery plug.

Check the battery electrolyte.
4-30
z Error Code A1-2 (Drive motor drive circuit high voltage)

Related portion
MB
P1 F1 P4
Drive motor
drive circuit
Probable cause:
(2) MB contactor defect (5) Drive motor drive circuit defect
If CB-1 is also displayed, perform troubleshooting with priority given to CB-1.

If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.
Error code A1-2
A1-2
error
Turn the key switch from OFF to ON to check for occurs.
Inspection:
errors. (Check of voltage of drive motor drive circuit)
A1-2 error does not Check the value of VDMD, using the Analyzer menu.
occur [ANL] I/O TEMP/VOLT 4/4
VDMD: Less than 55 V VDMD: 55 V or more
Inspection 1: (Check the battery voltage.)

battery plug.
Inspection 2: (Check of F1 fuse) Less than 55 V 55 V or more
battery plug. Drive motor drive circuit defect Battery defect
F1 fuse open
tester.
OK (0 Ω)
NO
* Check the battery plug.

* Check the battery electrolyte.
4-31
z Error Code A2-1 (Main controller overheating abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
(1) The ambient temperature around the Main controller is high. (3) Temperature sensor defect (Main controller defect)
(2) Overheating (continuous overload operation)

Error code A2-1

Turn on the key switch and check the value of TMCB

Record the value of
TMCB.
The TMCB temperature is 79°C or more and it has
lowered by 5°C or more compared to the TMCB
temperature previously checked.

The TMCB temperature is 79°C or more and it has not lowered by 5°C
TMCB: Less than 79°C
or more compared to the TMCB temperature previously checked.
(The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
4-32
z Error Code A2-2 (Drive motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-1

do not rotate.
[ANL] ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.

Turn on the key switch and check the value of TDMDB

Record the value of
TDMDB.
2
4-33
The TDMDB temperature is 73°C or more for both
compared to the TDMDB temperature previously
checked.

The TDMDB temperature is
TDMDB: 73°C or more and it has not
73°C to the TDMDB temperature
previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4-34
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4-35
z Error Code A2-3 (Pump motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

The fans
cooling fan compulsorily by using Active Test.
do not rotate.
1
FAN OFF → ON
The fans rotate.

[ANL] I/O TEMP/VOLT2/4

Record the value of
TDMDB.
2
4-36
checked.

previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4-37
Jp
Inspection:
4. Forcibly turn on the cooling fans, using Active Test
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4-38
z Error Code A3-1 (Battery connection incorrect )

Related portion
F5
P1 CN130-4 CN104-1(41, B48V)
Main
controller
Battery
N1
Probable cause:
(1) Set voltage defect.
(2) The voltage in the B48V line after the F5 fuse is above the set voltage.
(3) 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 1: Check of the set voltage

NG
Set voltage defect
[OPT] 36V YES/NO
OK
48V type: Less than 65V

Inspection: Check of battery voltage 36V type: Less than 48V
48V type: 65V or more

A
4-39
48V type: Less than 65 V

Check of battery voltage 36V type: Less than 48 V
P1[+]←→N1[-]
48V type:65 V or more

Check the battery, and replace it with a regular battery if necessary.
Inspection 1: Check of set voltage
Check [OPT] 1.OPTIONSET 36V setting.

(See page 3-58)
Vehicle specification Standard

36V type YES
48V type NO
4-40
z Error Code A5-1 (Seat switch GND short abnormality)

Related portion
CN103-6 (51, LS-) CN92-1
Main
Seat switch
controller
CN104-18 (67, SDM) CN92-2
Probable cause:
(1) Connector contact defect (3) Harness defect
(2) Seat switch defect (4) Main controller defect
Error code A5-1

the seat.

SDM: 0
SDM: 1

plug. SDM: 0
Seat switch defect
2. Disconnect the CN92 connector, connect the battery
SDM: 1
Inspection 1:
1. Turn off the key switch and disconnect the battery NG
plug. Harness defect
2. Disconnect the CN103, CN104 and CN92 connectors
and check the harnesses for their continuities.
OK

4-41
Inspection 1: Check each harness for its continuity.

Before this check, turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and
CN92 connectors, visually check inside each connector and the caulked portion of each wire for defects.

4-42
z Error Code A6-3 (Tilt lever switch abnormality)

Related portion
Tilt lever switch

CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
controller CN103-6 (51,LS-) CN9-2
CN9-4
Probable cause:
(1) The battery plug is connected while the tilt lever is being operated.
(2) Connector contact defect
(3) Tilt lever switch defect
(4) Tilt lever switch installation portion defect.
(5) Tilt lever switch harness defect
(6) Main controller defect
The A6-3 error may occur if the battery plug is connected while the tilt lever is being operated.
Error code A6-3

A6-3 error does not
occur.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
plug, and turn on the key switch to see if an error
occurs.
A6-3 error occurs.

A6-3 error
1. Disconnect the CN9connector. does not occur. • Tilt lever switch defect
2. Connect the battery plug and turn on the key switch.
• Tilt lever switch installation portion defect.
Check the error code.
A6-3 error occurs.

NG
2. Disconnect the CN102 and CN103 connectors and
check the harnesses for their continuities.
OK

4-43

Perform this check with the battery plug and the CN9, CN102and CN103 connectors disconnected, visually
check inside each connector and the caulked portion of each wire for defects.

4-44
z Error Code A8-1, -2 (F1 and F6 fuse abnormality (Open))

Related portion
MB F1 P4
P3
Battery CN104-2 (44, VBMB)

CN130-5
F6
Drive motor Main

drive circuit controller
Pump motor drive

circuit
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
4-45
Error code A8-1
* If CB-1, CB-3, CB-5, A8-2 or A9-2 occurs, perform troubleshooting with priority given to CB-1, CB-3, CB-5, A8-2 or
A9-2.
plug, and visually check the following terminals for
loose bolts: drive motor drive circuit positive terminal,
pump motor drive circuit positive terminal, contactor
panel P4 terminal, drive motor drive circuit negative
terminal, pump motor drive circuit negative terminal A8-1 error does not occur.
and contactor panel N1 terminal. Caution: Before Improper fastening of terminals
starting the job, measure the voltage between
positive terminal and GND; if there is any voltage,
insert a resistor at approx. 100Ω 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.
48V type:
All motor drive circuits
Inspection: Check of supply voltages to drive motor
Approx. 48 V
drive circuit and pump motor drive circuit. Drive motor drive circuit defect
1. Measure the voltage between the positive and Pump motor drive circuit defect
36V type:
negative terminals of each drive circuit.
Approx. 36 V
0V
Inspection: Check of installation of F1 fuse

plug. A8-1 error does not occur.
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 NG (∞ Ω)
plug. F1 fuse open
2. Remove the F1 fuse and measure the resistance
between its both ends with a circuit tester.
OK (0 Ω)
Motor drive circuit defect (*)

Turn off the key switch and disconnect the battery plug, remove the cupper bar for connection to the motor drive
circuit positive terminal.
Measure the resistance between the positive and negative terminals of the motor drive circuit.
When using an analog tester
Positive terminal: [-] probe
Negative terminal: [+] probe
}
Motor drivers are defective if their resistance measured is 10 Ω or less.
4-46
Error code A8-2
* If CB-1, CB-3 or CB-5 occurs, Perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
1. Before this check, disconnect the battery plug,
disconnect the CN130 connector, and visually check
inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE A8-2 error does not occur.
TROUBLESHOOTING.)
plug, and then turn on the key switch to check for
errors.
A8-2 error occurs.

A8-2 error occurs.
Inspection: Check of VBMBSL voltage

VBMBSL: Less than 25 V
Identify the causes of CB1 to CB5.
Check the value of VBMBSL, using the Analyzer menu.
VBMBSL: More than 25 V

plug. F6 fuse open
OK (0 Ω)
Inspection: Check of F6 fuse holder

NG (∞ Ω)
plug.
F6 fuse holder defect
2. Disconnect the CN130 connector and measure the
terminals (CN130-5 and P3 terminal), on the F6 fuse
side with the F6 fuse installed in the fuse holder.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN104, CN130 connector and P3
terminal and check the harnesses for their
continuities.
OK

4-47

Perform this check with the battery plug and the CN130, CN104 connectors and P3 terminal disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
Note:Tighten the P3 terminal surely.

CN130-5 (fuse side) to P3 terminal Continuity
CN104-2 to N1 No continuity
CN130-5 (fuse side) to N1 No continuity
4-48
z Error Code A9-2 (F7 fuse abnormality (Open))

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6
Main
controller
Probable cause:
(1) Connector contact defect (5) F7 fuse holder defect
(2) MB contactor defect (6) Harness defect
(3) F7 fuse installation defect (7) Main controller defect
(4) F7 fuse open
Error code A9-2
TROUBLESHOOTING.)
errors.
A9-2 error occurs.

A9-2 error occurs.
Inspection: Check of VBMB voltage

VBMB: Less than 25 V
Check the value of VBMB, using the Analyzer menu.
VBMB: 25 V or more
A
4-49

NG (∞ Ω)
plug. F7 fuse open
OK (0 Ω)

plug. NG (∞ Ω)
terminals (CN130-6 and P3), on the F6 and F7 fuse
box side with the F7 fuse installed in the fuse box.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN102, CN130 connectors and P3
terminal, and check the harnesses for their
continuities.
OK

Perform this check with the battery plug and the CN130, CN102 connectors and P3 terminal disconnected.

4-50
z Error Code AA-1 (Main controller temperature sensor abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
Error code AA-1
* If AA-1 is displayed, the Main controller is defective, so replace it.

4-51
z Error Code AA-2 (Drive motor drive board temperature sensor abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-2
* If AA-2 is displayed, the drive motor drive circuit is defective, so replace it.
4-52
z Error Code AA-4 (Pump motor drive board temperature sensor

abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-4
* If AA-4 is displayed, the pump motor drive circuit is defective, so replace it.
4-53
z Error Code AB-1 (Cooling fan drive circuit abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1
Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
CN113-1
Main
controller
Cooling fan 2
CN102-2 (99,FNDC1) CN113-2
CN114-1
Cooling fan 3
CN114-2
Probable cause:
(2) Cooling fan defect
(3) Harness defect
Error code AB-1

plug, disconnect the CN112, CN113 and CN114
connectors, and visually check inside the connector
2. Connect the CN112, CN113 and CN114 connectors, All cooling fans rotate.
connect the battery plug, turn on the key switch,
forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the
three cooling fans rotate.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON
One of the cooling fans stops.
Inspection: Check of cooling fan 1

connectors, and then connect the battery plug and
turn on the key switch. AB-1 error occurs.
B
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the error
code after two minutes.
FAN OFF → ON
AB-1 error does not occurs.
A
4-54

plug, connect the CN112 connector, disconnect the
CN113 and CN114 connectors, and then connect the
battery plug and turn on the key switch. Stop cooling fan 1.
Active Test in the Analyzer menu, and check if
cooling fan 1 rotates.
FAN OFF → ON Check the cooling fan 2
Cooling fan 1 rotates. sequentially.

CN112 and CN114 connectors, and then connect the Stop cooling fan 2.
battery plug and turn on the key switch. Cooling fan 2 defect

FAN OFF → ON
Cooling fan 3 rotates.

4-55

plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN113 and CN114
continuities.
OK

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,

4-56
z Error Code AC-1 (Semiconductor switch abnormality)

Related portion
MB
P2
P1
F5
CN104-1 (41,B48V)
CN101-4 (41,VBBT)
N1 Main
Pump motor drive CN111-1 CN103-4 (42,KYSAT) controller
circuit
Drive motor CN110-1

drive circuit
Probable cause:
(1) Drive motor drive circuit harness defect
(2) Pump motor drive circuit harness defect
(3) Drive motor drive circuit defect
(4) Pump motor drive circuit defect
4-57
Error code AC-1
Inspection: Harness check

plug. NG
Harness defect
continuities.
OK
Remove the F1 fuse.
Inspection: Check of Main controller

Connect the CN103 connector, connect the battery AC-1 error occurs.
errors.
AC-1 error does not occur.
Inspection: Check of pump motor drive circuit

Connect the CN103 and CN111 connectors, connect AC-1 error occurs.
the battery plug, and then turn on the key switch to
check for errors.
Inspection: Check of drive motor drive circuit

Disconnect CN111, connect CN110, connect the battery
errors.
Check pump motor drive circuit

Defect in sections where AC-1 error occurs during
drive motor drive circuit check

Perform this check with the battery plug and the CN103, CN111 and CN110 connectors disconnected, visually

4-58
z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication

abnormality)
Related portion
CN103-4 (KYSAT) CN110-1
CN103-11 (CAN1H) CN110-11
CN103-12 (CAN1L) CN110-12
Main CN103-5 (N2,N2) CN110-8 Drive motor

controller drive circuit
CN103-4 (N2,N2) CN110-9
CN103-5 (N2,N2) CN110-10
CN103-6 (N2,N2)
CN111-1
CN111-11
CN111-12
CN111-10 Pump motor

drive circuit
CN111-8(152,SETP)
CN111-9(152,0SETP)
Probable cause:
(1) Wrong motor driver type
(3) Harness defect
(4) Motor drive circuit defect
* If AC-1 occurs, perform troubleshooting with priority given to AC-1.

4-59
Error code AD-1, -2, -5, -6
Detach the battery plugs and check that an 8FBCU Motor driver other than
motor driver is installed. Especially if the motor driver 8FBCU installed
Wrong motor driver type
has just been replaced, check that a different model
motor driver hasn’t been installed.
8FBCU motor
driver installed
plug and visually check inside the CN110 and
CN111connectors and the caulked portions of their
wires for defects. (Refer to BEFORE AD-1, AD-2,
TROUBLESHOOTING.) AD-5, AD-6
2. Connect all the connectors, connect the battery plug, None of these error codes
and then turn on the key switch to check for errors. are displayed.
Especially if a motor drive circuit was replaced
immediately before the error occurred, check if the
connector is connected correctly.
AD-2 or AD-6 is displayed.
(*1: Record the error that has occurred.)
plug. NG
Harness defect
continuities.
OK
Check of battery voltage

1. Turn off the key switch, and then connect the CN103
and CN104 connectors. At that time, leave the Less than 15 V
CN110 and CN111 connectors disconnected.
2. Turn on the key switch and measure the voltage
between CN110-1 and N2.
15 V or more
Motor drive circuit defect
Error that was recorded in *1

AD-2: Drive motor drive circuit defect
AD-6: Pump motor drive circuit defect
Applicable model
28·30·32
Applicable model
20·25·H25
Note: Part numbers are subject to change without notice.
4-60

Portions to be checked Standard Point

CN110-8 to CN110-10 Continuity AD-1,2
CN110-9 to CN110-10 No continuity AD-1,2
CN111-10 to CN111-9 No continuity AD-5.6
CN111-8 to CN111-9 Continuity AD-5.6
4-61
z Error Code AF-1, -2, -3, -4, -5, -6, -7, -8 (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.

4-62
z Error Code C0-2 (Drive motor power-circuit short)

Related portion
P7
U
Drive P8
V Drive motor
motor
drive
circuit P9
W
Probable cause:
(1) Drive motor defect (3) Drive motor drive circuit defect
(2) Motor cable defect
* 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.
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.
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. C0-2 error
2. Disconnect the three motor cables from the drive circuit and occurs.
insulate the terminals of the cables disconnected.
4. Check if the C0-2 error occurs.
C0-2 error does not occur.
Inspection 1: (Check of motor cables)
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
3. Check the motor cables for its continuity.
OK
Inspection: (Check of motor drive circuit) *1
1. Replace the drive motor drive circuit with the drive pump drive C0-2 error
circuit or the pump motor drive circuit. occurs.
Drive motor defect
3. Check the error code that is displayed. (Ignore the error codes 32-1,
32-3.)
E0-2 error
occurs.
(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
4-63
*1 If the error codes C0-2, C0-4 and E0-2 are displayed all at once, perform the following
checks without checking the motor drive circuits.
Inspection: (Motor check)

NG
1. Turn off the key switch and disconnect the battery plug. Drive motor defect
2. Check the Drive motor. (See page 5-5)
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 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
4-64
z Error Code C1-1 (Drive motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code C1-1
* If C1-1 is displayed, the drive motor drive circuit is defective, so replace it.
4-65
z Error Code C1-2 (Drive motor current sensor over current)

Related portion
P7
U
Drive
motor V P8 Drive
drive motor
circuit
P9
W
Probable cause:
(1) Drive motor defect
Turn the key switch from OFF to ON, to check for C0-2 error occurs.
Proceed to identify the cause of C0-2.
errors.
C0-2 No error occurs.

plug and visually check the fastened or caulked C1-2
portions of the motor cables for defects. (Refer to No error occurs.
Improper fastening of motor cable
BEFORE TROUBLESHOOTING.)
2. Connect the cables, connect the battery plug, and
then turn on the key switch to check for errors.
C1-2 error occurs.

plug. NG
Drive motor cable defect
2. Disconnect the motors cables from both the motor
and the motor drive circuit.
OK
Inspection 2: (Check motor drive circuit)*1

plug.
C1-2 error occurs.
2. Replace the drive motor drive circuit with the pump Drive motor defect
motor drive circuit.
3. Connect the battery plug, and turn on the key switch.
4. Check the error code. (Disregard 32-1 & 32-3)
E1-2 error occurs.

4-66
*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
motor drive circuits.
Drive motor defect
plug.
2. Check the drive motor.
OK

Refer to BEFORE TROUBLESHOOTING.

4-67
z Error Code C2-1 (Drive motor temperature sensor abnormality)

Related portion
CN110-4 (86, STDM+) CN50-2
Drive motor Drive motor

drive circuit Temperature
CN110-5 (87, STDM) CN50-1 sensor
Probable cause:
Overheating (continuous overload operation)

Error code C2-1

Turn on the key switch.
Record the value of TDM.
Turn off the key switch and leave the vehicle standing The TDM temperature is 110° C or more for both the
for a while (about 30 minutes). drive motor temperature sensor and it has lowered by 5°
C or more compared to the TDM temperature previously
checked.
TDM: The TDM temperature is 110° C The TDM (R) temperature is 110° C or
less or more and it has not lowered more and it has not lowered by 5° C or
than by 5° C or more compared to the more compared to the TDM
110° C TDM temperature previously temperature previously checked.
checked.
4-68

Related portion
CN110-4 (86, STDM+) CN50-2

Probable cause:
(1) Connector contact defect (3) Drive motor temperature sensor harness defect
(2) Drive motor temperature sensor defect (4) Drive motor drive circuit defect
Error code C2-2

plug and visually check inside the CN50 connector
C2-2 error
and the caulked portions of their wires for defects.
does not occur.
errors.
C2-2 error occurs.
Inspection 1: (Check of temperature sensor unit)

NG
plug. Temperature sensor defect
2. Disconnect the CN50 connector and check the
temperature sensor as a single unit.
OK
Inspection 2: (Harness check)

NG
OK

4-69
Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN50-2 and CN50-1)
Standard value: Approx. 245 Ω and 600 kΩ
* Resistance change (It is a standard as for the following value).
Resistance
Temperature
(CN50-2⇔CN50-1)
20° C Approx. 13 kΩ
80° C Approx. 1.75 kΩ
Inspection 2: Harness continuity/shorts

Turn off the key switch and disconnect the battery plug, disconnect the CN110 and CN50 connectors, and

CN110-5 to CN50-2 Continuity *1
*1: Connect CN50-1 and CN50-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-5 and CN110-6.
4-70
z Error Code C3-1 (Drive motor power circuit temperature sensor

abnormality)
Related portion
Temperature sensor
TH101
Probable cause:
Error code C3-1
* If C3-1 is displayed, the drive motor is defective, so replace it.

4-71
z Error Code C4-1, -2, -3, -4, -5, -6 (Accelerator sensor abnormality)
Related portion
CN101-27 (53, VRA1+) CN29-5
CN102-30 (52, VRA1) CN29-4
CN101-22 (50, VRA-) CN29-6

Main Accelerator
controller CN101-26 (55, VRA2+) CN29-1 sensor
CN102-32 (54, VRA2) CN29-3
CN101-32 (51, POT-) CN29-2
Probable cause:
(1) Connector contact defect (4) Main controller defect
(2) Accelerator sensor defect (5) Accelerator fully open/fully closed matching error
(3) Accelerator sensor harness defect
Error code C4-1, -2, -3, -4, -5

plug, and visually check if the accelerator senor is
installed correctly, and also check inside the CN29
connector and the caulked portion of its wire for C4-1, -2, -3, -4, -5
defects. (Refer to BEFORE TROUBLESHOOTING.) No error occurs. Improper installation of acceleration sensor
2. Connect the CN29 connector, connect the battery Connector contact defect
plug, turn on the key switch, and depress and release
the accelerator pedal to check if an error occurs. (No
error code must be displayed when the accelerator is
operated.)*
C4-1, -2, -3, -4 or -5
error occurs.
Inspection 1: Check of accelerator sensor
NG
plug. Accelerator sensor defect
resistance of the accelerator sensor.
OK

NG
OK
* No error code must be displayed when the accelerator is operated.

4-72
Error code C4-6
After the completion of matching,

Inspection 3: Matching
Perform matching between the fully closed and fully Use the device as it is.
open states of the accelerator.

C4-6 error occurs.
Inspection 1: Check the accelerator sensor as a single unit.

Perform this check with the battery plug and CN29 disconnected and CN101 and CN102 connected.
(1) Measuring the resistance of the accelerator sensor
Standard (on sensor side):
CN29-5 to CN29-6 1.8 to 3.5 kΩ
CN29-1 to CN29-2 (Open state)
(2) Measuring the resistance of the accelerator sensor output circuit

CN29-4 to CN29-6 The resistance must increase as the
CN29-3 to CN29-2 potentiometer is rotated.

Perform this check with the battery plug, CN29, CN101 and CN102 disconnected.
{ : Items to be checked
C4
1 2 3 4 5 6
CN101-27 to CN29-5 Continuity { − − − { − *1
CN102-30 to CN29-4 Continuity { − − − − − *1
CN101-22 to CN29-6 Continuity − − { − { − *3
CN101-26 to CN29-1 Continuity − { − − { − *2
CN102-32 to CN29-3 Continuity − { − − − − *2
CN101-32 to CN29-2 Continuity − − − { { − *4
CN29-5 to CN29-6 No continuity { − − − − −
CN29-4 to CN29-6 No continuity { − − − { −
CN29-4 to CN29-5 No continuity − − { − { −
CN29-1 to CN29-6 No continuity − { − − − −
CN29-3 to CN29-6 No continuity − { − − { −
CN29-3 to CN29-5 No continuity − − − { { −
CN102-30 to CN102-32 No continuity − − − − { −
4-73
Inspection 3: Perform matching.

(See page 3-62)
4-74
z Error Code C8-1 (Drive motor speed (rotation) sensor open)

Related portion
CN110-2 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-6 (79, SSD1) CN155-2 CN51-1
Drive motor
drive circuit CN155-5 CN52-2
N1
- Rotation
sensor 2
CN110-7 (80, SSD2) CN155-3 CN52-1
Probable cause:
(1) Connector contact defect (4) Rotation sensor 2 defect
(2) Rotation sensor harness defect (5) Drive motor drive circuit defect
(3) Rotation sensor 1 defect
1. Turn off the key switch and disconnect the battery plug and visually check
inside the CN155 connector and the caulked portions of their wires for
No error occurs.
defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN155 connector, connect the battery plug, and then turn on the
An error occurs.
Between
CN110 and CN155
2. Disconnect the CN110 and CN155 connectors and check the harnesses for
Harness defect
their continuities.
OK
Other than
12 to 16 V
2. Disconnect the CN155 connector and connect the CN110 connector.
4. Measure the voltage between CN155-1 and N1.
12 to 16 V
Inspection: (Check of error code)
C8-1 error
2. Disconnect the CN155 connector.
occurs.
3. Connect CN155-3 to CN155-5, and CN155-1 to CN155-2 on the wire harness
side through 09232-13130-71 in order to short them.
5. Check the error code that appears.
C8-2 error occurs. Drive motor drive circuit defect
1
4-75
Inspection: (Check of motor drive circuits) At least one of the

1. Turn off the key switch and disconnect the battery plug. resistances is not
2. Measure the resistance between CN155-2 and N1 and that between CN155-3 approx. 100 Ω. Drive motor drive
and N1. circuit defect
Both the resistances are approx. 100 Ω.
Between
CN155 and CN51
or between
2. Disconnect the CN155, CN51 and CN52 connectors and check the harnesses
CN155 and CN52
for their continuities.
Harness defect
OK
Inspection: (Check of rotation sensor)

2. Connect the CN155, CN51 and CN52 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.
SSD: 0.2 or less/0.4 to 1.4 SSD: 0.4 to 1.4/0.2 or less SSD: 0.2 or less/0.2 or less
Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Turn off the key switch and disconnect the battery plug, disconnect CN110 and CN155, visually check inside
each connector and the caulked portion of each wire for defects and then check the CN110 and CN155
harnesses.

*1: Connect CN155-2 to CN155-1 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-2 to CN110-6.
4-76

Turn off the key switch and disconnect the battery plug, disconnect CN155, CN51 and CN52, visually check
inside each connector and the caulked portion of each wire for defects and then check the CN155 and CN51
harnesses and the CN155 to CN52 harnesses. (Refer to BEFORE TROUBLESHOOTING.)

*3: Connect CN51-1 to CN51-2 on the harness side through 09232-13130-71 and check if there is continuity
4-77
z Error Code C8-2 (Drive motor speed (rotation) sensor short)

Related portion
CN110-2 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-6 (79, SSD1) CN155-2 CN51-1
Drive motor
N1
- Rotation
sensor 2
CN110-7 (80, SSD2) CN155-3 CN52-1
Probable cause:
1. Disconnect the battery plug and visually check inside the CN155 connector
and the caulked portions of their wires for defects. (Refer to BEFORE
No error occurs.
TROUBLESHOOTING.) Connector contact defect
An error occurs.
Between
CN110 and CN155
Harness defect
their continuities.
OK
12 to 16 V
Other than
2. Disconnect the CN155 connector and connect the CN110 connector.
12 to 16 V
Inspection: (Check of error code) C8-2 error
1. Turn off the key switch and disconnect the battery plug. occurs.
1
4-78
Inspection: (Check of motor drive circuits) At least one of the

1. Turn off the key switch and disconnect the battery plug. resistances
2. Measure the resistance between CN155-2 and N1 and that between CN155-3 is not approx. 100 Ω. Drive motor drive
and N1. circuit defect
Between
CN155 and CN51
or between
CN155 and CN52
Harness defect
OK

C8-2.
SSD: 1.5 or less/0.4 to 1.4 SSD: 0.4 to 1.4/1.5 or less SSD: 1.5 or more/1.5 or more


harnesses.

4-79


4-80
z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion
MB
P1 P3 F1 P4
F7
CN130-6 CN102-3 (19, VBMBSL)
F6
CN130-5 CN104-2 (44, VBMB)
Main
F5 controller
CN130-4 CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN130-1 CN104-9 (2, CBAT-)

MB
contactor CN130-2 CN104-3 (1, CBAT+)
Probable cause:
(2) MB contactor defect
(3) Harness defect
(4) Fuse defect
4-81
Error code CB-1
CB-1
Disconnect and then connect the battery plug again, and turn on the No error occurs
Check the state of the battery.
key switch to see if an error occurs.
CB-1
An 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 F6, F7 fuse

1. Turn off the key switch and disconnect the battery plug. ∞Ω F6 fuse defect
2. Remove the F6 and F7 fuses and measure the resistance between F7 fuse defect
their both ends with a circuit tester.
0Ω
Inspection: Check of F6 and F7 fuse holders

1. Install the F6 and F7 fuses and disconnect the CN130 connector
∞Ω F6 fuse holder defect
from the fuse holder.
2. Measure the resistance between P3 and CN130-5 and that
between P3 and CN130-6 (fuse holder side).
0Ω
Inspection 1: Harness check NG

Harness defect
Disconnect the CN130, CN102, CN104 connectors and P3 terminal.
OK
Inspection: Check of voltage

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)
30 V or more
MB contactor defect
P1
P3
Less than 30 V

4-82
Error code CB-2
If the error codes AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, EC-1, -2, -3 and -4 are displayed all at once, perform
troubleshooting with priority given to AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, and EC-1, -2, -3 and -4.
If this error occurs, electric charge remains in the motor drive circuit 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.
Use the device as it is.

Disconnect and then connect the battery plug again, turn on the key CB-2
(There are cases where the
switch and wait for 5 seconds. After that, turn off the key switch and No error occurs.
residual charge cannot be
wait for 5 seconds. Then back on the key switch to see if an error
discharged for reasons of
occurs.
another error.)
CB-2 error occurs.
The contactor
opens.
Check if the MB contactor opens when the key switch is turned off. A
The contactor does not open.
Inspection: Check of MB contactor

The contactor does
not open.
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 contactor opens.

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

4-83
Error code CB-3, -5
1. Disconnect the battery plug and visually check inside the CN130
CB-3, -5
connector and the caulked portions of their wires for defects. (Refer
No error occurs.
to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN130 connector, connect the battery plug, and then
turn on the key switch to check for errors.
CB-3 or CB-5
An error occurs.
Inspection: Check of MB contactor coil
NG
2. Disconnect the CN130 connector and measure the resistance of MB contactor defect
the MB contactor coil (resistance between CN130-1 and CN130-2).
Standard value: Approx. 28 Ω: 20°C
OK

NG
Disconnect the CN104 and CN130 connectors and check the Harness defect
harnesses for their continuities.
OK

4-84
Error code CB-4
Disconnect the battery plug and visually check inside the CN130
connector and the caulked portions of their wires for defects. (Refer to

2. Disconnect the CN130 connector and measure the resistance of

Disconnect the CN104 and CN130 connectors and check the
Defective portion: Portion where a problem was found during a check of the MB contactor coil or harness.

Perform this check with the battery plug and the CN130, CN102, CN104 connectors and P3 terminal
disconnected, visually check inside each connector and the caulked portion of each wire for defects.

CN130-6 to CN102-3 Continuity CB-1
CN130-6 (fuse side) to P3 terminal Continuity CB-1
CN130-5 (fuse side) to N1 No continuity CB-1
CN130-5 to N1 No continuity CB-1

Before this check, disconnect the battery plug, disconnect the CN104 and CN130 connectors,

CN130-1 to CN136-2 No continuity CB-4, 5
CN130-1 to P1 No continuity CB-4
4-85
z Error Code CB-6 (MB contactor panel overheating abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
Temperature- CN131-2 CN101-18 (308,STCB) Main
sensor controller
Probable cause:
If CB-2, 4 or 5 is also displayed, perform troubleshooting with priority given to CB-2, 4 or 5.

Take adequate care when testing, as the parts may be hot.
4-86
Error code CB-6

Record the value of TCMB
The TCMB temperature is 130°C or more
and it has lowered by 5°C or more
compared to the TCMB temperature
previously checked.

The TCMB temperature is 130°C or more and it has not
TCMB:
lowered by 5°C or more compared to the TCMB temperature
less than130°C
previously checked.
Proceed to identify the cause of CB-7
Turn off the key switch and disconnect the battery plug,
and check the terminals for loose bolts in the contactor
panel (See the “CONTACTOR PANEL ASSY
:REASSEMBLY”). NG Terminal bolt tightening defect.
Disconnect the CN131 connector, and visually check Connector contact defect
inside the connector and the caulked portion of its wire
for defects.
OK
Check the following and take necessary action, and the

device as it is.
(The problem seems to be caused by continuous
overload operation. So check how the vehicle was
operated.)
4-87
z Error Code CB-7 (MB contacter Temperature-sensor abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
sensor controller
Probable cause:
(2) MB contacter Temperature-sensor defect
(3) MB contacter Temperature-sensor harness defect
Error code CB-7

plug, disconnect the CN131connector, and visually
check inside the connector and the caulked portion of CB-7 error does
its wire for defects. not occur
errors.
E0-2 error does not occur
Inspection 1:(Check of temperature-sensor as a single
unit)
Temperature-sensor defect
plug.
2. Disconnect the CN131and check the temperature-
sensor as a single unit.
E1-2 error occur
plug. NG
Harness defect
continuities.
OK
Inspection 1: Check of temperature-sensor as a single unit

Check item
Temperature-sensor resistance (on sensor side:CN131-2 and CN131-1)
Standard value: Approx. 12kΩ: at 20°C (5kΩ ~ 28kΩ at 0 to 40°C)
4-88

Turn off the key switch and disconnect the battery plug, disconnect the CN101, CN103 and CN131 connectors,
and visually check inside each connector and the caulked portion of each wire for defects.

