4460 00001-Up MM

Maintenance Manual
Model 4460 3-Wheel Sit-Down Counterbalanced

Lift Truck
Model: Serial Numbers:

4460 00001 and Up
Publication: 1237640B Revised: 25 May 2020

This publication, 1237640B, applies to Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck,
S/N 00001 and up, and to all subsequent releases of this product until otherwise indicated in new editions or
bulletins. Changes occur periodically to the information in this publication.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Sales and Service center.
To locate your local authorized Raymond Sales and Service center, go to www.raymondcorp.com.
©2020 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Raymond. All other brand and product
names are trademarks or registered trademarks of their respective companies.
i
Table of Contents
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
6. MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747
7. DRIVE UNIT AND FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 763
8. REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
9. STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
10. BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
11. BODY & FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
12. MATERIAL HANDLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 837
13. MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
14. CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871
15. OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 893
16. OIL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 899
17. OIL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957
18. PSS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965
19. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 985
ii
1. GENERAL 1-1
1. GENERAL 1
1.1. LIFT TRUCK EXTERIOR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2. LIFT TRUCK MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3. FRAME NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4. HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5. OPERATING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6. STANDARD BOLT & NUT TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 9
1.7. PRECOAT BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE . . . . . . . . . . 12
1.9. RECOMMENDED LUBRICANT QUANTITY AND TYPES . . . . . . . . . . . . 13
1.10. LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.11. PERIODIC MAINTENANCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.12. PERIODIC REPLACEMENT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1-2 1. GENERAL
1.1. LIFT TRUCK EXTERIOR VIEW

1. GENERAL 1-3
1.2. LIFT TRUCK MODELS 1
Capacity Capacity
Vehicle model
(L.C.500 mm) (L.C.24 inch) Voltage Control method
code
kg lbs.
C30S AC microcomputer
1500 3000 36/48V
C30 controller
C35S AC microcomputer
1750 3500 36/48V
C35 controller
AC microcomputer
C40 1810 4000 36/48V
controller
1.3. FRAME NUMBER
This illustration shows the punching position (a) of your frame number.
Lift truck model Punching format
C30S
C30
C35S 446-20-00001
C35
C40
(a) Frame serial number location

1-4 1. GENERAL
1.4. HOW TO USE THIS MANUAL
1.4.1. EXPLANATION METHOD

1) Operation procedure
• The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation or operation procedure by indication step numbers in one illustration, followed by
explanation of cautions and notes summarized as point operations.
Example
2) Matters omitted from this manual

This manual omits descriptions of the following jobs, but perform them in actual operation:
• Cleaning and washing of removed parts as required
• Visual inspection (partially described)
1. GENERAL 1-5
1.4.2. TERMINOLOGY 1
CAUTION
Important matters of which negligence may cause hazards on the human body. Make sure
to observe them.
NOTICE
Indicates information to be considered important, to do your job right and easier, and to keep your lift truck
running well.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
1.4.3. ABBREVIATIONS
Abbreviation Abbreviation
Meaning Meaning
(code) (code)
ASC Automatic Speed Control PS Power steering
Performance Stability System (PSS

ASSY Assembly PSS (SAS)
and SAS are interchangeable terms)
ATT Attachment QR Quick Reference
FR Front RH Right hand
LH Left hand RR Rear
Society of Automotive Engineers

L/ Less SAE
(USA)
OCL Over Current Limit SOL Solenoid
OCV Oil Control Valve SST Special service tool
OPS Operator Presence Sensor STD Standard
OPT Option T= Tightening torque
PKB Parking brake W/ With

1-6 1. GENERAL
1.5. OPERATING TIPS

1) Safe operation
• After jacking up, always support with wooden blocks or rigid stands.
• When hoisting the lift truck or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
• Always disconnect the battery plug before the inspection or servicing of electrical parts.
2) Careful operation
• Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge,
etc.) and SSTs before starting operation.
• Before disconnecting wiring, always check the cable color and wiring state.
• When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly
to prevent confusion.
• When disassembling and inspecting such a precision part as the control valve, use clean tools and operate
in a clean location.
• Follow the described procedures for disassembly, inspection and reassembly.
• Replace, gaskets, packing and O-rings with new ones each time they are disassembled.
• Use genuine Raymond parts for replacement.
• Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. (Tighten to
the center of the specified tightening torque range.) If no tightening torque is specified, tighten the bolt or nut
according to the standard tightening torque table.
3) Protection of functional parts
• Thoroughly check each connector for any failure in or imperfect connection before reconnecting the battery
plug after the end of lift truck 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 lift truck, 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
• Never apply impacts to electronic parts such as a microcomputer or relay.
• Never let electronic parts be exposed to a high temperature or humidity.
• Do not touch connector pins since they may be deformed or be damaged due to static electricity.
7) Disconnect the battery plug
When unplugging the battery plug, use the grip. Do not pull up on the cable.
1. GENERAL 1-7
1.5.1. JACK-UP POINT 1
(a)
(b)
(a) Jack-up point

(b) Wooden block or stand setting points
NOTICE
• A jack-up point is provided at the bottom of the frame to the rear of the front tire.
• The jack-up point is provided within a range of 5.9 in. (150 mm) from the fender. Jack up the lift truck at
the specified jack-up point.
1-8 1. GENERAL
1.5.2. HOISTING THE VEHICLE
NOTICE
• Position the mast in the full rearward tilt position.

• Remove any Optional Lamps that are installed at the rear of the overhead guard.
• When preparing the lift truck for hoisting (and the lifting straps are tight), confirm that the draw bar has
not moved upward. If the draw bar has moved upward, push the draw bar downward.
• The length of lifting straps are different based on the specification of the lift truck and mast. When
hoisting the lift truck, adjust the length of the lifting straps to prevent deformation of the overhead guard
at the contact points with the overhead guard.
• Use protective padding if there is contact between the lifting straps and the overhead guard.
1. GENERAL 1-9
1.6. STANDARD BOLT & NUT TIGHTENING TORQUE 1

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.
1-10 1. GENERAL
1.6.1. BOLT STRENGTH TYPE IDENTIFICATION METHOD

IDENTIFICATION BY BOLT SHAPE
Shape Class
4 = 4T
5 = 5T
Bolt head No. 6 = 6T
Hexagon head bolt 7 = 7T
8 = 8T
No mark 4T
Hexagon flange bolt No mark 4T
Hexagon head bolt Two protruding lines 5T
Hexagon flange bolt Two protruding lines 6T
Hexagon head bolt Three protruding lines 7T
Hexagon head bolt Four protruding lines 8T
Welded bolt 4T
No mark 4T
Stud bolt
Grooved 6T
IDENTIFICATION BY PART NO.
Hexagon head bolt Stud bolt

1. GENERAL 1-11
1.6.2. TIGHTENING TORQUE TABLE 1
Specified torque Specified torque
Hexagon flange bolt

Hexagon head bolt
Diameter Pitch
Class mm mm ft-lbf. N•m ft-lbf. N•m
4T 6 1.0 48 in-lbf. 5.4 52 in-lbf. 5.9
8 1.25 9 13 10 14
10 1.25 19 25 21 28
12 1.25 35 47 39 53
14 1.5 55 75 61 83
16 1.5 83 113 - -
5T 6 1.0 56 in-lbf. 6.4 65 in-lbf. 7.5
8 1.25 12 16 13 18
10 1.25 24 32 26 36
12 1.25 43 59 48 65
14 1.5 67 91 76 100
16 1.5 101 137 116 157
6T 6 1.0 69 in-lbf. 7.8 78 in-lbf. 8.8
8 1.25 14 19 16 21
10 1.25 29 38 32 43
12 1.25 53 72 59 79
14 1.5 80 110 90 123
16 1.5 127 170 141 191
7T 6 1.0 8 11 9 12
8 1.25 19 25 21 28
10 1.25 38 52 43 58
12 1.25 70 95 76 103
14 1.5 108 147 123 167
16 1.5 166 226 - -
8T 6 1.0 9 12 9 14
8 1.25 22 29 24 32
10 1.25 45 61 50 68
12 1.25 80 108 90 123
14 1.5 127 172 145 196
16 1.5 195 265 221 299
1-12 1. GENERAL
1.7. PRECOAT BOLTS

(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the following cases:
• After it is removed.
• When the precoat bolt is moved (loosened or tightened) by tightness check, etc.
NOTICE
For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten
it according to the steps below.
2. Method for reuse of precoat bolts

• Wash the bolt and threaded hole. (The threaded hole must
be washed even for replacement of the bolt.)
• Perfectly dry the washed parts by air blowing.
• Coat the specified seal lock agent to the threaded portion of
the bolt.
1.8. HIGH PRESSURE HOSE FITTING TIGHTENING

TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with a clean
cloth to remove foreign matters and dirt.
Also check that there are no dents or other damage on the contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter Standard tightening torque Hose nominal size

of screw ft-lbf. [N•m] in. (mm)
Standard Tightening range
7/16 - 20UNF 18.4 [25] 17.7 to 19.2 0.24 (6)
[24 to 26]
9/16 - 18UNF 25.1 [34] 23.6 to 26.6 0.35 (9)
[32 to 36]
3/4 - 16UNF 43.5 [59] 41.3 to 45.7 0.47 (12)
7/8 - 14UNF [56 to 62]
7/8 - 14UNF 57.5 [78] 54.6 to 60.5 0.59 (15)
[74 to 82]
1 1/16 - 12UNF 87.1 [118] 82.6 to 90.7 0.75 (19)
[112 to 123]
1. GENERAL 1-13
1 5/16 - 12UNF 101.1 [137] 95.9 to 106.2 0.98 (25) 1

[130 to 144]
PF1/4 18.4 [25] 17.7 to 19.2 0.24 (6)
[24 to 26]
PF3/8 25.1 [34] 23.6 to 26.6 0.35 (9)
[32 to 36]
PF1/2 43.5 [59] 41.3 to 45.7 0.47 (12)
[56 to 62]
PF3/4 87.1 [118] 82.6 to 90.7 0.75 (19)
[112 to 123]
PF1 101.1 [137] 95.9 to 106.2 0.98 (25)
[130 to 144]
1.9. RECOMMENDED LUBRICANT QUANTITY AND TYPES
Application Type Capacity
Drive unit (ATF) AUTOMATIC TRANSMISSION FLUID Approx.0.145 US gal (0.55 L)

T-IV or MOBIL ATF 3309
Hydraulic oil STD: Hydraulic oil (ISO VG32) See “Hydraulic oil level by lifting
height” below
Cold storage lift truck: Castle Auto Fluid Special
Chassis parts MP grease Appropriate amount

Molybdenum disulfide grease
Esso beacon 325
Battery Distilled water Appropriate amount
Brake fluid SAE J-1703 DOT3 Appropriate amount
Hydraulic oil level by lifting height
Lifting height All models

US gal (L)
To 118 in. Capacity 4.70 (17.8)

(3000mm)
Hydraulic oil level in the tank 3.59 (13.6)
To 157.5 in. Capacity 5.17 (19.6)

(4000mm)
To 275.6 in. Capacity 5.41 (20.5)

(7000mm)
1-14 1. GENERAL
1.10. LUBRICATION CHART
G 15
○: Inspection and addition

●: Replacement
I. Inspection every 8 hours (daily)
A: MP grease II. Inspection every 40 hours (weekly)
B: Motor oil III. Inspection every 500 hours (3 months)
C: AUTOMATIC TRANSMISSION FLUID T-IV IV. Inspection every 1000 hours (6 months)
D: Hydraulic oil ISO VG 32
Castle auto special (cold storage models) V. Inspection 2000 hours (annual)
E: Molybdenum disulfide grease
F: Brake fluid SAE J-1703, DOT-3
G: Moliwhite TA No. 1 or equivalent
1. Mast strip 8. Steering rack and pinion gear

2. Tilt cylinder front pin 9. Accelerator link
3. Mast support bushing 10. Oil tank
4. Lift chain 11. Tilt steering lock device
5. Drive unit 12. Rear wheel bearing
6. Brake link 13. Rear axle bearing
7. Oil control valve lever pin 14. Master cylinder or Reservoir tank
15. Hydraulic Oil Pump Splines
1. GENERAL 1-15
1.11. PERIODIC MAINTENANCE TABLE 1

INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T: Retightening
C: Cleaning
L: Lubrication
*Same as the left column
*1: For new lift truck
*2: Fissure and crack detector
Inspection Period Every Every Every

Every
(Accomplish based on operating hours or months, whichever 3 6 12
6 weeks
is soonest.) months months months
Every Every Every Every

250 500 1000 2000
Item hours hours hours hours
ELECTRICAL SYSTEM
Motor Rotation sound I*1 I * *
Terminal looseness T*1 T * *
Insulation resistance M * *
Battery Charging level I* 1 I * *
Electrolyte level I*1 I * *
Electrolyte specific gravity M*1 M * *
Terminal looseness I*1 I * *
Abnormality in the upper porting of the I*1 I * *
battery case
Insulation resistance M * *
Voltage measurement of each battery cell M
after charging
Magnetic contactor Contact looseness, damage, abrasion I*1 I * *
Operating condition of the auxiliary I*1 I * *
contact, contamination, abrasion
Mounting condition of the arc shooter I
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead I
wire looseness
Micro switch Operating condition and timing I*1 I * *
Damage and looseness of installing parts I*1 I * *
Direction control Operating condition, damage I*1 I * *
lever
1-16 1. GENERAL

Every
6 weeks

250 500 1000 2000
Direction switch Contact inspection I*1 I * *
Controller Operating condition I*1 I * *
Interior contamination, damage C*1 C * *
Overcorrect limited value M
Fuse Looseness I*1 I * *
Wiring (including Harness deterioration, clamp damage and I*1 I * *
charging cord) looseness
Looseness in connecting parts, taping I*1 I * *
condition
Connection condition and damage of the I*1 I * *
battery connector
Wiring harness insulation damage I
POWER TRANSMISSION SYSTEM
Drive unit Oil leak I*1 I * *
Oil level I*1 I * *
Bolt or nut looseness T
DRIVE SYSTEM
Wheels Tire cuts, damage and uneven wearing I*1 I * *
Loose rim and hub nuts T*1 T * *
Tire groove depth M*1 M * *
Metal chips, pebbles and other foreign I*1 I * *
matter trapped in tire grooves
Rim, side bearing and disc wheel damage I*1 I * *
Abnormal sound and looseness of front I*1 I * *
wheel bearing
Abnormal sound and looseness of rear I*1 I * *
wheel bearing
Front axle Damage and deformation I
Rear axle Damage and deformation I
STEERING SYSTEM
Steering wheel Play and looseness I*1 I * *
Function I*1 I * *
Steering valve Oil leak I*1 I * *
Looseness of mounting T*1 T * *
Steering system Left and right turn angle I
1. GENERAL 1-17
Inspection Period
Every
Every Every Every 1
6 weeks

250 500 1000 2000
Power steering Oil leak and oil level I*1 I * *
Mounting and linkage looseness I*1 I * *
Damage of power steering hose I
BRAKING SYSTEM
Brake pedal Braking effect I*1 I * *
Parking brake Operating force I*1 I * *
Braking effect I*1 I * *
Brake pipe Leak, damage and mounting condition I*1 I * *
Reservoir tanks Leak and fluid level I*1 I * *
Master cylinder Function, wear, damage, leak and I
mounting looseness
Rod and cable Looseness and damage I*1 I * *
Operating condition I*1 I * *
Wet Brake Oil leak I*1 I * *
Cooling oil level (Drive unit oil level) I*1 I * *
Brake valve function, damage, or I
looseness in the installed parts
Brake disc clearance adjustment (disc I
wear)
LOAD HANDLING SYSTEM
Forks Abnormality of fork and stopper pin I*1 I * *
Misalignment between left and right fork I*1 I * *
fingers
Cracks at fork heel and hangers I*2
Mast and carriage Deformation and damage of each part and I*1 I * *
cracks on welded part
Roller bearing looseness I*1 I * *
Mast and carriage looseness I*1 I * *
Mast support metal wear and damage I*1 I * *
Wear, damage and rotating condition of I*1 I * *
rollers
Wear and damage of roller pins I
1-18 1. GENERAL

Every
6 weeks

250 500 1000 2000
Chain and chain Tension, deformation and damage of I*1 I * *
wheel chains
Chain lubrication I*1 I * *
Abnormality of chain anchor bolt I*1 I * *
Wear, damage and rotating condition of I*1 I * *
chain wheel
Chain wheel bearing wear I*1 I * *
Various Abnormality and mounting condition of I*1 I * *
attachments each part
(Option)
HYDRAULIC SYSTEM Cylinder
Cylinder Loosening and damage of cylinder T*1 T * *
mounting
Deformation and damage of rod, rod screw I*1 I * *
and rod end
Cylinder operation I*1 I * *
Natural drop and natural forward tilt M*1 M * *
(hydraulic drift)
Oil leak and damage I*1 I * *
Wear and damage of pin and cylinder I*1 I * *
support
Lifting speed M*1 M * *
Uneven movement I*1 I * *
Oil pump Oil leak and abnormal sound I*1 I * *
Drive system wear I(L)
Hydraulic oil tank Oil level and contamination I*1 I * *
Tank and oil strainer C *
Oil leak I* 1 I * *
Hydraulic filter Filter clogging I
Control lever Loose linkage I*1 I * *
Operation I*1 I * *
Oil control valve Oil leak I*1 I * *
Relief pressure measurement M
Relief valve and tilt lock valve functions I*1 I * *
1. GENERAL 1-19
Inspection Period
Every
Every Every Every 1
6 weeks

250 500 1000 2000
Hydraulic piping Oil leak I*1 I * *
Deformation and damage I*1 I * *
Loose joint T*1 T * *
SAFETY DEVICES, ETC.
Overhead guard Cracks at welded portion I*1 I * *
Deformation and damage I*1 I * *
Back-rest Loosening of mounting T*1 T * *
Deterioration, cracks and damage I*1 I * *
Lighting system Function and mounting condition I*1 I * *
(Option)
Horn Function and mounting condition I*1 I * *
Grease horn contact ring and horn contact L
spring
Turn signals Function and mounting condition I*1 I * *
(Option)
Instruments Functions I*1 I * *
Buck-up buzzer Function and mounting condition T*1 I * *
(Option)
Rear-view mirror Dirt, damage I*1 I * *
(Option)
Rear reflection status I*1 I * *
Deformation, cracking and damage I*1 I * *
PSS Functions I*1 I * *
Loosening and damage at sensor I*1 I * *
mounting portion
Damage, deformation, oil leakage and I*1 I * *
loosening of the mounting of functional
parts
Loosening and damage of wire harnesses I*1 I * *
Rusting and corrosion of load sensor I
Operator Presence Functions I*1 I * *
Sensor System
1-20 1. GENERAL

Every
6 weeks

250 500 1000 2000
Seat Loosening and damage of mounting I*1 I * *
Seat damage and function I*1 I * *
Operating condition of seat switch I*1 I * *
Seat belt Mounting looseness I*1 I * *
Webbing damage (cut, frayed straps, loose I*1 I * *
stitching)
Tongue damage I*1 I * *
Buckle and retractor damage I*1 I * *
Function (retract and locks) I*1 I * *
Body Damage and cracks of frame, cross I
members, etc.
Bolt looseness T
Others Grease up L*1 L * *
1. GENERAL 1-21
1.12. PERIODIC REPLACEMENT TABLE 1

Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
NOTICE
• Periodic maintenance is fundamental. Replace even before replacement interval if abnormality is seen in
Periodic Maintenance, because deterioration differs from condition.
• Have customers conduct weekly maintenance (40 hr) as mentioned in Operator's Manual.
•: Replacement
Inspection Period
(Accumulated hours of operation or Every Every Every Every
monthly periods of operation, 6 weeks 3 months 6 months 12 months
whichever comes sooner.)