CN131-1 ~ CN103-7 Continuity *1
CN103-7 ~ CN101-18 No continuity
*1: Connect CN103-71 and CN101-18 on the harness side through 09232-13130-71 and check if there is
continuity between CN131-1 and CN131-2.
4-89
z Error Code CC-1,-2,-3,-4,-5,-6,-7,-8 (CPU error)

Related portion
Drive motor
drive circuit
Probable cause:
Error code CC-1,-2,-3,-4,-5,-6,-7,-8
* If CC is displayed, the drive motor drive circuit is defective, so replace it.

4-90
z Error Code E0-2 (Pump motor drive power circuit short)

Related portion
P14
P4 U
+
Pump
motor P15
Pump
V
drive motor
circuit
N2 P16
- W
Probable cause:
(1) Pump motor drive circuit defect (3) Pump motor drive circuit defect
* If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
1. Disconnect the battery plug and visually check the fastened or

E0-2 error
caulked portions of the motor cables for defects. (Refer to BEFORE
does not occur.
TROUBLESHOOTING.) Improper fastening of motor cable
E0-2 error occurs.
1. Turn off the key switch and disconnect the battery plug. E0-2 error
4. Check if the E0-2 error occurs.
E0-2 error does not occur.
NG
drive circuit.
OK
E0-2 error
2. Replace the pump motor drive circuit with the drive motor drive
occurs.
circuit. Pump motor defect
32-2 and 32-3.)
C0-2 error
occurs.
4-91
*1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the motor drive
circuits.

NG
1. Turn off the key switch and disconnect the battery plug. Pump motor drive circuit defect
2. Check the pump motor. (See page 5-14)
OK


4-92
z Error Code E1-1 (Pump motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code E1-1
* If E1-1 is displayed, the pump motor drive circuit is defective, so replace it.
4-93
z Error Code E1-2 (Pump motor current sensor over current)

Related portion
P4 P14
+ U
Pump
motor P15 Pump
V
N2 drive motor
- circuit P16
W
Probable cause:
(1) Pump motor defect
(2) Pump motor cable defect
disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below
3V.
Error code E1-2
Turn the key switch from OFF to ON to check for E0-2 E0-2 error occur
Proceed to identify the cause of E0-2
error.
Turn off the key switch and disconnect the battery plug
and visually check the fastened or caulked portions of
E1-2 error
the motor cables for defects. (Refer to BEFORE
does not occur
TROUBLESHOOTING) Improper fastening of motor cable
After installing the cables, connect the battery plug and
turn the key switch ON. Sit in the seat and perform a
load handling operation (lift or tilt), checking for errors.
E1-2 error occur

plug. NG
Motor cable defect
2. Disconnect the motor cables from both the motor and
3. Check motor cables for its continuity.
OK
1
4-94
Inspection: (Check of motor drive circuit)*1

1. Replace the pump motor drive circuit with the drive
motor drive circuit. E1-2 error occur
Pump motor defect
3. Check the error code that is displayed. (Ignore the
error codes 32-1 and 32-2)
C1-2 error occur

(Note: Drive circuit that is originally the drive motor drive
circuit before replacement)
Pump motor defect
plug.
OK

(Refer to BEFORE TROUBLESHOOTING)

4-95
z Error Code E2-1 (Pump motor temperature sensor increase abnormality)

Related portion
CN111-4 (88, STPM+) CN41-2
Pump motor Pump motor

CN111-5 (89, STPM) CN41-1 sensor
Probable cause:

Error code E2-1

Turn on the key switch and check the value of TPM
Record the value of TPM.
The TPM temperature is 101°C or more and it has
lowered by 5°C or more compared to the TPM

TPM: The TPM temperature is 101°C or
Less than more and it has not lowered by 5°C or
101°C more compared to the TPM
Proceed to identify the cause of E2-2.
4-96
z Error Code E2-2 (Pump motor temperature sensor abnormality)

Related portion
CN111-4 (88, STPM+) CN41-2

Probable cause:
(2) Pump motor temperature sensor defect
(3) Pump motor temperature sensor harness defect
Error code E2-2

E2-2 error
does not occurs.
(Refer to BEFORE TROUBLESHOOTING) Connector contact defect
errors.
E2-2 error occurs.

NG
OK

NG
OK

4-97

Check item
Standard value Approx. 245 Ω and 600 kΩ
* Resistance changes (It is a standard as for the following value).
Resistance
Temperature
(CN50-2⇔CN50-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ

Turn off the key switch and disconnect the battery plug and the CN111 and CN41 connectors and with SST

4-98
z Error Code E3-1 (Pump motor drive power circuit temperature sensor
abnormality)
Related portion
Pump motor
drive circuit
Temperature sensor
Probable cause:
Error code E3-1
4-99
z Error Code E8-1 (Pump motor speed (rotation) sensor open)

Related portion
P4 CN111-2 (81, SSP+) CN42-2

+
Pump motor Rotation
drive circuit sensor
N2 CN111-6 (82, SSP1) CN42-1
-
Probable cause:
(1) Connector contact defect (3) Rotation sensor defect
(2) Rotation sensor harness defect (4) Pump motor drive circuit defect
1. Disconnect the battery plug and visually check inside the CN42 connector and the
No error
caulked portions of their wires for defects. (Refer to BEFORE
occurs.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN42 connector, connect the battery plug, and then turn on the key
switch to check for errors.
An error occurs.
Harness defect
2. Disconnect the CN111 and CN42 connectors and check the harnesses for their
continuities.
OK
1. Turn off the key switch and disconnect the battery plug. Other than
2. Disconnect the CN42 connector and connect the CN111 connector. 12 to 16 V Pump motor drive circuit
3. Connect the battery plug and turn on the key switch. defect
12 to 16 V
2. Disconnect the CN42 connector. occur. Pump motor drive circuit
3. Using SST 09232-13240-71, connect the CN42-1 and CN42-2. defect
E8-2 error occurs.
Inspection: (Check of motor drive circuits) Other than
1. Turn off the key switch and disconnect the battery plug. Approx.
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). 100 Ω Pump motor drive circuit
3. Insert 09240-13240-71 in the CN111 connector and connect it to the pump motor defect
drive circuit.
4. Measure the resistance between CN42-1 and N2 on the SST side.
Approx. 100 Ω
Rotation sensor defect
4-100

Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN42, and visually check inside
each connector and the caulked portion of each wire for defects and then check each harness.

4-101
z Error Code E8-2 (Pump motor speed (rotation) sensor short)

Related portion
P4 CN111-2 (81, SSP+) CN42-2

+
Pump motor Rotation
N2 CN111-6 (82, SSP1) CN42-1
-
Probable cause:
1. Turn off the key switch and disconnect the battery plug and visually check inside
No error
the CN42 connector and the caulked portions of their wires for defects. (Refer to
occurs.
BEFORE TROUBLESHOOTING) Connector contact defect
An error occurs.
Harness defect
continuities.
OK
1. Turn off the key switch and disconnect the battery plug. Other than
2. Disconnect the CN42 connector and connect the CN111 connector. 12 to 16 V Pump motor drive circuit
3. Connect the battery plug and turn on the key switch. defect
12 to 16 V
2. Disconnect the CN42 connector. occurs. Pump motor drive circuit
E8-1 error occurs.
Inspection: (Check of motor drive circuits) Approx.
1. Turn off the key switch and disconnect the battery plug. 100 Ω
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). Other than Pump motor drive circuit
drive circuit.
Approx. 100 Ω
4-102


4-103
z Error Code EC-1, -2, -3, -4, -5, -6, -7, -8 (CPU error)
Related portion
Pump motor drive

circuit
Probable cause:
Error code EC-1, -2, -3, -4,- 5, -6, -7, -8
* If EC is displayed, the pump motor drive circuit is defective, so replace it.

4-104
z Error Code EE-1, -2 (Display → Main controller communication error)

Related portion
CN103-3 (14, DGND) CN27-4
CN103-14 (16, D7V) CN27-5

Main
Display
controller CN103-11 (145, CAN1H) CN27-16
CN103-12 (146, CAN1L) CN27-15
Probable cause:
(2) Harness defect
(3) Display defect
Error code EE-1, 2
* Identify the cause of F1-1 or F1-2.

4-105
z Error Code F1-1, -2 (Main controller → Display communication error)

Related portion
CN103-11 (145,CAN1H) CN27-16 (145, CAN1H)
Main
Multi-display
controller
CN103-12 (146,CAN1L) CN27-15 (146, CAN1L)
Probable cause:
(2) Harness defect (4) Display defect
Error code F1-1, F1-2
Turn off the key switch and disconnect the battery plug and visually
check inside CN103 to CN27 connectors and the caulked portion of
each wire for defects.
No error occurs.
Connect the connector, connect the battery plug and turn on the key
switch, and if an error occurs.
An error occurs. If the version of at least one motor drive circuit is

displayed
Inspection 1:
Check the version information on the I/O monitor.
If the version of a motor drive
circuit is not displayed:
Inspection 2:
NG Harness (between CN103 and
CN27) defect
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.
Inspection 2: Check harnesses for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN27 and CN103 connectors and check
the harnesses for their continuities.

CN103-11 to CN27-16 Continuity (Approx. 0 Ω)
CN27-15 to CN27-16 No continuity (Not 0 Ω)
4-106
z Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error)

Related portion
Multi-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.

4-107
z Error Code FF-1, -2 (Power supply circuit over current)

Related portion
CN103-14 (16,D7V) CN27-5
DISPLAY
CN103-3 (14, DGND) CN27-4
Main
controller CN103-13 (311, SSTR+) CN3-1
Steering-wheel
angle sensor
CN103-6 (51, LS-) CN3-2
Probable cause:
(2) Display or steering angle sensor defect
(3) Harness defect
Error code FF-1
1. Turn off the key switch and disconnect the battery plug, disconnect
the CN27 connector and visually check inside the connector and the A screen is displayed.
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
2. Connect the connector, connect the battery plug, and then turn on
the key switch to see if a screen is displayed.
No screen is displayed.
Inspection: Check of display

2. Disconnect the CN27. 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 CN27-5 and CN27-4 connectors
on the harness side.
0V

NG
Harness defect
2. Disconnect the CN103 connector and check the harnesses for their
continuities.
OK

4-108

Disconnect the battery plug, disconnect the CN27 and CN103 connectors, and visually check inside each
connector and the caulked portion of each wire for defects.

Error code FF-2
1. Disconnect the battery plug, disconnect the CN3 connector, and

visually check inside the connector and the caulked portion of its FF-2 error does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN3 connector, connect the battery plug, and then turn
on the key switch to check for errors.
FF-2 error occurs.
Inspection: Check of steering angle sensor

3. Connect the battery plug and turn on the key switch. Steering angle sensor defect
Measure the voltage between the CN3-1 and CN3-2 connectors on
the harness side.
0V

NG
Harness defect
continuities.
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN3 and CN103 connectors, and visually

4-109
z Error Code 32-1 (Drive motor drive circuit EEPROM abnormality)

Related portion
CN110-8 (151, 0SETD)
Drive motor drive circuit CN110-9 NC
CN110-10 (151, 0SETD2)
Probable cause:
*: When a new motor drive circuit is installed on the vehicle, the 32-1 error always occurs (which does not mean that
the new drive circuit 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

32-1
visually check inside the connector and the caulked portion of its
error does not occur. Drive motor drive circuit
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
connector contact defect
32-1
error occurs.
4-110
z Error Code 32-3 (Pump motor drive circuit EEPROM abnormality)

Related portion
CN111-8 (152, 0SETP)
Pump motor drive circuit CN111-9 (152, SETP)
CN111-10 NC
Probable cause:
*: When a drive motor drive circuit is installed as a pump motor drive circuit, the 32-3 error always occurs (which does
not mean that the new drive motor drive circuit is defective).
Error code 32-3

32-3
error does not occur. Pump motor drive circuit
32-3 error occurs.
4-111
z Error code 52-1,-2,-3 Yaw rate sensor abnornality

Related portion
CN104-13 (321,SYR+) CN34-1

CN103-27 (322,SYR) CN34-3
Main controller Yaw rate sensor
CN104-11 (323,SYR-) CN34-2
Probable cause:
(2) Yaw rate sensor harness defect
(3) Yaw rate sensor defect
Error code 52-1

visually check inside the connector and the caulked portion of its 52-1error does
wire for defects. (Refer to BEFORE TROUBLESHOOTING) not occur.
2. Connect the CN34 connector, connect the battery plug, turn on the
key switch, and then raise the lift from its lowermost to uppermost
position to see if an error occurs.
52-1error occurs
Inspection: Check of the yaw rate sensor

1. Turn off the key switch and disconnect the battery plug. 52-2error
2. Disconnect the CN34 connector and connect CN34-1 to CN34-2 on occurs.
Yaw rate sensor defect
the harness side through SST 09232-13130-71.
3. Connect the battery plug, and then turn on the key switch to check
for errors.
52-1error occurs

Harness defect
2. Disconnect the CN103 and CN104 connectors and check the
OK

4-112
Error code 52-2, -3
the CN34 connector, and visually check inside the connector and 52-2,-3error
the caulked portion of its wire for defects. (Refer to BEFORE does not occur.
TROUBLESHOOTING)
2. Connect the CN34 connector, connect the battery plug and turn on
52-2,-3error occurs
Inspection: Check of the yaw rate sensor.

52-1error
occurs.
2. Disconnect the CN34 connector. Yaw rate sensor defect
for errors.
52-2,-3error occurs

Harness defect
OK
Inspection 1,2: Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN34, CN103 and CN104 and perform the
check without connecting SST.

CN104-13 to CN34-1 Continuity 52-1 *1
CN104-11 to CN34-2 Continuity 52-2,-3 *2
CN34-1 to CN34-2 No continuity 52-1
CN34-1 to CN34-3 No continuity 52-2,-3
4-113
z Error Code 54-1,-2,-3,-4 (Swing lock solenoid abnormality)

Related portion
CN103-1 (327, SLSW+) CN43-1
CN103-2 (328, SLSW-) CN43-2
CN103-5 (N2, N2)

Main Swing lock
controller CN104-4 (N2, N2) solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Swing lock solenoid harness defect
(3) Swing lock solenoid defect
If the 54-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code 54-1
the CN43 connector, and visually check inside the connector and 54-1
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING)
turn on the key switch to see if an error occurs.
54-1 error occurs. 54-4
error occurs. Track down the
Check if the 54-4 error has also occurred.
cause of the 54-4 error.
54-4 error does not occur.
Inspection: Check of swing lock solenoid
2. Disconnect the CN43 connector and measure the resistance of the
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C)

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
4-114
Error code 54-2
TROUBLESHOOTING)
54-2 error occurs.
54-3
Check if the 54-3 error has also occurred. error occurs. Track down the
2. Disconnect the CN43 connector and measure the resistance of the NG
Swing lock solenoid defect
swing lock solenoid
OK
NG
harnesses for its continuities.
OK
Error code 54-3
Turn off the key switch and disconnect the battery plug, disconnect the
CN43 connector, and visually check inside the connector and the
TROUBLESHOOTING)

swing lock solenoid

4-115
Error code 54-4
the CN43 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
turn on the key switch.
Forcibly turn off the output of the swing lock solenoid, using Active 54-4
Test, to see if an error occurs. error does not occur.
[ANL] ACTIVE TEST 1/3 SWING SOL
54-4 error occurs.
swing lock solenoid
OK
NG
OK


CN103-1 to CN43-1 Continuity 54-4 *
CN43-1 to CN43-2 No continuity 54-1,2,3,4
CN43-2 to P1 No continuity 54-1,2,3,4
* Connect the CN43 connector and measure the resistance between CN103-1 and CN103-2, to see if it falls
between 4 and 11 Ω (approx. 6 Ω at 20°C)
4-116
z Error Code 61-1,-2 (Load sensor abnormality)

Related portion
CN104-12 (58, SPLF+) CN7-1
CN103-29 (59, SPLF) CN7-2

Main
Load sensor
controller
CN101-32 (51, POT-) CN7-3
Probable cause:
(2) Load sensor defect
(3) Load sensor harness defect
Error code 61-1
the CN7 connector, and visually check inside the connector and the 61-1
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING)
61-1 error occurs.
Inspection: Check of load sensor
1. Turn off the key switch and disconnect the battery plug. 61-2
2. Disconnect the CN7 connector and connect CN7-1 to CN7-2 on the error occurs.
Load sensor defect
harness side through SST09230-13700-71.
61-1 error occurs.
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for its continuities.
OK
4-117
Error code 61-2
61-2 error occurs.
61-1
error occurs.
2. Disconnect the CN7 connector. Lord sensor defect
61-2 error occurs.
Harness defect
OK
Inspection 1, 2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN7, CN101, CN103 and CN104
connectors, and with SST disconnected, visually check inside each connector and the caulked portion of each
wire for defects.

*1: Connect CN7-1 and CN7-2 on the harness side through 09230-13700-71 and check
if there is continuity between CN104-12 and CN103-29.
4-118
z Error Code 62-1,-2 (Tilt angle sensor abnormality)

Related portion
CN101-20 (57, VRTA+) CN26-1
CN103-17 (56, VRTA) CN26-2

Main Tilt angle
controller sensor
CN101-32 (51, POT-) CN26-3
Probable cause:
(2) Tilt angle sensor defect
(3) Tilt angle sensor harness defect
Error code 62-1
TROUBLESHOOTING)
62-1 error occurs.
Inspection: Check of tilt angle sensor
2. Disconnect the CN26 connector and connect CN26-1 and CN26-2 error occurs.
Tilt angle sensor defect
on the harness side through 09232-13130-71.
62-1 error occurs.
Harness defect
OK
4-119
Error code 62-2
62-2 error occurs.
62-1
error occurs.
2. Disconnect the CN26 connector. Tilt angle sensor defect
62-2 error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN86, CN101, and CN103 connectors,
and with SST disconnected, visually check inside each connector and the caulked portion of each wire for
defects.

between CN101-20 and CN103-17
4-120
z Error Code 63-1,-2,-3 (Tilt switch abnormality)

Related portion
Tilt switch
CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
CN9-4
Probable cause:
(2) Tilt switch adjustment defect.
(3) Tilt switch defect
(4) Tilt switch harness defect
Error code 63-1, -2, -3
the CN9 connector, and visually check inside the connector and the A6-3
caulked portion of its wire for defects. error occurs. Track down the cause of the
(Refer to BEFORE TROUBLESHOOTING) A6-3 error.
2. Connect the CN9 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
A6-3 error does not occur.
63-1
• Tilt switch defect
error occurs.
Operate the tilt lever and check the error code. • Tilt switch installation portion
defect.
[ANL] I/O M.HANDLING 6/8
Use the analyzer to check the values for the SWTF (forward tilt switch) Either switch
and SWTR (backward tilt switch). displaying “1”
Check the status of the switches when the tilt lever is operated in
either direction and returned to center.
Both switches displaying “0” after
OK
operation repeated several times
Stored in diagnosis memory
Memory 63-1 Memory 63-2, 63-3

The forward and backward tilt The tilt lever has been turned ON
lever switches turned ON at the for two minutes or more in the
same time in the past. past.(Normal)
(Check and adjustment of each
switch installation)
4-121
z Error Code 64-1,-2,-3,-4 (Lift lower lock solenoid abnormality)

Related portion
CN101-1 (3, SOLLU+) CN8-1
CN102-16 (4, SLLL-) CN8-2
CN103-5 (N2, N2)

Main Lift lock
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Lift lock solenoid harness defect
(3) Lift lock solenoid defect
Error code 64-1
caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 64-4 error.
No error occurs.
64-1
error does not occur.
Lower the lift to see if an error occurs. Connector contact defect
64-1 error occurs.

Inspection: Check of lift lock solenoid
2. Disconnect the connector CN8 and measure the resistance of the
lift lock solenoid

2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
Portion where a problem was found during a check of the lift lock solenoid or its harness.
4-122
Error code 64-2
No error occurs. 64-2
64-2 error occurs.

2. Disconnect the connector CN8 and measure the resistance of the NG
Lift lock solenoid defect
lift lock solenoid
OK
Harness defect
OK
Error code 64-3
TROUBLESHOOTING)

lift lock solenoid

4-123
Error code 64-4
TROUBLESHOOTING)
64-4 error occurs.
lift lock solenoid
OK
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN8, CN101, CN102, CN103 and CN104
connectors, and

* Connect the CN8 connector and measure the resistance between CN101-1 and CN102-16 to see if it falls
4-124
z Error Code 65-1,-2,-3,-4 (Tilt control solenoid abnormality)

Related portion
CN101-2 (6, SLTFB+) CN14-1
CN102-19 (7, SLTFL-) CN14-2
CN103-5 (N2, N2)

Main
Tilt solenoid
controller CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Tilt control solenoid defect
(3) Tilt control solenoid harness defect
Error code 65-1
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
Tilt the mast forward to check again if an error occurs. Connector contact defect
65-1 error occurs.

Inspection: Check of tilt control solenoid
tilt control solenoid

Portion where a problem was found during a check of the tilt control solenoid or its harness.
4-125
Error code 65-2
TROUBLESHOOTING) 65-3
65-2 error occurs.

Tilt control solenoid defect
OK
Harness defect
OK
Error code 65-3
TROUBLESHOOTING)


4-126
Error code 65-4
the caulked portion of its wire for defects. (Refer to BEFORE error not occur.
TROUBLESHOOTING)
65-4 error occurs.
OK
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN14, CN101, CN102, CN103 and
CN104 connectors, and

4-127
z Error Code 66-1 (Outside matching value range for tilt angle error)
Related portion
Main
controller
Probable cause:
(1) The tilt horizontal angle matching value is outside the specified matching range.
(2) The forward tilt angle matching value is outside the specified matching range.
(3) The load sensor matching value is outside the specified matching range.
Matching After the completion of matching,

Perform matching of the tilt horizontal angle, the forward tilt angle, and 66-1error does not occur.
the load sensor. Use the device as it is.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION / MACHING
After the completion of
matching,
66-1 error occurs.
4-128
z Error Code 67-1 (Lifting height switch open)

Related portion
V mast, mast height: ~H2500
CN102-10 (51, LS-)

Main CN104-22 (90, SH1)
controller
CN103-24 (91, SH2-1)
N.C.
Others:
Lifting height
CN102-10 (51, LS-) CN96-1 switch
CN104-22 (90, SH1) CN96-2

Main
controller
CN103-24 (91, SH2-1) CN96-3
Probable cause:
(1) Connector contact defect (3) Lifting height switch defect
(2) Harness defect (4) Main controller defect
Error code 67-1
67-1
67-1 error occurs.
Inspection: Check of lifting switch input value
Turn on the key switch and check the value of SH using the Analyzer SH: 000
1
menu.
SH: Other than 000
1. Lower the lift to its lowermost position.
SH: 000
3. Disconnect the CN96 connector. Lifting height switch defect
4. Turn on the key switch and check the value of SH using the
Analyzer menu.
SH: Other than 000
A
4-129

Harness defect
OK
Is the lifting height switch equipped? NO

2
YES
Lifting height switch arm is released.

Inspection: Check of mast lifting height (High lifting height)
Visually check the state of the lifting switch when an error is detected. 3
Lifting height switch arm is held.

(Low lifting height)
Inspection: Check of the lifting height switch as a single unit.
1. Keep the conditions under which the error occurs.
NG
3. Disconnect the CN96. Lifting height switch defect
4. Check for continuity on the switch side.
OK
Harness defect
OK

NG
Disconnect the CN102, CN103 and CN104 connectors and check the Harness defect
OK
4-130

NG
OK
NG
Disconnect the CN102,103 and CN104 connectors and check the Harness defect
OK

Perform this check with the battery plug and the CN96, CN102,CN103 and CN104 connectors disconnected.
Visually check inside each connector and the caulked portion of each wire for defects.


Perform this check with the CN102, CN103 and CN104 connectors disconnected.

4-131
z Error Code 68-1,-2,-3 (Lifting height sensor abnormality)

Related portion
CN101-32 (51, POT-) CN97-1
CN101-24 (219, VRH+) CN97-2

Main Lifting height
controller sensor
CN103-28 (220, VRH) CN97-3
Probable cause:
(1) Lifting height sensor defect
(3) Lifting height sensor harness defect
Error code 68-1
68-1 error does not
occur.
turn on the key switch to check how the vehicle operates and if an
error occurs.
68-1 error occurs.
Inspection: Check of lifting height sensor as a single unit
2. Disconnect CN97 and connect CN97-2 to CN97-3 on the harness 68-2 error occurs.
Lifting height sensor defect
side through 09238-13130-71.
68-1 error occurs.
Inspection 1: Continuity and short check of harness
Harness defect
OK
4-132
Error code 68-2
68-2
error occurs.
68-2 error occurs.
68-1 error occurs.
2. Disconnect the CN97 connector. Lifting height sensor defect
68-2 error occurs.
Harness defect
OK
Error code 68-3
Visual check of lifting height sensor

• Is the wire broken? NG
• Is the wire wound around or pulled out of the reel correctly when the
lift is raised to or lowered from an elevated position?
OK
TROUBLESHOOTING)
Inspection: Check of lifting height sensor input value

Raise the lift to an elevated position.
Change in VRH value:
Then, further raise the lift by 1 m from this position and check the
0.5 or more Normal
change in the value of VRH at that time.
(Connector contact defect)
Turn on the key switch and check the value of VRH using the Analyzer
menu.
Less than 0.5
Harness defect
OK
4-133


CN101-24 to CN97-2 Continuity 68-1, 3 *1
CN97-1 to CN97-3 No continuity 68-1, 3
4-134
z Error Code 71-1,-2,-3 (Tire angle sensor abnormality)

Related portion
CN101-23 (316, VRTRA+) CN94-3
CN102-31 (317, VRTRA) CN94-2

Main Tire angle
controller sensor
CN102-26 (51, POT-) CN94-1
Probable cause:
(2) Tire angle sensor harness defect
(3) Tire angle sensor defect
(4) Tire angle sensor joint, rear axle link system defect
Error code 71-1
71-1
TROUBLESHOOTING) 71-1 error occurs.
turn on the key switch to check how the steering operates and if an
error occurs.
71-1 error occurs.
Inspection: Check of tire angle sensor
2. Disconnect the CN94connector and connect CN94-3 and CN94-2 error occurs.
Tire angle sensor defect
3. Connect the battery plug and turn on the key switch to check the
error code.
71-1 error occurs.
Harness defect
2. Disconnect the battery plug and the CN101 and CN102 connectors
and check the harness for their continuities.
OK
4-135
Error code 71-2, -3
71-2, 71-3
error occurs.
71-2 or 71-3 error occurs.
71-1
1. Turn off the key switch and disconnect the battery plug. Tire angle sensor defect
error occurs.
2. Disconnect the CN94 connector. Tire angle sensor installation
3. Connect the battery plug and turn on the key switch to check the portion defect.
error code.
71-2 error occurs or
no error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug and the CN94, CN101 and CN102 connectors and with
SST disconnected visually check inside each connector and the caulked portion of each wire for defects.

CN94-1 to CN94-2 Continuity 71-1
4-136
z Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality)

Related portion
CN103-13 (311, SSTR+) CN3-1
CN104-30 (312, SSTR1) CN3-3
Main CN104-31 (313, SSTR2) CN3-4 Steering

controller angle sensor
CN104-24 (314, SSTRC) CN3-5
CN102-10 (51, LS-) CN3-2
Probable cause:
(2) Steering angle sensor harness defect
(3) Steering angle sensor defect
The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is rotated.
Error code 72-1
TROUBLESHOOTING)
key switch, and turn the steering wheel to see if an error occurs.
72-1 error occurs.
Inspection: Checking the state, turning the steering wheel
Turn on the key switch and check the value of SSTR using the SSTR: 1**
Analyzer menu. (* represents either 0 or 1.)
[ANL] I/O STEERING 1/1
SSTR: 0**
(* represents either 0 or 1.)
A
Turn off the key switch, disconnect the battery plug and disconnect the
CN3 connector. After that, connect CN3-2 to CN3-3 (on the main
harness side) through 09232-13130-71 to short them, and then
connect the battery plug and turn on the key switch.
B
4-137
SSTR: 1**
Inspection: Checking the state, turning the steering wheel (* represents either 0
Turn on the key switch and check the value of SSTR using the or 1.) Steering angle sensor
Analyzer menu. defect
SSTR: 0**
Main harness defect
2. Disconnect the CN104 connectors and check the harnesses for
their continuities.
OK
Disconnect the CN104 connector and disconnect the CN3 connector.

Connect the battery plug and turn on the key switch.
SSTR: 0**
(* represents either 0
or 1.)
Turn on the key switch and check the value of SSTR using the Steering angle sensor defect
Analyzer menu.
SSTR: 1**
Main harness defect
their continuities.
OK
4-138
Error code 72-2
TROUBLESHOOTING.)
72-2 error occurs
SSTR: *1*
Turn on the key switch and check the value of SSTR using the (* represents either 0
Analyzer menu. or 1.)
SSTR: *0* C
SSTR: *1*
or 1.)
Analyzer menu.
SSTR: *0*
Main harness defect
their continuities.
OK

SSTR: *0*
SSTR: *1*
Main harness defect
their continuities.
OK
4-139
Error code 72-3
TROUBLESHOOTING)
72-3 error occurs.
Inspection: Checking the state, turning the steering wheel SSTR: **1
SSTR: **0 E
SSTR: **1
Turn on the key switch and check the value of SSTR using the or 1.)
Steering angle sensor defect
Analyzer menu.
SSTR: **0
Main harness defect
their continuities.
OK
4-140
Turn off the key switch and disconnect the CN104 connector and
disconnect the CN3 connector.
Turn on the key switch and check the value of SSTR using the (* represents either 0 or 1.)
Analyzer menu. Steering angle sensor defect
SSTR: **1
Main harness defect
their continuities.
OK
Error code 72-4
the CN3 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE 72-4
TROUBLESHOOTING) error does not occur.
(If the steering wheel cannot be turned easily, perform this check
with the direction switch in the Forward or Reverse position.)
72-4 error occurs.
Inspection: Check of sensor supply voltage
1. Turn off the key switch and disconnect the battery plug. Approx. 15 V
4. Check the supply voltage to the sensor.
CN3-1 ⇔ CN3-2
Approx. 0 V
their continuities.
OK Main harness defect
Turn off the key switch, disconnect the battery plug, and then connect CN3.
Track down the cause of 72-1 (SSTR1).

Proceed to identify the cause of 72-2 (SSTR2).
4-141

Turn off the key switch and disconnect the battery plug, disconnect CN3, CN102, CN103 and CN104 and
perform the check without connecting SST.

4-142
z Error Code 73-1,-2,-3,-4 (Steering knob synchronizer solenoid abnormality)

Related portion
CN102-7 (329, SLS+) CN37-1
CN102-14 (330, SLS-) CN37-2
CN103-5 (N2, N2)

Main Steering knob
controller CN104-4 (N2, N2) synchronizer
solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Knob position compensation solenoid defect
(2) Knob position compensation solenoid harness defect (4) Main controller defect
Error code 73-1
1. Turn off the key switch and disconnect the battery plug,
disconnect the CN37 connector, and visually check inside the 73-4
connector and the caulked portion of its wire for defects. (Refer to error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) 73-4 error.
Connect the CN37 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.
No error occurs.
73-1
Using Active Test, forcibly turn on the output of the knob position
compensation solenoid to see if an error occurs. Connector contact defect
[ANL] ACTIVE TEST 1/3 STEERING SOL
73-1 error occurs.

Inspection: Check of knob position compensation solenoid
2. Disconnect the connector CN37 and measure the resistance of
the knob position compensation solenoid

Disconnect the CN102, CN103 and CN104 connectors and check
Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
4-143
Error code 73-2
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of
TROUBLESHOOTING) the 73-3 error.
Connect the CN37 connector, connect the battery plug, and turn on
No error occurs.
73-2
compensation solenoid to see if an error occurs. Connector contact
defect
73-2 error occurs.

Knob position
2. Disconnect CN37 and measure the resistance of the knob position NG
compensation solenoid
defect
OK
NG
OK
Error code 73-3
TROUBLESHOOTING)

2. Disconnect CN37 and measure the resistance of the knob position

Disconnect the CN102, CN103 and CN104 connectors and check the
4-144
Error code 73-4
TROUBLESHOOTING)
73-4 error occurs.
2. Disconnect the connector CN37 and measure the resistance of the NG Knob position compensation
knob position compensation solenoid solenoid defect
OK
NG
OK

connectors, Visually check inside each connector and the caulked portion of each wire for defects.

between 7 and 17 Ω (approx. 10 Ω at 20°C).
4-145
z Error Code 74-1 (Outside matching value range for tire angle error)
Related portion
Steering knob synchronizer

solenoid
Probable cause:
Tire straight running matching value is outside the specified matching range.
If the 71-1, 71-2 or 71-3 error occurs, identify the cause of it first, and then perform the following.

matching, 74-1 error
Matching has been made
Perform tire straight running matching. Refer to MULTI-FUNCTION does not occur.
correctly.
DISPLAY / MUSK FUCTION / MACHING
74-1 error occurs.
4-146
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer

abnormality-Conventional lever)
Related portion
CN101-25 (28, VRL+) CN47-4
CN103-26 (20, VRL1) CN47-3

Main Lift lever
controller CN103-18 (21, VRL2) CN47-2 potentiometer
CN102-26 (51, POT-) CN47-1
If the lever was removed for a check, be sure to perform matching after installing it.
The H1-4 error may occur if the key switch is turned on while the lift lever is being operated.
Probable cause:
(2) Lift lever potentiometer harness defect
(3) Lift lever potentiometer defect
Error code H1-1, -2, -3
the CN47 connector, and visually check inside the connector and H1-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
TROUBLESHOOTING)
H1-1, -2 or -3 error
One of these errors occurs.
H1-1 error occurs and
Inspection: Check of lift lever potentiometer
H1-2, H2-3 error does
not occur.
2. Disconnect the lift lever potentiometer connector (CN47). A
H1, -2 or -3 error
Harness defect
2. Disconnect the CN101,CN102 and CN103 connectors and check
OK

4-147
H1-2 error Inspection: Check of lift lever potentiometer

does not 1. Turn off the key switch and disconnect the battery
occur. plug.
2. Connect the CN47-3 to CN47-4 on the harness side
through SST 09230-13700-71.
H1-2 error occurs.

plug.
H1-2 error occurs.
2. Disconnect the CN47 connector. Lift lever
3. Connect the CN47-2 to CN47-4 on the harness side potentiometer defect
through SST 09230-13700-71.
H1-2 error does not occur.

plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103
continuities.
OK

4-148
Error code H1-4
the CN47 connector, and visually check inside the connector and H1-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
TROUBLESHOOTING)
H1-4 error occurs.

2. Check if the lift lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the lift lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION /
MACHING
NG
Lift lever potentiometer defect
Error code H1-5
Matching of the lift lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK H1-5 error does not occur. Matching has been made correctly.
FUCTION / MACHING Use the device as it is.
matching, H1-5 error
occurs.

With the battery plug and the CN47, CN101, CN102 and CN103 connectors disconnected,
H1
1 2 3 4 5
CN101-25 to CN47-4 Continuity { − − − −
CN102-26 to CN47-1 Continuity − { − − −
CN47-2 to CN47-1 No continuity { − { − −
CN47-2 to CN47-4 No continuity − { { − −
CN47-2 to CN47-3 No continuity − − { − −
4-149
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer abnormality-Mini lever)
Related portion
CN101-25 (28, VRL+) CN79-4
CN103-26 (20, VRL1) CN79-3

Main Lift lever
CN102-26 (51, POT-) CN79-1
Probable cause:
TROUBLESHOOTING)
1. Turn off the key switch and disconnect the battery plug. H2-1, -2 or -3 error One
2. Replace the lift lever potentiometer connector (CN79) with the tilt of these errors occurs. Lift lever potentiometer
lever potentiometer connector (CN80). H1-4, H2-4 can be defect
3. Connect the battery plug and turn on the key switch. ignored.
Harness defect
OK

4-150
Error code H1-4
TROUBLESHOOTING)
H1-4 error occurs.

OK
MACHING
NG
Error code H1-5

occurs.

H1
1 2 3 4 5
4-151
z Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality)
Related portion
CN101-28 (29, VRT+) CN80-4
CN102-23 (22, VRT1) CN80-3

Main Tilt lever
controller CN102-22 (23, VRT2) CN80-2 potentiometer
CN102-26 (51, POT-) CN80-1
The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.
Probable cause:
(2) Tilt lever potentiometer harness defect
(3) Tilt lever potentiometer defect
the CN80 connector, and visually check inside the connector and H2-1, -2, -3
TROUBLESHOOTING)
Inspection: Check of tilt lever potentiometer H1-1, -2 or -3 error
1. Turn off the key switch and disconnect the battery plug. One of these errors
2. Replace the tilt lever potentiometer connector (CN80) with the lift occurs.
Tilt lever potentiometer defect
lever potentiometer connector (CN79). H1-4, H2-4
3. Connect the battery plug and turn on the key switch. can be ignored.
Harness defect
OK

4-152
Error code H2-4
TROUBLESHOOTING)
H2-4 error occurs.
Inspection: Check of tilt lever potentiometer

2. Check if the tilt lever potentiometer is installed correctly.
OK
4. Perform matching of the tilt lever potentiometer.
MACHING
NG
Error code H2-5
Matching of the tilt lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK H2-5 error does not occur.
correctly.
FUCTION / MACHING
occurs.

H2
1 2 3 4 5
4-153
z Error Code H3-1, -2, -3, -4, -5 (Attachment 1 lever potentiometer

abnormality)
Related portion
CN101-29 (30, VRAT1+) CN48-4
CN102-21 (24, VRA11) CN48-3

Main Attachment 1
controller CN102-20 (25, VRA12) CN48-2 lever
potentiometer
CN102-26 (51, POT-) CN48-1
The H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being operated.
* The mini lever specification changes CN48 in CN81 and CN47 is changed into CN79.
Probable cause:
(1) Connector contact defect (3) Attachment 1 lever potentiometer defect
(2) Attachment 1 lever potentiometer harness defect (4) Main controller defect
TROUBLESHOOTING)
Inspection: Check of attachment 1 lever potentiometer H1-1, -2 or -3 error
2. Replace the attachment 1 lever potentiometer connector (CN48) occurs. Attachment 1 lever
with the lift lever potentiometer connector (CN47). H1-4, H3-4 can be potentiometer defect
Harness defect
OK

4-154
Error code H3-4
• Attachment 1 operation stop. (Conventional Lever)

• Load handling stop. (Mini Lever/Joystick Lever)
TROUBLESHOOTING)
H3-4 error occurs.
Inspection: Check of attachment 1 lever potentiometer

2. Check if the attachment 1 lever potentiometer is installed correctly.
OK
4. Perform matching of the attachment 1 lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION /
MACHING
NG
Attachment 1 lever potentiometer defect
Error code H3-5

Matching of the attachment 1 lever potentiometer. Matching has been made
Refer to MULTI-FUNCTION DISPLAY / MUSK correctly.

occurs.

Perform this check with the battery plug and the CN48, CN101 and CN102 connectors disconnected,
H3
1 2 3 4 5
4-155

abnormality) If unit has Clamp Release Interlock, click
here for info on calibrating lever, before
Related portion following this troubleshooting procedure
CN101-30 (31, VRAT2+) CN49-4
CN102-29 (26, VRA21) CN49-3

Main Attachment 2
potentiometer
CN102-26 (51, POT-) CN49-1
Probable cause:
TROUBLESHOOTING)
Harness defect
OK

4-156
Error code H4-4

TROUBLESHOOTING)
H4-4 error occurs.

OK
MACHING
NG
Error code H4-5
Matching of the attachment 2 lever potentiometer. After the completion of matching,

occurs.

With the battery plug and the CN49, CN101 and CN102 connectors disconnected, visually check inside each
H4
1 2 3 4 5
4-157
z Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-5

Lift push
CN101-16 (11, SLPS-) CN11-1 solenoid
CN10-5
Lift pull
CN101-17 (10, SLPL-) CN10-1 solenoid
Main
controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Lift pull solenoid harness defect
(2) Lift push solenoid harness defect (5) Lift pull solenoid defect
(3) Lift push solenoid defect (6) Main controller defect
If the H5-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H5-1, -3
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H5-6 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H5-6 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.
No error occurs
Push and hold down the lift lever and pull and hold it up for more than not occur.
1 second each to check if an error occurs.
H5-1 or H5-3 error occurs.
Inspection: Check of lift solenoid

2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).

Portion where a problem was found during a check of the lift solenoid or its harness.
4-158
Error code H5-2, -4
No error occurs.

2. Disconnect the CN10 and CN11 connectors and measure the NG
Lift solenoid defect
(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK
Error code H5-5
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

(CN10-5 to CN10-1, CN11-5 to CN11-1).

4-159
Error code H5-6
disconnect the CN10 and CN11 connectors, and visually check H5-6 error does not
inside the connector and the caulked portion of its wire for defects. occur.
H5-6 error occurs.
HB-2 error occurs. Track down the cause of the

Check if the HB-2 error has also occurred.
HB-2 error.
HB-2 error does not occur.

(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK

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

CN101-5 to CN10-5 Continuity H5-6 *1
CN101-5 to CN104-4 No continuity H5-6
CN10-5 to CN10-1 No continuity H5-1, 2, 3, 4, 5, 6
CN10-1 to P1 No continuity H5-1, 2, 3, 4, 5, 6
*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-17
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
4-160
z Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-6

Tilt push
CN101-13 (34, STPS-) CN11-2 solenoid
CN10-6
Tilt pull
CN101-12 (33, STPL-) CN10-2 solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Tilt pull solenoid harness defect
(2) Tilt push solenoid harness defect (5) Tilt pull solenoid defect
(3) Tilt push solenoid defect (6) Main controller defect
Error code H6-1, -3
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur.
Inspection: Check of tilt proportional solenoid

resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).

Portion where a problem was found during a check of the tilt solenoid or its harness.
4-161
Error code H6-2, -4
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur. Connector contact defect

Tilt solenoid defect
(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK
Error code H6-5
TROUBLESHOOTING)

(CN10-6 to CN10-2, CN11-6 to CN11-2).

4-162
Error code H6-6
the CN10 and CN11 connectors, and visually check inside the H6-6 error does not
connector and the caulked portion of its wire for defects. (Refer to occur.
BEFORE TROUBLESHOOTING)
H6-6 error occurs.

HB-2 error.

(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK


4-163
z Error Code H7-1, -2, -3, -4, -5, -6 (Attachment 1 PUSH/PULL solenoid
abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-7

Attachment 1
CN101-11 (37, SA1PS-) CN11-3 push solenoid
CN10-7
Attachment 2
CN101-10 (36, SA1PL-) CN10-3 push solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Attachment 1 pull solenoid harness defect
(2) Attachment 1 push solenoid harness defect (5) Attachment 1 pull solenoid defect
(3) Attachment 1 push solenoid defect (6) Main controller defect
Error code H7-1, -3
No error occurs.
Push and hold down the attachment 1 lever and pull and hold it up for not occur.
more than 1 second each to check if an error occurs.
Inspection: Check of attachment 1 solenoid

2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 1 solenoid
(CN10-7 to CN10-3, CN11-7 to CN11-3).

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
4-164
Error code H7-2, -4
No error occurs.

2. Disconnect the CN10 and CN11 connectors. NG Attachment 1
Measure the resistance of attachment 1 solenoid solenoid defect
(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK
Error code H7-5

(CN10-7 to CN10-3, CN11-7 to CN11-3).

4-165
Error code H7-6
H7-6 error occurs.

HB-2 error.

(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK


4-166
abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-8

Attachment 2
CN10-8
Attachment 2
CN101-14 (39, SA2PL-) CN10-4 pull solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
Error code H8-1, -3
Track down the
connector and the caulked portion of its wire for defects. (Refer to H8-6 error occurs.
cause of the H8-6
error.
No error occurs.
H8-1, H8-3
Push and hold down the attachment 2 lever and pull and hold it up for No error occurs Connector contact
more than 1 second each to check if an error occurs. defect
H8-1 or
H8-3 error occurs.
(CN10-8 to CN10-4, CN11-8 to CN11-4).

4-167
Error code H8-2, -4
the CN10 and CN11 connectors, and visually check inside the H8-5
No error occurs.
H8-2, H8-4
Push and hold down the attachment 2 lever and pull and hold it up for error occurs

2. Disconnect the CN10 and CN11 connectors. NG
Attachment 2 solenoid defect
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK

Harness defect
OK
Error code H8-5
TROUBLESHOOTING)

(CN10-8 to CN10-4, CN11-8 to CN11-4).

4-168
Error code H8-6
1. Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector H8-6
and the caulked portion of its wire for defects. (Refer to BEFORE No error occurs
TROUBLESHOOTING.)
2. Connect the CN10 and CN11 connector, connect the battery plug, and
H8-6 error occurs.
HB-2 error.
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check the
OK


*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-14 to see if it falls
4-169
z Error Code HB-1, -2, -3, (Solenoid power supply circuit over current)
Related portion
F7
CN130-6 (19, F7)
CN102-5 (17, SOLCOM) CN132-8 (17, SOLCOM)

CN102-6 (17, SOLCOM)
RY1
CN102-13 (335, RY1) CN132-4 (335, RY1) CN132-2 (97, FAN+)
CN101-3 (97, FAN+)
CN101-5 (9, SLLA2+) CN11-5

Lift PUSH
CN101-17 (10, SLPL-) CN10-5

Lift PULL
CN10-1 solenoid
CN101-6 (32, SLTA1+) CN11-6

Tilt PUSH
CN101-12 (33, STPL-) CN10-6

Tilt PULL
Main
CN10-2 solenoid
controller
CN11-7
ATT1 PUSH
CN101-11 (37, SA1PS-) CN11-3 solenoid
CN101-10 (36, SA1PL-) CN10-7

ATT1 PULL
CN10-3 solenoid
CN11-8
ATT2 PUSH
CN101-14 (39, SA2PL-) CN10-8

ATT2 PULL
CN103-5 (N2, N2) CN10-4 solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

4-170
Probable cause:
(2) Harness defect
(3) RY1 defect
Error code HB-1
the CN132 connector, and visually check inside the connector and HB-1 error does not
TROUBLESHOOTING)
2. Connect the CN132 connector, connect the battery plug, and turn
HB-1 error occurs.

Harness defect
OK
Relay defect (*1)

*1 If the symptom persists after replacement of the relay, there should be any other problems,
so replace the Main controller.
Error code HB-2
the CN132, CN10 and CN11 connectors, and visually check inside HB-2 error does not
the connector and the caulked portion of its wire for defects. occur.
2. Connect the CN132, CN10 and CN11 connector, connect the
battery plug, and turn on the key switch to see if an error occurs.
HB-2 error occurs.

Harness defect
2. Disconnect the CN101, CN102, CN103, CN104, CN10 and CN11
OK

4-171
Error code HB-3
TROUBLESHOOTING)
HB-3 error occurs.

Harness defect
OK
Inspection: Relay check

2. Disconnect the connector CN132, check the relay and measure its NG
Relay defect
resistance on the primary side
(resistance between CN132-4 and CN132-2).
OK

With the battery plug and the CN101, CN102, and CN132 connectors disconnected, visually check inside each

CN102-13 to CN132-4 Continuity HB-1
4-172

With the battery plug and the CN101, CN102, CN103, CN104, CN10 and CN11 connectors disconnected,

CN102-5 to CN104-4 No continuity HB-2


CN132-4 to P1 No continuity HB-3
4-173
z Error Code HC-1, -2, -3, -4, (Unload valve solenoid abnormality)
Related portion
CN101-1 (3, SOLLU+) CN13-1
CN102-17 (5, SLUL-) CN13-2
CN103-5 (N2, N2)

Main Unload valve
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Unload valve solenoid defect
(2) Unload valve solenoid harness defect (4) Main controller defect
If the HC-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
0
Error code HC-1
the caulked portion of its wire for defects. (Refer to BEFORE HC-4 error occurs. Track down the cause of the
TROUBLESHOOTING) HC-4 error.
No error occurs.
HC-1 error does not
Lower the lift to see if an error occurs. occur. Connector contact defect
HC-1 error occurs.
Inspection: Check of unload valve solenoid

unload valve solenoid

Portion where a problem was found during a check of the unload valve solenoid or its harness
4-174
Error code HC-2
No error occurs.
HC-2 error does not
occur.
HC-2 error occurs.

Unload valve solenoid defect
OK

Harness defect
OK
Error code HC-3
TROUBLESHOOTING)


4-175
Error code HC-4
the CN13 connector, and visually check inside the connector and HC-4 error does not
TROUBLESHOOTING)
HC-4 error occurs.

OK

Harness defect
OK

CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects.

CN101-1 to CN13-1 Continuity HC-4 *
CN101-1 to CN104-4 No continuity HC-4
CN13-2 to CN13-1 No continuity HC-1, 2, 3, 4
CN13-2 to P1 No continuity HC-1, 2, 3, 4
4-176
z Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality)
Related portion
CN103-8 (300, IPL+) CN39-3
CN103-30 (301, IPL1) CN39-2

Shock sensor 1
CN101-32 (51, POT-) CN39-1
Main
controller CN40-3
CN103-19 (302, IPL2) CN40-2

Shock sensor 2
CN40-1
Probable cause:
(2) Shock sensor harness defect
(3) Shock sensor defect
Error code G5-1 or G5-4 (For G-5-4, read the numbers in brackets, which refer to the corresponding error code,
connector number, etc.)
the CN39 [CN40] connectors, and visually check inside the G5-1 [G5-4]
connector and the caulked portion of its wire for defects. (Refer to error does not occur.
2. Connect the CN39 [CN40] connector, connect the battery plug, and
G5-1 [G5-4] error occurs.
Inspection: Check of shock sensor 1 [shock sensor 2]

1. Turn off the key switch and disconnect the battery plug. G5-2 [G5-5]
2. Disconnect the CN39 [CN40] connector and connect the CN39-3 to error occurs. Shock sensor 1
CN39-2 [CN40-3 to CN40-2] on the harness side through [shock sensor 2] defect
09232-13130-71.

NG
Harness defect
OK

4-177

G5-1 [G5-4]
error occurs. Shock sensor 1
2. Disconnect the CN39 [CN40] connector.
[shock sensor 2] defect

Harness defect
OK
turn on the key switch to see if an error occurs. (after one minute)

G5-1 [G5-4]
G5-1 [G5-4] error does not occur.

Harness defect
OK

4-178

Turn off the key switch and disconnect the battery plug, disconnect CN39 [CN40], CN101 and CN103 and

CN103-8 to CN39-3 Continuity G5-1 *1
CN101-32 to CN39-1 Continuity G5-2, -3 *2
CN39-2 to CN39-1 No continuity G5-1
CN39-3 to CN39-2 No continuity G5-2, -3
sec04.book
WHEN NO ERROR CODE IS DISPLAYED
Probable causes of problems for which no error code is displayed
Note:
179 ページ
If an error code is displayed or the spanner light is on, be sure to perform checks with priority given to it.
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Emergency switch main body (with
Emergency switch) – • Release the emergency switch.
: Switch is held down.
２０１１年１月２５日
Check the battery voltage.

Battery
: Battery plug is disconnected. • Charge the Battery
火曜日
: Low voltage
Key switch main body
: Open failure
Emergency switch main body (with • Check the switch, and replace it if
Emergency switch) necessary.
: Open failure – • Check the harness and repair or

Key switch harness replace it if necessary.
: Wire breakage, short circuit or • Replace the F5 fuse.
Although the key switch or ten-key leakage (harness, connector or F5
operation is turned on, power is not fuse)
Power-supply supplied. Numeric keypad harness (with PIN
related control (The multi-function screen does not • Check the harness and repair or
code entry) –
appear, and the vehicle does not replace it if necessary.
: Open failure
move, either.)
Check the operation of each switch.
: Check if a response (lighting of LED
or sounding of buzzer) is given only
to a particular switch.
Numeric keypad main body (with PIN If there are two types of switches:
code entry) switch to which a response is given • Replace the numeric keypad.
: Switch failure 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.
Multi-function display (with PIN code
Using the Administrator menu, check if • Register PIN using the Administrator
entry)
PIN has been registered. menu.
: PIN not registered
4-179
sec04.book
Control
systems
4-180
Display power supply and ground
harness (with PIN code entry)
180 ページ
Although the key switch is turned on, : Wire breakage, short circuit,
• Check the harness and repair or
power is not supplied. leakage (harness or connector)
replace it if necessary.
(The multi-function screen does not Multi-function display (with PIN code –
• Replace the display.
appear, and the vehicle does not entry)
• Replace the main controller.
move, either.) : Internal failure
Main controller
Power-supply : Internal failure (D7V, DGND)
２０１１年１月２５日
related control
Display power supply or ground
harness
火曜日
: Wire breakage, short circuit, • Check the harness and repair or

The multi-function screen does not
leakage (harness or connector) replace it if necessary.
appear. –
Multi-function display • Replace the display.
(The vehicle runs normally.)
: Internal failure • Replace the main controller.
Main controller
: Internal failure
After the key switch was turned on, the
accelerator was not released or the
– Operate them correctly.
direction switch was not returned to
neutral.
Check the direction switch, using
Analyzer.
Direction switch main body
: Accelerator is fully closed. • Check the switch, and replace it if
: Open failure
Operate the direction switch to see if necessary.
Direction switch harness
it turns on and off normally. • Check the harness and repair or
: Wire breakage, short circuit
(The vehicle does not run if the replace it if necessary.
(harness or connector)
forward and reverse switches are
turned on simultaneously.)
The vehicle does not run.
Traveling Direction switch installation portions
(The drive motor does not rotate.)
(EZ pedal)
Check the operation of the direction • Repair or replace the part that does
: One of the installation portions is
switch (microswitch). not operate normally.
broken or damaged or does not
operate normally.
Accelerator sensor main body
: Internal failure Check the accelerator sensor voltage,
Accelerator sensor installation portion using Analyzer. • Check the sensor and replace it if
: The link or the installation portion is : Direction switch is in neutral. necessary.
broken or damaged. Fully open and close the drive to • Check the harness and repair or
Accelerator sensor harness check the change in voltage at that replace it if necessary.
: Wire breakage, short circuit, time.
leakage (harness or connector)
sec04.book
Control
systems
Accelerator fully closed/fully open
Check the matching value on the
matching value • Perform matching again.
181 ページ
Matching screen.
: No agreement with the vehicle state
Check the brake switch voltage, using
Brake switch main body Analyzer.
• Check the switch and replace it if
: Open failure : Direction switch in neutral, drive
necessary.
Brake switch harness fully closed
: Wire breakage, short circuit, Fully open and close the brake
２０１１年１月２５日
leakage (harness or connector) cylinder valve to check the change

in voltage.
Check the seat switch, using Analyzer.
火曜日
Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
: Open failure fully closed necessary.
Seat switch harness Check if the switch turns on and off • Check the harness and repair or
: Wire breakage (harness, connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Brake Check the brake and the drive motor.

• Check the brake, and repair or
: Dragging (internal failure) : With the battery plug disconnected,
Drive motor the parking brake released and the
The vehicle does not run. • Check the drive motor, and repair or
Traveling : Seizure or dragging of drive motor front wheels off the ground, rotate
(The drive motor does not rotate.) replace it if necessary.
(internal failure) each tire to see if it rotates smoothly.
Main body of drive motor rotation
sensor Check the voltage of the drive motor
: Internal failure rotation sensor, using Analyzer. • Check the drive motor rotation
Drive motor rotation sensor installation : Seated in seat, direction switch in sensor, and adjust or replace it if
portion forward position, brake released necessary.
: Gap improperly adjusted Operate the accelerator and check • Check the harness and repair or
Drive motor harness the change in the rotation sensor replace it if necessary.
: Wire breakage, short circuit, voltage.
Check the voltage of the drive motor
Drive motor drive circuit current sensor, using Analyzer.
: Internal failure : Seated in seat, direction switch in • Check the cable, and repair or
Motor cables forward position, brake released replace it if necessary.
: Wire breakage, short circuit or Operate the accelerator and check • Replace the drive motor drive circuit.
leakage (cable or terminal board) the change in the current sensor
voltage.
Main controller
– • Replace the main controller.
: Internal failure
4-181
sec04.book
Control
systems
4-182
Pump motor rotation sensor main body
: Internal failure Check the voltage of the drive motor
182 ページ
• Check the pump motor rotation

Pump motor rotation sensor rotation sensor, using Analyzer.
sensor, and adjust or replace it if
installation portion : Seated in the seat
necessary.
: Gap improperly adjusted Operate the direction switch and
Pump motor harness check the change in the rotation
: Wire breakage, short circuit, sensor voltage.
Load handling cannot be performed
２０１１年１月２５日
and the steering is heavy. Measure the voltage of the pump

(The pump motor does not work for motor current sensor, using Analyzer. • Check the motor cables, and repair
: Internal failure
material handling operation, steering : Seated in the seat or replace them if necessary.
火曜日
Motor cables
operation and direction switch Operate the direction switch and • Replace the pump motor drive
: Wire breakage, short circuit or
operation.) check the change in the current circuit.
leakage (cable or terminal board)
sensor voltage.
Pump • Check the pump, and repair or
: Seizure replace it if necessary.
–
Pump motor • Check the pump motor, and repair or
Main controller
– • Replace the Main controller.
Load handling : Internal failure
and power Main body of load handling lever
steering potentiometer
: Internal failure Measure the voltage of the load
Only load handling cannot be Installation of load handling lever handling lever potentiometer, using
• Check the sensor and replace it if
performed. potentiometer Analyzer.
necessary.
(The pump motor operates normally : Installation portion is broken or : Leave the seat
during steering operation and direction damaged. Tilt the load handling lever forward
switch operation.) Load handling lever potentiometer and backward to check the change
harness in voltage.
: Wire breakage, short circuit,
Main body of tilt forward/backward
switch (Conventional lever)
: Internal failure
Check the tilt forward/backward
Only load handling cannot be Installation of tilt forward/backward
switch, using Analyzer. • Check the switch and replace it if
performed. switch
: Seated in the seat necessary.
(The pump motor operates normally : Installation portion is broken or
Operate the tilt lever forward to • Check the harness and repair or
during steering operation and direction damaged.
backward position to check the replace it if necessary.
switch operation.) Tilt forward/backward switch
switch turns on and off normally.
harness
sec04.book
Control
systems
Seat switch main body • Check the seat and replace it if
: Load handling lever in neutral
183 ページ
: Open failure necessary.

Check if the switch turns on and off
Seat switch harness • Check the harness and repair or
normally, sitting in the seat or
: Wire breakage (harness, connector) replace it if necessary.
standing beside it.
Oil control valve (Conventional lever) • Check the oil control valve, and
Only load handling cannot be : Seizure of or leakage from unload repair or replace it if necessary.
performed. valve • Check the unload valve solenoid
–
２０１１年１月２５日
(The pump motor operates normally Harness of unload valve solenoid and replace it if necessary.
during steering operation and direction : Wire breakage, short circuit, • Check the harness and repair or
switch operation.) leakage (harness or connector) replace it if necessary.
火曜日

: Leak replace it if necessary.
–
Load handling Priority valve • Check the priority valve, and repair
and power : Leak, seizure or replace it if necessary.
steering Main controller

: Internal failure
Only lowering is impossible. If a current flows, turn on the lowering
Lowering lock valve • Check the lowering lock valve, and
(Other load handling operations, lock solenoid using Active Test to
: Seizure (internal damage) repair or replace it if necessary.
including raising, are possible.) lower the fork.
Only forward tilting is impossible.
If a current flows, turn on the tilt control
(Other load handling operations, Tilt control valve • Check the tilt control valve, and
solenoid using Active Test to lower the
including backward tilting, are : Seizure (internal damage) repair or replace it if necessary.
fork.
possible.)
Direction switch • Check the switch, and replace it if
The steering is heavy. Analyzer.
(The pump motor operates normally : Accelerator is fully closed.
Direction switch harness • Check the harness and repair or
during material handling.) Operate the direction switch to see if
it turns on and off normally.
4-183
sec04.book
Control
systems
4-184
Main body of steering angle sensor
: Internal damage
184 ページ
Check the steering angle sensor, using • Check the sensor and replace it if
Installation of steering angle sensor
Analyzer. necessary.
: Cam or steering wheel is defective.
: Turn the steering wheel to check the • Check the harness and repair or
Steering angle sensor harness
input signal. replace it if necessary.
The steering is heavy. leakage (harness or connector)
(The pump motor operates normally Pump • Check the pump, and repair or
２０１１年１月２５日
Load handling during material handling.) : Leak replace it if necessary.

and power Priority valve • Check the priority valve, and repair
–
steering : Leak, seizure or replace it if necessary.
火曜日
PS valve • Check the PS valve, and repair or

: Leak, seizure replace it if necessary.
Main controller
: Internal failure
Display setting
Although ATT1 (ATT2) is operated, no : The serial number setting is not in Check the set value on the Option Set • Change the setting (see "MULTI
operation is performed. agreement with that of the vehicle. screen. FUNCTION DISPLAY")
(OCV WAY)
Backup buzzer main body
• Check the backup buzzer and
: Internal damage
Backup buzzer harness –
: Wire breakage, short circuit or leakage
(harness, connector or F5 fuse)
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Open failure
The backup buzzer (option) does not and replace it if necessary.
Auxiliary equipment relay harness –
sound. • Check the harness and repair or
Auxiliary Backup relay main body (EZ pedal)
• Check the backup relay and replace
equipment : Open failure
it if necessary.
Backup relay harness –
: Wire breakage, short circuit.
Main controller (EZ pedal)
• Replace the Main controller.
: Internal failure
: Internal breakage
The backup buzzer (option) does not replace it if necessary.
stop sounding. • Check the harness and repair or
: Short circuit, leakage (harness or
connector)
sec04.book
Control
systems
: Short circuit
185 ページ
and replace it if necessary.

connector)
The backup buzzer (option) does not Backup relay main body (EZ pedal)
stop sounding. : Short circuit
it if necessary.
２０１１年１月２５日

connector)
火曜日

: Internal failure
Backup light main body
: Internal breakage, burnout of light • Check the backup light and replace
Auxiliary bulb it if necessary.
–
equipment Backup light harness • Check the harness and repair or

: Wire breakage, short circuit, replace it if necessary.
: Open failure
The backup light (option) does not go Auxiliary equipment relay harness –
on. : Short circuit, leakage (harness or
connector)
Backup relay main body (EZ pedal)
: Open failure
it if necessary.
connector)
: Internal failure
4-185
sec04.book
Control
systems
4-186
• Check the backup light and replace
: Internal breakage,
186 ページ
it if necessary.
Backup light harness –
: Short circuit
Auxiliary The backup light (option) does not go • Check the harness and repair or
２０１１年１月２５日

equipment out. replace it if necessary.
connector)
火曜日

: Short circuit
it if necessary.
connector)

: Internal failure
Display setting
: OPS operation notification buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
disabled screen. FUNCTION DISPLAY")
OPS operation warning does not (OPS BUZZER, SEAT BUZZER)
sound.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Display setting
: Return-to-neutral warning buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
Buzzer-related The traveling OPS return-to-neutral (OPS BUZZER)
control warning does not sound.
Display setting
The load handling OPS return-to- (OPS BUZZER)
neutral warning does not sound.
sec04.book
Control
systems
Check the parking brake switch, using
Analyzer.
187 ページ
Parking brake switch main body