Item
250 hours 500 hours 1000 hours 2000 hours
Hydraulic oil ●
●
Hydraulic oil return filter ●
(New Truck)
Brake fluid ●
Drive unit gear oil
●
(Wet disc brake oil)
Wheel bearing grease ●
Power steering hoses Every 2 years *1
Power steering rubbers parts Every 2 years *1
Hydraulic hoses Every 2 years *1
Chains Every 3 years *2
*1: Replace without reservation at indicated interval in case of hard operation conditions mentioned below.
In case of normal operating condition, the distributors are entrusted with the responsibility for determining whether
the parts should be replaced or not.
If the replacement is determined to be unnecessary, make sure to inspect at the next periodic maintenance.
Note: Definition of “hard operation” is the following.
• Extended heavy duty operations (e.g. multi-shift or continuous use)
• High temperature areas (e.g. steel mills or foundries)
• Low-temperature operations (e.g. freezer operation)
• Sudden temperature changes (e.g. traveling between freezer, room temperature, and oven or furnace
environments)
• Dusty or sandy conditions (e.g. cement plants, lumber or flour mills, coal dust or stone-crushing areas)
• Corrosive chemical atmosphere (e.g. fish, meat, or poultry processing plants, tanneries, chlorine or sea
salt air environments)
• High humidity, wet, damp, or moist conditions
*2: The distributors are entrusted with the responsibility for determining whether the parts should be replaced or not.
If the replacement is determined to be unnecessary, make sure to inspect at the next periodic maintenance.
1-22 1. GENERAL
2. BATTERY 2-23
2. BATTERY
2
2.1. BATTERY COMPARTMENT SIZE AND NECESSARY WEIGHTS
OF BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2. SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5. BATTERY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1. BATTERY COMPARTMENT SIZE AND NECESSARY

WEIGHTS OF BATTERY
When installing a battery, refer to the table below and adjust the weight so that the necessary minimum and
maximum weight is satisfied.
Battery compartment dimensions Necessary Necessary

in. (mm) minimum maximum
Model battery weight battery weight
Forward- (with case) (with case)
Width Y Height Z
Rear X lbs. (kg) lbs. (kg)
C30S 17.7 (451) 39.2 (997) 24.5 (623) 1475 (670) 1775 (805)
C30
21.7 (551) ↑ ↑ 1543 (700) 2270 (1030)
STD
C35S
C35
25.1 (638) ↑ ↑ 2105 (955) 2710 (1230)
C40
16.8 (427) or
39.0 (992) 24.1 (613) 1475 (670) 1775 (805)
less
C30S
16.9 (428) to
↑ 23.1 (587) ↑ ↑
17.7 (451)
20.7 (527) or
Battery C30 ↑ 24.1 (613) 1543 (700) 2270 (1030)
less
Compartment
Rollers* 20.8 (528) to
C35S ↑ 23.1 (587) ↑ ↑
21.7 (551)
24.1 (614) or
C35 ↑ 24.1 (613) 2105 (955) 2710 (1230)
less
24.2 (615) to
C40 ↑ 23.1 (587) ↑ ↑
25.1 (638)
* R/O: Battery Compartment Rollers specification

2-24 2. BATTERY
2.2. SERVICE STANDARDS
Specific gravity upon full charge 1.280 [68°F (20°C)]
Specific gravity upon end of discharge 1.150 [68°F (20°C)]
Discharge end voltage 36V 32V
48V 42.5V
Electrolyte Refined dilute sulfuric acid
Fluid to be added Distilled water
Insulation resistance 1 MΩ or more

2. BATTERY 2-25
2.2.1. Battery list

The recommended batteries are shown in the table below. Refer to Battery Compartment Size and Necessary
Weights of Battery for the necessary minimum weight. 2
Installed Battery Battery Case
Vehicle dimensions
Voltage Capacity Weight
Model Supplier Model length width height
(AH/6HR)
(lbs.) (kg) (in.) (mm) (in.) (mm) (in.) (mm)
18- 15.6 38.2 23.3

510 1458 662 398 972 593
ENER- 85G-13 8 7 6
36
SYS 18- 15.6 38.2 23.3
660 1584 719 398 972 593
E110-13 8 7 6
C30S
24- 14.7 38.2 23.3
360 1344 610 374 972 593
ENER- E90-9 4 8 6
48
SYS 24- 14.7 38.2 23.3
440 1464 665 374 972 593
E110-9 4 8 6
18- 17.9 38.5 23.3
770 1818 825 456 979 593
ENER- E110-15 4 3 6
SYS 18- 20.2 38.3 23.3
880 2070 940 513 974 593
E110-17 1 3 6
18-85S- 18.6 37.7 22.8
595 1818 825 475 959 581
15 9 5 8
36
18-85S- 20.1 38.2 22.8
Crown 680 2070 940 511 972 581
STD 17 3 5 8
18-110-1 20.1 38.2 22.8
880 2106 956 511 972 581
7 3 5 8
18-85C- 19.9 38.2 22.6
GNB 680 1933 878 506 972 575
C30 17 4 5 3
C35S 24- 17.7 37.9 23.3
550 1776 806 450 965 593
ENER- E110-11 1 8 6
SYS 24- 20.7 37.9 23.3
660 2112 959 526 964 593
E110-13 2 7 6
24-75S- 17.6 37.7 22.8
375 1728 785 448 959 581
11 3 5 8
48
24-85S- 20.6 37.7 22.8
Crown 510 2000 908 524 959 581
13 3 5 8
24-110-1 20.6 37.7 22.8
660 2095 951 524 959 581
3 3 5 8
24-85C- 20.5 38.0 22.6
GNB 510 1869 849 521 965 575
13 0 0 3
2-26 2. BATTERY
Vehicle dimensions
Voltage Capacity Weight
Model Supplier Model length width height
(AH/6HR)
18- 22.4 38.3 23.3
990 2322 1054 570 974 593
ENER- E110-19 6 3 6
SYS 18- 24.5 38.3 23.3
1100 2574 1169 623 974 593
E110-21 4 3 6
18-85S- 22.3 38.1 22.9
765 2322 1054 567 969 583
19 1 3 4
36
18-85S- 24.6 38.2 22.8
Crown 850 2484 1128 626 972 581
21 3 5 8
18-110-2 24.6 38.2 22.8
1100 2520 1144 626 972 581
1 3 5 8
C35 18-85C- 24.5 38.2 22.6
STD GNB 850 2314 1051 624 972 575
C40 21 6 5 3
24- 20.7 37.9 23.3
660 2112 959 526 964 593
ENER- E110-13 2 7 6
SYS 24- 23.7 38.7 23.3
770 2424 1100 603 983 593
E110-15 4 1 6
24-110-1 20.6 37.7 22.8
48 660 2095 951 524 959 581
3 3 5 8
Crown
24-110-1 23.6 38.2 22.8
770 2460 1117 600 972 581
5 3 5 8
24-85C- 23.5 38.1 22.6
GNB 595 2148 975 597 970 575
15 0 9 2
18- 17.9 38.5 23.3
770 1818 825 456 979 593
ENER- E110-15 4 3 6
SYS 18- 20.2 38.3 23.3
880 2070 940 513 974 593
E110-17 1 3 6
18-85S- 20.1 38.2 22.8
36 680 2070 940 511 972 581
17 3 5 8
Crown
18-110-1 20.1 38.2 22.8
880 2106 956 511 972 581
7 3 5 8
18-85C- 19.9 38.2 22.6
Battery GNB 680 1933 878 506 972 575
C30 17 4 5 3
Compartment
Rollers C35S 24- 17.7 37.9 23.3
550 1776 806 450 965 593
ENER- E110-11 1 8 6
SYS 24- 20.7 37.9 23.3
660 2112 959 526 964 593
E110-13 2 7 6
24-85S- 20.6 37.7 22.8
48 510 2000 908 524 959 581
13 3 5 8
Crown
24-110-1 20.6 37.7 22.8
660 2095 951 524 959 581
3 3 5 8
24-85C- 20.5 38.0 22.6
GNB 510 1869 849 521 965 575
13 0 0 3
2. BATTERY 2-27
Vehicle dimensions
Voltage Weight
Model Supplier Model
Capacity
length width height 2
(AH/6HR)
C35 36 ENER- 18-E110- 990 2322 1054 22.4 570 38.3 974 23.3 593
C40 SYS 19 6 3 6
Crown 18-85S- 765 2322 1054 22.3 567 38.1 969 22.9 583
19 1 3 4
GNB 18-85C- 850 2314 1051 24.5 624 38.2 972 22.6 575
21 6 5 3
48 ENER- 24- 660 2112 959 20.7 526 37.9 964 23.3 593
Battery SYS E110-13 2 7 6
Compartment
Rollers 24- 770 2424 1100 23.7 603 38.7 983 23.3 593
E110-15 4 1 6
Crown 24-110-1 660 2095 951 20.6 524 37.7 959 22.8 581
3 3 5 8
24-110-1 770 2460 1117 23.6 600 38.2 972 22.8 581
5 3 5 8
GNB 24-85C- 595 2148 975 23.5 597 38.1 970 22.6 575
15 0 9 2
2-28 2. BATTERY
2.3. DISPLAY
Battery Charge Indicator
The battery charge indicator indicates 10 levels of

battery charge on the LCD.
Battery LCD
discharged state % 10 9 8 7 6 5 4 3 2 1
F E
0 to 10 (exclusive) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
10 to 20 (exclusive) − ○ ○ ○ ○ ○ ○ ○ ○ ○
20 to 30 (exclusive) − − ○ ○ ○ ○ ○ ○ ○ ○
30 to 40 (exclusive) − − − ○ ○ ○ ○ ○ ○ ○
40 to 50 (exclusive) − − − − ○ ○ ○ ○ ○ ○
50 to 60 (exclusive) − − − − − ○ ○ ○ ○ ○
60 to 70 (exclusive) − − − − − − ○ ○ ○ ○
70 to 80 (exclusive) − − − − − − − ○ ○ ○
80 to 90 (exclusive) − − − − − − − − ○ ○
90 to 100 (exclusive) − − − − − − − − − ○
100 or more − − − − − − − − − −
Battery Overdischarge Warning

When the battery charge drops below the preset level in active “low battery level warning”, all segments in the battery
level indicator blink and a buzzer sounds to warn the operator.
Low Remaining Battery Charge Warning
When the battery charge drops below the preset level, the battery level indicator blinks. When the operator turns the
key switch from OFF to ON with this condition, a buzzer will sound for five seconds to warn the operator.
2. BATTERY 2-29
2.4. TROUBLESHOOTING
2
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Excessive charging
Defect of electrolyte
Insufficient current
Defective electrolyte
electrolyte
Overdischarge Excessive ambient
Battery defect
temperature
Crack or
Damaged Improper chipping of cell
separator water supply Imperfect
Overcharge terminal
connection
Deposition of freed Fouled terminal or

active substance connecting plug
at bottom of cell
Short circuit Electrolyte leakage and reduction Loosened or corroded connection

2-30 2. BATTERY
2.5. BATTERY ASSY
2.5.1. REMOVAL AND INSTALLATION
Removal Procedure
1) Disconnect the battery plug.
2) Release the steering release lever.
3) Open the battery hood.
4) Remove the battery ASSY. [Point 1]
Installation Procedure
The installation procedure is the reverse of the removal procedure.
2. BATTERY 2-31
Point Operations
[POINT1]
Removal and Installation: 2
SST 979-001/276
2.5.2. INSPECTION
1. Electrolyte inspection
The battery electrolyte is normal when it is
transparent. Check turbidity when inspecting the
specific gravity. If it cannot be checked clearly, put the
electrolyte in a beaker for inspection.
2. Battery electrolyte specific gravity inspection

Use a hydrometer to measure the specific gravity of
the electrolyte.
Specific gravity upon complete charging....
1.280 [68°F (20°C)]
Specific gravity upon end of discharge....
1.150 [68°F (20°C)]
The specific gravity of the electrolyte at 68°F (20°C) is

used.
Equation for converting specific gravity
S20=St+0.0007 (t-20)
S20: Specific gravity at 68°F (20°C)
St: Specific gravity at t°C
t: Electrolyte temperature upon measurement (°C)
2-32 2. BATTERY
* How to use the hydrometer

(1) Insert the nozzle (d) of the hydrometer (b) into the
electrolyte port and use the rubber bulb (a) to allow the
(b) electrolyte to be sucked into its outer tube (c).
(2) Let the hydrometer float without contact with the
(a) outer tube, top or bottom, and read the scale at the
(c) highest point of the electrolyte surface as illustrated at
left when the bubbles in the electrolyte disappear.
(3) After the measurement, wash the inside and
(d) outside of the hydrometer well with clear water. Wipe
water off with a clean cloth and store it.
3. Insulation resistance inspection

Measure the resistance between the battery and
battery case with an insulation resistance meter
(megohmmeter).
Insulation resistance.... 1 MΩ or more
NOTICE! When the insulation resistance is less than
1 MΩ, wash the battery with water after removing
it from the lift truck. Fully dry the washed battery
and measure the insulation resistance again. Install
the battery on the lift truck after confirming that
the insulation resistance is 1 MΩ or more.
* Battery control table

Prepare a control table for each battery to record and maintain the inspection results.
Inspection date Specific Electrolyte Added water

Inspected cell No. Remarks Inspector
and time gravity temperature quantity
2.5.3. REPLACING BATTERY PLUG TERMINAL

1. Disconnect battery plug cable one by one.
CAUTION
Never disconnect more than one cable at the same time. A
short circuit may cause a fatal accident.
2. BATTERY 2-33
2. Insert a screwdriver (c) from the terminal side (a), push down
the spring (b) at the bottom of the terminal and pull the cable to
(a) draw it out of the terminal.
(c) 2
(b) (b)
3. Peel off the tip of the cable for Approx. 1.18 in. (30 mm),
solder sufficiently and insert it in the contact portion of the new
terminal.
NOTICE! Make sure to prevent solder from pouring out and
adhering to the contact surface of the terminal.
4. Crimping method: When crimping cables, never bend the

terminal with a crimping tool.
(a) Crimping tool
(a) (b) Pad (To prevent the contact piece from bending)
(b)
5. Insert the terminal into the battery plug.

Check that the tip of the terminal goes over the tip of the spring
(a) (b) and is securely set in position.
(a) Case
(b) Terminal
(c) Spring
(d) Cable
(c) (d)
2-34 2. BATTERY
3. CONTROLLER 3-35
3. CONTROLLER
3.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2. ELECTRICAL COMPONENTS LAYOUT DRAWING . . . . . . . . . . . . . . . . 38 3
3.3. LAYOUT OF CONTROLLER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5. BEFORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6. CONNECTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7. DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.8. MAIN CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.9. DRIVE AND PUMP MOTOR DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.10. CONTACTOR PANEL (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.11. FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.12. DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.13. COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.14. ACCELERATOR SENSOR (POTENTIOMETER) . . . . . . . . . . . . . . . . . . . 82
3.15. BRAKE SENSOR (POTENTIOMETER) . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.16. BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.17. OVER CURRENT LIMIT (OCL) MEASUREMENT . . . . . . . . . . . . . . . . . . 87
3-36 3. CONTROLLER
3.1. GENERAL
3.1.1. Controller system configuration

The controller system to drive the AC motors has:
• Microcomputer-assisted inverter control,
• CAN (Controller Area Network) communication function between the main controller, drive/pump motor drivers,
and the multi-function display.
This is a multi-functional control system with advanced electronics technologies.

The pump motor driver is also used for the PS (Power Steering) control.
The multi-function display has been connected to the CAN communication. This lift truck has optional features such
as “PIN Code Entry System”.
The controller offers the power select feature and power keep feature that take full advantage of the AC power
system.
3.1.2. Controller configuration

(1) Construction of main controller
The main controller has been designed with small parts on the printed circuit board and efficiently configured inner
construction. In addition, the weight of the controller has been kept light by using case materials from aluminum and
resin.
The degree of protection provided by enclosures (IP code) is equivalent to IP20.
(2) Construction of motor driver
The main circuit device is trench MOS-FET that has lowered dissipation.
The drive motor driver is the same as the pump motor driver.
The degree of protection provided by enclosures (IP code) is equivalent to IP65.
3. CONTROLLER 3-37
(c)
(d)
(b)
(a)
(e)
(a) Drive motor driver (c) Aluminum (e) Main controller

(b) Pump motor driver (d) Resin
3-38 3. CONTROLLER
3.2. ELECTRICAL COMPONENTS LAYOUT DRAWING
(1) Main controller (a) Drive motor driver RH (e) Pump motor driver
(2) Brake sensor (b) Drive motor driver LH (f) Combination switch
(3) Accelerator sensor (c) Contactor panel (g) Ten-key
(4) Stop lamp switch (d) Fan (h) Multi-function display
3. CONTROLLER 3-39
3.3. LAYOUT OF CONTROLLER CABLES
(a) (b) (c) (d) (q) (e) (f) (g)
3
N2 N2
45° 45° 45°
45° 60° 45°

WR WL (h)
30° 45° 45°

(q)
VR VR VL V
(p)
30° 30° 30°
UR UL U
90°
P4 P4 P4 P4
(i)
90°
P1
(m)
(n) (k)
(o) (j)
(l) (f)
(a) Drive motor driver RH (g) DC/DC harness N2 (m) To the drive motor LH
(b) Connector cable N2 (h) DC/DC harness (n) To the drive motor RH
(c) Drive motor driver LH (i) Pump motor driver (o) To the battery plug
(d) Main harness N2 (j) DC/DC harness P4 (p) Connector cable
(e) Contactor panel (k) To the pump motor (q) Main harness
(f) Copper bar (l) Connector cable P1
CAUTION! Caution for installation

1. The angles at which cables are shown assembled are for reference only.
During actual assembly, run the cables so that they do not touch adjacent terminals.
2.Terminal tightening torque
T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]
3.4. SPECIFICATIONS
36V spec. 48V spec.
Fuse F1 (for drive and pump circuit) 700A 600A
Contactor MB (for power supply) Standard: ←
ME255
3-40 3. CONTROLLER
3.5. BEFORE INSPECTION
3.5.1. Inspection
1) Insulation resistance measurement
NOTE: Always measure before inspecting the
controller.
(1) Disconnect the battery plug and measure the
resistance between battery plug and body.
Measurement terminals Controller side of battery plug-body

Standard: Resistance value depends greatly on the lift truck operating state, place and
weather. (Approx. 1 MΩ or more)
Some components can be inspected after they are removed from the lift truck, while others can only be inspected
as installed on the lift truck.
3.5.2. Discharge of the power condenser
WARNING
The power condenser in the driver may have electrical charge.
So, before Inspection / repairing / troubleshooting, discharge the power condenser in the driver and check
the voltage (less than 3V). [Terminal between P4 and N1].
3.6. CONNECTOR INSPECTION
3.6.1. TO USE SST

Use SSTs for quick and accurate measure on the C30S, C30, C35S, C35, and the C40. The check will fail if the
connection method is wrong. Since boards may be damaged by incorrect connection, use care when performing
this operation.
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

979-001/159 Measure the voltage or resistance For use CN101 to CN104
for main controller.
3. CONTROLLER 3-41
3.6.2. 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
3
• 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
3-42 3. CONTROLLER
Main controller
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 Approx. 0.0V
(3, SOLLU+) (4, SLLL-) (OFF operation with ACTIVE TEST)
Lift lock solenoid Approx. 11V
(ON operation with ACTIVE TEST)
CN101-2 CN102-19 Tilt forward solenoid Approx. 0.0V
(6, SLTFB+) (7, SLTFL-) (OFF operation with ACTIVE TEST)
Tilt forward solenoid Approx. 11V
CN101-3 - Unused -
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 -
CN101-12 - Unused -
CN101-13 - Unused -
CN101-14 - Unused -
CN101-15 - Unused -
CN101-16 - Unused -
CN101-17 - Unused -
CN101-18 - Unused -
CN101-19 CN104-4 Key switch OFF Approx. 0.0V
(43, VBKY) (N2, N2) Key switch ON Battery voltage
3. CONTROLLER 3-43