(The switch can also be checked by
: Short circuit • Check the switch, and adjust or
checking if the parking indicator on the
Installation of parking brake switch replace it if necessary.
display goes on and out.)
: Switch is held down. • Check the harness and repair or
: Direction switch is in neutral.
Parking brake switch harness replace it if necessary.
The parking brake lever release Operate the parking brake lever
: Short circuit (harness or connector)
reminder does not sound. lever to see if the switch turns on
and off normally.
２０１１年１月２５日

火曜日

Main controller
: Internal failure
Analyzer.
: Open failure • Check the switch, and adjust or
Buzzer-related Installation of parking brake switch replace it if necessary.
When the vehicle runs with the parking display goes on and out.)
control : Switch is off. • Check the harness and repair or
brake lever released, the parking : Direction switch is in neutral.
brake release reminder sounds. Operate the parking brake lever to
: Wire breakage (harness, connector)
see if the switch turns on and off
normally.
Main controller
: Internal failure
Display setting
: Parking brake reminder buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
(PKB BUZZER)
The parking brake lever reminder does Parking brake switch main body Analyzer.
not sound. (The switch can also be checked by
: Switch is off. • Check the harness and repair or
Operate the parking brake lever to
normally.
4-187
sec04.book
Control
systems
4-188
Seat switch main body Check the seat switch, using Analyzer. • Check the seat and replace it if
: Short circuit : Check if the switch turns on and off necessary.
188 ページ
Seat switch harness normally, sitting in the seat or • Check the harness and repair or
: Short circuit (harness or connector) standing beside it. replace it if necessary.
The parking brake lever reminder does
not sound. Display • If the buzzer does not sound,
Main controller
２０１１年１月２５日
: Internal failure
Parking brake switch main body Check the parking brake switch, using
火曜日
Buzzer-related : Short circuit Analyzer. • Check the switch, and adjust or

control Installation of parking brake switch : Direction switch is in neutral. replace it if necessary.
: Switch is held down. Operate the parking brake lever to • Check the harness and repair or
Parking brake switch harness see if the switch turns on and off replace it if necessary.
: Short circuit (harness or connector) normally.
Although the parking brake lever is

pulled up, the parking brake reminder
Seat switch main body : Direction switch in neutral, drive • Check the seat switch and replace it
does not stop sounding.
: Open failure fully closed if necessary.
standing beside it.
Main controller
: Internal failure
Display setting
The height selector function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Height selector function disabled
screen does not appear. screen. FUNCTION DISPLAY")
(H-SELECTOR)
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. : In NL
necessary.
Lifting switch harness Raise and lower the lift to its
Height selector • Check the harness and repair or
The lifting stop position cannot be set. : Wire breakage, short circuit uppermost and lowermost positions
(option) replace it if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Main controller
: Internal failure
Display setting
No limit is placed on the maximum Check the set value on the lifting stop • Change the setting (see "MULTI-
: The maximum lifting height is not be
lifting height. position setting screen. FUNCTION DISPLAY")
set.
sec04.book
Control
systems
Display setting
Check the set value on the lifting stop • Change the setting (see "MULTI-
: The automatic lifting stop position is
189 ページ
position setting screen. FUNCTION DISPLAY")

not set.
Height selector switch main body
: Open failure, short circuit
Mechanical detection unit of height Check the height selector switch,
Although the height selector switch is • Check the height selector switch,
selector switch using Analyzer.
pressed, the automatic lifting stop and adjust or replace it if necessary.
: Gap in detection unit is improperly : Vehicle stopped
position cannot be selected. • Check the harness and repair or
２０１１年１月２５日
adjusted. Operate the height selector switch

Height selector switch harness to see if it turns on and off normally.
火曜日
Main controller
: Internal failure
If the loading conditions, the tilt angle
of the mast, etc at that time are

different from those when the lifting – –
height was set, the fork stop position
Height selector may not agree with the set position.
(option) Lifting height sensor main body
: Dragging or improper winding of wire Check the lifting sensor voltage, using
Installation of lifting height sensor Analyzer.
The fork stop position is far away from : Breakage of sensor installation : In NL
necessary.
the lifting height set position (100 mm portion, breakage of wire routing Raise and lower the lift to its
or more). portion uppermost (relief) and lowermost
Lifting height sensor harness positions to check the change in the
Change over time of lifting sensor
detection unit
Main controller
: Internal failure
• Check the positional relationship
The automatic lifting stop position
The automatic lifting stop position among automatic lifting stop
cannot be selected if the maximum
cannot be selected, although it was set – position, maximum lifting height and
lifting height or the lifting height limit is
for sure. lifting height limit, and set them
set below it.
properly.
Display setting
Shock sensor The shock detection function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Shock detection function disabled
(option) screen does not appear. screen. FUNCTION DISPLAY")
(SHOCK SENSOR)
4-189
sec04.book
Control
systems
4-190
Way in which the vehicle collides
: The degree of shock that the shock
190 ページ
sensor receives vary depending on

the way and direction in which the
– –
vehicle collides and the object with
which it collides. The shock sensor
does not necessarily detect all kinds
of shock.
２０１１年１月２５日
Display setting
• Change the setting (see "MULTI-
: A too large (improper) value is set –
Although shock is applied, the shock FUNCTION DISPLAY")
for shock detection.
火曜日
detection alarm does not go on.

Shock sensor main body
Check the voltages of shock sensors 1
: Sensitivity reduced
and 2, using Analyzer.
Installation of shock sensor • Check the sensor and replace it if
: Vehicle stopped 2.0 ± 0.21 V
: Improper installation (loosening), necessary.
Apply shock to each sensor to see if
interference • Check the harness and repair or
its voltage changes.

Shock sensor harness replace it if necessary.
(Compare the voltages of sensors 1
and 2.)
Shock sensor
Main controller
(option) – • Replace the main controller.
: Internal failure
• Change the setting.
Display setting
(Set a value that corresponds to
: A too small (improper) value is set –
shock unlikely to be applied during
normal operation.)
: Internal damage (excessive
response)
Installation of shock sensor
Although no shock is applied, the : Improper installation (loosening), • Check the sensor and replace it if
shock detection alarm sets off. interference necessary.
Shock sensor harness • Check the harness and repair or
its voltage changes excessively.
and 2.)
(Especially if there are half-broken
wires in the harness, shock may be
detected frequently.)
Main controller
: Internal failure
sec04.book
Control
systems
191 ページ
One of the following matching

* If accelerator pedal fully closed and
operations is not performed.
fully open matching is finished by
• Tire straight running angle matching
simply performing fully closed
• Forward tilt limit angle matching
matching and fully open matching in
• Tilt horizontal angle matching
[Diagnostic mode indicator] this order, the setting will not be
• Tilt no-load matching Check the matching value on the
Although no error code is displayed, saved.
• Accelerator pedal fully closed Matching screen.
the diagnostic mode indicator is left on.
２０１１年１月２５日
matching
* If brake pedal fully closed and
• Accelerator pedal fully open
operating point matching is finished
matching
火曜日
by simply performing fully closed

• Mini-lever neutral voltage matching
matching and operating point
• Tire diameter data
matching in this order, the setting will
not be saved.
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,

Multi-function Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
display : The link or the installation portion is : In NL replace it if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
[Tilt indicator] : Wire breakage, short circuit, change in voltage.
The correct tilt angle is not displayed. leakage (harness or connector)
Tilt angle sensor leveling matching
value • Perform matching again.
Matching screen.
No problem if the tilt angle is 0° under
A load is carried. –
no-load conditions.
When a load is carried, the position
where the fork stops when automatic
[Tilt indicator] fork leveling is finished does not
The tilt angle is not indicated as 0° always agree with the position of the
when the automatic fork leveling is fork when its tilt angle is indicated as
finished. 0° on the tilt indicator, so the tilt angle
may not be indicated as 0°, depending
on the load.
4-191
sec04.book
Control
systems
4-192
• Check the tires and replace them if
Tire specification necessary.
192 ページ
–
: Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
Lock cylinder main body
: Leakage, incapable of locking • Check the lock cylinder, and repair
Check the lock cylinder, using Active
Installation of lock cylinder or replace it if necessary.
Test.
: Installation portion is damaged or • Check the swing solenoid and
: Forcibly turn on (unlocked) and off
２０１１年１月２５日
broken. replace it if necessary.

(locked) the swing solenoid to check
Swing solenoid harness • Check the harness and repair or
the state of the lock cylinder.
: Short circuit, leakage (harness or replace it if necessary.
火曜日
connector)
Check the load sensor voltage, using
Load sensor main body Analyzer.
: Internal damage : In NL
necessary.
Load sensor harness Raise and lower the lift to its

: Wire breakage, short circuit, uppermost (relief) and lowermost
leakage (harness or connector) positions to check the change in the
voltage.
The vehicle lacks stability during
traveling.
Swing lock Lifting height switch main body Analyzer.
(The swing mechanism does not lock • Check the switch, and replace it if
easily or at all during traveling.) necessary.
: Wire breakage, short circuit uppermost and lowermost positions
normally.
Yaw rate sensor main body Check the sensor voltage, using
: Internal failure Analyzer.
necessary.
Yaw rate sensor harness : Vehicle stopped
: Wire breakage, short circuit, Check the sensor voltage approx.
leakage (harness or connector) 2.5V.
sensor
: Internal failure
necessary.
Drive motor rotation sensor harness
– • Check the harness and repair or
• Replace the drive motor drive circuit.
: Internal failure
Main controller
: Internal failure
sec04.book
Control
systems
• Check the lock cylinder, and repair
Lock cylinder main body Check the lock cylinder, using Active
or replace it if necessary.
193 ページ
: Seizure of lock cylinder Test.

• Check the solenoid and replace it if
Swing solenoid harness : Forcibly turn on (unlocked) and off
necessary.
: Wire breakage, short circuit, (locked) the swing solenoid to check
leakage (harness or connector) the state of the lock cylinder.
２０１１年１月２５日
necessary.
火曜日
voltage.
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the lifting height switch, and
: In NL
detected. replace it if necessary.

The swing mechanism always locks Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
Swing lock during traveling or load handling, uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
or it locks frequently. to see if the switch turns on and off
normally.
necessary.
sensor
: Internal failure
necessary.
: Internal failure
Main controller
: Internal failure
4-193
sec04.book
Control
systems
4-194
194 ページ
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is : In NL replace it if necessary.
: Wire breakage, short circuit, change in voltage.
２０１１年１月２５日

Matching screen.
火曜日
When tilted forward for leveling, the Main body of automatic fork leveling
fork does not stop automatically in a switch
Check the automatic fork leveling
horizontal position. : Open failure
switch, using Analyzer. • Check the switch, and replace it if
(The fork tilts to its forward tilt limit Mechanical detection unit of automatic
: Load handling lever in neutral necessary.
without stopping in a horizontal fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
position.) : Gap in detection unit is improperly
switch to see if it turns on and off replace it if necessary.
adjusted.
normally.
Automatic fork leveling switch harness
Tilt control : Wire breakage (harness, connector)
Oil control valve Check the tilt control valve, using • Check the oil control valve, and
: Seizure of or leakage from tilt Active Test. repair or replace it if necessary.
control valve : Tilt solenoid forcibly turned off • Check the solenoid and replace it if
Tilt solenoid harness (forward tilting stopped) necessary.
: Short circuit, leakage (harness or Tilt the fork forward to check the • Check the harness and repair or
connector) operation. replace it if necessary.
Main controller
: Internal failure
When the fork tilted forward for : The link or the installation portion is : In NL replace it if necessary.
leveling, it does not stop automatically broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
in a horizontal position. Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
(The fork does not stop in a horizontal : Wire breakage, short circuit, change in voltage.
position.) leakage (harness or connector)
Matching screen.
sec04.book
Control
systems
195 ページ

necessary.
When the fork tilted forward for Load sensor harness Raise and lower the lift to its
leveling, it does not stop automatically : Wire breakage, short circuit, uppermost (relief) and lowermost
in a horizontal position. leakage (harness or connector) positions to check the change in the
(The fork does not stop in a horizontal voltage.
position.) Load sensor no-load matching value Check the matching value on the
• Perform matching again.
２０１１年１月２５日
: No agreement with the vehicle state Matching screen.

Main controller
: Internal failure
火曜日

Tilt control Check the matching value on the
Matching screen.
When tilted forward for leveling, the Check the load sensor voltage, using
fork does not stop automatically in a Load sensor main body Analyzer.
horizontal position. : Internal breakage : In NL
necessary.
(When tilted forward for leveling, the Load sensor harness Raise and lower the lift to its
fork stops where it is when the : Wire breakage, short circuit, uppermost (relief) and lowermost
automatic fork leveling switch is leakage (harness or connector) positions to check the change in the
pressed.) voltage.
Load sensor no-load matching value Check the matching value on the
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
: In NL
detected. necessary.
Raise and lower the lift to its
uppermost and lowermost positions
to see if the switch turns on and off
normally.
Main controller
: Internal failure
4-195
sec04.book
Control
systems
4-196
196 ページ
(Mini Lever / Joystick Lever)
２０１１年１月２５日

When the fork is tilted backward for Check the matching value on the
value • Perform matching again
leveling, it does not stop automatically Matching screen.
火曜日
in a horizontal position.
(The fork tilts to its backward tilt limit Main body of automatic fork leveling
without stopping in a horizontal switch
position.) : Open failure
Mechanical detection unit of automatic
fork leveling switch
: Gap in detection unit is improperly
adjusted.
normally.
Tilt control Main controller
: Internal failure
When the fork is tilted backward for See "When the fork is tilted forward for
leveling, it does not stop automatically leveling, it does not stop automatically
– –
in a horizontal position. in a horizontal position (The fork does
(The fork does not stop in a horizontal not stop in a horizontal position.)"
position.)
(Mini Lever / Joystick Lever) : The link or the installation portion is : In NL replace it if necessary.
When the fork is tilted backward for broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
leveling, it does not stop automatically Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
in a horizontal position. : Wire breakage, short circuit, change in voltage.
(The fork stops where it is when the leakage (harness or connector)
automatic fork leveling switch is Tilt angle sensor leveling matching
pressed.) value • Perform matching again.
Matching screen.
Main controller
: Internal failure
sec04.book
Control
systems
Main body of automatic fork leveling
switch
197 ページ

: Open failure
adjusted.
normally.
２０１１年１月２５日
Check the tilt control valve, using • Check the oil control valve, and
Oil control valve
Active Test. repair or replace it if necessary.
火曜日
: Seizure of tilt control valve

The mast backward tilting speed is not Tilt solenoid harness : Tilt solenoid forcibly turned on • Check the solenoid and replace it if
limited. (backward tilting speed limited) necessary.
Tilt the mast backward to check the • Check the harness and repair or
operation. replace it if necessary.

necessary.
Tilt control : Wire breakage, short circuit uppermost and lowermost positions
normally.
Main controller
: Internal failure
switch
: Short circuit
adjusted.
The mast backward tilting speed is normally.
always slow. : Short circuit (harness or connector)
Tilt solenoid harness (backward tilting speed not limited) necessary.
: Short circuit, leakage (harness or Tilt the mast backward to check the • Check the harness and repair or
4-197
sec04.book
Control
systems
4-198
Analyzer.
198 ページ

: In NL
The mast backward tilting speed is Lifting switch harness • Check the harness and repair or
always slow. : Wire breakage, short circuit replace it if necessary.
normally.
Main controller
２０１１年１月２５日
: Internal failure
Display setting
Check the set value on the Option Set • Change the setting
: Forward tilting speed setting
火曜日
screen. (see "MULTI-FUNCTION DISPLAY")

(T F-SPD LIM)
Although the load is lifted high, the • Check the switch, and replace it if
Tilt control mast forward tilting speed is not necessary.

limited. • Check the harness and repair or
normally.
Main controller
: Internal failure
Analyzer.
: In NL
The mast forward tilting speed is Lifting switch harness • Check the harness and repair or
normally.
Main controller
: Internal failure
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
Knob position The knob is displaced from its normal damaged. fully closed • Check the harness and repair or
compensation position to a certain position. Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
control (10° or more from the straight running : Wire breakage, short circuit, the change in voltage.
(OPT) position) leakage (harness or connector)
Tire angle sensor straight running
angle matching value • Perform matching again.
Matching screen.
sec04.book
Control
systems
: Internal damage
199 ページ
Check the knob position compensation
２０１１年１月２５日
The knob is displaced from its normal valve, using Active Test.
Knob position compensation valve • Check the knob position
position to a certain position. : Tire end
main body compensation valve, and repair or
(10° or more from the straight running Forcibly turn on (bypass) and off (no
火曜日
: Leakage, seizure (internal damage) replace it if necessary.

position) bypass) the knob position
Knob position compensation solenoid • Check the solenoid and replace it if
compensation solenoid to check
harness necessary.
how the steering system operates.
Forcibly ON ... Steering idles (light).
Forcibly OFF ... Steering does not
idles (heavy).
Knob position The road surface is inclined. – –

compensation Main controller
control : Internal failure
(OPT) Tire angle sensor main body
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
The knob is displaced from its normal leakage (harness or connector)
position. Tire angle sensor straight running
(The knob position is not constant angle matching value • Perform matching again.
Matching screen.
during straight running.) : No agreement with the vehicle state
: Internal damage
4-199
sec04.book
Control
systems
4-200
valve, using Active Test.
200 ページ

: Tire end
Forcibly turn on (bypass) and off (no
bypass) the knob position
Knob position The knob is displaced from its normal compensation solenoid to check
harness necessary.
compensation position. how the steering system operates.
control (The knob position is not constant Forcibly ON ... Steering idles (light).
２０１１年１月２５日
(OPT) during straight running.)

idles (heavy).
PS cylinder system link is defective. • Check the cylinder, and repair or
火曜日
–
: Eccentric pin or kingpin is defective replace it if necessary.
Main controller
: Internal failure
Seat switch main body : Direction switch in neutral, drive • Check the switch, and replace it if
: Short circuit fully closed necessary.
Neither traveling OPS nor load Seat switch harness Check if the switch turns on and off • Check the harness and repair or
handling OPS operates. : Short circuit (harness or connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
: Internal failure
– • Replace the drive motor drive circuit.
: Internal failure
Only traveling OPS does not operate.
Main controller
OPS : Internal failure
Only load handling OPS does not connector) operation. replace it if necessary.
operate. Oil control valve • Check the oil control valve, and
Check the lift lowering lock valve,
: Seizure of or leakage from lift repair or replace it if necessary.
using Active Test.
lowering lock valve • Check the solenoid and replace it if
: Lift lock solenoid forcibly turned off
Lift lock solenoid harness necessary.
(lift lock)
: Short circuit, leakage (harness or • Check the harness and repair or
Lower the lift to check the operation.
connector) replace it if necessary.
sec04.book
Control
systems
• Check the oil control valve, and
Oil control valve (Conventional Lever)
repair or replace it if necessary.
201 ページ
: Seizure of or leakage from load

• Check the material handling
handling proportional valve
proportional valve solenoid, and
: Seizure of or leakage from unload
– replace it if necessary.
Only load handling OPS does not valve
OPS • Check the unload valve solenoid
operate. Harness of unload valve solenoid
２０１１年１月２５日
Main controller
: Internal failure
火曜日

necessary.
voltage.
Display setting
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI-
agreement with the data on the Matching screen. FUNCTION DISPLAY")
Traveling Although no load is applied, the speed actual vehicle state.
control (option) is limited when the lift is raised high. • In traveling control, the attachment
weight and the mast weight are
treated as part of the load weight,
because they affect the longitudinal
stability of the vehicle. For a very
Heavy attachment, mast with a high
– heavy mast or an FSV or FV mast
lifting height
with a high lifting height, if its inner
middle mast is rather heavy, a limit
may sometimes be placed on the
speed even under no-load
conditions.
4-201
sec04.book
Control
systems
4-202
When the lift is raised to its uppermost
position, the load sensor cannot
202 ページ
distinguish this situation from a

situation in which a heavy load is
carried, because, in that situation, a
relief pressure remains in the lift
Lift relief pressure detected. –
Although no load is applied, the speed cylinder pressure that the load sensor
is limited when the lift is raised high. senses.
After a lift relief, however, it becomes
２０１１年１月２５日
possible to perform operation because

the relief pressure is discharged when
火曜日
the lift is lowered even a little.

Main controller
: Internal failure

necessary.
Traveling replace it if necessary.
control (option) voltage.
necessary.
Although a load is carried, the speed is replace it if necessary.
not limited when the lift is raised high. normally.
Display setting
: Traveling control setting disabled
Check the set value on the Option Set • Change the setting (see "MULTI-
Load sensing speed restriction
screen. FUNCTION DISPLAY")
disabled
(ASC W/LOAD, MODE)
Display setting
actual vehicle state.
Main controller
: Internal failure
sec04.book
Control
systems
Analyzer.
203 ページ

: In NL
Although the fork is not raised high, Raise and lower the lift to its
the speed is limited when a load is uppermost and lowermost positions
carried. to see if the switch turns on and off
normally.
Main controller
Traveling – • Replace the main controller.
２０１１年１月２５日
: Internal failure
control (option)
Display setting • Change the setting (see "MULTI-
Check the set value.
: Maximum speed limit is set very low. FUNCTION DISPLAY")
火曜日
Display setting
A limit is always placed on the speed
regardless of whether a load is carried
or not.
Main controller
: Internal failure
4-203
sec04_2.fm 204 ページ２０１１年２月１日火曜日午前１０時１１分
Chassis Electrical
CE11-001R
May 13, 2011
Clamp Release Interlock (Mini
Lever Units)
7FBEU15-20, 7FBEHU18,
SERVICE INFORMATION BULLETIN 8FGCU15-32 and 8FGU15-32
Subject: Clamp Release Interlock (Mini Lever Units) Page 1 of 4
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 8FGCU15-32 and 8FGU15-32
Starting with units built in October 2010, new units with mini levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments must
have a second release method (2 moves to open the attachment) to prevent accidental opening. Please
refer to Product Bulletins 19-10 and 24-10.
Toyota Designed Circuit for ANSI B56.1
Factory Programmed
The function of the controller is to maintain the

Attachment 2 (ATT21 and ATT22) potentiometer
voltage at a neutral status until the additional switch
(Hall Effect type) on the mini lever is depressed.
System Components:
Clamp Release Interlock (CRI) Controller

• 7FBEU models it is located in the left
step in front of the battery (under the fan
box).
• 8FBCU models it is located behind the
hydraulic tank under the battery.
• 8FGCU and 8FGU models it is located
on the right frame near the transmission.
Clamp Release Controller connector

plug is numbered. Due to changes in
various models and options the color
code can change so it is preferred to
use the pin connection on each unit
and track back to the power supply
and mini lever potentiometer.
12 volt power supply is only used on

the electric trucks (7FBEU or
8FBCU) and is wired to P1 and
N1/N2. It is located near the Clamp
Release Controller.
System Components Continued:
Mini Lever
Potentiometer
Wiring.
680 Ohm Resistor
Calibration Instructions:
Note – Calibration only required when controller is replaced. See note on page 4.
1. Turn truck off.
2. Unplug power supply for CRI controller.
3. Unplug calibration jumper harness.
4. Turn truck on.
5. Plug power supply back in for CRI controller
6. After waiting 15 seconds, place calibration jumper back on harness.
7. Perform matching for lever that has CRI.
Note: After extended usage the variable resistor (level angle sensor ATT2) could encounter a
slight neutral voltage drift and error codes H4-3 and/or H4-4 could be logged. Before replacing
any parts, first recalibrate the CRI module (see page 3) then perform matching of the level
angle sensor (see page 3-68 in repair manual CU331).
Chassis Electrical
CE11-002
August 31, 2011
8FBCU Horn Wires Breaking
Subject: 8FBCU Horn Wires Breaking Page 1 of 1
MODEL APPLICATION:
Beginning with Serial Numbers:

8FBC(H)U20/25-60636
8FBCU30/32-60233
REPAIR INFORMATION:
Starting 11/12/2010 the main wiring harness was changed to lengthen the horn wires. For units built
prior to this change, here is the procedure to modify units in operation that may encounter this
condition:
Chassis Electrical
CE11-003
August 31, 2011
Clamp Release Interlock
(Standard Lever Units)
7FBE(H)U15-20, 8FBC(H)U20-
SERVICE INFORMATION BULLETIN 32, 7FBCU15-55, 8FG(C)U15-32,
7FGCU35-70 and 7FGU35-80
Subject: Clamp Release Interlock (Standard Lever Units) Page 1 of 4
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 7FBCU15-55
8FGCU15-32, 8FGU15-32, 7FGCU35-70 and 7FGU35-80
Starting with October 2010, new units with standard hydraulic levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments
must have a 2nd release method (2 moves to open the attachment) to prevent accidental opening.
Please refer to product bulletins 19-10 and 24-10.

Switch and Wiring Installation
Clamp release switch

Switch assembly and wiring as routed
by the factory.
Wire routing through boot and lever

connects to relay circuit.
Solenoid and Hydraulic Hose Connections
Hose Connection at Oil Control Valve Hose to Attachment Spacer Plate
Bolts
Relay
Solenoids 12, 36 and

48 volts (Voltage
Specific).
Hose from Fitting

valve
This drawling is an example of an

8FBCU25 only. Most locations of the
solenoid and relay are close to the
Oil Control Valve (right side of
frame).
Power and Ground Wire Connections
This drawing is an example of the

panel connections for an 8FBCU25
and will be similar on all electric
products. For IC trucks, the
positive and negative sources are
connected directly to the battery.
Chassis Electrical
CE14-005
August 15, 2014
Special Grounding Strap
(30)/7FBCU15-32, 7FBCHU25,
SERVICE INFORMATION BULLETIN 8FBCU20-32
Subject: Special Grounding Strap Page 1 of 2
MODEL APPLICATION:
(30)/7FBCU15-32, 7FBCHU25, 8FBCU20-32
This special grounding strap can be added to the models mentioned above. This strap has
excellent conductance to reduce ESD (Electro Static Discharge) when using non marking tires.
Parts Required for One Unit
56184-21320-71 (2 PCS)
Install earth wire after setting
collars.
56401-21320-71
Mount using the rear
91551-80816 (2 PCS)
steer axle mounting
bolts.
56412-21320-71
56185-21320-71
If the grounding strap cannot be attached to the rear axle, use the alternate method below.
sec04A.book 1 ページ２０１１年１月２５日火曜日午後６時３５分
4A-1
TROUBLESHOOTING (2010.10~)
Page
BEFORE TROUBLESHOOTING......................... 4A-2
CONNECTOR HANDLING...................................... 4A-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ..................................................... 4A-2
TROUBLESHOOTING METHOD ........................ 4A-4
TO USE SST........................................................ 4A-5
DIAGNOSIS CODE LIST..................................... 4A-6
WHEN ERROR CODE IS DISPLAYED ............. 4A-22
WHEN NO ERROR CODE IS DISPLAYED..... 4A-193 4A
Note:
This chapter has been changed due to replacement of the Motor Driver from
October 2010 TIEM production.

1 Added Service Manual Change History 2 8/31/12
2 Added SIB CC12-003 219 8/31/12
3 Added SIB CE11-001R 223- 11/15/2012
226
4 Added links to Table of Contents 1 2/15/13
5 Added SIB CE11-002 227 2/15/13
6 Added SIB CE11-003 228 2/15/13
7 Added SIB MA12-004 232 2/15/13
8 Added SIB CE14-005 246- 8/15/14
247
Page 1 of 1
Hotline Tech Tips

4A-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
harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard:10 W or less
Note:
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.
4A-3
Short circuit check

harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends.
ǡ

and sideways.
3. Measure the resistance between a terminal corresponding to

the connector terminal and N1. Always inspect the connectors
at both ends.
The wiring may short-circuit due to pinching by the body or

defective clamping.
4A
ǡ ǡ
Visual and contact pressure checks

• Disconnect the connectors at both ends of the corresponding
harness.
• Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
• Inspect that there is no loosening or damage at the locked
portion. Also, lightly pull the wire harness from the connector to
check that it does not come off.
• 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.
Click here for information on

Special Grounding Strap to help
reduce static electricity issues.
4A-4
TROUBLESHOOTING METHOD
Inspection: Check of seat switch condition Defective portion
1. Turn off the key switch and disconnect the battery Repair or replacement
SDM: 0
plug.
2. Disconnect the CN43 connector, connect the battery Seat switch defect
SDM: 1 To the next step depending on the result.
Inspection 1:
plug. NG
Harness defect
continuities.
OK
Explanation of Frames
A single frame indicates measurement with a tester or an
ordinary step.
the seat.

A double frame indicates inspection by an analyzer
function.
Test item.
4A-5
TO USE SST
Use SSTs for quick, accurate electrical troubleshooting on the 8FBCU series.
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

-
09230-13240-71 Main controller check harness
(for power source check)
C8-1, 2
09240-13241-71 AC drive check harness
E8-1, 2
09230-13700-71 CN76 short harness 61-1, 2
C2-2
C4-1 to 6
C5-1 to 6
C8-1, 2
CN7 IC check pin E2-2

09232-13130-71 Check harness E8-1, 2
Each short harness FB-1, 2
4A
62-1, 2
71-1 to 3
72-1 to 4
G5-1 to 6
CN97 harness
09238-13130-71 68-1 to 3
CN99 check harness
Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
sec04A.book
DIAGNOSIS CODE LIST
4A-6
Indication : Information can be checked on the display when vehicle trouble occurs.
Memory : Use indication information that can be checked when the mask function DIAG MEMORY is used.
6 ページ
Indicator : Diagnostic mode

O/H

O/H
DCR A0-1 Drive motor drive power circuit overheating abnormality Traveling stop.
lighting
２０１１年１月２５日

PCR A0-2 Pump motor drive power circuit overheating abnormality
火曜日
Diagnostic
Unable to traveling and load handling
A1-1 A1-1 mode Main controller high voltage
blinking
Diagnostic
A1-2 A1-2 mode Drive motor drive circuit high voltage Traveling stop.
午後６時３５分
blinking
Diagnostic
Load handling stop.
A1-4 A1-4 mode Pump motor drive circuit high voltage
Steering become stiff
blinking
O/H Drive motor output restricted.
C/R A2-1 Main controller circuit board overheating abnormality
lighting Unable to load handling
Diagnostic
Traveling and load handling stop.
A3-1 A3-1 mode Battery connection incorrect
blinking
Diagnostic
OPSS function invalidity
A5-1 A5-1 mode Seat switch GND short abnormality
Parking brake reminder alarm partially disable.
blinking
Diagnostic
A6-3 A6-3 mode Tilt switch GND short abnormality Tilt stop.
blinking
Diagnostic
Traveling stop.
A8-2 A8-2 mode F6 fuse abnormality (Open)
Load handling stop.
blinking
Diagnostic
blinking
sec04A.book
Diagnostic
AA-1 AA-1 mode Main controller temperature sensor abnormality
Load handling stop.
7 ページ
blinking
Diagnostic
Cooling fan stop.
AB-1 AB-1 mode Cooling fan drive circuit abnormality
blinking
AC-1 AC-1 mode Semiconductor switch abnormality Load handling stop.
２０１１年１月２５日
Diagnostic
AD-1 AD-1 mode Drive motor driver → Main controller communication abnormality
火曜日
blinking Traveling stop.