CN101-20 CN101-32 - Approx. 4.8V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22 - - - 3
(50, VRA-)
CN101-23 CN101-32 - Approx. 4.8V
(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 CN101-22 - Approx. 4.8V
(53, VRA1+) (50, VRA-)
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 CN101-32 - Approx. 4.8V
(74, VRB2+) (51, POT-)
CN101-34 CN101-22 - Approx. 4.8V
(72, VRB1+) (50, VRA-)
*1: W/ ATT1
*2: W/ ATT2

CN102-1 CN104-4 Fan 1 stop Battery voltage
(98, FNDC1) (N2, N2) (OFF operation with ACTIVE TEST)
Fan 1 rotate Approx. 0.0V
CN102-2 CN104-4 Fan 2 stop Battery voltage
(99, FNDC2) (N2, N2) (OFF operation with ACTIVE TEST)
Fan 2 rotate Approx. 0.0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-5 - Unused -
CN102-6 - Unused -
CN102-7 CN102-14 Steering synchronizer solenoid Approx. 0.0V
(329, SLS+) (330, SLS-) (OFF operation with ACTIVE TEST)
Steering synchronizer solenoid Approx. 11V
3-44 3. CONTROLLER

CN102-8 CN104-4 Key switch OFF Approx. 14V
(333, OACC3) (N2, N2) Key switch ON Approx. 0.0V
CN102-9 CN104-4 Buzzer OFF Approx. 14V *1
(332, OACC2) (N2, N2) Buzzer ON Approx. 0.0V
CN102-10 - - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
CN102-13 - Unused -
CN102-14 CN102-7 Resistance measurement with Approx. 10 Ω
(330, SLS-) (329, SLS+) battery plug disconnected
CN102-15 - Unused -
(4, SLLL-) (3, SOLLU+) battery plug disconnected
(5, SLUL-) (3, SOLLU+) battery plug disconnected
(8, SLTBL-) (6, SLTFB+) battery plug disconnected
(7, SLTFL-) (6, SLTFB+) battery plug disconnected
CN102-20 CN102-26 Attachment 1 lever in the neutral Approx. 2.3V *2
(25, VRA12) (51, POT-) position
Attachment 1 lever in the forward or Approx. 0.5V to
backward position 4V
CN102-22 CN102-26 Key switch OFF, tilt lever in the Approx. 5V
(23, VRT2) (51, POT-) neutral position
(62, SWTR) Key switch OFF, tilt lever in the Approx. 0.0V
backward position
CN102-23 CN102-26 Key switch OFF, tilt lever in the Approx. 5V
(22, VRT1) (51, POT-) neutral position
(61, SWTF) Key switch OFF, tilt lever in the Approx. 0.0V
forward position
CN102-24 CN102-35 - Approx. 2.5V
(304, CSBAT) (305, CSBAT-)
CN102-25 CN102-26 Key switch OFF, brake pedal pressed Approx. 0.8 to
(73, VRB2) (51, POT-) 4.7V
CN102-26 - - -
(51, POT-)
CN102-27 - Unused -
3. CONTROLLER 3-45

3
CN102-30 CN101-22 Key switch OFF, accelerator pedal Approx. 0.4V to
(52, VRA1) (50, VRA-) pressed 4.7V
CN102-31 CN102-26 Tire position in neutral Approx. 2.5V
(317, VRTRA) (51, POT-)
(54, VRA2) (51, POT-) pressed 4.7V
CN102-33 CN101-22 Key switch OFF, brake pedal pressed Approx. 0.5V to
(71, VRB1) (50, VRA-) 4.7V
CN102-34 - Unused -
CN102-35 - - -
(305, CSBAT-)
*1: W/ Forward/Reverse Pedal or motion alarm

*2: W/ ATT1
*3: W/ ATT2

CN103-1 - Unused -
CN103-2 - Unused -
CN103-3 - - -
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5 - - -
(N2, N2)
CN103-6 - - -
(51, LS-)
CN103-7 - Unused -
CN103-8 CN102-26 - Approx. 5V
(300, IPL+) (51, POT-)
CN103-9 - Unused -
CN103-10 - Unused -
CN103-11 - Immeasurable -
(145, CAN1H)
(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
3-46 3. CONTROLLER

CN103-18 CN102-26 Lift lever in the neutral position Approx. 2.3V
(21, VRL2) (51, POT-) Lift lever in the forward or backward Approx. 0.5V to
position 4V
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 Key switch OFF, mast height switch Approx. 5V
(91, SH2-1) (51, LS-) 2-1 OFF
Key switch OFF, mast height switch Approx. 0.0V
2-1 ON
CN103-25 - Unused -
CN103-26 CN102-26 Lift lever in the neutral position Approx. 2.3V
position 4V
CN103-27 - Unused -
CN103-28 - Unused -
CN103-29 CN102-26 Forks on the ground Approx. 1V or
(59, SPLF) (51, POT-) less
Amount of change between raising Approx. 0.5V to
and lowering on the lift with a load 4.5V
CN103-30 CN102-26 - Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
CN103-32 CN103-6 Key switch OFF, automatic fork Approx. 5V
(70, STK) (51, LS-) leveling switch OFF
Key switch OFF, automatic fork Approx. 0.0V
leveling switch ON
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
CN104 Connector basic conditions (battery plug connected, key switch ON)

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 to
12V
CN104-4 - - -
(N2, N2)
CN104-5 - - -
(N2, N2)
CN104-6 - - -
(N2, N2)
3. CONTROLLER 3-47

CN104-7 - Unused -
CN104-8 - Unused -
(2, CBAT-) (1, CBAT+) battery plug disconnected 3
CN104-10 CN102-35 - Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN104-11 - Unused -
CN104-12 CN102-26 - Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 - Unused -
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 OFF Approx. 5V
(67, SDM) (51, LS-) Key switch OFF, seat switch ON Approx. 0.0V
CN104-19 CN103-6 Key switch OFF, direction switch Approx. 5V
(46, DSR) (51, LS-) neutral
Key switch OFF, direction switch Approx. 0.0V
backward
CN104-20 CN103-6 Key switch OFF, parking brake switch Approx. 5V
(66, SPB) (51, LS-) lock
Key switch OFF, parking brake switch Approx. 0.0V
release
CN104-21 - Unused -
CN104-22 CN103-6 Key switch OFF, mast height switch 1 Approx. 0.0V
(90, SH1) (51, LS-) ON
Key switch OFF, mast height switch 1 Approx. 5V
OFF
CN104-23 - Unused -
CN104-24 CN103-6 Steering operation Approx. 0.0V to
(314, SSTRC) (51, LS-) 5V
CN104-25 - Unused -
CN104-26 CN103-6 Key switch OFF, direction switch Approx. 5V
(45, DSF) (51, LS-) neutral
Key switch OFF, direction switch Approx. 0.0V
forward
CN104-27 - Unused -
CN104-28 - Unused -
CN104-29 - Unused -
(312, SSTR1) (51, LS-) 5V
(313, SSTR2) (51, LS-) 5V
3-48 3. CONTROLLER
Fingertip Control Lever

Lift lock solenoid

(OFF operation with ACTIVE TEST) Approx. 0V
CN101-1 CN102-16
(3, SOLLU+) (4, SLLL-)
Lift lock solenoid
Approx. 11V
Tilt forward solenoid

Approx. 0V
CN101-2 (OFF operation with ACTIVE TEST)
CN102-19
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid
Approx. 11V

(97, FAN+) (335, RY1) Key switch ON Approx. 12V
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
Variation upon changeover from

CN101-5 CN101-16 Approx. 0V to
forward
(9, SLLA2+) (11, SLPS-) 10V
to backward lifting
CN101-6 CN101-12 Variation upon changeover from Approx. 0V to

(32, SLTA1+) (33, STPL-) for-ward to backward tilting 10V
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
CN101-10 CN101-6 Resistance measurement with

Approx. 7 Ω *1
(36, SA1PL-) (32, SLTA1+) battery plug disconnected

Approx. 7 Ω *1
(37, SA1PS-) (32, SLTA1+) battery plug disconnected

Approx. 7 Ω
(33, STPL-) (32, SLTA1+) battery plug disconnected

Approx. 7 Ω
(34, STPS-) (32, SLTA1+) battery plug disconnected

Approx. 7 Ω *2
(39, SA2PL-) (9, SLLA2+) battery plug disconnected

Approx. 7 Ω *2
(40, SA2PS-) (9, SLLA2+) battery plug disconnected

Approx. 7 Ω
(11, SLPS-) (9, SLLA2+) battery plug disconnected
3. CONTROLLER 3-49

Approx. 7 Ω
(10, SLPL-) (9, SLLA2+) battery plug disconnected
CN101-18 - Unused -
CN101-19 CN104-4 Key switch OFF Approx. 0V 3

(43, VBKY) (N2, N2) Key switch ON Battery voltage
CN101-20 CN101-32
- Approx. 4.8V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN101-32
- Approx. 4.8V
(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+) (50, VRA-)
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 CN101-32
- Approx. 4.8V
(74, VRB2+) (51, POT-)
CN101-34 CN101-22
- Approx. 4.8V
(72, VRB1+) (50, VRA-)
*1: W/ ATT1
*2: W/ ATT2
3-50 3. CONTROLLER
Fan 1 stop
Battery voltage
CN102-1 CN104-4 (OFF operation with ACTIVE TEST)
(98, FNDC1) (N2, N2) Fan 1 rotate
Approx. 0 V
Fan 2 stop
Battery voltage
(99, FNDC2) (N2, N2) Fan 2 rotate
Approx. 0 V
Key switch OFF Approx. 0V

CN102-3 CN104-4


(17, SOLCOM) (N2, N2) Key switch ON Battery voltage

(17, SOLCOM) (N2, N2) Key switch ON Battery voltage
Steering synchronizer solenoid Approx. 0V

(329, SLS+) (330, SLS-) Steering synchronizer solenoid Approx. 11V

(333, OACC3) (N2, N2) Key switch ON Approx. 0V
CN102-9 CN104-4 Buzzer OFF Approx. 14V

*1
(332, OACC2) (N2, N2) Buzzer ON Approx. 0V
CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
Key switch OFF Battery voltage

CN102-13 CN104-4
(335, RY1) (N2, N2) Battery voltage -
Key switch ON
Approx. 12V

(330, SLS-) (329, SLS+) battery plug disconnected
3. CONTROLLER 3-51
CN102-15 - Unused -

(4, SLLL-) (3, SOLLU+) battery plug disconnected
CN102-17 - Unused - 3
CN102-18 - Unused -

(7, SLTFL-) (6, SLTFB+) battery plug disconnected
Attachment 1 lever in the neutral Approx. 2.3 V

CN102-20 CN102-26 position
*2
(25, VRA12) (51, POT-) Attachment 1 lever in the forward or Approx. 0.5V to
Attachment 1 lever in the neutral Approx. 2.3 V

*2
Key switch OFF, tilt lever in the

neutral Approx. 2.3V
CN102-22 position
CN102-26
(23, VRT2)
(51, POT-) Key switch OFF, tilt lever in the
(62, SWTR) Approx. 0.5V to
backward
4V
position
Key switch OFF, tilt lever in the

neutral Approx. 2.3V
CN102-23 position
CN102-26
(22, VRT1)
(51, POT-) Key switch OFF, tilt lever in the
(61, SWTF) Approx. 0.5V to
forward
4V
position
CN102-24 CN102-35
- Approx. 2.5V
(304, CSBAT) (305, CSBAT-)
CN102-25 CN102-26 Key switch OFF, brake pedal Approx. 0.8V to

(73, VRB2) (51, POT-) depressed 4.7V
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
Attachment 2 lever in the neutral Approx. 2.3V

*3
3-52 3. CONTROLLER
Attachment 2 lever in the neutral Approx. 2.3V

*3

(52, VRA1) (50, VRA-) depressed 4.7V
CN102-31 CN102-26
Tire position in neutral Approx. 2.5V
(317, VRTRA) (51, POT-)

(54, VRA2) (51, POT-) depressed 4.7V
CN102-33 CN101-22 Key switch OFF, brake pedal Approx. 0.5V to

(71, VRB1) (50, VRA-) depressed 4.7V
CN102-34 - Unused -
CN102-35
- - -
(305, CSBAT-)
*1: W/ Forward/Reverse Travel pedal or motion alarm

*2: W/ ATT1
*3: W/ ATT2
CN103-1 - Unused -
CN103-2 - Unused -
CN103-3
- - -
(14, DGND)

(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 - Unused -
CN103-8 Approx. 5V
CN102-26
(300, IPL+) -
(51, POT-)
CN103-9 - Unused -
CN103-10 - Unused -
3. CONTROLLER 3-53
CN103-11 Immeasurable -
-
(145, CAN1H)
CN103-12 Immeasurable -
-
(146, CAN1L)
3
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
position 4V
CN103-19 CN102-26 - Approx. 2V

(302, IPL2) (51, POT-)
CN103-20 - Unused -
CN103-21 - Unused -
CN103-22 - Unused -
CN103-23 - Unused -
Key switch OFF, mast height switch

2-1 OFF
CN103-24 CN103-6
(91, SH2-1) (51, LS-) Key switch OFF, mast height switch
2-1 ON
CN103-25 - Unused
Lift lever in the neutral position

CN103-26 CN102-26
(20, VRL1) (51, POT-) Lift lever in the forward or backward
position
CN103-27 - Unused
CN103-28 - Unused
Forks on the ground

CN103-29 CN102-26
(59, SPLF) (51, POT-) Amount of change between raising
and lowering on the lift with a load
CN103-30 CN102-26 -
(301, IPL1) (51, POT-)
3-54 3. CONTROLLER
CN103-31 - Unused
Key switch OFF, automatic fork

leveling
switch OFF
CN103-32 CN103-6
(70, STK) (51, LS-) Key switch OFF, automatic fork
leveling
switch ON
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
CN104 Connector basic conditions (battery plug connected, key switch ON)
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)

(44, VBMB) (N2, N2) Key switch ON Battery voltage
Key switch OFF Approx. 0V

CN104-3 CN104-9
(1, CBAT+) (2, CBAT-) Approx. 11V to
Key switch ON
12V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
CN104-6
- - -
(N2, N2)
CN104-7 - Unused -
CN104-8 - Unused -
Resistance measurement with

CN104-9 CN104-3
battery Approx. 20 Ω
(2, CBAT-) (1, CBAT+)
plug disconnected
CN104-10 CN102-35
- Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN104-11 - Unused -
CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 - Unused -
3. CONTROLLER 3-55
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 CN104-4
- Approx. 14V
(60, PSSW+) (N2, N2)
3
CN104-16 - Unused -
CN104-17 - Unused -
CN104-18 CN103-6 Key switch OFF, seat switch OFF Approx. 5V

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

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

CN104-20 CN103-6 switch lock
(66, SPB) (51, LS-) Key switch OFF, parking brake Approx. 0V
switch release
CN104-21 - Unused -
Key switch OFF, mast height switch

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

CN104-26 CN103-6 neutral
(45, DSF) (51, LS-) Key switch OFF, direction switch Approx. 0V
forward
CN104-27 - Unused -
Key switch OFF, load switch OFF

CN104-28 CN103-6 Approx. 5V
(68, SHS) (51, LS-)
Key switch OFF, load switch ON Approx. 0V
CN104-29 - Unused -
3-56 3. CONTROLLER
CN104-30 CN103-6
(312, SSTR1) (51, LS-)
CN104-31 CN103-6
(313, SSTR2) (51, LS-)
Drive motor driver LH
CN109
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16

CN109-1 - Unused -
CN109-2 - Unused -
CN109-3 - Unused -
CN109-4 - Unused -
CN109-5 - Unused -
CN109-6 - Unused -
CN109-7 - Unused -
CN109-8 - - Battery voltage
(42, KYSAT) (N1, N1)
CN109-9 - - Approx. 5V
(86, STDML+) (N1, N1)
CN109-10 - - Approx. 1V to 4V
(87, STDML) (N1, N1)
CN109-11 - Unused -
CN109-12 - Unused -
CN109-13 - - L: Approx. 0.5V
(80, SSDL2) (N1, N1) or
H: Approx. 1.5V
CN109-14 - - L: Approx. 0.5V
(79, SSDL1) (N1, N1) or
H: Approx. 1.5V
CN109-15 - - Approx. 15V
(78, SSDL+) (N1, N1)
(146, CAN1L)
(145, CAN1H)
CN109-18 - Unused -
CN109-19 - Unused -
3. CONTROLLER 3-57

CN109-20 - Unused -
CN109-21 - Unused -
CN109-22 - Unused -
CN109-23 - Unused - 3
3-58 3. CONTROLLER
Drive motor driver RH
CN110
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16

CN110-1 - Unused -
CN110-2 - Unused -
CN110-3 - Unused -
CN110-4 - Unused -
CN110-5 - Unused -
CN110-6 - Unused -
CN110-7 - - Approx. 0.0V
(150, SETDR0) (N1, N1)
(42, KYSAT) (N1, N1)
(86, STDMR+) (N1, N1)
(85, STDMR) (N1, N1)
CN110-11 - Unused -
CN110-12 - Unused -
CN110-13 - - L: Approx. 0.5V
(77, SSDR2) (N1, N1) or
H: Approx. 1.5V
CN110-14 - - L: Approx. 0.5V
(76, SSDR1) (N1, N1) or
H: Approx. 1.5V
CN110-15 - - Approx. 15V
(75, SSDR+) (N1, N1)
(146, CAN1L)
(145, CAN1H)
CN110-18 - Unused -
CN110-19 - Unused -
CN110-20 - Unused -
CN110-21 - Unused -
CN110-22 - Unused -
CN110-23 - - Approx. 0.0V
(150, SETDR-) (N1, N1)
3. CONTROLLER 3-59
Pump motor driver
CN111
8 7 6 5 4 3 2 1 3
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16

CN111-1 - Unused -
CN111-2 - Unused -
CN111-3 - Unused -
CN111-4 - Unused -
CN111-5 - Unused -
CN111-6 - - Approx. 0.0V
(152, SETP1) (N1, N1)
CN111-7 - Unused -
(42, KYSAT) (N1, N1)
(88, STPM+) (N1, N1)
(89, STPM) (N1, N1)
CN111-11 - Unused -
CN111-12 - Unused -
CN111-13 - Unused -
CN111-14 - - L: Approx. 0.5V
(82, SSP1) (N1, N1) or
H: Approx. 1.5V
CN111-15 - - Approx. 15V
(81, SSP+) (N1, N1)
(146, CAN1L)
(145, CAN1H)
CN111-18 - Unused -
CN111-19 - Unused -
CN111-20 - Unused -
CN111-21 - Unused -
CN111-22 - Unused -
CN111-23 - - Approx. 0.0V
(152, SETP-) (N1, N1)
3-60 3. CONTROLLER
Contactor panel ASSY
CN136 CN137 CN138

1 1
3 2 1
3 2 2 3

CN136-1 CN136-2 Battery plug disconnected, and the STD spec:
(2, CBAT-) (1, CBAT+) CN136 connector disconnected Approx. 20 Ω
CN136-2 CN136-1 Apply the negative probe to the STD spec:
(1, CBAT+) (2, CBAT-) CN136-1 to measure voltage. Approx. 11V
CN136-3 P3 terminal Battery plug disconnected, and the Approx. 0 Ω
(44, VBMB) (P3, P3) CN136 connector disconnected

(P2, FLP) (P2, P2) CN137 connector disconnected
(41, VBBT) (P2, P2) CN137 connector disconnected
3. CONTROLLER 3-61

(19, VBMBSL) (P3, P3) CN137 connector disconnected
3
CN138-1 CN138-2 Apply the negative probe to the Approx. 5V
(303, CSBAT+) (305, CSBAT-) CN138-2 to measure voltage.
CN138-2 - - -
(305, CSBAT-)
CN138-3 CN138-2 Apply the negative probe to the Approx. 2.5V
(304, CSBAT) (305, CSBAT-) CN138-2 to measure voltage.
Drive motor, pump motor, all auxiliary
machines OFF
Multi-function display
CN70
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