Diagnostic Knob position correcting stop.
Drive motor driver → Main controller communication abnormality (on
AD-2 AD-2 mode
start up)
blinking
Diagnostic
AD-5 AD-5 mode Pump motor driver → Main controller communication abnormality
blinking Load handling stop.
Pump motor driver → Main controller communication abnormality (on
AD-6 AD-6 mode
start up)
blinking
Diagnostic
blinking
Diagnostic
blinking Unable to traveling and load handling
blinking
Diagnostic
blinking
4A-7
sec04A.book
4A-8
Diagnostic
8 ページ
blinking
Diagnostic
blinking
Some control operations not stable.
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
C0-2 C0-2 mode Drive motor power-circuit short
blinking
Diagnostic
C1-1 C1-1 mode Drive motor current sensor neutral voltage error. Traveling stop.
blinking
Diagnostic
C1-2 C1-2 mode Drive motor current sensor over current.
blinking
O/H
DM C2-1 Drive motor overheating abnormality.
lighting
Diagnostic
C2-2 C2-2 mode Drive motor temperature sensor abnormality.
blinking Drive motor output restricted.
Diagnostic
C3-1 C3-1 mode Drive motor power circuit temperature sensor abnormality.
blinking
sec04A.book
Diagnostic
9 ページ
blinking
Diagnostic
blinking
Display only
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
C4-5 C4-5 mode Accelerator sensor offset abnormality. Traveling stop.
blinking
Diagnostic
C4-6 C4-6 mode Accelerator sensor matching value error. Drive motor output restricted.
blinking
Diagnostic
C8-1 C8-1 mode Drive motor speed sensor open.
blinking
Traveling stop.
Diagnostic
C8-2 C8-2 mode Drive motor speed sensor short.
blinking
CB-1 CB-1 mode MB contactor open. Load handling stop.
Diagnostic
CB-2 CB-2 mode MB contactor short. Display only
blinking
Diagnostic
CB-3 CB-3 mode MB contactor drive circuit open.
blinking
CB-4 CB-4 mode MB contactor drive circuit short. Load handling stop.
Diagnostic
CB-5 CB-5 mode MB contactor drive circuit short.
blinking
4A-9
sec04A.book
O/H
4A-10
C/P CB-6 MB contactor panel overheating abnormality.
lighting
10 ページ
Diagnostic Pump motor output restricted.

CB-7 CB-7 mode MB contactor panel temperature sensor abnormality.
blinking
Diagnostic
blinking
Traveling stop.
Diagnostic
２０１１年１月２５日

blinking
火曜日
Diagnostic
CC-6 CC-6 mode Drive motor drive CPU error. Display only
blinking
Diagnostic
E0-2 E0-2 mode Pump motor drive power circuit abnormality.
blinking
Diagnostic
Unable to load handling.
E1-1 E1-1 mode Pump motor current sensor neutral voltage error.
blinking
Diagnostic
E1-2 E1-2 mode Pump motor current sensor over current.
blinking
O/H
PM E2-1 Pump motor overheating abnormality.
lighting
Diagnostic
E2-2 E2-2 mode Pump motor temperature sensor abnormality.
Pump motor output restricted.
blinking
Diagnostic
E3-1 E3-1 mode Pump motor drive power circuit temperature sensor abnormality.
blinking
sec04A.book
Diagnostic
E8-1 E8-1 mode Pump motor speed sensor open.
blinking
11 ページ
Diagnostic
E8-2 E8-2 mode Pump motor speed sensor short.
blinking Unable to load handling.
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
EC-6 EC-6 mode Pump motor drive CPU error. Display only
blinking
Diagnostic
EE-1 EE-1 mode Display → Main controller communication error. Settings cannot be changed by display operation.
blinking
Diagnostic
EE-2 EE-2 mode Display → Main controller communication error. Unable to display operation
blinking
Diagnostic
blinking Vehicle settings cannot be changed by display
Diagnostic operation.
blinking
Diagnostic
blinking Traveling and load handling cannot be performed
Diagnostic simultaneously.
F4-2 F4-2 mode Display CPU error. Disable the traveling control function.
blinking W/ PIN Code Entry System:
Diagnostic PIN code entry system disable.
blinking
Diagnostic
F4-4 F4-4 mode Display CPU error. Display only
blinking
4A-11
sec04A.book
Diagnostic
4A-12
F4-5 F4-5 mode Display CPU error. Display function not stable.
blinking
12 ページ
Diagnostic
blinking
Diagnostic
F4-7 F4-7 mode Display CPU error. Some control operations not stable.
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
FF-1 FF-1 mode D7V power supply circuit over current. Display turns OFF.
blinking
Diagnostic

FF-2 FF-2 mode SSTR+ power supply circuit over current.
blinking
Diagnostic
31-1 31-1 mode Declining of actibvating voltage for Drive motor drive circuit. Travelling stop.
blinking
Diagnostic
Load handling stop.
31-3 31-3 mode Declining of actibvating voltage for Pump motor drive circuit.
blinking
Diagnostic
32-1 32-1 mode Drive motor driver ID abnormality.
blinking
Display only.
Diagnostic
32-3 32-3 mode Pump motor driver ID abnormality.
blinking
Diagnostic
33-1 33-1 mode Main controller → Drive motor driver CAN communication abnormality. Travelling stop.
blinking
Diagnostic
Load handling stop.
33-3 33-3 mode Main controller → Pump motor driver CAN communication abnormality.
sec04A.book
Diagnostic
52-1 52-1 mode Yaw late sensor open.
blinking
13 ページ
Diagnostic
52-2 52-2 mode Yaw late sensor short. Swing lock disable.
blinking
Diagnostic
52-3 52-3 mode Yaw late sensor neutral voltage error.
blinking
２０１１年１月２５日
Diagnostic
54-1 54-1 mode Swing lock solenoid open.
火曜日
blinking
Diagnostic
54-2 54-2 mode Swing lock solenoid short. Swing lock failed.
blinking
Diagnostic
54-3 54-3 mode Swing lock solenoid drive circuit abnormality.

blinking
Diagnostic
54-4 54-4 mode Swing lock solenoid abnormality. Partial limitation of rear wheel swing control function.
blinking
Diagnostic
61-1 61-1 mode Load sensor open.
blinking Partial limitation of mast control function.
Diagnostic Partial limitation of OPSS function.
61-2 61-2 mode Load sensor short.
blinking
4A-13
sec04A.book
Diagnostic
4A-14
62-1 62-1 mode Tilt angle sensor open.
blinking
14 ページ
Diagnostic
62-2 62-2 mode Tilt angle sensor short.
blinking
Diagnostic
63-1 63-1 mode Tilt switch forward/backward simultaneous operation short. Partial limitation of mast control function.
blinking
２０１１年１月２５日
Diagnostic
63-2 63-2 mode Tilt switch forward position short.
火曜日
blinking
Diagnostic
63-3 63-3 mode Tilt switch backward position short.
blinking
Diagnostic
64-1 64-1 mode Lift lock solenoid open. Lift lower may stop.
blinking
Diagnostic
64-2 64-2 mode Lift lock solenoid short. Lift lower may stop.
blinking
Diagnostic
64-3 64-3 mode Lift lock solenoid drive circuit abnormality.
blinking
Diagnostic
64-4 64-4 mode Lift lock solenoid its continuity.
blinking
Diagnostic
65-1 65-1 mode Tilt control solenoid open. Tilt forward may stop.
blinking
Diagnostic
65-2 65-2 mode Tilt control solenoid short. Tilt forward may stop.
blinking
Diagnostic
65-3 65-3 mode Tilt control solenoid drive circuit abnormality.
blinking
sec04A.book
Diagnostic
65-4 65-4 mode Tilt control solenoid its continuity.
15 ページ
blinking
Diagnostic
66-1 66-1 mode Outside matching value range for tilt angle sensor. Partial limitation of mast control function.
blinking
Partial limitation of mast control function.
Diagnostic
67-1 67-1 mode Lifting height switch abnormality.
２０１１年１月２５日

blinking
Partial limitation of OPSS function.
火曜日
Diagnostic
68-1 68-1 mode Lifting height sensor open.
blinking
Diagnostic
68-2 68-2 mode Lifting height sensor short.
Lift speed limited.

blinking
Diagnostic
68-3 68-3 mode Lifting height sensor abnormality.
blinking
Diagnostic
71-1 71-1 mode Tire angle sensor open.
blinking
Diagnostic
71-2 71-2 mode Tire angle sensor short.
blinking
Diagnostic
blinking Knob position correcting stop.
blinking
Diagnostic
72-3 72-3 mode Steering angle sensor SSC open. Knob position correcting stop.
blinking
Diagnostic
72-4 72-4 mode Steering angle sensor power circuit open.
blinking
4A-15
sec04A.book
Diagnostic
4A-16
73-1 73-1 mode Knob position synchronizer solenoid open.
blinking
16 ページ
Diagnostic
73-2 73-2 mode Knob position synchronizer solenoid short.
blinking
Diagnostic
73-3 73-3 mode Knob position synchronizer solenoid power circuit abnormality. Knob position correcting stop.
blinking
２０１１年１月２５日
Diagnostic
73-4 73-4 mode Knob position synchronizer solenoid abnormality.
火曜日
blinking
Diagnostic
74-1 74-1 mode Outside matching value range for tire angle error.
blinking
Diagnostic
H1-1 H1-1 mode Lift lever potentiometer open.

blinking
Diagnostic
H1-2 H1-2 mode Lift lever potentiometer short. Lift stop.
blinking
Diagnostic
H1-3 H1-3 mode Lift lever potentiometer output abnormality.
blinking
Diagnostic
Lift stop. (Conventional lever)
H1-4 H1-4 mode Lift lever potentiometer neutral error.
blinking
Diagnostic
H1-5 H1-5 mode Lift lever potentiometer matching value error. Lift stop.
blinking
Diagnostic
H2-1 H2-1 mode Tilt lever potentiometer open.
blinking
Diagnostic
H2-2 H2-2 mode Tilt lever potentiometer short. Tilt stop.
blinking
Diagnostic
H2-3 H2-3 mode Tilt lever potentiometer output abnormality.
blinking
sec04A.book
Diagnostic
H2-4 H2-4 mode Tilt lever potentiometer neutral error. Load handling stop.
blinking
17 ページ
Diagnostic
H2-5 H2-5 mode Tilt lever potentiometer matching value error. Tilt stop.
blinking
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
blinking
Diagnostic

blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
Diagnostic
blinking
4A-17
sec04A.book
Diagnostic
4A-18
H5-1 H5-1 mode Lift proportional solenoid open. (PULL)
blinking
18 ページ
Upward lift stop.

Diagnostic
H5-2 H5-2 mode Lift proportional solenoid short. (PULL)
blinking
Diagnostic
H5-3 H5-3 mode Lift proportional solenoid open. (PUSH)
blinking
２０１１年１月２５日
Downward lift stop.

Diagnostic
H5-4 H5-4 mode Lift proportional solenoid short. (PUSH)
火曜日
blinking
Diagnostic
H5-5 H5-5 mode Lift proportional solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H5-6 H5-6 mode Lift proportional solenoid (PULL/PUSH) abnormality.

blinking
Diagnostic
H6-1 H6-1 mode Tilt backward solenoid open.
blinking
Backward tilt stop.
Diagnostic
H6-2 H6-2 mode Tilt backward solenoid short.
blinking
Diagnostic
H6-3 H6-3 mode Tilt forward solenoid open.
blinking
Forward tilt stop.
Diagnostic
H6-4 H6-4 mode Tilt forward solenoid short.
blinking
Diagnostic
H6-5 H6-5 mode Tilt solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H6-6 H6-6 mode Tilt forward/backward solenoid abnormality.
blinking
sec04A.book
Diagnostic
blinking
19 ページ
Diagnostic
blinking
Attachment 1 stop.
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
blinking
Load handling stop.
Diagnostic

blinking
Diagnostic
blinking
Diagnostic
blinking
Attachment 2 stop.
Diagnostic
blinking
Diagnostic
blinking
4A-19
sec04A.book
Diagnostic
4A-20
blinking
20 ページ
Diagnostic
blinking
Diagnostic
HB-1 HB-1 mode Proportional solenoid power supply circuit (RY1) open. Load handling stop.
blinking
２０１１年１月２５日
Diagnostic
HB-2 HB-2 mode Proportional solenoid power supply circuit short.
火曜日
blinking
Diagnostic
HB-3 HB-3 mode Proportional solenoid power supply circuit over current.
blinking
Diagnostic

HC-1 HC-1 mode Unload solenoid open.
operating.
blinking
Diagnostic
HC-2 HC-2 mode Unload solenoid short.
operating.
blinking
Diagnostic
HC-3 HC-3 mode Unload solenoid drive circuit abnormality. Loading operations other than lower may not operate.
blinking
Diagnostic
HC-4 HC-4 mode Unload solenoid abnormality.
operating.
blinking
sec04A.book
Diagnostic
blinking
21 ページ
Diagnostic
blinking
Diagnostic
blinking
２０１１年１月２５日
Shock sensor disabled.

Diagnostic
火曜日
blinking
Diagnostic
blinking
Diagnostic

blinking
4A-21
4A-22
WHEN ERROR CODE IS DISPLAYED

z Error Code A0-1 (Drive motor power-circuit overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-1

do not rotate.
[ANL]ACTIVE TEST 2/3 FAN 1
FAN OFF → ON
The fans rotate.

Record the value of

TDMDH.
2
4A-23
The TDMDH temperature is 78°C or more for both
compared to the TDMDH temperature previously
checked.

The TDMDH temperature is
TDMDH: 78°C or more and it has not
78°C to the TDMDH temperature
previously checked.

Jp

Harness defect
OK
Inspection:
2. Disconnect the CN112, CN113 and CN114 connectors. Either
4. Forcibly turn on the cooling fans, using Active Test. 36V type: Excluding approx. 36V
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.
3
4A-24
Jp
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.
Inspection:
2. Connect the CN114 and disconnect the CN112 and CN113. The fans do
3. Turn on the key switch and connect the battery plug. not rotate.
FAN OFF → ON
The fans rotate.


4A-25
z Error Code A0-2 (Pump motor power-circuit overheating abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

do not rotate.
[ANL]ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.

Record the value of

TPMDH.
2
4A-26
The TPMDH temperature is 78°C or more for both
compared to the TPMDH temperature previously
checked.

The TPMDH temperature is
TPMDH:
78°C or more and it has not
Less than
lowered by 5°C or more compared
78°C
to the TPMDH temperature
previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4A-27
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.


4A-28
z Error Code A1-1 (Main controller high voltage)

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6 (19, VBMBSL)
Main
controller
Probable cause:
(2) MB contactor defect (5) Battery overvoltage
(After the key switch is turned on and off,
A9-2 will be displayed.)
Error code A1-1
A1-1
An error
occurs.
Turn off and back on the key switch. Inspection: Check of VBMBSL voltage
Check the VBMBSL voltage, using the Analyzer menu.
A1-1 No error occurs [ANL] I/O TEMP/VOLT 3/4
VBMBSL: Less than 65 V VBMBSL: More than 65 V
Inspection: Check of battery voltage

battery plug.
Inspection: Check of F7 fuse Approx. 48 V 65 V or more
battery plug. Main controller defect Replace the battery.
F7 fuse open
tester.
OK (0 Ω)
NO
Check the battery plug.

Check the battery electrolyte.
4A-29
z Error Code A1-2 (Drive motor drive circuit high voltage)

Related portion
MB
P1 F1 P4
Drive motor
drive circuit
Probable cause:
(2) MB contactor defect (5) Drive motor drive circuit defect

Error code A1-2
A1-2
error
Inspection:
errors. (Check of voltage of drive motor drive circuit)

battery plug.
battery plug. Drive motor drive circuit defect Battery defect
F1 fuse open
tester.
OK (0 Ω)
NO

4A-30
z Error Code A1-4 (Pump motor drive circuit high voltage)

Related portion
MB
P1 F1 P4
Pump motor
drive circuit
Probable cause:
(2) MB contactor defect (5) Pump motor drive circuit defect

Error code A1-4
A1-4
error
Inspection:
errors. (Check of voltage of pump motor drive circuit)

battery plug.
battery plug. Pump motor drive circuit defect Battery defect
F1 fuse open
tester.
OK (0 Ω)
NO

4A-31
z Error Code A2-1 (Main controller overheating abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
(1) The ambient temperature around the Main controller is high. (3) Temperature sensor defect (Main controller defect)
(2) Overheating (continuous overload operation)

Error code A2-1


Record the value of
TMCB.
The TMCB temperature is 79°C or more and it has
lowered by 5°C or more compared to the TMCB

The TMCB temperature is 79°C or more and it has not lowered by 5°C
TMCB: Less than 79°C
or more compared to the TMCB temperature previously checked.
4A-32
z Error Code A2-2 (Drive motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-1

do not rotate.
[ANL] ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.


Record the value of
TDMDB.
2
4A-33
checked.

previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4A-34
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4A-35
z Error Code A2-3 (Pump motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

The fans
cooling fan compulsorily by using Active Test.
do not rotate.
1
FAN OFF → ON
The fans rotate.

[ANL] I/O TEMP/VOLT2/4

Record the value of
TDMDB.
2
4A-36
checked.

previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4A-37
Jp
Inspection:
4. Forcibly turn on the cooling fans, using Active Test
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4A-38
z Error Code A3-1 (Battery connection incorrect )

Related portion
F5
P1 CN130-4 CN104-1(41, B48V)
Main
controller
Battery
N1
Probable cause:
(1) Set voltage defect.
(2) The voltage in the B48V line after the F5 fuse is above the set voltage.
(3) 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
A3-1 error occurs.
Inspection 1: Check of the set voltage

NG
Set voltage defect
[OPT] 36V YES/NO
OK
48V type: Less than 65V

Inspection: Check of battery voltage 36V type: Less than 48V

A
4A-39
48V type: Less than 65 V

Check of battery voltage 36V type: Less than 48 V
P1[+]←→N1[-]

Check the battery, and replace it with a regular battery if necessary.
Inspection 1: Check of set voltage
Check [OPT] 1.OPTIONSET 36V setting.

(See page 3-58)
Vehicle specification Standard

36V type YES
48V type NO
4A-40
z Error Code A5-1 (Seat switch GND short abnormality)

Related portion
CN103-6 (51, LS-) CN92-1
Main
Seat switch
controller
CN104-18 (67, SDM) CN92-2
Probable cause:
(1) Connector contact defect (3) Harness defect
(2) Seat switch defect (4) Main controller defect
Error code A5-1

the seat.

SDM: 0
SDM: 1

plug. SDM: 0
Seat switch defect
2. Disconnect the CN92 connector, connect the battery
SDM: 1
Inspection 1:
2. Disconnect the CN103, CN104 and CN92 connectors
and check the harnesses for their continuities.
OK

4A-41

Before this check, turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and
CN92 connectors, visually check inside each connector and the caulked portion of each wire for defects.

4A-42
z Error Code A6-3 (Tilt lever switch abnormality)

Related portion
Tilt lever switch

CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
CN9-4
Probable cause:
(1) The battery plug is connected while the tilt lever is being operated.
(3) Tilt lever switch defect
(4) Tilt lever switch installation portion defect.
(5) Tilt lever switch harness defect
The A6-3 error may occur if the battery plug is connected while the tilt lever is being operated.
Error code A6-3

A6-3 error does not
occur.
plug, and turn on the key switch to see if an error
occurs.
A6-3 error occurs.

A6-3 error
1. Disconnect the CN9connector. does not occur. • Tilt lever switch defect
• Tilt lever switch installation portion defect.
A6-3 error occurs.

NG
OK

4A-43

Perform this check with the battery plug and the CN9, CN102and CN103 connectors disconnected, visually

4A-44
z Error Code A8-1, -2 (F1 and F6 fuse abnormality (Open))

Related portion
MB F1 P4
P3
Battery CN104-2 (44, VBMB)

CN130-5
F6
Drive motor Main

drive circuit controller
Pump motor drive

circuit
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
4A-45
Error code A8-1
* If CB-1, CB-3, CB-5, A8-2 or A9-2 occurs, perform troubleshooting with priority given to CB-1, CB-3, CB-5, A8-2 or
A9-2.
plug, and visually check the following terminals for
loose bolts: drive motor drive circuit positive terminal,
pump motor drive circuit positive terminal, contactor
panel P4 terminal, drive motor drive circuit negative
terminal, pump motor drive circuit negative terminal A8-1 error does not occur.
and contactor panel N1 terminal. Caution: Before Improper fastening of terminals
starting the job, measure the voltage between
positive terminal and GND; if there is any voltage,
insert a resistor at approx. 100Ω between + and GND
to discharge the capacitor.
A8-1 error occurs.
48V type:
Inspection: Check of supply voltages to drive motor
Approx. 48 V
drive circuit and pump motor drive circuit. Drive motor drive circuit defect
1. Measure the voltage between the positive and Pump motor drive circuit defect
36V type:
negative terminals of each drive circuit.
Approx. 36 V
0V

3. Connect the power cable, connect the battery plug,
and then turn on the key switch.
A8-1 error occurs.

plug. F1 fuse open
OK (0 Ω)

Turn off the key switch and disconnect the battery plug, remove the cupper bar for connection to the motor drive
circuit positive terminal.
Measure the resistance between the positive and negative terminals of the motor drive circuit.
When using an analog tester
Positive terminal: [-] probe
Negative terminal: [+] probe
}
Motor drivers are defective if their resistance measured is 10 Ω or less.
4A-46
Error code A8-2
* If CB-1, CB-3 or CB-5 occurs, Perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
TROUBLESHOOTING.)
errors.
A8-2 error occurs.

A8-2 error occurs.
Inspection: Check of VBMBSL voltage

VBMBSL: Less than 25 V
Check the value of VBMBSL, using the Analyzer menu.
VBMBSL: More than 25 V

plug. F6 fuse open
OK (0 Ω)

NG (∞ Ω)
plug.
terminals (CN130-5 and P3 terminal), on the F6 fuse
side with the F6 fuse installed in the fuse holder.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN104, CN130 connector and P3
terminal and check the harnesses for their
continuities.
OK

4A-47

Perform this check with the battery plug and the CN130, CN104 connectors and P3 terminal disconnected,

4A-48
z Error Code A9-2 (F7 fuse abnormality (Open))

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6
Main
controller
Probable cause:
(1) Connector contact defect (5) F7 fuse holder defect
(2) MB contactor defect (6) Harness defect
(3) F7 fuse installation defect (7) Main controller defect
(4) F7 fuse open
Error code A9-2
TROUBLESHOOTING.)
errors.
A9-2 error occurs.

A9-2 error occurs.
Inspection: Check of VBMB voltage

VBMB: Less than 25 V
Check the value of VBMB, using the Analyzer menu.
VBMB: 25 V or more
A
4A-49

NG (∞ Ω)
plug. F7 fuse open
OK (0 Ω)

plug. NG (∞ Ω)
terminals (CN130-6 and P3), on the F6 and F7 fuse
box side with the F7 fuse installed in the fuse box.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN102, CN130 connectors and P3
terminal, and check the harnesses for their
continuities.
OK

Perform this check with the battery plug and the CN130, CN102 connectors and P3 terminal disconnected.

4A-50
z Error Code AA-1 (Main controller temperature sensor abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
Error code AA-1
* If AA-1 is displayed, the Main controller is defective, so replace it.

4A-51
z Error Code AA-2 (Drive motor drive board temperature sensor abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-2
* If AA-2 is displayed, the drive motor drive circuit is defective, so replace it.
4A-52
z Error Code AA-4 (Pump motor drive board temperature sensor

abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-4
* If AA-4 is displayed, the pump motor drive circuit is defective, so replace it.
4A-53
z Error Code AB-1 (Cooling fan drive circuit abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1
Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
CN113-1
Main
controller
Cooling fan 2
CN102-2 (99,FNDC1) CN113-2
CN114-1
Cooling fan 3
CN114-2
Probable cause:
(2) Cooling fan defect
(3) Harness defect
Error code AB-1

connectors, and visually check inside the connector
2. Connect the CN112, CN113 and CN114 connectors, All cooling fans rotate.
connect the battery plug, turn on the key switch,
forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the
three cooling fans rotate.
FAN OFF → ON
One of the cooling fans stops.

connectors, and then connect the battery plug and
turn on the key switch. AB-1 error occurs.
B
Active Test in the Analyzer menu, and check the error
code after two minutes.
FAN OFF → ON
AB-1 error does not occurs.
A
4A-54


CN112 and CN114 connectors, and then connect the Stop cooling fan 2.
battery plug and turn on the key switch. Cooling fan 2 defect

FAN OFF → ON
Cooling fan 3 rotates.

4A-55

plug. NG
Harness defect
continuities.
OK


4A-56
z Error Code AC-1 (Semiconductor switch abnormality)

Related portion
MB
P2
P1 F5
CN104-1 (41,B48V)
CN101-4 (41,VBBT)
Main
N1 CN143-2
controller
Pump motor drive CN111-8 (KYSAT)
Pre-charge unit
circuit
CN143-1
Drive motor CN110-8 (KYSAT)
drive circuit
CN103-4 (42,KYSAT)
Probable cause:
(6) Pre-charge unit defect
4A-57
Error code AC-1

plug. NG
Harness defect
continuities.
OK
Remove the F1 fuse.
Inspection: Check of Main controller

Connect the CN103 connector, connect the battery AC-1 error occurs.
errors.
AC-1 error does not occur.
Inspection: Check of pre-charge unit

Connect the CN103, CN143 connectors, connect the AC-1 error occurs.
Pre-charge unit defect
battery plug and then turn on the key switch to check
the errors.
Inspection: Check of pump motor drive circuit

Connect the CN103, CN143 and CN111 connectors, AC-1 error occurs.
connect the battery plug, and then turn on the key
Inspection: Check of drive motor drive circuit

Disconnect CN111, connect CN110, connect the battery
errors.
Check pump motor drive circuit

Defect in sections where AC-1 error occurs during
drive motor drive circuit check

Perform this check with the battery plug and the CN103, CN111 and CN110 connectors disconnected, visually

4A-58
z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication

abnormality)
Related portion
CN143-1 CN143-2
CN103-4 (KYSAT) Pre- CN110-8
charge
CN103-11 (CAN1H) CN110-17
CN103-12 (CAN1L) CN110-10
Main CN103-3 (DGND) CN110-2 Drive motor

controller drive circuit
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
CN111-8
CN111-17
CN111-10
CN111-2 Pump motor

drive circuit
CN111-12
CN111-11
Probable cause:
(1) Wrong motor driver type
(3) Harness defect
(4) Motor drive circuit defect
* If AC-1 occurs, perform troubleshooting with priority given to AC-1.

4A-59
Error code AD-1, -2, -5, -6
Detach the battery plugs and check that an 8FBCU Motor driver other than
motor driver is installed. Especially if the motor driver 8FBCU installed
Wrong motor driver type
has just been replaced, check that a different model
motor driver hasn’t been installed.
8FBCU motor
driver installed
plug and visually check inside the CN110 and
CN111connectors and the caulked portions of their
wires for defects. (Refer to BEFORE AD-1, AD-2,
TROUBLESHOOTING.) AD-5, AD-6
2. Connect all the connectors, connect the battery plug, None of these error codes
and then turn on the key switch to check for errors. are displayed.
Especially if a motor drive circuit was replaced
immediately before the error occurred, check if the
connector is connected correctly.
AD-2 or AD-6 is displayed.
(*1: Record the error that has occurred.)
plug. NG
Harness defect
2. Disconnect the CN103, CN104, CN110, CN111 and
CN143 connectors and check the harnesses for their
continuities.
OK
Check of battery voltage

1. Turn off the key switch, and then connect the CN103,
CN104 and CN143 connectors. At that time, leave Less than 15 V
the CN110 and CN111 connectors disconnected.
2. Turn on the key switch and measure the voltage
between CN110-8 and N2.
15 V or more
Motor drive circuit defect
Error that was recorded in *1

AD-2: Drive motor drive circuit defect
AD-6: Pump motor drive circuit defect
4A-60


CN103-4 to CN143-1 Continuity AD-1, 2, 5, 6
CN143-2 to CN110-8 Continuity AD-1, 2
CN110-8 to CN110-17 No continuity AD-1, 2
4A-61
z Error Code AF-1, -2, -3, -4, -5, -6, -7, -8 (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.

4A-62
z Error Code C0-2 (Drive motor power-circuit short)

Related portion
P7
U
Drive P8
V Drive motor
motor
drive
circuit P9
W
Probable cause:
(1) Drive motor defect (3) Drive motor drive circuit defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

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
C0-2 error occurs.
1. Turn off the key switch and disconnect the battery plug. C0-2 error
4. Check if the C0-2 error occurs.
NG
drive circuit.
OK
1. Replace the drive motor drive circuit with the drive pump drive C0-2 error
circuit or the pump motor drive circuit. occurs.
Drive motor defect
32-3.)
E0-2 error
occurs.
4A-63
*1 If the error codes C0-2, C0-4 and E0-2 are displayed all at once, perform the following
checks without checking the motor drive circuits.

NG
1. Turn off the key switch and disconnect the battery plug. Drive motor defect
2. Check the Drive motor. (See page 5-5)
OK


4A-64
z Error Code C1-1 (Drive motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code C1-1
* If C1-1 is displayed, the drive motor drive circuit is defective, so replace it.
4A-65
z Error Code C1-2 (Drive motor current sensor over current)

Related portion
P7
U
Drive
motor V P8 Drive
drive motor
circuit
P9
W
Probable cause:
(1) Drive motor defect
* If C8-1, 2 is also displayed, perform troubleshooting with priority given to C8-1, 2.

Turn the key switch from OFF to ON, to check for C0-2 error occurs.
errors.
C0-2 No error occurs.

plug and visually check the fastened or caulked C1-2
portions of the motor cables for defects. (Refer to No error occurs.
Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and
then turn on the key switch to check for errors.
C1-2 error occurs.

plug. NG
Drive motor cable defect
2. Disconnect the motors cables from both the motor
and the motor drive circuit.
OK
Inspection 2: (Check motor drive circuit)*1

plug.
C1-2 error occurs.
2. Replace the drive motor drive circuit with the pump Drive motor defect
3. Connect the battery plug, and turn on the key switch.
4. Check the error code. (Disregard 32-1 & 32-3)
E1-2 error occurs.

4A-66
motor drive circuits.
Drive motor defect
plug.
2. Check the drive motor.
OK


4A-67

Related portion
CN110-23 (86, STDM+) CN50-2

Probable cause:

Error code C2-1

Record the value of TDM.
Turn off the key switch and leave the vehicle standing The TDM temperature is 110° C or more for both the
for a while (about 30 minutes). drive motor temperature sensor and it has lowered by 5°
C or more compared to the TDM temperature previously
checked.
TDM: The TDM temperature is 110° C The TDM (R) temperature is 110° C or
less or more and it has not lowered more and it has not lowered by 5° C or
than by 5° C or more compared to the more compared to the TDM
110° C TDM temperature previously temperature previously checked.
checked.
4A-68

Click here for updated troubleshooting information from MA12-004
Related portion
CN110-23 (86, STDM+) CN50-2

Probable cause:
(1) Connector contact defect (3) Drive motor temperature sensor harness defect
(2) Drive motor temperature sensor defect (4) Drive motor drive circuit defect
Error code C2-2

C2-2 error
does not occur.
errors.
C2-2 error occurs.

NG
OK

NG
OK

4A-69

Check item
Standard value: Approx. 245 Ω and 600 kΩ
* Resistance change (It is a standard as for the following value).
Resistance
Temperature
(CN50-2⇔CN50-1)
80° C Approx. 1.75 kΩ


4A-70
z Error Code C3-1 (Drive motor power circuit temperature sensor

abnormality)
Related portion
Temperature sensor
TH101
Probable cause:
Error code C3-1
* If C3-1 is displayed, the drive motor is defective, so replace it.

4A-71
z Error Code C4-1, -2, -3, -4, -5, -6 (Accelerator sensor abnormality)
Related portion
CN101-27 (53, VRA1+) CN29-5
CN102-30 (52, VRA1) CN29-4
CN101-22 (50, VRA-) CN29-6

Main Accelerator
controller CN101-26 (55, VRA2+) CN29-1 sensor
CN102-32 (54, VRA2) CN29-3
CN101-32 (51, POT-) CN29-2
Probable cause:
(2) Accelerator sensor defect (5) Accelerator fully open/fully closed matching error
(3) Accelerator sensor harness defect
Error code C4-1, -2, -3, -4, -5

plug, and visually check if the accelerator senor is
installed correctly, and also check inside the CN29
connector and the caulked portion of its wire for C4-1, -2, -3, -4, -5
defects. (Refer to BEFORE TROUBLESHOOTING.) No error occurs. Improper installation of acceleration sensor
2. Connect the CN29 connector, connect the battery Connector contact defect
plug, turn on the key switch, and depress and release
the accelerator pedal to check if an error occurs. (No
error code must be displayed when the accelerator is
operated.)*
C4-1, -2, -3, -4 or -5
error occurs.
Inspection 1: Check of accelerator sensor
NG
plug. Accelerator sensor defect
resistance of the accelerator sensor.
OK

NG
OK
* No error code must be displayed when the accelerator is operated.

4A-72
Error code C4-6

Inspection 3: Matching
Perform matching between the fully closed and fully Use the device as it is.
open states of the accelerator.

C4-6 error occurs.
Inspection 1: Check the accelerator sensor as a single unit.

Perform this check with the battery plug and CN29 disconnected and CN101 and CN102 connected.
(1) Measuring the resistance of the accelerator sensor
CN29-5 to CN29-6 1.8 to 3.5 kΩ
CN29-1 to CN29-2 (Open state)
(2) Measuring the resistance of the accelerator sensor output circuit

CN29-4 to CN29-6 The resistance must increase as the
CN29-3 to CN29-2 potentiometer is rotated.

Perform this check with the battery plug, CN29, CN101 and CN102 disconnected.
C4
1 2 3 4 5 6
CN101-27 to CN29-5 Continuity { − − − { − *1
CN102-30 to CN29-4 Continuity { − − − − − *1
CN101-22 to CN29-6 Continuity − − { − { − *3
CN101-26 to CN29-1 Continuity − { − − { − *2
CN102-32 to CN29-3 Continuity − { − − − − *2
CN101-32 to CN29-2 Continuity − − − { { − *4
CN102-30 to CN102-32 No continuity − − − − { −
4A-73
Inspection 3: Perform matching.

(See page 3-62)
sec04A.fm 74 ページ２０１１年２月１日火曜日午前１０時１２分
4A-74
z Error Code C8-1 (Drive motor speed (rotation) sensor open)

Related portion
CN110-6 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-4 (79, SSD1) CN155-2 CN51-1
Drive motor
N1
- Rotation
sensor 2
CN110-3 (80, SSD2) CN155-3 CN52-1
Probable cause:
1. Turn off the key switch and disconnect the battery plug and visually check
inside the CN155 connector and the caulked portions of their wires for
No error occurs.
defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
An error occurs.
Between
CN110 and CN155
Harness defect
their continuities.
OK
Other than
9 to 13 V
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive
5. Measure the voltage between CN110-6 and N1 on the SST side.
9 to 13 V
C8-1 error
occurs.
3. Connect CN155-3 to CN155-5, and CN155-1 to CN155-2 on the wire harness
side through 09232-13130-71 in order to short them.
1
4A-75

2. Disconnect 09232-13130-71 from the CN155 connector (on the wire harness At least one of the
side). resistances is not
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive approx. 100 Ω. Drive motor drive
motor drive circuit. circuit defect
4. Measure the resistance between CN155-2 and N1 and that between CN155-3
and N1.
Between
CN155 and CN51
or between
CN155 and CN52
Harness defect
OK

C8-1.
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


harnesses.

4A-76


4A-77
z Error Code C8-2 (Drive motor speed (rotation) sensor short)

Click here for updated troubleshooting information from MA12-004
Related portion
CN110-6 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-4 (79, SSD1) CN155-2 CN51-1
Drive motor
N1
- Rotation
sensor 2
CN110-3 (80, SSD2) CN155-3 CN52-1
Probable cause:
1. Disconnect the battery plug and visually check inside the CN155 connector
and the caulked portions of their wires for defects. (Refer to BEFORE
No error occurs.
TROUBLESHOOTING.) Connector contact defect
An error occurs.
Between
CN110 and CN155
Harness defect
their continuities.
OK
9 to 13 V
Other than
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive
9 to 13 V
Inspection: (Check of error code) C8-2 error
1. Turn off the key switch and disconnect the battery plug. occurs.
1
4A-78

2. Disconnect 09232-13130-71 from the CN155 connector (on the wire harness At least one of the
side). resistances
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive is not approx. 100 Ω. Drive motor drive
motor drive circuit. circuit defect
4. Measure the resistance between CN155-2 and N1 and that between CN155-3
and N1.
Between
CN155 and CN51
or between
CN155 and CN52
Harness defect
OK

C8-2.
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


harnesses.

4A-79


4A-80
z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion
MB
P1 P3 F1 P4
F7
CN130-6 CN102-3 (19, VBMBSL)
F6
CN130-5 CN104-2 (44, VBMB)
Main
F5 controller
CN130-4 CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN130-1 CN104-9 (2, CBAT-)

MB
contactor CN130-2 CN104-3 (1, CBAT+)
Probable cause:
(2) MB contactor defect
(3) Harness defect
(4) Fuse defect
4A-81
Error code CB-1
CB-1
Disconnect and then connect the battery plug again, and turn on the No error occurs
Check the state of the battery.
key switch to see if an error occurs.
CB-1
An error occurs.
No actuation
Check if the MB contactor actuation sound is heard when the key sound
switch is turned on.
Actuation sound
Inspection: Check of F6, F7 fuse

1. Turn off the key switch and disconnect the battery plug. ∞Ω F6 fuse defect
2. Remove the F6 and F7 fuses and measure the resistance between F7 fuse defect
their both ends with a circuit tester.
0Ω
Inspection: Check of F6 and F7 fuse holders

1. Install the F6 and F7 fuses and disconnect the CN130 connector
∞Ω F6 fuse holder defect
from the fuse holder.
2. Measure the resistance between P3 and CN130-5 and that
between P3 and CN130-6 (fuse holder side).
0Ω
Inspection 1: Harness check NG

Harness defect
Disconnect the CN130, CN102, CN104 connectors and P3 terminal.
OK

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)
30 V or more
MB contactor defect
P1
P3
Less than 30 V

4A-82
Error code CB-2
If the error codes AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, EC-1, -2, -3 and -4 are displayed all at once, perform
troubleshooting with priority given to AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, and EC-1, -2, -3 and -4.
If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is

Disconnect and then connect the battery plug again, turn on the key CB-2
(There are cases where the
switch and wait for 5 seconds. After that, turn off the key switch and No error occurs.
residual charge cannot be
wait for 5 seconds. Then back on the key switch to see if an error
discharged for reasons of
occurs.
another error.)
CB-2 error occurs.
The contactor
opens.
Check if the MB contactor opens when the key switch is turned off. A
The contactor does not open.
Inspection: Check of MB contactor

The contactor does
not open.
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 contactor opens.

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

4A-83
Error code CB-3, -5
1. Disconnect the battery plug and visually check inside the CN130
CB-3, -5
connector and the caulked portions of their wires for defects. (Refer
No error occurs.
to BEFORE TROUBLESHOOTING.) Connector contact defect
CB-3 or CB-5
An error occurs.
NG
2. Disconnect the CN130 connector and measure the resistance of MB contactor defect
OK

NG
OK

4A-84
Error code CB-4
Disconnect the battery plug and visually check inside the CN130
connector and the caulked portions of their wires for defects. (Refer to

2. Disconnect the CN130 connector and measure the resistance of

Defective portion: Portion where a problem was found during a check of the MB contactor coil or harness.

Perform this check with the battery plug and the CN130, CN102, CN104 connectors and P3 terminal


Before this check, disconnect the battery plug, disconnect the CN104 and CN130 connectors,

CN130-1 to CN136-2 No continuity CB-4, 5
4A-85
z Error Code CB-6 (MB contactor panel overheating abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
sensor controller
Probable cause:
If CB-2, 4 or 5 is also displayed, perform troubleshooting with priority given to CB-2, 4 or 5.

Take adequate care when testing, as the parts may be hot.
4A-86
Error code CB-6

Record the value of TCMB
The TCMB temperature is 130°C or more
and it has lowered by 5°C or more
compared to the TCMB temperature
previously checked.

The TCMB temperature is 130°C or more and it has not
TCMB:
lowered by 5°C or more compared to the TCMB temperature
less than130°C
previously checked.
Proceed to identify the cause of CB-7
Turn off the key switch and disconnect the battery plug,
and check the terminals for loose bolts in the contactor
panel (See the “CONTACTOR PANEL ASSY
:REASSEMBLY”). NG Terminal bolt tightening defect.
Disconnect the CN131 connector, and visually check Connector contact defect
inside the connector and the caulked portion of its wire
for defects.
OK
Check the following and take necessary action, and the

device as it is.
(The problem seems to be caused by continuous
overload operation. So check how the vehicle was
operated.)
4A-87
z Error Code CB-7 (MB contacter Temperature-sensor abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
sensor controller
Probable cause:
(2) MB contacter Temperature-sensor defect
(3) MB contacter Temperature-sensor harness defect
Error code CB-7

plug, disconnect the CN131connector, and visually
check inside the connector and the caulked portion of CB-7 error does
its wire for defects. not occur
errors.
Inspection 1:(Check of temperature-sensor as a single
unit)
Temperature-sensor defect
plug.
2. Disconnect the CN131and check the temperature-
sensor as a single unit.
E1-2 error occur
plug. NG
Harness defect
continuities.
OK
Inspection 1: Check of temperature-sensor as a single unit

Check item
Temperature-sensor resistance (on sensor side:CN131-2 and CN131-1)
Standard value: Approx. 12kΩ: at 20°C (5kΩ ~ 28kΩ at 0 to 40°C)
4A-88

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

CN103-7 ~ CN101-18 No continuity
*1: Connect CN103-71 and CN101-18 on the harness side through 09232-13130-71 and check if there is
continuity between CN131-1 and CN131-2.
4A-89
z Error Code CC-1, -4, -6 (CPU error)

Click here for updated troubleshooting information from SIB MA12-004
Related portion
Drive motor
drive circuit
Probable cause:
Error code CC-1, -4, -6
* If CC is displayed, the drive motor drive circuit is defective, so replace it.

4A-90
z Error Code E0-2 (Pump motor drive power circuit short)

Related portion
P14
P4 U
+
Pump
motor P15
Pump
V
drive motor
circuit
N2 P16
- W
Probable cause:
(1) Pump motor drive circuit defect (3) Pump motor drive circuit defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

1. Disconnect the battery plug and visually check the fastened or

E0-2 error
caulked portions of the motor cables for defects. (Refer to BEFORE
does not occur.
TROUBLESHOOTING.) Improper fastening of motor cable
E0-2 error occurs.
4. Check if the E0-2 error occurs.
E0-2 error does not occur.
NG
drive circuit.
OK
E0-2 error
2. Replace the pump motor drive circuit with the drive motor drive
occurs.
circuit. Pump motor defect
32-2 and 32-3.)
C0-2 error
occurs.
4A-91
*1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the motor drive
circuits.

NG
1. Turn off the key switch and disconnect the battery plug. Pump motor drive circuit defect
OK


4A-92
z Error Code E1-1 (Pump motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code E1-1
4A-93
z Error Code E1-2 (Pump motor current sensor over current)

Related portion
P4 P14
+ U
Pump
motor P15 Pump
V
N2 drive motor
- circuit P16
W
Probable cause:
(1) Pump motor defect
(2) Pump motor cable defect
disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below
3V.
Error code E1-2
Turn the key switch from OFF to ON to check for E0-2 E0-2 error occur
Proceed to identify the cause of E0-2
error.
Turn off the key switch and disconnect the battery plug
and visually check the fastened or caulked portions of
E1-2 error
the motor cables for defects. (Refer to BEFORE
does not occur
TROUBLESHOOTING) Improper fastening of motor cable
After installing the cables, connect the battery plug and
turn the key switch ON. Sit in the seat and perform a
load handling operation (lift or tilt), checking for errors.
E1-2 error occur

plug. NG
Motor cable defect
2. Disconnect the motor cables from both the motor and
3. Check motor cables for its continuity.
OK
1
4A-94
Inspection: (Check of motor drive circuit)*1

1. Replace the pump motor drive circuit with the drive
motor drive circuit. E1-2 error occur
Pump motor defect
3. Check the error code that is displayed. (Ignore the
error codes 32-1 and 32-2)
C1-2 error occur

(Note: Drive circuit that is originally the drive motor drive
circuit before replacement)
Pump motor defect
plug.
OK


4A-95
z Error Code E2-1 (Pump motor temperature sensor increase abnormality)

Related portion
CN111-23 (88, STPM+) CN41-2

Probable cause:

Error code E2-1

Record the value of TPM.
The TPM temperature is 101°C or more and it has
lowered by 5°C or more compared to the TPM

TPM: The TPM temperature is 101°C or
Less than more and it has not lowered by 5°C or
101°C more compared to the TPM
Proceed to identify the cause of E2-2.
4A-96
z Error Code E2-2 (Pump motor temperature sensor abnormality)

Click here for updated troubleshooting information from SIB MA12-004
Related portion
CN111-23 (88, STPM+) CN41-2

Probable cause:
(2) Pump motor temperature sensor defect
(3) Pump motor temperature sensor harness defect
Error code E2-2

E2-2 error
does not occurs.
errors.
E2-2 error occurs.

NG
OK

NG
OK

4A-97

Check item
Standard value Approx. 245 Ω and 600 kΩ
* Resistance changes (It is a standard as for the following value).
Resistance
Temperature
(CN41-2⇔CN41-1)
80°C Approx. 1.75 kΩ

Turn off the key switch and disconnect the battery plug and the CN111 and CN41 connectors and with SST

4A-98
z Error Code E3-1 (Pump motor drive power circuit temperature sensor
abnormality)
Related portion
Pump motor
drive circuit
Temperature sensor
Probable cause:
Error code E3-1
4A-99
z Error Code E8-1 (Pump motor speed (rotation) sensor open)

Related portion
P4 CN111-6 (81, SSP+) CN42-2

+
Pump motor Rotation
N2 CN111-4 (82, SSP1) CN42-1
-
Probable cause:
1. Disconnect the battery plug and visually check inside the CN42 connector and the
No error
caulked portions of their wires for defects. (Refer to BEFORE
occurs.
An error occurs.
Harness defect
continuities.
OK
2. Disconnect the CN42 connector. Other than
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor 9 to 13 V Pump motor drive circuit
drive circuit. defect
9 to 13 V
2. Disconnect the CN42 connector. occur. Pump motor drive circuit
E8-2 error occurs.
Inspection: (Check of motor drive circuits) Other than
1. Turn off the key switch and disconnect the battery plug. Approx.
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). 100 Ω Pump motor drive circuit
drive circuit.
Approx. 100 Ω
4A-100


sec04A.fm 101 ページ２０１１年１月２６日水曜日午後３時５３分
4A-101
z Error Code E8-2 (Pump motor speed (rotation) sensor short)

Click here for troubleshooting information from SIB MA12-004
Related portion
P4 CN111-6 (81, SSP+) CN42-2

+
Pump motor Rotation
N2 CN111-4 (82, SSP1) CN42-1
-
Probable cause:
1. Turn off the key switch and disconnect the battery plug and visually check inside
No error
the CN42 connector and the caulked portions of their wires for defects. (Refer to
occurs.
An error occurs.
Harness defect
continuities.
OK
2. Disconnect the CN42 connector. Other than
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor 9 to 13 V Pump motor drive circuit
drive circuit. defect
9 to 13 V
2. Disconnect the CN42 connector. occurs. Pump motor drive circuit
E8-1 error occurs.
Inspection: (Check of motor drive circuits) Approx.
1. Turn off the key switch and disconnect the battery plug. 100 Ω
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). Other than Pump motor drive circuit
drive circuit.
Approx. 100 Ω
4A-102


4A-103
z Error Code EC-1, -4, -6 (CPU error)

Related portion
Click here for troubleshooting information, in SIB MA12-004
Pump motor drive

circuit
Probable cause:
Error code EC-1, -4, -6
* If EC is displayed, the pump motor drive circuit is defective, so replace it.

4A-104
z Error Code EE-1, -2 (Display → Main controller communication error)

Related portion
CN103-3 (14, DGND) CN27-4
CN103-14 (16, D7V) CN27-5

Main
Display
controller CN103-11 (145, CAN1H) CN27-16
CN103-12 (146, CAN1L) CN27-15
Probable cause:
(2) Harness defect
(3) Display defect
Error code EE-1, 2
* Identify the cause of F1-1 or F1-2.

4A-105
z Error Code F1-1, -2 (Main controller → Display communication error)

Related portion
CN103-11 (145,CAN1H) CN27-16 (145, CAN1H)
Main
Multi-display
controller
CN103-12 (146,CAN1L) CN27-15 (146, CAN1L)
Probable cause:
(2) Harness defect (4) Display defect
Error code F1-1, F1-2
Turn off the key switch and disconnect the battery plug and visually
check inside CN103 to CN27 connectors and the caulked portion of
each wire for defects.
No error occurs.
Connect the connector, connect the battery plug and turn on the key
switch, and if an error occurs.
An error occurs. If the version of at least one motor drive circuit is

displayed
Inspection 1:
Check the version information on the I/O monitor.
If the version of a motor drive
circuit is not displayed:
Inspection 2:
NG Harness (between CN103 and
CN27) defect
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.
Inspection 2: Check harnesses for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN27 and CN103 connectors and check

CN27-15 to CN27-16 No continuity (Not 0 Ω)
4A-106
z Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error)

Related portion
Multi-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.

4A-107
z Error Code FF-1, -2 (Power supply circuit over current)

Related portion
CN103-14 (16,D7V) CN27-5
DISPLAY
CN103-3 (14, DGND) CN27-4
Main
controller CN103-13 (311, SSTR+) CN3-1
Steering-wheel
angle sensor
CN103-6 (51, LS-) CN3-2
Probable cause:
(2) Display or steering angle sensor defect
(3) Harness defect
Error code FF-1
the CN27 connector and visually check inside the connector and the A screen is displayed.
TROUBLESHOOTING)
2. Connect the connector, connect the battery plug, and then turn on
the key switch to see if a screen is displayed.
No screen is displayed.
Inspection: Check of display

3. Connect the battery plug and turn on the key switch. Display defect
Measure the voltage between the CN27-5 and CN27-4 connectors
0V

NG
Harness defect
continuities.
OK

4A-108

Disconnect the battery plug, disconnect the CN27 and CN103 connectors, and visually check inside each

Error code FF-2

visually check inside the connector and the caulked portion of its FF-2 error does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING) Connector contact defect
FF-2 error occurs.
Inspection: Check of steering angle sensor

3. Connect the battery plug and turn on the key switch. Steering angle sensor defect
Measure the voltage between the CN3-1 and CN3-2 connectors on
the harness side.
0V

NG
Harness defect
continuities.
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN3 and CN103 connectors, and visually

4A-109
z Error code 31-1 Declining of activating voltage for Drive motor drive circuit
Click here for SIB explaining
Related portion this fault code
MB
P1 P3 P4 +
Drive motor
F1 CN110-8 drive circuit
F6
CN143-2
N1 RCP
Pre-charge CN103-4 (42, KYSAT)
CN143-5 unit CN143-1
Main
CN104-2 (44, VBMB) controller
CN104-1 (41, B48V)

F5
CN101-4 (41, VBBT)
Probable cause:
(1) Battery defect
(2) RCP resistance defect
(3) F1 fuse defect
(4) F5 fuse defect
(5) F6 fuse defect
(9) Wire-harness defect
4A-110
Error code 31-1
Disconnect the battery plug, connector CN143, CN103

and CN110 and visually check inside the connector and
the caulked portion of its wire for defect (Refer to No error
BEFORE TROUBLESHOOTING). occurs
And visually check the Drive motor drive circuit plus,
P1, P3, P4 whether the terminal is loosened or not.
Connect the connectors and battery plug, then turn on
the key switch to check for error.
error occurs
1.Turn off the key switch and disconnect the battery
NG
plug.
1
2. Disconnect the CN103, CN104 and the plus terminal
of Drive motor drive circuit and check the harness.
OK
Inspection: (Check of Input voltage for Motor drive
circuit)
plug.
More than 20 V
2. Connect the CN103, CN104 and the plus terminal of Drive motor driver circuit defect
Drive motor drive circuit.
3. Connect battery plug and turn on the key switch.
4. Measure the voltage between the plus terminal of
Drive motor driver and N1.
Less than 20 V
Inspection: Voltage check of B48 V
plug. More than 20 V
2. Disconnect the CN104.
4. Measure the voltage between the CN104-1and N1.
Less than 20 V
Inspection: F5 fuse
∞Ω
plug. F5 fuse defect
0Ω
Inspection: Check battery voltage More than 20 V Harness defect between the P1 and
P1[+] ← → N1[-] CN104-1
Less than 20 V
Battery defect
4A-111

NG
plug. Harness defect between CN103 and CN143
2. Disconnnect the CN103, CN143 and check the
harness.
OK
Inspection: F1 fuse
∞Ω
0Ω

plug. No continuity Harness defect between P3 and plus
2. Connect the CN103, CN104 and install the F1 fuse. terminal of the Motor driver
3. Check the continuity between the Plus terminal of
Drive motor driver and P3.
Continuity
Inspection 3: (Pre-charge unit)

NG
plug. Pre-charge unit defect
2. Disconnect the CN143 and check the Pre-charge
unit.
OK
Inspection: F6 fuse check

∞Ω
0Ω
RCP defect, Harness defect between

CN143-5 and P3.
4A-112

Check each harness for its continuity
Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of Drive
motor driver, and visually check inside each connector and caulked portion. Then check the continuity between
the CN103 and plus terminal of Drive motor driver.
After inspection, plus terminal of Drive motor driver should be surely tightened.

CN103-4[+] to Plus terminal of Motor driver[-] ∞Ω
CN103-4[-] to Plus terminal of motor driver [+] Approx. 70 Ω (10 Ω range)
※ [+], [-]: In case of analogue tester

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside
each connector and caulked portion. Then check the harness between CN103 and CN143.

Inspection 3: Pre-charge unit check

Check the Pre-charge unit
Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each
connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity.

CN143-1[+] to CN143-5[-] ∞Ω
CN143-1[-] to CN143-5[+] Approx. 50 Ω (10 Ω range)
4A-113
z Error code 31-3 Declining of activating voltage for Pump motor drive circuit
Click here for SIB explaining Pre-
Related portion Charge Circuit
MB
P1 P3 P4 +
Pump motor
F1 drive circuit
CN110-8
F6
CN143-2
N1
RCP
Pre-charge CN103-4 (42, KYSAT)
CN143-5 unit CN143-1
Main
CN104-2 (44, VBMB) controller
CN104-1 (41, B48V)

F5
CN101-4 (41, VBBT)
Probable cause:
(1) Battery defect
(2) RCP resistance defect
(3) F1 fuse defect
(4) F5 fuse defect
(5) F6 fuse defect
(9) Wire-harness defect
4A-114
Error code 31-3
Disconnect the battery plug, connector CN143, CN103

and CN111 and visually check inside the connector and
the caulked portion of its wire for defect (Refer to
No error occurs
BEFORE TROUBLESHOOTING).
And visually check the Pump motor drive circuit plus,
P1, P3, P4 whether the terminal is loosened or not.
Connect the connectors and battery plug, then turn on
the key switch to check for error.
error occurs
NG
plug.
1
2. Disconnect the CN103, CN104 and the plus terminal
of Pump motor drive circuit and check the harness.
OK
Inspection: (Check of Input voltage for Motor drive
circuit)
plug.
More than 20 V
2. Connect the CN103, CN104 and the plus terminal of Pump motor driver circuit defect
Pump motor drive circuit.
3. Connect battery plug and turn on the key switch.
4. Measure the voltage between the plus terminal of
Pump motor driver and N1.
Less than 20 V
Inspection: Voltage check of B48 V
plug. More than 20 V
2. Disconnect the CN104.
4. Measure the voltage between the CN104-1and N1.
Less than 20 V
Inspection: F5 fuse
∞Ω
0Ω
Inspection: Check battery voltage More than 20 V Harness defect between the P1 and
P1[+] ← → N1[-] CN104-1
Less than 20 V
Battery defect
4A-115

NG
plug. Harness defect between CN103 and CN143
2. Disconnnect the CN103, CN143 and check the
harness.
OK
Inspection: F1 fuse
∞Ω
0Ω

plug. No continuity Harness defect between P3 and plus
2. Connect the CN103, CN104 and install the F1 fuse. terminal of the Motor driver
3. Check the continuity between the Plus terminal of
Pump motor driver and P3.
Continuity
Inspection 3: (Pre-charge unit)

NG
plug. Pre-charge unit defect
2. Disconnect the CN143 and check the Pre-charge
unit.
OK
Inspection: F6 fuse check

∞Ω
0Ω
RCP defect, Harness defect between

CN143-5 and P3.
4A-116

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of
Pump motor driver, and visually check inside each connector and caulked portion. Then check the continuity
between the CN103 and plus terminal of Pump motor driver.
After inspection, plus terminal of Pump motor driver should be surely tightened.

CN103-4[+] to Plus terminal of motor driver[-] ∞Ω
CN103-4[-] to Plus terminal of motor driver [+] Approx. 70 Ω (10 Ω range)

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside
each connector and caulked portion. Then check the harness between CN103 and CN143.

Inspection 3: Pre-charge unit check

Check the Pre-charge unit
Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each
connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity.

CN143-1[+] to CN143-5[-] ∞Ω
CN143-1[-] to CN143-5[+] Approx. 50 Ω (10 Ω range)
4A-117
z Error Code 32-1 (Drive motor drive circuit EEPROM abnormality)

Related portion
Probable cause:
*: When a new motor drive circuit is installed on the vehicle, the 32-1 error always occurs (which does not mean that
the new drive circuit is defective).
Error code 32-1

32-1
error does not occur. Drive motor drive circuit
32-1
error occurs.
4A-118
z Error Code 32-3 (Pump motor drive circuit EEPROM abnormality)

Related portion
CN111-12 (152, 0STEP)
Pump motor drive circuit CN111-11 (152, STEP-)
Probable cause:
*: When a drive motor drive circuit is installed as a pump motor drive circuit, the 32-3 error always occurs (which does
not mean that the new drive motor drive circuit is defective).
Error code 32-3

32-3
error does not occur. Pump motor drive circuit
32-3 error occurs.
4A-119
z Error code 33-1 Main controller → Drive motor driver CAN communication
abnormality
Related portion
CN103-4 (KYSAT) CN143-1 Pre-charge CN143-2 CN110-8

CN103-11 (CAN1H) unit CN110-17
Drive motor
CN103-12 (CAN1L) CN110-10
driver circuit
CN103-3 (DGND) CN110-2
Main
CN103-5 (N2,N2)
controller
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Probable cause
(2) Harness defect
(3) Motor driver circuit defect
*If AD-1, 2 occurs, perform troubleshooting with priority given to AD-1, 2.
4A-120
Error code 33-1
Disconnect the battery plug, connector CN110, CN143 and visually

check inside the connector and the caulked portion of its wire for
defect (Refer to BEFORE TROUBLESHOOTING). 33-1 No error occurs
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the motor driver circuit, should be confirmed
the connection of each connector.
33-1
error occurs
NG
Harness defect
2. Disconnect the CN103, CN104, CN143, CN110 and check the
harness.
OK
Turn the key off and connect the CN103, CN143, CN104, CN110 then 33-1 No error occurs
turn the key on.
33-1
error occurs
Inspection: (Motor driver circuit) ∗1

1. Replacing the Drive motor driver and Pump motor driver. 33-1 No error occurs
2. Connect the battery plug and turn on the key switch. Main controller defect
3. Check the error code (The 32-1 and 32-3 can be ignored even if
displayed).
33-3
error occurs
Drive motor driver circuit defect
(note: this is Drive motor driver before repalcing)
4A-121

Check each harness for its continuity and short
visually check inside each connector and caulked portion. Then check the continuity and short of each harness
(Refer to BEFORE TROUBLESHOOTING).
Portion to be checked Standard

4A-122
z Error code 33-3 Main controller → Pump motor driver CAN communication
abnormality
Related portion
CN103-4 (KYSAT) CN143-1 Pre-charge CN143-2 CN111-8

CN103-11 (CAN1H) unit CN111-17
Pump motor
CN103-12 (CAN1L) CN111-10
driver circuit
CN103-3 (DGND) CN111-2
Main
CN103-5 (N2, N2)
controller
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause
(2) Harness defect
(3) Motor driver circuit defect
*If AD-5, 6 occurs, perform troubleshooting with priority given to AD-5, 6.
4A-123
Error code 33-3
Disconnect the battery plug, connector CN111, CN143 and visually

check inside the connector and the caulked portion of its wire for
33-3
defect (Refer to BEFORE TROUBLESHOOTING).
No error occurs
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the motor driver circuit, should be confirmed
the connection of each connector.
33-3
error occurs
Harness defect
2. Disconnect the CN103, CN104, CN143, CN110, CN111 and check
the harness.
OK
33-3
Turn the key off and connect the CN103, CN143, CN104, CN110, No error occurs
CN111 then turn the key on.
33-3
error occurs
Inspection: (Motor driver circuit) ∗1

33-3
1. Replacing the Drive motor driver and Pump motor driver.
No error occurs
2. Connect the battery plug and turn on the key switch. Main controller defect
3. Check the error code (The 32-1 and 32-3 can be ignored even if
displayed).
33-1
error occurs
Pump motor driver circuit defect
(Note: this is Pump motor driver before repalcing)
4A-124

Check each harness for its continuity and short
Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104, CN143, CN110, CN111
and visually check inside each connector and caulked portion. Then check the continuity and short of each
harness (Refer to BEFORE TROUBLESHOOTING).
Portion to be checked Standard

4A-125
z Error code 52-1,-2,-3 Yaw rate sensor abnornality

Related portion
CN104-13 (321,SYR+) CN34-1

CN103-27 (322,SYR) CN34-3
Main controller Yaw rate sensor
CN104-11 (323,SYR-) CN34-2
Probable cause:
(2) Yaw rate sensor harness defect
(3) Yaw rate sensor defect
Error code 52-1

visually check inside the connector and the caulked portion of its 52-1error does
wire for defects. (Refer to BEFORE TROUBLESHOOTING) not occur.
52-1error occurs
Inspection: Check of the yaw rate sensor

1. Turn off the key switch and disconnect the battery plug. 52-2error
2. Disconnect the CN34 connector and connect CN34-1 to CN34-2 on occurs.
Yaw rate sensor defect
the harness side through SST 09232-13130-71.
for errors.
52-1error occurs

Harness defect
OK

4A-126
Error code 52-2, -3
the CN34 connector, and visually check inside the connector and 52-2,-3error
the caulked portion of its wire for defects. (Refer to BEFORE does not occur.
TROUBLESHOOTING)
2. Connect the CN34 connector, connect the battery plug and turn on
52-2,-3error occurs
Inspection: Check of the yaw rate sensor.

52-1error
occurs.
2. Disconnect the CN34 connector. Yaw rate sensor defect
for errors.
52-2,-3error occurs

Harness defect
OK
Inspection 1,2: Check each harness for its continuity.

CN104-11 to CN34-2 Continuity 52-2,-3 *2
4A-127
z Error Code 54-1,-2,-3,-4 (Swing lock solenoid abnormality)

Related portion
CN103-1 (327, SLSW+) CN43-1
CN103-2 (328, SLSW-) CN43-2
CN103-5 (N2, N2)

Main Swing lock
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Swing lock solenoid harness defect
(3) Swing lock solenoid defect
Error code 54-1
TROUBLESHOOTING)
54-1 error occurs. 54-4
error occurs. Track down the
Check if the 54-4 error has also occurred.
swing lock solenoid

4A-128
Error code 54-2
TROUBLESHOOTING)
54-2 error occurs.
54-3
Check if the 54-3 error has also occurred. error occurs. Track down the
swing lock solenoid
OK
NG
OK
Error code 54-3
TROUBLESHOOTING)

swing lock solenoid

4A-129
Error code 54-4
TROUBLESHOOTING)
Forcibly turn off the output of the swing lock solenoid, using Active 54-4
Test, to see if an error occurs. error does not occur.
[ANL] ACTIVE TEST 1/3 SWING SOL
54-4 error occurs.
swing lock solenoid
OK
NG
OK


* Connect the CN43 connector and measure the resistance between CN103-1 and CN103-2, to see if it falls
4A-130
z Error Code 61-1,-2 (Load sensor abnormality)

Related portion
CN104-12 (58, SPLF+) CN7-1
CN103-29 (59, SPLF) CN7-2

Main
Load sensor
controller
CN101-32 (51, POT-) CN7-3
Probable cause:
(2) Load sensor defect
(3) Load sensor harness defect
Error code 61-1
TROUBLESHOOTING)
61-1 error occurs.
2. Disconnect the CN7 connector and connect CN7-1 to CN7-2 on the error occurs.
Load sensor defect
harness side through SST09230-13700-71.
61-1 error occurs.
Harness defect
the harnesses for its continuities.
OK
4A-131
Error code 61-2
61-2 error occurs.
61-1
error occurs.
2. Disconnect the CN7 connector. Lord sensor defect
61-2 error occurs.
Harness defect
OK

connectors, and with SST disconnected, visually check inside each connector and the caulked portion of each
wire for defects.