CN70-1 - Unused -
CN70-2 - Unused -
CN70-3 - - -
(169, TGND)
CN70-4 - - -
(14, DGND)
CN70-5 CN70-4 - Approx. 6.3V
(16, D7V) (14, DGND)
CN70-6 CN70-3 - Approx. 5V *1
(162, ITKY3) (169, TGND)
CN70-7 - Unused -
CN70-8 CN70-3 - Approx. 5V *1
(160, ITKY1) (169, TGND)
(166, OTKY3)
(165, OTKY2)
(164, OTKY1)
CN70-12 CN70-3 - Approx. 0.0V *1
(167, LEDTKY1) (169, TGND)
CN70-13 - Unused -
3-62 3. CONTROLLER

CN70-14 - Unused -
(146, CAN1L)
(145, CAN1H)
CN70-17 - Unused -
CN70-18 - Unused -
CN70-19 CN70-3 - Approx. 3V *1
(168, LEDTKY2) (169, TGND)
CN70-20 CN70-3 - Approx. 5V *1
(161, ITKY2) (169, TGND)
CN70-21 CN70-3 - Approx. 5V *1
(163, IPSTKY1) (169, TGND)
CN70-22 - Unused -
CN70-23 - Unused -
CN70-24 - Unused -
CN70-25 - Unused -
CN70-26 - Unused -
CN70-27 - Unused -
CN70-28 - Unused -
CN70-29 - Unused -
CN70-30 - Unused -
CN70-31 - Unused -
CN70-32 - Unused -
CN70-33 - Unused -
CN70-34 - Unused -
CN70-35 - Unused -
CN70-36 - Unused -
*1: W/ PIN code entry system

Ten-key (w/ pin code entry system)
CN33
5 4 3 2 1
10 9 8 7 6
CN33connector basic conditions (battery plug connected, key switch ON)

CN33-1 CN33-7 - Approx. 5V
(160, ITKY1) (169, TGND)
(161, ITKY2) (169, TGND)
(162, ITKY3) (169, TGND)
3. CONTROLLER 3-63

(165, OTKY2)
CN33-5 CN33-7 - Approx. 0.0V
(167, LEDTKY1) (169, TGND) 3
(163, IPSTKY1) (169, TGND)
CN33-7 - - -
(169, TGND)
(164, OTKY1)
(166, OTKY3)
(168, LEDTKY2) (169, TGND)
3.7. DISASSEMBLY PROCEDURE

Overhauling the control panel is rarely necessary. In most cases, failed parts are 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.
3.7.1. Caution for Part Replacement

• Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tightening may
cause another failure.
• When disconnecting the bars and harness, record the connecting location and place tags. When connecting
them again, make sure to confirm with the record and tags to prevent incorrect connection. Incorrect connection
may cause another failure.
• Always apply new silicon grease when reassembling parts originally coated with silicon grease. Otherwise,
overheating may occur.
• After installation, check that there is no interference of the bar and harness connection with other portion.
• Additionally, before installation, perform continuity inspection on points by the tester.
• (Refer to CONTACTOR PANEL INSULATING RESISTANCE TEST PROCEDURE)
Discharge of the power condenser
WARNING
The power condenser in the driver may have electrical charge.
Before Inspection/Repairing/Troubleshooting, discharge the power condenser in the driver and check the
voltage (less than 3V). [Terminal between P4 and N1, between P22 and N1.]
3-64 3. CONTROLLER
3.8. MAIN CONTROLLER
CAUTION
When replacing the main controller, always check the part number.
3. CONTROLLER 3-65
3.8.1. CONNECTOR-PIN ASSIGNMENT
CN101 CN102 CN103 CN104

3
CN101
No. Terminal name Circuit mode Remarks

102 SOLLU+ SOLLU+ UNLOAD, LIFT+
103 SLTFB+ SLTFB+ TILTF, R+
104 FAN+ FAN+ RYR, FAN+
105 VBBT VBBT
106 SLLA2+ SOL1, 4+
107 SLLA1+ SOL2, 3+
108 --- SOL5+
109 --- SOL5B
110 --- SOL5A
111 SA1PL- SOL3B
112 SA1PS- SOL3A
113 STPL- SOL2B
114 STPS- SOL2A
115 SA2PL- SOL4B
116 SA2PS- SOL4A
117 SLPS- SOL1A
118 SLPL- SOL1B
119 --- VBBA VBBA
120 VBKY VBKY
121 VRTA+ VRTA+ TILT ANGLE SENSOR POWER SUPPLY
122 --- VRS+ SWING ANGLE SENSOR POWER SUPPLY
123 VRA- VRA- ACCELERATOR SENSOR GND
124 VRTRA+ VRTRA+ TIRE ANGLE SENSOR POWER SUPPLY
125 --- VRH+ HEIGHT SENSOR POWER SUPPLY
126 VRL+ VRL+ LIFT POT POWER SUPPLY
127 VRA2+ VRA2+ ACCELERATOR SENSOR 2 POWER SUPPLY
128 VRA1+ VRA1+ ACCELERATOR SENSOR 1 POWER SUPPLY
129 VRT+ VRT+ TILT POT POWER SUPPLY
130 VRAT1+ VRAT1+ ATTACHMENT 1 POWER SUPPLY
131 VRAT2+ VRAT2+ ATTACHMENT 2 POWER SUPPLY
132 --- VRAT3+ ATTACHMENT 3 POWER SUPPLY
133 POT- POT- GND3
134 VRB2+ VRB2+ BRAKE SENSOR 2 POWER SUPPLY
135 VRB1+ VRB1+ BRAKE SENSOR 1 POWER SUPPLY
3-66 3. CONTROLLER
CN102

67 FNDC1 FNDC1 FAN1
68 FNDC2 FNDC2 FAN2
69 VBMBSL VBMBSL VBMBSOL
70 VBMBSL VBMBSL VBMBSOL
71 SOLCOM SOLCOM SOLCOM
72 SOLCOM SOLCOM SOLCOM
73 SLS+ SLS+ KNOB, MPS+
74 OACC3 OACC3 ACCESSORY 3 (for FORWARD → FLEET
MANAGEMENT)
75 OACC2 OACC2 ACCESSORY 2 (for BACKWARD)
76 LS- LS- GND2
77 --- OACC1 ACCESSORY 1 (for BRAKE)
78 --- RY2- RYR2
79 RY1 RY1- RYR1
80 SLS- SLS- KNOB-
81 --- MPS-
82 SLLL- SLLL- LIFT-
83 SLUL- SLUL- UNLOAD-
84 SLTBL- SLTBL- TILTR-
85 SLTFL- SLTFL- TILTF-
86 VRA12 VRA12 ATTACHMENT 12
88 VRT2, SWTR VRT2 TILT LEVER SENSOR 2
89 VRT1, SWTF VRT1 TILT LEVER SENSOR 1
90 CSBAT CSBAT BATTERY CURRENT SENSOR
91 VRB2 VRB2 BRAKE SENSOR 2
92 POT- POT- GND4
93 --- CHK5V 5V POWER SUPPLY for CHECK
96 VRA1 VRA1 ACCELERATOR SENSOR 1
97 VRTRA VRTRA TIRE ANGLE SENSOR
98 VRA2 VRA2 ACCELERATOR SENSOR 2
99 VRB1 VRB1 BRAKE SENSOR 1
100 --- VRS SWING ANGLE SENSOR
101 CSBAT- CSBAT-
CN103

32 --- SLSW+ SWING+
33 --- SLSW- SWING-
34 DGND DGND DISPLAY GND
35 KYSAT KYSAT KEYSTART
36 N2 N2
37 LS- LS- GND4
38 --- SMTSA
3. CONTROLLER 3-67

39
40 --- CAN2H
41 --- CAN2L
42 CAN1H CAN1H 3
43 CAN1L CAN1L
44 SSTR+ SSTR+ STEERING WHEEL ANGLE SENSOR AND ULTRA
SONIC SENSOR POWER SUPPLY (combined use)
45 D7V D7V DISPLAY POWER SUPPLY
46 --- CHK15V 15V POWER SUPPLY for CHECK
47 --- CHK33V 3.3V POWER SUPPLY for CHECK
48 VRTA VRTA TILT ANGLE SENSOR
49 VRL2 VRL2 LIFT LEVER SENSOR 2
50
51 --- SSTMA
52 --- SMTSK
53 --- SSTMK
54 --- OPTSS2
55 SH2-1 SH2-1 LIFTING HEIGHT SWITCH 2-1
56 --- SHL LIFTING HEIGHT LIMIT SWITCH
57 VRL1 VRL1 LIFT LEVER SENSOR 1
58 --- SYR
59 --- VRH HEIGHT SENSOR
60 SPLF SPLF PRESSURE SENSOR
61
62 --- SH2-2 LIFTING HEIGHT SWITCH 2-2
63 STK STK AUTOMATIC FORK LEVELING SWITCH
64 --- OLM+ LASER POINTER POWER SUPPLY
65 --- VRA32 ATT32
66 --- VRA31 ATT31 (SWITCH for 4/5-WAY SW)
CN104

1 B48V B48V B80V
2 VBMB VBMB
3 CBAT+ CBAT+ MB, P+
4 N2 N2
5 N2 N2
6 N2 N2
7 --- N2
8 --- MP-
9 CBAT- CBAT- MB-
10 CSBAT+ CSBAT+ BATTERY CURRENT SENSOR POWER SUPPLY
11 --- SYR-
12 SPLF+ SPLF+ PRESSURE SENSOR POWER SUPPLY
13 --- SYR+ YAW RATE SENSOR POWER SUPPLY
14 PSACC+ PSACC+ ACCESSORY POWER SUPPLY
3-68 3. CONTROLLER