4A-132
z Error Code 62-1,-2 (Tilt angle sensor abnormality)

Related portion
CN101-20 (57, VRTA+) CN26-1
CN103-17 (56, VRTA) CN26-2

Main Tilt angle
controller sensor
CN101-32 (51, POT-) CN26-3
Probable cause:
(2) Tilt angle sensor defect
(3) Tilt angle sensor harness defect
Error code 62-1
TROUBLESHOOTING)
62-1 error occurs.
2. Disconnect the CN26 connector and connect CN26-1 and CN26-2 error occurs.
Tilt angle sensor defect
on the harness side through 09232-13130-71.
62-1 error occurs.
Harness defect
OK
4A-133
Error code 62-2
62-2 error occurs.
62-1
error occurs.
2. Disconnect the CN26 connector. Tilt angle sensor defect
62-2 error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN86, CN101, and CN103 connectors,
and with SST disconnected, visually check inside each connector and the caulked portion of each wire for
defects.

4A-134
z Error Code 63-1,-2,-3 (Tilt switch abnormality)

Related portion
Tilt switch
CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
CN9-4
Probable cause:
(2) Tilt switch adjustment defect.
(3) Tilt switch defect
(4) Tilt switch harness defect
Error code 63-1, -2, -3
the CN9 connector, and visually check inside the connector and the A6-3
caulked portion of its wire for defects. error occurs. Track down the cause of the
(Refer to BEFORE TROUBLESHOOTING) A6-3 error.
A6-3 error does not occur.
63-1
• Tilt switch defect
error occurs.
Operate the tilt lever and check the error code. • Tilt switch installation portion
defect.
Use the analyzer to check the values for the SWTF (forward tilt switch) Either switch
and SWTR (backward tilt switch). displaying “1”
Check the status of the switches when the tilt lever is operated in
either direction and returned to center.
Both switches displaying “0” after
OK
operation repeated several times
Stored in diagnosis memory
Memory 63-1 Memory 63-2, 63-3

The forward and backward tilt The tilt lever has been turned ON
lever switches turned ON at the for two minutes or more in the
same time in the past. past.(Normal)
(Check and adjustment of each
switch installation)
4A-135
z Error Code 64-1,-2,-3,-4 (Lift lower lock solenoid abnormality)

Related portion
CN101-1 (3, SOLLU+) CN8-1
CN102-16 (4, SLLL-) CN8-2
CN103-5 (N2, N2)

Main Lift lock
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Lift lock solenoid harness defect
(3) Lift lock solenoid defect
Error code 64-1
No error occurs.
64-1
64-1 error occurs.

lift lock solenoid

4A-136
Error code 64-2
64-2 error occurs.

lift lock solenoid
OK
Harness defect
OK
Error code 64-3
TROUBLESHOOTING)

lift lock solenoid

4A-137
Error code 64-4
TROUBLESHOOTING)
64-4 error occurs.
lift lock solenoid
OK
Harness defect
OK

connectors, and

4A-138
z Error Code 65-1,-2,-3,-4 (Tilt control solenoid abnormality)

Related portion
CN101-2 (6, SLTFB+) CN14-1
CN102-19 (7, SLTFL-) CN14-2
CN103-5 (N2, N2)

Main
Tilt solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Tilt control solenoid defect
(3) Tilt control solenoid harness defect
Error code 65-1
65-1 error occurs.


4A-139
Error code 65-2
TROUBLESHOOTING) 65-3
65-2 error occurs.

OK
Harness defect
OK
Error code 65-3
TROUBLESHOOTING)


4A-140
Error code 65-4
the caulked portion of its wire for defects. (Refer to BEFORE error not occur.
TROUBLESHOOTING)
65-4 error occurs.
OK
Harness defect
OK

CN104 connectors, and

4A-141
z Error Code 66-1 (Outside matching value range for tilt angle error)
Related portion
Main
controller
Probable cause:
(1) The tilt horizontal angle matching value is outside the specified matching range.
(2) The forward tilt angle matching value is outside the specified matching range.
(3) The load sensor matching value is outside the specified matching range.
Matching After the completion of matching,

Perform matching of the tilt horizontal angle, the forward tilt angle, and 66-1error does not occur.
the load sensor. Use the device as it is.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION / MACHING
matching,
66-1 error occurs.
4A-142
z Error Code 67-1 (Lifting height switch open)

Related portion
V mast, mast height: ~H2500
CN102-10 (51, LS-)

Main CN104-22 (90, SH1)
controller
CN103-24 (91, SH2-1)
N.C.
Others:
Lifting height
CN102-10 (51, LS-) CN96-1 switch
CN104-22 (90, SH1) CN96-2

Main
controller
CN103-24 (91, SH2-1) CN96-3
Probable cause:
(1) Connector contact defect (3) Lifting height switch defect
(2) Harness defect (4) Main controller defect
Error code 67-1
67-1
67-1 error occurs.
Turn on the key switch and check the value of SH using the Analyzer SH: 000
1
menu.
SH: Other than 000
1. Lower the lift to its lowermost position.
SH: 000
4. Turn on the key switch and check the value of SH using the
Analyzer menu.
SH: Other than 000
A
4A-143

Harness defect
OK
Is the lifting height switch equipped? NO

2
YES
Lifting height switch arm is released.

Inspection: Check of mast lifting height (High lifting height)
Visually check the state of the lifting switch when an error is detected. 3
Lifting height switch arm is held.

(Low lifting height)
NG
3. Disconnect the CN96. Lifting height switch defect
OK
Harness defect
OK

NG
OK
4A-144

NG
OK
NG
Disconnect the CN102,103 and CN104 connectors and check the Harness defect
OK

Perform this check with the battery plug and the CN96, CN102,CN103 and CN104 connectors disconnected.


Perform this check with the CN102, CN103 and CN104 connectors disconnected.

4A-145
z Error Code 68-1,-2,-3 (Lifting height sensor abnormality)

Related portion
CN101-32 (51, POT-) CN97-1
CN101-24 (219, VRH+) CN97-2

Main Lifting height
controller sensor
CN103-28 (220, VRH) CN97-3
Probable cause:
(1) Lifting height sensor defect
(3) Lifting height sensor harness defect
Error code 68-1
68-1 error does not
occur.
error occurs.
68-1 error occurs.
2. Disconnect CN97 and connect CN97-2 to CN97-3 on the harness 68-2 error occurs.
side through 09238-13130-71.
68-1 error occurs.
Harness defect
OK
4A-146
Error code 68-2
68-2
error occurs.
68-2 error occurs.
68-1 error occurs.
2. Disconnect the CN97 connector. Lifting height sensor defect
68-2 error occurs.
Harness defect
OK
Error code 68-3
Visual check of lifting height sensor

• Is the wire broken? NG
• Is the wire wound around or pulled out of the reel correctly when the
lift is raised to or lowered from an elevated position?
OK
TROUBLESHOOTING)
Inspection: Check of lifting height sensor input value

Raise the lift to an elevated position.
Then, further raise the lift by 1 m from this position and check the
0.5 or more Normal
change in the value of VRH at that time.
(Connector contact defect)
Turn on the key switch and check the value of VRH using the Analyzer
menu.
Less than 0.5
Harness defect
OK
4A-147


4A-148
z Error Code 71-1,-2,-3 (Tire angle sensor abnormality)

Related portion
CN101-23 (316, VRTRA+) CN94-3
CN102-31 (317, VRTRA) CN94-2

Main Tire angle
controller sensor
CN102-26 (51, POT-) CN94-1
Probable cause:
(2) Tire angle sensor harness defect
(3) Tire angle sensor defect
(4) Tire angle sensor joint, rear axle link system defect
Error code 71-1
71-1
TROUBLESHOOTING) 71-1 error occurs.
error occurs.
71-1 error occurs.
2. Disconnect the CN94connector and connect CN94-3 and CN94-2 error occurs.
Tire angle sensor defect
3. Connect the battery plug and turn on the key switch to check the
error code.
71-1 error occurs.
Harness defect
2. Disconnect the battery plug and the CN101 and CN102 connectors
and check the harness for their continuities.
OK
4A-149
Error code 71-2, -3
71-2, 71-3
error occurs.
71-2 or 71-3 error occurs.
71-1
1. Turn off the key switch and disconnect the battery plug. Tire angle sensor defect
error occurs.
2. Disconnect the CN94 connector. Tire angle sensor installation
3. Connect the battery plug and turn on the key switch to check the portion defect.
error code.
71-2 error occurs or
no error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug and the CN94, CN101 and CN102 connectors and with
SST disconnected visually check inside each connector and the caulked portion of each wire for defects.

4A-150
z Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality)

Related portion
CN103-13 (311, SSTR+) CN3-1
CN104-30 (312, SSTR1) CN3-3
Main CN104-31 (313, SSTR2) CN3-4 Steering

controller angle sensor
CN104-24 (314, SSTRC) CN3-5
CN102-10 (51, LS-) CN3-2
Probable cause:
(2) Steering angle sensor harness defect
(3) Steering angle sensor defect
The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is rotated.
Error code 72-1
TROUBLESHOOTING)
72-1 error occurs.
Turn on the key switch and check the value of SSTR using the SSTR: 1**
Analyzer menu. (* represents either 0 or 1.)
SSTR: 0**
A
B
4A-151
SSTR: 1**
SSTR: 0**
Main harness defect
their continuities.
OK

SSTR: 0**
or 1.)
Analyzer menu.
SSTR: 1**
Main harness defect
their continuities.
OK
4A-152
Error code 72-2
TROUBLESHOOTING.)
72-2 error occurs
SSTR: *1*
SSTR: *0* C
SSTR: *1*
or 1.)
Analyzer menu.
SSTR: *0*
Main harness defect
their continuities.
OK

SSTR: *0*
SSTR: *1*
Main harness defect
their continuities.
OK
4A-153
Error code 72-3
TROUBLESHOOTING)
72-3 error occurs.
SSTR: **0 E
SSTR: **1
Turn on the key switch and check the value of SSTR using the or 1.)
Steering angle sensor defect
Analyzer menu.
SSTR: **0
Main harness defect
their continuities.
OK
4A-154
Turn off the key switch and disconnect the CN104 connector and
disconnect the CN3 connector.
Turn on the key switch and check the value of SSTR using the (* represents either 0 or 1.)
Analyzer menu. Steering angle sensor defect
SSTR: **1
Main harness defect
their continuities.
OK
Error code 72-4
the CN3 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE 72-4
TROUBLESHOOTING) error does not occur.
(If the steering wheel cannot be turned easily, perform this check
with the direction switch in the Forward or Reverse position.)
72-4 error occurs.
Inspection: Check of sensor supply voltage
1. Turn off the key switch and disconnect the battery plug. Approx. 15 V
4. Check the supply voltage to the sensor.
CN3-1 ⇔ CN3-2
Approx. 0 V
their continuities.
OK Main harness defect
Turn off the key switch, disconnect the battery plug, and then connect CN3.
Track down the cause of 72-1 (SSTR1).

Proceed to identify the cause of 72-2 (SSTR2).
4A-155

Turn off the key switch and disconnect the battery plug, disconnect CN3, CN102, CN103 and CN104 and

4A-156
z Error Code 73-1,-2,-3,-4 (Steering knob synchronizer solenoid abnormality)

Related portion
CN102-7 (329, SLS+) CN37-1
CN102-14 (330, SLS-) CN37-2
CN103-5 (N2, N2)

Main Steering knob
controller CN104-4 (N2, N2) synchronizer
solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Knob position compensation solenoid defect
(2) Knob position compensation solenoid harness defect (4) Main controller defect
Error code 73-1
disconnect the CN37 connector, and visually check inside the 73-4
BEFORE TROUBLESHOOTING) 73-4 error.
Connect the CN37 connector, connect the battery plug, and turn
No error occurs.
73-1
compensation solenoid to see if an error occurs. Connector contact defect
73-1 error occurs.

2. Disconnect the connector CN37 and measure the resistance of
the knob position compensation solenoid

Disconnect the CN102, CN103 and CN104 connectors and check
4A-157
Error code 73-2
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of
TROUBLESHOOTING) the 73-3 error.
No error occurs.
73-2
compensation solenoid to see if an error occurs. Connector contact
defect
73-2 error occurs.

Knob position
2. Disconnect CN37 and measure the resistance of the knob position NG
defect
OK
NG
OK
Error code 73-3
TROUBLESHOOTING)

2. Disconnect CN37 and measure the resistance of the knob position

Disconnect the CN102, CN103 and CN104 connectors and check the
4A-158
Error code 73-4
TROUBLESHOOTING)
73-4 error occurs.
2. Disconnect the connector CN37 and measure the resistance of the NG Knob position compensation
knob position compensation solenoid solenoid defect
OK
NG
OK

connectors, Visually check inside each connector and the caulked portion of each wire for defects.

4A-159
z Error Code 74-1 (Outside matching value range for tire angle error)
Related portion
Steering knob synchronizer

solenoid
Probable cause:
Tire straight running matching value is outside the specified matching range.
If the 71-1, 71-2 or 71-3 error occurs, identify the cause of it first, and then perform the following.

matching, 74-1 error
Perform tire straight running matching. Refer to MULTI-FUNCTION does not occur.
correctly.
DISPLAY / MUSK FUCTION / MACHING
74-1 error occurs.
4A-160
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer

abnormality-Conventional lever)
Related portion
CN101-25 (28, VRL+) CN47-4
CN103-26 (20, VRL1) CN47-3

Main Lift lever
CN102-26 (51, POT-) CN47-1
Probable cause:
TROUBLESHOOTING)
H1-1 error occurs and
not occur.
2. Disconnect the lift lever potentiometer connector (CN47). A
H1, -2 or -3 error
Harness defect
OK

4A-161
H1-2 error Inspection: Check of lift lever potentiometer

does not 1. Turn off the key switch and disconnect the battery
occur. plug.
2. Connect the CN47-3 to CN47-4 on the harness side
through SST 09230-13700-71.
H1-2 error occurs.

plug.
H1-2 error occurs.
2. Disconnect the CN47 connector. Lift lever
3. Connect the CN47-2 to CN47-4 on the harness side potentiometer defect
through SST 09230-13700-71.

plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103
continuities.
OK

4A-162
Error code H1-4
TROUBLESHOOTING)
H1-4 error occurs.

OK
MACHING
NG
Error code H1-5

occurs.

H1
1 2 3 4 5
4A-163
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer abnormality-Mini lever)
Related portion
CN101-25 (28, VRL+) CN79-4
CN103-26 (20, VRL1) CN79-3

Main Lift lever
CN102-26 (51, POT-) CN79-1
Probable cause:
TROUBLESHOOTING)
1. Turn off the key switch and disconnect the battery plug. H2-1, -2 or -3 error One
2. Replace the lift lever potentiometer connector (CN79) with the tilt of these errors occurs.
lever potentiometer connector (CN80). H1-4, H2-4 can be
Harness defect
OK

4A-164
Error code H1-4
TROUBLESHOOTING)
H1-4 error occurs.

OK
MACHING
NG
Error code H1-5

occurs.

H1
1 2 3 4 5
4A-165
z Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality)
Related portion
CN101-28 (29, VRT+) CN80-4
CN102-23 (22, VRT1) CN80-3

Main Tilt lever
controller CN102-22 (23, VRT2) CN80-2 potentiometer
CN102-26 (51, POT-) CN80-1
The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.
Probable cause:
(2) Tilt lever potentiometer harness defect
(3) Tilt lever potentiometer defect
the CN80 connector, and visually check inside the connector and H2-1, -2, -3
TROUBLESHOOTING)
Inspection: Check of tilt lever potentiometer H1-1, -2 or -3 error
2. Replace the tilt lever potentiometer connector (CN80) with the lift occurs.
lever potentiometer connector (CN79). H1-4, H2-4
3. Connect the battery plug and turn on the key switch. can be ignored.
Harness defect
OK

4A-166
Error code H2-4
TROUBLESHOOTING)
H2-4 error occurs.
Inspection: Check of tilt lever potentiometer

2. Check if the tilt lever potentiometer is installed correctly.
OK
4. Perform matching of the tilt lever potentiometer.
MACHING
NG
Error code H2-5
Matching of the tilt lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK H2-5 error does not occur.
correctly.
FUCTION / MACHING
occurs.

H2
1 2 3 4 5
4A-167

abnormality)
Related portion
CN101-29 (30, VRAT1+) CN48-4
CN102-21 (24, VRA11) CN48-3

Main Attachment 1
potentiometer
CN102-26 (51, POT-) CN48-1
Probable cause:
TROUBLESHOOTING)
Harness defect
OK

4A-168
Error code H3-4

TROUBLESHOOTING)
H3-4 error occurs.

OK
MACHING
NG
Error code H3-5

Matching of the attachment 1 lever potentiometer. Matching has been made
Refer to MULTI-FUNCTION DISPLAY / MUSK correctly.

occurs.

Perform this check with the battery plug and the CN48, CN101 and CN102 connectors disconnected,
H3
1 2 3 4 5
4A-169

abnormality) If truck is equipped with Clamp Release
Interlock feature, click here for calibration
Related portion information before following this
troubleshooting guide.
CN101-30 (31, VRAT2+) CN49-4
CN102-29 (26, VRA21) CN49-3

Main Attachment 2
potentiometer
CN102-26 (51, POT-) CN49-1
Probable cause:
TROUBLESHOOTING)
Harness defect
OK

4A-170
Error code H4-4

TROUBLESHOOTING)
H4-4 error occurs.

OK
MACHING
NG
Error code H4-5
Matching of the attachment 2 lever potentiometer. After the completion of matching,

occurs.

With the battery plug and the CN49, CN101 and CN102 connectors disconnected, visually check inside each
H4
1 2 3 4 5
4A-171
z Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-5

Lift push
CN10-5
Lift pull
CN101-17 (10, SLPL-) CN10-1 solenoid
Main
controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Lift pull solenoid harness defect
(2) Lift push solenoid harness defect (5) Lift pull solenoid defect
(3) Lift push solenoid defect (6) Main controller defect
Error code H5-1, -3
No error occurs

(CN10-5 to CN10-1, CN11-5 to CN11-1).

4A-172
Error code H5-2, -4
No error occurs.

(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK
Error code H5-5
TROUBLESHOOTING)

(CN10-5 to CN10-1, CN11-5 to CN11-1).

4A-173
Error code H5-6
disconnect the CN10 and CN11 connectors, and visually check H5-6 error does not
inside the connector and the caulked portion of its wire for defects. occur.
H5-6 error occurs.

HB-2 error.

(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK


4A-174
z Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-6

Tilt push
CN10-6
Tilt pull
CN101-12 (33, STPL-) CN10-2 solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Tilt pull solenoid harness defect
(2) Tilt push solenoid harness defect (5) Tilt pull solenoid defect
(3) Tilt push solenoid defect (6) Main controller defect
Error code H6-1, -3
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur.

(CN10-6 to CN10-2, CN11-6 to CN11-2).

4A-175
Error code H6-2, -4
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur. Connector contact defect

(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK
Error code H6-5
TROUBLESHOOTING)

(CN10-6 to CN10-2, CN11-6 to CN11-2).

4A-176
Error code H6-6
H6-6 error occurs.

HB-2 error.

(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK


4A-177
abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-7

Attachment 1
CN10-7
Attachment 2
CN101-10 (36, SA1PL-) CN10-3 push solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
Error code H7-1, -3
No error occurs.

(CN10-7 to CN10-3, CN11-7 to CN11-3).

4A-178
Error code H7-2, -4
No error occurs.

(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK
Error code H7-5

(CN10-7 to CN10-3, CN11-7 to CN11-3).

4A-179
Error code H7-6
H7-6 error occurs.

HB-2 error.

(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK


4A-180
abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-8

Attachment 2
CN10-8
Attachment 2
CN101-14 (39, SA2PL-) CN10-4 pull solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
Error code H8-1, -3
Track down the
connector and the caulked portion of its wire for defects. (Refer to H8-6 error occurs.
cause of the H8-6
error.
No error occurs.
H8-1, H8-3
Push and hold down the attachment 2 lever and pull and hold it up for No error occurs Connector contact
more than 1 second each to check if an error occurs. defect
H8-1 or
H8-3 error occurs.
(CN10-8 to CN10-4, CN11-8 to CN11-4).

4A-181
Error code H8-2, -4
the CN10 and CN11 connectors, and visually check inside the H8-5
No error occurs.
H8-2, H8-4
Push and hold down the attachment 2 lever and pull and hold it up for error occurs

2. Disconnect the CN10 and CN11 connectors. NG
Attachment 2 solenoid defect
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK

Harness defect
OK
Error code H8-5
TROUBLESHOOTING)

(CN10-8 to CN10-4, CN11-8 to CN11-4).

4A-182
Error code H8-6
1. Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector H8-6
and the caulked portion of its wire for defects. (Refer to BEFORE No error occurs
TROUBLESHOOTING.)
2. Connect the CN10 and CN11 connector, connect the battery plug, and
H8-6 error occurs.
HB-2 error.
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check the
OK


4A-183
z Error Code HB-1, -2, -3, (Solenoid power supply circuit over current)
Related portion
F7
CN130-6 (19, F7)
CN102-5 (17, SOLCOM) CN132-8 (17, SOLCOM)

CN102-6 (17, SOLCOM)
RY1
CN102-13 (335, RY1) CN132-4 (335, RY1) CN132-2 (97, FAN+)
CN101-3 (97, FAN+)
CN101-5 (9, SLLA2+) CN11-5

Lift PUSH
CN101-17 (10, SLPL-) CN10-5

Lift PULL
CN10-1 solenoid
CN101-6 (32, SLTA1+) CN11-6

Tilt PUSH
CN101-12 (33, STPL-) CN10-6

Tilt PULL
Main
CN10-2 solenoid
controller
CN11-7
ATT1 PUSH
CN101-10 (36, SA1PL-) CN10-7

ATT1 PULL
CN10-3 solenoid
CN11-8
ATT2 PUSH
CN101-14 (39, SA2PL-) CN10-8

ATT2 PULL
CN103-5 (N2, N2) CN10-4 solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

4A-184
Probable cause:
(2) Harness defect
(3) RY1 defect
Error code HB-1
TROUBLESHOOTING)
HB-1 error occurs.

Harness defect
OK
Relay defect (*1)

*1 If the symptom persists after replacement of the relay, there should be any other problems,
so replace the Main controller.
Error code HB-2
the CN132, CN10 and CN11 connectors, and visually check inside HB-2 error does not
the connector and the caulked portion of its wire for defects. occur.
2. Connect the CN132, CN10 and CN11 connector, connect the
battery plug, and turn on the key switch to see if an error occurs.
HB-2 error occurs.

Harness defect
2. Disconnect the CN101, CN102, CN103, CN104, CN10 and CN11
OK

4A-185
Error code HB-3
TROUBLESHOOTING)
HB-3 error occurs.

Harness defect
OK
Inspection: Relay check

2. Disconnect the connector CN132, check the relay and measure its NG
Relay defect
resistance on the primary side
(resistance between CN132-4 and CN132-2).
OK

With the battery plug and the CN101, CN102, and CN132 connectors disconnected, visually check inside each

4A-186

With the battery plug and the CN101, CN102, CN103, CN104, CN10 and CN11 connectors disconnected,



4A-187
z Error Code HC-1, -2, -3, -4, (Unload valve solenoid abnormality)
Related portion
CN101-1 (3, SOLLU+) CN13-1
CN102-17 (5, SLUL-) CN13-2
CN103-5 (N2, N2)

Main Unload valve
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Unload valve solenoid defect
(2) Unload valve solenoid harness defect (4) Main controller defect
If the HC-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
0
Error code HC-1
No error occurs.
HC-1 error does not
Lower the lift to see if an error occurs. occur. Connector contact defect
HC-1 error occurs.


4A-188
Error code HC-2
No error occurs.
HC-2 error does not
occur.
HC-2 error occurs.

OK

Harness defect
OK
Error code HC-3
TROUBLESHOOTING)


4A-189
Error code HC-4
the CN13 connector, and visually check inside the connector and HC-4 error does not
TROUBLESHOOTING)
HC-4 error occurs.

OK

Harness defect
OK

CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects.

CN13-2 to CN13-1 No continuity HC-1, 2, 3, 4
4A-190
z Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality)
Related portion
CN103-8 (300, IPL+) CN39-3
CN103-30 (301, IPL1) CN39-2

Shock sensor 1
CN101-32 (51, POT-) CN39-1
Main
controller CN40-3
CN103-19 (302, IPL2) CN40-2

Shock sensor 2
CN40-1
Probable cause:
(2) Shock sensor harness defect
(3) Shock sensor defect

1. Turn off the key switch and disconnect the battery plug. G5-2 [G5-5]
2. Disconnect the CN39 [CN40] connector and connect the CN39-3 to error occurs. Shock sensor 1
CN39-2 [CN40-3 to CN40-2] on the harness side through [shock sensor 2] defect
09232-13130-71.

NG
Harness defect
OK

4A-191

G5-1 [G5-4]

Harness defect
OK
turn on the key switch to see if an error occurs. (after one minute)

G5-1 [G5-4]
G5-1 [G5-4] error does not occur.

Harness defect
OK

4A-192

Turn off the key switch and disconnect the battery plug, disconnect CN39 [CN40], CN101 and CN103 and

sec04A.book
WHEN NO ERROR CODE IS DISPLAYED
Probable causes of problems for which no error code is displayed
Note:
193 ページ
If an error code is displayed or the spanner light is on, be sure to perform checks with priority given to it.
Control
systems
Emergency switch main body (with
Emergency switch) – • Release the emergency switch.
: Switch is held down.
２０１１年１月２５日

Battery
: Battery plug is disconnected. • Charge the Battery
: Low voltage
火曜日

Key switch main body
: Open failure
Emergency switch main body (with • Check the switch, and replace it if
Emergency switch) necessary.
: Open failure – • Check the harness and repair or

Key switch harness replace it if necessary.
: Wire breakage, short circuit or • Replace the F5 fuse.
Although the key switch or ten-key leakage (harness, connector or F5
operation is turned on, power is not fuse)
Power-supply supplied. Numeric keypad harness (with PIN
related control (The multi-function screen does not • Check the harness and repair or
code entry) –
appear, and the vehicle does not replace it if necessary.
: Open failure
move, either.)
Check the operation of each switch.
: Check if a response (lighting of LED
or sounding of buzzer) is given only
to a particular switch.
Numeric keypad main body (with PIN If there are two types of switches:
code entry) switch to which a response is given • Replace the numeric keypad.
: Switch failure 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.
Multi-function display (with PIN code
Using the Administrator menu, check if • Register PIN using the Administrator
entry)
PIN has been registered. menu.
: PIN not registered
4A-193
Control
sec04A.book
systems
4A-194
Display power supply and ground
harness (with PIN code entry)
194 ページ
Although the key switch is turned on, : Wire breakage, short circuit,
power is not supplied. leakage (harness or connector)
(The multi-function screen does not Multi-function display (with PIN code –
• Replace the display.
appear, and the vehicle does not entry)
• Replace the main controller.
move, either.) : Internal failure
Main controller
Power-supply : Internal failure (D7V, DGND)
２０１１年１月２５日
related control
Display power supply or ground
harness
火曜日

The multi-function screen does not
appear. –
Multi-function display • Replace the display.
(The vehicle runs normally.)
: Internal failure • Replace the main controller.
Main controller
: Internal failure
After the key switch was turned on, the
accelerator was not released or the
– Operate them correctly.
direction switch was not returned to
neutral.
Analyzer.
Direction switch main body
: Accelerator is fully closed. • Check the switch, and replace it if
: Open failure
Operate the direction switch to see if necessary.
Direction switch harness
it turns on and off normally. • Check the harness and repair or
(The vehicle does not run if the replace it if necessary.
forward and reverse switches are
turned on simultaneously.)
The vehicle does not run.
Traveling Direction switch installation portions
(The drive motor does not rotate.)
(EZ pedal)
Check the operation of the direction • Repair or replace the part that does
: One of the installation portions is
switch (microswitch). not operate normally.
broken or damaged or does not
operate normally.
Accelerator sensor main body
: Internal failure Check the accelerator sensor voltage,
Accelerator sensor installation portion using Analyzer. • Check the sensor and replace it if
: The link or the installation portion is : Direction switch is in neutral. necessary.
broken or damaged. Fully open and close the drive to • Check the harness and repair or
Accelerator sensor harness check the change in voltage at that replace it if necessary.
: Wire breakage, short circuit, time.
Control
sec04A.book
systems
Accelerator fully closed/fully open
matching value • Perform matching again.
Matching screen.
195 ページ

Check the brake switch voltage, using
Brake switch main body Analyzer.
• Check the switch and replace it if
: Open failure : Direction switch in neutral, drive
necessary.
Brake switch harness fully closed
: Wire breakage, short circuit, Fully open and close the brake
leakage (harness or connector) cylinder valve to check the change
２０１１年１月２５日
in voltage.
火曜日
Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
: Open failure fully closed necessary.
standing beside it.
Brake Check the brake and the drive motor.

• Check the brake, and repair or
: Dragging (internal failure) : With the battery plug disconnected,
Drive motor the parking brake released and the
The vehicle does not run. • Check the drive motor, and repair or
Traveling : Seizure or dragging of drive motor front wheels off the ground, rotate
(The drive motor does not rotate.) replace it if necessary.
(internal failure) each tire to see if it rotates smoothly.
sensor Check the voltage of the drive motor
: Internal failure rotation sensor, using Analyzer. • Check the drive motor rotation
Drive motor rotation sensor installation : Seated in seat, direction switch in sensor, and adjust or replace it if
portion forward position, brake released necessary.
: Gap improperly adjusted Operate the accelerator and check • Check the harness and repair or
Drive motor harness the change in the rotation sensor replace it if necessary.
Check the voltage of the drive motor
Drive motor drive circuit current sensor, using Analyzer.
: Internal failure : Seated in seat, direction switch in • Check the cable, and repair or
Motor cables forward position, brake released replace it if necessary.
: Wire breakage, short circuit or Operate the accelerator and check • Replace the drive motor drive circuit.
leakage (cable or terminal board) the change in the current sensor
voltage.
Main controller
: Internal failure
4A-195
Control
sec04A.book
systems
4A-196
Pump motor rotation sensor main body
: Internal failure Check the voltage of the drive motor
• Check the pump motor rotation
196 ページ
Pump motor rotation sensor rotation sensor, using Analyzer.

sensor, and adjust or replace it if
installation portion : Seated in the seat
necessary.
: Gap improperly adjusted Operate the direction switch and
Pump motor harness check the change in the rotation
: Wire breakage, short circuit, sensor voltage.
Load handling cannot be performed
and the steering is heavy. Measure the voltage of the pump
２０１１年１月２５日

(The pump motor does not work for motor current sensor, using Analyzer. • Check the motor cables, and repair
: Internal failure
material handling operation, steering : Seated in the seat or replace them if necessary.
Motor cables
火曜日
operation and direction switch Operate the direction switch and • Replace the pump motor drive
: Wire breakage, short circuit or
operation.) check the change in the current circuit.
leakage (cable or terminal board)
sensor voltage.
–
Pump motor • Check the pump motor, and repair or

Main controller
Load handling : Internal failure
and power Main body of load handling lever
steering potentiometer
: Internal failure Measure the voltage of the load
Only load handling cannot be Installation of load handling lever handling lever potentiometer, using
performed. potentiometer Analyzer.
necessary.
(The pump motor operates normally : Installation portion is broken or : Leave the seat
during steering operation and direction damaged. Tilt the load handling lever forward
switch operation.) Load handling lever potentiometer and backward to check the change
harness in voltage.
Main body of tilt forward/backward
switch (Conventional lever)
: Internal failure
Check the tilt forward/backward
Only load handling cannot be Installation of tilt forward/backward
switch, using Analyzer. • Check the switch and replace it if
performed. switch
: Seated in the seat necessary.
(The pump motor operates normally : Installation portion is broken or
Operate the tilt lever forward to • Check the harness and repair or
during steering operation and direction damaged.
backward position to check the replace it if necessary.
switch operation.) Tilt forward/backward switch
switch turns on and off normally.
harness
Control
sec04A.book
systems
Seat switch main body • Check the seat and replace it if
: Load handling lever in neutral
197 ページ
Check if the switch turns on and off

Seat switch harness • Check the harness and repair or
normally, sitting in the seat or
standing beside it.
Oil control valve (Conventional lever) • Check the oil control valve, and
Only load handling cannot be : Seizure of or leakage from unload repair or replace it if necessary.
performed. valve • Check the unload valve solenoid
–
(The pump motor operates normally Harness of unload valve solenoid and replace it if necessary.
２０１１年１月２５日
during steering operation and direction : Wire breakage, short circuit, • Check the harness and repair or
switch operation.) leakage (harness or connector) replace it if necessary.
火曜日

: Leak replace it if necessary.
–
Load handling Priority valve • Check the priority valve, and repair
and power : Leak, seizure or replace it if necessary.
steering Main controller

: Internal failure
Only lowering is impossible. If a current flows, turn on the lowering
Lowering lock valve • Check the lowering lock valve, and
(Other load handling operations, lock solenoid using Active Test to
: Seizure (internal damage) repair or replace it if necessary.
including raising, are possible.) lower the fork.
Only forward tilting is impossible.
If a current flows, turn on the tilt control
(Other load handling operations, Tilt control valve • Check the tilt control valve, and
solenoid using Active Test to lower the
including backward tilting, are : Seizure (internal damage) repair or replace it if necessary.
fork.
possible.)
Direction switch • Check the switch, and replace it if
The steering is heavy. Analyzer.
(The pump motor operates normally : Accelerator is fully closed.
Direction switch harness • Check the harness and repair or
during material handling.) Operate the direction switch to see if
it turns on and off normally.
4A-197
Control
sec04A.book
systems
4A-198
: Internal damage
198 ページ

The steering is heavy. leakage (harness or connector)
(The pump motor operates normally Pump • Check the pump, and repair or
Load handling during material handling.) : Leak replace it if necessary.
２０１１年１月２５日
and power Priority valve • Check the priority valve, and repair
–
steering : Leak, seizure or replace it if necessary.
火曜日
PS valve • Check the PS valve, and repair or

Main controller
: Internal failure
Display setting
Although ATT1 (ATT2) is operated, no : The serial number setting is not in Check the set value on the Option Set • Change the setting (see "MULTI
operation is performed. agreement with that of the vehicle. screen. FUNCTION DISPLAY")
(OCV WAY)
: Internal damage
: Wire breakage, short circuit or leakage
(harness, connector or F5 fuse)
: Open failure
The backup buzzer (option) does not and replace it if necessary.
sound. • Check the harness and repair or
Auxiliary Backup relay main body (EZ pedal)
equipment : Open failure
it if necessary.
: Wire breakage, short circuit.
• Replace the Main controller.
: Internal failure
: Internal breakage
The backup buzzer (option) does not replace it if necessary.
stop sounding. • Check the harness and repair or
connector)
Control
sec04A.book
systems
: Short circuit
199 ページ

connector)
The backup buzzer (option) does not Backup relay main body (EZ pedal)
stop sounding. : Short circuit
it if necessary.
２０１１年１月２５日
connector)
火曜日

: Internal failure
: Internal breakage, burnout of light • Check the backup light and replace
Auxiliary bulb it if necessary.
–
equipment Backup light harness • Check the harness and repair or

: Open failure
The backup light (option) does not go Auxiliary equipment relay harness –
on. : Short circuit, leakage (harness or
connector)
: Open failure
it if necessary.
connector)
: Internal failure
4A-199
Control
sec04A.book
systems
4A-200
• Check the backup light and replace
: Internal breakage,
it if necessary.
200 ページ
Backup light harness –

: Short circuit
Auxiliary The backup light (option) does not go • Check the harness and repair or
２０１１年１月２５日
equipment out. replace it if necessary.

connector)
火曜日

: Short circuit
it if necessary.
connector)

: Internal failure
Display setting
: OPS operation notification buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
OPS operation warning does not (OPS BUZZER, SEAT BUZZER)
sound.
Display setting
Buzzer-related The traveling OPS return-to-neutral (OPS BUZZER)
control warning does not sound.
Display setting
The load handling OPS return-to- (OPS BUZZER)
neutral warning does not sound.
Control
sec04A.book
systems
Analyzer.
201 ページ

: Short circuit • Check the switch, and adjust or
: Switch is held down. • Check the harness and repair or
The parking brake lever release Operate the parking brake lever
: Short circuit (harness or connector)
reminder does not sound. lever to see if the switch turns on
and off normally.
２０１１年１月２５日

火曜日
Main controller
: Internal failure
Analyzer.

Buzzer-related Installation of parking brake switch replace it if necessary.
When the vehicle runs with the parking display goes on and out.)
control : Switch is off. • Check the harness and repair or
brake lever released, the parking : Direction switch is in neutral.
brake release reminder sounds. Operate the parking brake lever to
normally.
Main controller
: Internal failure
Display setting
: Parking brake reminder buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
(PKB BUZZER)
The parking brake lever reminder does Parking brake switch main body Analyzer.
not sound. (The switch can also be checked by
: Switch is off. • Check the harness and repair or
Operate the parking brake lever to
normally.
4A-201
Control
sec04A.book
systems
4A-202
Seat switch main body Check the seat switch, using Analyzer. • Check the seat and replace it if
: Short circuit : Check if the switch turns on and off necessary.
202 ページ
Seat switch harness normally, sitting in the seat or • Check the harness and repair or
: Short circuit (harness or connector) standing beside it. replace it if necessary.
The parking brake lever reminder does
not sound. Display • If the buzzer does not sound,
Main controller
２０１１年１月２５日
: Internal failure
Parking brake switch main body Check the parking brake switch, using
: Short circuit Analyzer. • Check the switch, and adjust or
火曜日
Buzzer-related
control Installation of parking brake switch : Direction switch is in neutral. replace it if necessary.
: Switch is held down. Operate the parking brake lever to • Check the harness and repair or
Parking brake switch harness see if the switch turns on and off replace it if necessary.
: Short circuit (harness or connector) normally.
Although the parking brake lever is

pulled up, the parking brake reminder
Seat switch main body : Direction switch in neutral, drive • Check the seat switch and replace it
does not stop sounding.
: Open failure fully closed if necessary.
standing beside it.
Main controller
: Internal failure
Display setting
The height selector function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Height selector function disabled
screen does not appear. screen. FUNCTION DISPLAY")
(H-SELECTOR)
necessary.
Height selector • Check the harness and repair or
The lifting stop position cannot be set. : Wire breakage, short circuit uppermost and lowermost positions
(option) replace it if necessary.
normally.
Main controller
: Internal failure
Display setting
No limit is placed on the maximum Check the set value on the lifting stop • Change the setting (see "MULTI-
: The maximum lifting height is not be
lifting height. position setting screen. FUNCTION DISPLAY")
set.
Control
sec04A.book
systems
Display setting
: The automatic lifting stop position is
203 ページ
not set.
Height selector switch main body
: Open failure, short circuit
Mechanical detection unit of height Check the height selector switch,
Although the height selector switch is • Check the height selector switch,
selector switch using Analyzer.
pressed, the automatic lifting stop and adjust or replace it if necessary.
: Gap in detection unit is improperly : Vehicle stopped
position cannot be selected. • Check the harness and repair or
adjusted. Operate the height selector switch
２０１１年１月２５日
Height selector switch harness to see if it turns on and off normally.
火曜日
Main controller
: Internal failure
If the loading conditions, the tilt angle
of the mast, etc at that time are
different from those when the lifting – –

height was set, the fork stop position
Height selector may not agree with the set position.
(option) Lifting height sensor main body
: Dragging or improper winding of wire Check the lifting sensor voltage, using
Installation of lifting height sensor Analyzer.
The fork stop position is far away from : Breakage of sensor installation : In NL
necessary.
the lifting height set position (100 mm portion, breakage of wire routing Raise and lower the lift to its
or more). portion uppermost (relief) and lowermost
Lifting height sensor harness positions to check the change in the
Change over time of lifting sensor
detection unit
Main controller
: Internal failure
• Check the positional relationship
The automatic lifting stop position
The automatic lifting stop position among automatic lifting stop
cannot be selected if the maximum
cannot be selected, although it was set – position, maximum lifting height and
lifting height or the lifting height limit is
for sure. lifting height limit, and set them
set below it.
properly.
Display setting
Shock sensor The shock detection function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Shock detection function disabled
(option) screen does not appear. screen. FUNCTION DISPLAY")
(SHOCK SENSOR)
4A-203
Control
sec04A.book
systems
4A-204
Way in which the vehicle collides
: The degree of shock that the shock
204 ページ
sensor receives vary depending on

the way and direction in which the
– –
vehicle collides and the object with
which it collides. The shock sensor
does not necessarily detect all kinds
of shock.
Display setting
２０１１年１月２５日
• Change the setting (see "MULTI-

: A too large (improper) value is set –
Although shock is applied, the shock FUNCTION DISPLAY")
detection alarm does not go on.
火曜日

: Sensitivity reduced
Installation of shock sensor • Check the sensor and replace it if
: Improper installation (loosening), necessary.
interference • Check the harness and repair or
its voltage changes.
Shock sensor harness replace it if necessary.

and 2.)
Shock sensor
Main controller
(option) – • Replace the main controller.
: Internal failure
Display setting
(Set a value that corresponds to
: A too small (improper) value is set –
shock unlikely to be applied during
normal operation.)
: Internal damage (excessive
response)
Installation of shock sensor
Although no shock is applied, the : Improper installation (loosening), • Check the sensor and replace it if
shock detection alarm sets off. interference necessary.
Shock sensor harness • Check the harness and repair or
its voltage changes excessively.
and 2.)
(Especially if there are half-broken
wires in the harness, shock may be
detected frequently.)
Main controller
: Internal failure
Control
sec04A.book
systems
One of the following matching
205 ページ
* If accelerator pedal fully closed and

operations is not performed.
fully open matching is finished by
• Tire straight running angle matching
simply performing fully closed
• Forward tilt limit angle matching
matching and fully open matching in
• Tilt horizontal angle matching
[Diagnostic mode indicator] this order, the setting will not be
• Tilt no-load matching Check the matching value on the
Although no error code is displayed, saved.
• Accelerator pedal fully closed Matching screen.
the diagnostic mode indicator is left on.
matching
２０１１年１月２５日
* If brake pedal fully closed and

• Accelerator pedal fully open
operating point matching is finished
matching
by simply performing fully closed
火曜日
• Mini-lever neutral voltage matching

matching and operating point
• Tire diameter data
matching in this order, the setting will
not be saved.

Multi-function Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
display : The link or the installation portion is : In NL replace it if necessary.
[Tilt indicator] : Wire breakage, short circuit, change in voltage.
The correct tilt angle is not displayed. leakage (harness or connector)
Matching screen.
No problem if the tilt angle is 0° under
no-load conditions.
When a load is carried, the position
where the fork stops when automatic
[Tilt indicator] fork leveling is finished does not
The tilt angle is not indicated as 0° always agree with the position of the
when the automatic fork leveling is fork when its tilt angle is indicated as
finished. 0° on the tilt indicator, so the tilt angle
may not be indicated as 0°, depending
on the load.
4A-205
Control
sec04A.book
systems
4A-206
• Check the tires and replace them if
Tire specification necessary.
–
206 ページ
: Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
Lock cylinder main body
: Leakage, incapable of locking • Check the lock cylinder, and repair
Check the lock cylinder, using Active
Installation of lock cylinder or replace it if necessary.
Test.
: Installation portion is damaged or • Check the swing solenoid and
: Forcibly turn on (unlocked) and off
broken. replace it if necessary.
２０１１年１月２５日
(locked) the swing solenoid to check

Swing solenoid harness • Check the harness and repair or
the state of the lock cylinder.
: Short circuit, leakage (harness or replace it if necessary.
火曜日
connector)
necessary.

voltage.
The vehicle lacks stability during
traveling.
Swing lock Lifting height switch main body Analyzer.
(The swing mechanism does not lock • Check the switch, and replace it if
easily or at all during traveling.) necessary.
normally.
necessary.
sensor
: Internal failure
necessary.
: Internal failure
Main controller
: Internal failure
Control
sec04A.book
systems
• Check the lock cylinder, and repair
Lock cylinder main body Check the lock cylinder, using Active
or replace it if necessary.
: Seizure of lock cylinder Test.
207 ページ
• Check the solenoid and replace it if

Swing solenoid harness : Forcibly turn on (unlocked) and off
necessary.
: Wire breakage, short circuit, (locked) the swing solenoid to check
leakage (harness or connector) the state of the lock cylinder.
２０１１年１月２５日
necessary.
火曜日

voltage.
Analyzer.
: A high lifting height is always • Check the lifting height switch, and
: In NL
detected. replace it if necessary.
The swing mechanism always locks Raise and lower the lift to its
Swing lock during traveling or load handling, uppermost and lowermost positions
or it locks frequently. to see if the switch turns on and off
normally.
necessary.
sensor
: Internal failure
necessary.
: Internal failure
Main controller
: Internal failure
4A-207
Control
sec04A.book
systems
4A-208
208 ページ
２０１１年１月２５日

Matching screen.
火曜日
When tilted forward for leveling, the Main body of automatic fork leveling
fork does not stop automatically in a switch
horizontal position. : Open failure
(The fork tilts to its forward tilt limit Mechanical detection unit of automatic
without stopping in a horizontal fork leveling switch
position.) : Gap in detection unit is improperly

adjusted.
normally.
Tilt control : Wire breakage (harness, connector)
Main controller
: Internal failure
When the fork tilted forward for : The link or the installation portion is : In NL replace it if necessary.
leveling, it does not stop automatically broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
in a horizontal position. Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
(The fork does not stop in a horizontal : Wire breakage, short circuit, change in voltage.
position.) leakage (harness or connector)
Matching screen.
Control
sec04A.book
systems
209 ページ
necessary.
When the fork tilted forward for Load sensor harness Raise and lower the lift to its
leveling, it does not stop automatically : Wire breakage, short circuit, uppermost (relief) and lowermost
in a horizontal position. leakage (harness or connector) positions to check the change in the
(The fork does not stop in a horizontal voltage.
position.) Load sensor no-load matching value Check the matching value on the
２０１１年１月２５日
Main controller
: Internal failure
火曜日

Tilt control Check the matching value on the
Matching screen.
When tilted forward for leveling, the Check the load sensor voltage, using
fork does not stop automatically in a Load sensor main body Analyzer.
horizontal position. : Internal breakage : In NL
necessary.
(When tilted forward for leveling, the Load sensor harness Raise and lower the lift to its
fork stops where it is when the : Wire breakage, short circuit, uppermost (relief) and lowermost
automatic fork leveling switch is leakage (harness or connector) positions to check the change in the
pressed.) voltage.
Load sensor no-load matching value Check the matching value on the
Analyzer.
: In NL
normally.
Main controller
: Internal failure
4A-209
Control
sec04A.book
systems
4A-210
210 ページ
(Mini Lever / Joystick Lever) Tilt angle sensor leveling matching
２０１１年１月２５日
When the fork is tilted backward for Check the matching value on the
value • Perform matching again
leveling, it does not stop automatically Matching screen.
in a horizontal position.
火曜日
(The fork tilts to its backward tilt limit Main body of automatic fork leveling
without stopping in a horizontal switch
position.) : Open failure

adjusted.
normally.
Tilt control Main controller
: Internal failure
When the fork is tilted backward for See "When the fork is tilted forward for
leveling, it does not stop automatically leveling, it does not stop automatically
– –
in a horizontal position. in a horizontal position (The fork does
(The fork does not stop in a horizontal not stop in a horizontal position.)"
position.)
(Mini Lever / Joystick Lever) : The link or the installation portion is : In NL replace it if necessary.
When the fork is tilted backward for broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
leveling, it does not stop automatically Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
in a horizontal position. : Wire breakage, short circuit, change in voltage.
(The fork stops where it is when the leakage (harness or connector)
automatic fork leveling switch is Tilt angle sensor leveling matching
pressed.) value • Perform matching again.
Matching screen.
Main controller
: Internal failure
Control
sec04A.book
systems
switch
211 ページ
: Open failure
adjusted.
normally.
２０１１年１月２５日
Check the tilt control valve, using • Check the oil control valve, and
Oil control valve
Active Test. repair or replace it if necessary.
: Seizure of tilt control valve
火曜日
The mast backward tilting speed is not Tilt solenoid harness : Tilt solenoid forcibly turned on • Check the solenoid and replace it if
limited. (backward tilting speed limited) necessary.
Tilt the mast backward to check the • Check the harness and repair or
operation. replace it if necessary.

necessary.
Tilt control : Wire breakage, short circuit uppermost and lowermost positions
normally.
Main controller
: Internal failure
switch
: Short circuit
adjusted.
The mast backward tilting speed is normally.
always slow. : Short circuit (harness or connector)
Tilt solenoid harness (backward tilting speed not limited) necessary.
: Short circuit, leakage (harness or Tilt the mast backward to check the • Check the harness and repair or
4A-211
Control
sec04A.book
systems
4A-212
Analyzer.
212 ページ
: In NL
The mast backward tilting speed is Lifting switch harness • Check the harness and repair or
normally.
Main controller
: Internal failure
２０１１年１月２５日
Display setting
Check the set value on the Option Set • Change the setting
: Forward tilting speed setting
火曜日
screen. (see "MULTI-FUNCTION DISPLAY")

(T F-SPD LIM)
Although the load is lifted high, the • Check the switch, and replace it if
Tilt control mast forward tilting speed is not necessary.
limited. • Check the harness and repair or

normally.
Main controller
: Internal failure
Analyzer.
: In NL
The mast forward tilting speed is Lifting switch harness • Check the harness and repair or
normally.
Main controller
: Internal failure
Tire angle sensor main body
Knob position The knob is displaced from its normal damaged. fully closed • Check the harness and repair or
compensation position to a certain position. Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
control (10° or more from the straight running : Wire breakage, short circuit, the change in voltage.
(OPT) position) leakage (harness or connector)
Tire angle sensor straight running
angle matching value • Perform matching again.
Matching screen.
Control
sec04A.book
systems
: Internal damage
213 ページ

The knob is displaced from its normal valve, using Active Test.
２０１１年１月２５日

position to a certain position. : Tire end
(10° or more from the straight running Forcibly turn on (bypass) and off (no
: Leakage, seizure (internal damage) replace it if necessary.
火曜日
position) bypass) the knob position

compensation solenoid to check
harness necessary.
how the steering system operates.
Forcibly ON ... Steering idles (light).
idles (heavy).
Knob position The road surface is inclined. – –

compensation Main controller
control : Internal failure
(OPT) Tire angle sensor main body
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
The knob is displaced from its normal leakage (harness or connector)
position. Tire angle sensor straight running
(The knob position is not constant angle matching value • Perform matching again.
Matching screen.
during straight running.) : No agreement with the vehicle state
: Internal damage
4A-213
Control
sec04A.book
systems
4A-214
valve, using Active Test.
214 ページ
: Tire end
Forcibly turn on (bypass) and off (no
bypass) the knob position
Knob position The knob is displaced from its normal compensation solenoid to check
harness necessary.
compensation position. how the steering system operates.
control (The knob position is not constant Forcibly ON ... Steering idles (light).
(OPT) during straight running.) Forcibly OFF ... Steering does not
２０１１年１月２５日
idles (heavy).
PS cylinder system link is defective. • Check the cylinder, and repair or
–
火曜日
: Eccentric pin or kingpin is defective replace it if necessary.

Main controller
: Internal failure
Seat switch main body : Direction switch in neutral, drive • Check the switch, and replace it if
: Short circuit fully closed necessary.

Neither traveling OPS nor load Seat switch harness Check if the switch turns on and off • Check the harness and repair or
handling OPS operates. : Short circuit (harness or connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
: Internal failure
– • Replace the drive motor drive circuit.
: Internal failure
Only traveling OPS does not operate.
Main controller
OPS : Internal failure
Only load handling OPS does not connector) operation. replace it if necessary.
operate. Oil control valve • Check the oil control valve, and
Check the lift lowering lock valve,
: Seizure of or leakage from lift repair or replace it if necessary.
using Active Test.
lowering lock valve • Check the solenoid and replace it if
: Lift lock solenoid forcibly turned off
Lift lock solenoid harness necessary.
(lift lock)
: Short circuit, leakage (harness or • Check the harness and repair or
Lower the lift to check the operation.
connector) replace it if necessary.
Control
sec04A.book
systems
• Check the oil control valve, and
Oil control valve (Conventional Lever)
repair or replace it if necessary.
: Seizure of or leakage from load
215 ページ
• Check the material handling

handling proportional valve
proportional valve solenoid, and
: Seizure of or leakage from unload
– replace it if necessary.
Only load handling OPS does not valve
OPS • Check the unload valve solenoid
operate. Harness of unload valve solenoid
２０１１年１月２５日
Main controller
: Internal failure
火曜日

necessary.

voltage.
Display setting
Traveling Although no load is applied, the speed actual vehicle state.
control (option) is limited when the lift is raised high. • In traveling control, the attachment
weight and the mast weight are
treated as part of the load weight,
because they affect the longitudinal
stability of the vehicle. For a very
Heavy attachment, mast with a high
– heavy mast or an FSV or FV mast
lifting height
with a high lifting height, if its inner
middle mast is rather heavy, a limit
may sometimes be placed on the
speed even under no-load
conditions.
4A-215
Control
sec04A.book
systems
4A-216
When the lift is raised to its uppermost
position, the load sensor cannot
216 ページ
distinguish this situation from a

situation in which a heavy load is
carried, because, in that situation, a
relief pressure remains in the lift
Lift relief pressure detected. –
Although no load is applied, the speed cylinder pressure that the load sensor
is limited when the lift is raised high. senses.
After a lift relief, however, it becomes
２０１１年１月２５日
possible to perform operation because

the relief pressure is discharged when
the lift is lowered even a little.
火曜日
Main controller
: Internal failure
necessary.
Traveling replace it if necessary.
control (option) voltage.
necessary.
Although a load is carried, the speed is replace it if necessary.
not limited when the lift is raised high. normally.
Display setting
: Traveling control setting disabled
Check the set value on the Option Set • Change the setting (see "MULTI-
Load sensing speed restriction
screen. FUNCTION DISPLAY")
disabled
(ASC W/LOAD, MODE)
Display setting
Main controller
: Internal failure
Control
sec04A.book
systems
Analyzer.
217 ページ
: In NL
Although the fork is not raised high, Raise and lower the lift to its
the speed is limited when a load is uppermost and lowermost positions
carried. to see if the switch turns on and off
normally.
Main controller
Traveling – • Replace the main controller.
: Internal failure
２０１１年１月２５日
control (option)
Display setting • Change the setting (see "MULTI-
Check the set value.
: Maximum speed limit is set very low. FUNCTION DISPLAY")
火曜日
Display setting
A limit is always placed on the speed
regardless of whether a load is carried
or not.
Main controller
: Internal failure
4A-217
Control Circuit
CC12-003
August 31, 2012
8FBCU Pre-charge Circuit Explanation
SERVICE INFORMATION BULLETIN 8FBCU20-32, 8FBCHU25 (-9/2010)
Subject: 8FBCU Pre-charge Circuit Explanation (Error Codes 31-1 and 31-3) Page 1 of 3
MODEL APPLICATION:
8FBCU20-32, 8FBCHU25 (Produced after 9/2010)
REPAIR INFORMATION:
Circuit explanation:
• UICL= Unit In-rush Current Limit: This is a small printed board (black cover and sits in front of
the pump motor controller in the left lower compartment). Inside this box there are 3
thermistors (PTC’s) that are used for slowing in-rush currents.
• RCP=Resistor Current Protect: This is used to control voltage/current timing and is located
behind the controller air box (The wiring is viewable if the battery is removed and battery tray
lifted/removed on left side).
• Why do we need these items?
With the new Kollmorgen controller (much different than the Toyota controllers) they must
check the capacitor banks in each controller by time/voltage rise, so the controller requires a
trickle up effect and current flows through the PTC’s (UICL) and resistor (RCP) to P4 before
closing the MB contactor. If the capacitor banks (inside motor controllers) do not charge to 22
volts in less than 250ms then the motor controller sends an error code to our CPU by CAN
communication (MB never closes). The charge cycle prevents MOSFET’s from being damaged
in the controller if the capacitor circuit is open.
P3 and P4: Do Not connect any UICL=Unit In-rush Current Limit

electrical devices to this circuit.
RCP (Resistor Current Protect). RCP

is located on the air box back side.
Chassis Electrical
CE11-001R
May 13, 2011
Clamp Release Interlock (Mini
Lever Units)
7FBEU15-20, 7FBEHU18,
SERVICE INFORMATION BULLETIN 8FGCU15-32 and 8FGU15-32
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 8FGCU15-32 and 8FGU15-32
Starting with units built in October 2010, new units with mini levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments must
have a second release method (2 moves to open the attachment) to prevent accidental opening. Please
refer to Product Bulletins 19-10 and 24-10.
Factory Programmed
The function of the controller is to maintain the

Attachment 2 (ATT21 and ATT22) potentiometer
voltage at a neutral status until the additional switch
(Hall Effect type) on the mini lever is depressed.
System Components:
Clamp Release Interlock (CRI) Controller

• 7FBEU models it is located in the left
step in front of the battery (under the fan
box).
• 8FBCU models it is located behind the
hydraulic tank under the battery.
• 8FGCU and 8FGU models it is located
on the right frame near the transmission.
Clamp Release Controller connector

plug is numbered. Due to changes in
various models and options the color
code can change so it is preferred to
use the pin connection on each unit
and track back to the power supply
and mini lever potentiometer.
12 volt power supply is only used on

the electric trucks (7FBEU or
8FBCU) and is wired to P1 and
N1/N2. It is located near the Clamp
Release Controller.
System Components Continued:
Mini Lever
Potentiometer
Wiring.
680 Ohm Resistor
Calibration Instructions:
Note – Calibration only required when controller is replaced. See note on page 4.
1. Turn truck off.
2. Unplug power supply for CRI controller.
3. Unplug calibration jumper harness.
4. Turn truck on.
5. Plug power supply back in for CRI controller
6. After waiting 15 seconds, place calibration jumper back on harness.
7. Perform matching for lever that has CRI.
Note: After extended usage the variable resistor (level angle sensor ATT2) could encounter a
slight neutral voltage drift and error codes H4-3 and/or H4-4 could be logged. Before replacing
any parts, first recalibrate the CRI module (see page 3) then perform matching of the level
angle sensor (see page 3-68 in repair manual CU331).
Chassis Electrical
CE11-002
August 31, 2011
8FBCU Horn Wires Breaking
Subject: 8FBCU Horn Wires Breaking Page 1 of 1
MODEL APPLICATION:
Beginning with Serial Numbers:

8FBC(H)U20/25-60636
8FBCU30/32-60233
REPAIR INFORMATION:
Starting 11/12/2010 the main wiring harness was changed to lengthen the horn wires. For units built
prior to this change, here is the procedure to modify units in operation that may encounter this
condition:
Chassis Electrical
CE11-003
August 31, 2011
Clamp Release Interlock
(Standard Lever Units)
7FBE(H)U15-20, 8FBC(H)U20-
SERVICE INFORMATION BULLETIN 32, 7FBCU15-55, 8FG(C)U15-32,
7FGCU35-70 and 7FGU35-80
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 7FBCU15-55
8FGCU15-32, 8FGU15-32, 7FGCU35-70 and 7FGU35-80
Starting with October 2010, new units with standard hydraulic levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments
must have a 2nd release method (2 moves to open the attachment) to prevent accidental opening.
Please refer to product bulletins 19-10 and 24-10.

Switch and Wiring Installation
Clamp release switch

Switch assembly and wiring as routed
by the factory.
Wire routing through boot and lever

connects to relay circuit.
Solenoid and Hydraulic Hose Connections
Hose Connection at Oil Control Valve Hose to Attachment Spacer Plate
Bolts
Relay
Solenoids 12, 36 and

48 volts (Voltage
Specific).
Hose from Fitting

valve
This drawling is an example of an

8FBCU25 only. Most locations of the
solenoid and relay are close to the
Oil Control Valve (right side of
frame).
Power and Ground Wire Connections
This drawing is an example of the

panel connections for an 8FBCU25
and will be similar on all electric
products. For IC trucks, the
positive and negative sources are
connected directly to the battery.
Maintenance
MA12-004
May 31, 2012
8FBCU Repair Manual Updates
SERVICE INFORMATION BULLETIN Models 8FBCU20-32
Subject: 8FBCU Repair Manual Updates Page 1 of 14
MODEL APPLICATION:
8FBCU20-32
Please replace the following pages in your repair manual CU347-1.
Chassis Electrical
CE14-005
August 15, 2014
Special Grounding Strap
(30)/7FBCU15-32, 7FBCHU25,
SERVICE INFORMATION BULLETIN 8FBCU20-32
MODEL APPLICATION:
(30)/7FBCU15-32, 7FBCHU25, 8FBCU20-32
This special grounding strap can be added to the models mentioned above. This strap has
excellent conductance to reduce ESD (Electro Static Discharge) when using non marking tires.
Parts Required for One Unit
56184-21320-71 (2 PCS)
Install earth wire after setting
collars.
56401-21320-71
Mount using the rear
91551-80816 (2 PCS)
steer axle mounting
bolts.
56412-21320-71
56185-21320-71
If the grounding strap cannot be attached to the rear axle, use the alternate method below.

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Sec Index.

fm 1 ページ ２０１１年１月２６日 水曜日 午後３時４９分

Hotline Tech Tips

Technical News Brief

Hotline Tech Tips

Vehicle Model Punching format

(1) Never apply impacts to electronic parts such as a

ATTENTIVE POINTS ON SAS

(2) Digital circuit tester

Forward direction Reverse direction

2 Difference in result of measurement with circuit tester

4 Germanium This manual describes the results of measurement with a

3 Difference in measurement result by measurement range (analog type)

Power source: 1.5V

Hotline Tech Tips

1. Insulation resistance measurement

Measurement terminals Controller side of battery plug-body

Caution for part replacement

Measurement method and standard list

Connecror No. ļ Connector No. Conditions Standard Remarks

Terminal name Conditions for measurement

Electric Level No.

Connector pin No.

CN101 CN102 CN103 CN104

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN104-9 CN104-3 Resistance measurement with battery

Revised January 31, 2012

Connector No. ⇔ Connector No. Conditions Standard Remarks

CN104-18 CN103-6 Key switch OFF, seat switch ON Approx. 0V

Key switch OFF, direction switch Approx. 0V

Key switch OFF, parking brake switch Approx. 0V

Key switch OFF, mast height switch Approx. 0V

Key switch OFF, direction switch Approx. 0V

Revised January 31, 2012

Mini lever/Joystick lever

Revised January 31, 2012

Connector No. ⇔ Connector No. Conditions Standard Remarks

*1: W/ ATT1, *2: W/ ATT2

Revised January 31, 2012

Connector No. ⇔ Connector No. Conditions Standard Remarks

Connector No. ⇔ Connector No. Conditions Standard Remarks

Revised January 31, 2012

Connector No. ⇔ Connector No. Conditions Standard Remarks

TRAVELING AC DRIVER (~2010.9)

CN110 and CN111

Connector No. ⇔ Connector No. Conditions Standard Remarks

LOAD HANDLING AC DRIVER (~2010.9)

TRAVELING AC DRIVER (2010.10~)

CN110 and CN111

Connector No. ⇔ Connector No. Conditions Standard Remarks

LOAD HANDLING AC DRIVER (2010.10~)

CONTACTOR PANEL ASSY

BACK RELAY (W/ EZ pedal)

Connector No. ⇔ Connector No. Conditions Standard Remarks

fm 1 ページ２０１１年１月２６日水曜日午後３時４９分

1: W/ ATT1, 2: W/ ATT2