15 PSSW+ PSSW+ POWER SUPPLY for Fingertip Control Lever (LOAD
METER, AUTOMATIC FORK LEVELING and
SWITCH for 4/5-WAY SW)
16 --- CHKG
17 --- OPT2
18 SDM SDM SEAT SWITCH
19 DSR DSR DIRECTION SWITCH REVERSE
20 SPB SPB PARKING BRAKE
21 --- OPTSSC
22 SH1 SH1 LIFTING HEIGHT SWITCH 1
23 --- SWA ACCELERATOR SWITCH
24 SSTRC SSTRC STEERING WHEEL ANGLE SENSOR 3 (only SSC
combined with SW)
25 --- OPTSS1
26 DSF DSF DIRECTION SWITCH FORWARD
27 --- LSOPT1
28 SHS SLM LOAD METER
29 --- BMP
30 SSTR1 SSTR1 STEERING WHEEL ANGLE SENSOR 1 (only SSC
combined with SW)
31 SSTR2 SSTR2 STEERING WHEEL ANGLE SENSOR 2 (only SSC
combined with SW)
3. CONTROLLER 3-69
3
2
10
a
a
8
7
a: T = 2.84 to 5.28 ft-lbf. N·m [3.9 to 7.2]
Removal Procedure
2) Open the battery hood.
3) Remove the side cover LH.
4) Remove the DC/DC converter connector cover.
5) Disconnect the wiring of the DC/DC converter connector.
6) Remove the DC/DC converter.
7) Remove the main controller connector cover.
8) Remove the main controller cover.
9) Disconnect the wiring of the main controller.
10) Remove the main controller.
3-70 3. CONTROLLER
3.9. DRIVE AND PUMP MOTOR DRIVER
5 b
7
a
9
a
a 7 b 9
a: T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]

b: 2.84 to 5.28 ft-lbf. [3.9 to 7.2 N•m]
Removal Procedure
1) Remove the battery. (Refer to BATTERY ASSY.)
2) Remove the rear cover.
3) Remove the rear lower cover.
4) Remove the upper cover.
5) Remove the battery guard.
6) Remove the F1 fuse.
7) Remove the copper bars.
8) Disconnect the wiring of the drive motor driver LH, the drive motor driver RH and the pump motor driver at the
connectors and terminals.
9) Remove the drive motor driver LH, the drive motor driver RH and the pump motor driver.
3. CONTROLLER 3-71
3.10. CONTACTOR PANEL (STANDARD)
3.10.1. COMPONENTS
3
h
a
b
g
d
f
a: P1 - P2 Copper bar
b: P3 Copper bar
c: F1 Fuse
d: Current sensor
e: Terminal
f: Harness
g: Insulating sheet
h: Contactor ASSY
3-72 3. CONTROLLER
5
7
a
a
7 9
a: T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]
Removal Procedure
1) Remove the battery. (Refer to BATTERY ASSY.)
2) Remove the rear cover.
3) Remove the rear lower cover.
4) Remove the upper cover.
5) Remove the battery guard.
6) Remove the F1 fuse.
7) Remove the copper bars.
8) Disconnect the wiring of the contactor panel.
9) Remove the contactor panel. [POINT 1]
3. CONTROLLER 3-73
Point Operations
[POINT 1]
Inspection:
3
Disconnect CN136 connector, and measure the
resistance of the MB coil.
Portion to be inspected Measurement terminals Standard Tester range

MB coil Both terminals Approx. 20 Ω (at Ωx1
of 68°F [20°C])
CN136-1
CN136-2
Measure the insulation resistance of the F1 fuse.
F1
Portion to be inspected Measurement terminals Standard Tester range

F1 fuse Both terminals of fuse 0Ω Ωx1
3-74 3. CONTROLLER
3.10.3. REASSEMBLY
Contactor Panel Reassembly Drawing
1. Tightening torque view
6 7
2
3
10
11
5 4
No. Tightening torque ft-lbf. [N·m]

1-2 5.75 to 8.71 [7.8 to 11.8]
3-5 8.26 to 12.39 [11.2 to 16.8]
6 - 10 1.48 to 2.21 [2.0 to 3.0]
11 0.96 to 1.55 [1.3 to 2.1]
3. CONTROLLER 3-75
2. How to use the F1 fuse separately

Install the F1 fuse while checking the number and color seal attached on the fuse.
Application models 36V spec. 48V spec.

Outline drawing
3
9
700A
Numeral 9 1
Color seal - Red
Rated current (A) 700 600
3. F1 fuse installing direction

Install the F1 fuse in the direction shown below.
4. Installing order sequence of F1 fuse.

Installing order sequence of the bolt w/washer (a), F1 fuse (b) and copper bar (c) position on the terminal (d) as
shown below.
(b)
(a)
(c)
(d)
3-76 3. CONTROLLER
5. Installing angle of P2 harness and P3 harness, and installing order sequence of P2 harness and P3 harness.
Install with angles of P2 harness and P3 harness, and the installing order sequence of the bolt, nut, washer, copper
bar and terminal on P2 harness and P3 harness portion as shown below.
(a)
(c)
(d)
(e)
(f)
(g)
(b) (h)
45° 45°
(i)
(j)
90°
(a) P2 harness (c) Bolt w/ washer (e) Copper bar (g) Spring washer (i) Terminal
(white - red)
(b) P3 harness (d) Terminal (f) Nut (h) Plate washer (j) Copper bar
(blue - black)
3. CONTROLLER 3-77
3.10.4. CONTACTOR PANEL INSULATING RESISTANCE TEST

PROCEDURE
Make sure to perform an insulating resistance test.
3
CN136
1
3 2
CN136 (a)
CN137
1
2 3
CN137 (a)
CN136 CN137
No. Measurement place Standard Locator

(a) Measurement place instruction view
(Measure the insulating resistance between A and B.)
A B
1 Base CN136 (Only No.1, 2 Pin: DC 500V applied Insulation
Reference above chart) 10 MΩ more resistance
tester
CN137 (Only No.1, 3 Pin:
Reference above chart)
2 CN137 (Only No.1, 3 Pin: CN136 (Only No.1, 2 Pin:
Reference above chart) Reference above chart)
3-78 3. CONTROLLER
3.11. FAN
a: T = 1.0 to 1.3 ft-lbf. [1.3 to 1.7 N·m]
Removal Procedure
1) Remove the counterweight. (Refer to COUNTERWEIGHT.)
2) Disconnect the wiring of the fans.
3) Remove the fans. [Point 1]
3. CONTROLLER 3-79
Point Operations
[POINT 1]
Inspection:
Disconnect the fan connector, and measure the 3
resistance of the fan.
Measurement terminals Standard Tester range

CN112-1 (474) - CN112-2 (98) ∞Ω Ωx1
CN113-1 (475) - CN113-2 (98)
3.12. DISPLAY
If there is trouble with the display, measure the voltage at the display connector.
CN70
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
3-80 3. CONTROLLER
CN70 connector basic condition (Battery plug connected)
Connector No. ? Connector No. Conditions Standard: Remarks

CN70-5 CN70-4 - Approx. 6.3V
(16, D7V) (14, DGND)
3.13. COMBINATION SWITCH
a: T = 18.1 to 33.6 ft-lbf. [24.5 to 45.5 N·m]

b: T = 1.5 to 1.8 ft-lbf. [2.0 to 2.5 N·m]
Removal Procedure
2) Remove the steering wheel. [Point 1]
3) Remove the hand release lever knob.
4) Remove the column cover.
5) Disconnect the wiring of the combination switch.
6) Remove the combination switch ASSY.
3. CONTROLLER 3-81
Point Operations
3
[POINT 1]
Remove:
SST
Use the SST to remove the steering wheel.
SST 979-001/181
3.13.2. DISASSEMBLY, INSPECTION AND REASSEMBLY
3 2
3-82 3. CONTROLLER
Disassembly Procedure
1) Remove the cam.
2) Remove the horn contact.
3) Remove the steering angle sensor.
4) Remove the light control switch ASSY.
5) Remove the direction switch ASSY.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
3.14. ACCELERATOR SENSOR (POTENTIOMETER)
1. Remove the accelerator potentiometer.

2. Check the resistance between terminals.
6 5 4 3 2 1
Terminal 5 - 6 1.8 to 3.5 k Ω

Terminal 4 - 6 When the potentiometer is rotated, the resistance must increase in proportion
to its number of rotations.
Terminal 1- 2 1.8 to 3.5 k Ω
Terminal 2- 3 When the potentiometer is rotated, the resistance must increase in proportion
3. Temporarily install the accelerator potentiometer.
NOTICE!
Mount the accelerator potentiometer and turn it
about 10 degrees in the clockwise direction and
tighten the screws.
3. CONTROLLER 3-83
4. Display the matching menu and check the output

voltage of the accelerator potentiometer.
Standard: VRA1 0.40V to 1.24V
Standard: VRA2 0.65V to 2.31V
If the voltage is within the standard range: 3
Press and hold down the switch (1) for more than 2
seconds to perform matching.
If the voltage is outside the standard range:
(1) Loosen 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
5. Fully press the accelerator pedal and check the

voltage at that time.
Standard:
VRA1 2.00V to 4.79V
VRA2 2.42V to 4.79V
CAUTION!
Before pressing the accelerator pedal, make sure
that the Spanner indicator on the display is
blinking.
If the voltage is within the standard range:
Replace the accelerator potentiometer or accelerator
pedal.
(1) Switch 1 NOTICE!
On models with the Forward/Reverse pedal option,
the forward direction side of the accelerator pedal
should be stepped on.
6. Tighten the screw after adjustment and mark an “I”
on the screw head with a yellow paint pen.
NOTICE!
• After performing the ACCEL OFF matching,
make sure to perform ACCEL ON matching.
• While the DRIVE is selected on the matching
menu, the spanner indicator 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.
3-84 3. CONTROLLER
3.15. BRAKE SENSOR (POTENTIOMETER)
1. Remove the brake potentiometer.

2. Check the resistance between terminals.
6 5 4 3 2 1
Terminal 5 - 6 1.8 to 3.5 k Ω

Terminal 4 - 6 When the potentiometer is rotated, the resistance must increase in proportion
Terminal 1- 2 1.8 to 3.5 k Ω
Terminal 2- 3 When the potentiometer is rotated, the resistance must increase in proportion
3. Temporarily install the brake potentiometer. The

parking brake should be in the release (not applied)
position.
4. Display the matching menu and check the output
voltage of the brake potentiometer.
Standard: VRB1 0.50V to 1.79V
Standard: VRB1 0.79V to 2.88V
(1) Loosen the screw and adjust the voltage to the
standard value while checking the display and rotating
the brake potentiometer.
(2) Tighten the screw.
(3) Press and hold down the switch (1) for more than 2
3. CONTROLLER 3-85
5. Step on the brake pedal perpendicularly with 34.1 to

37.8 lbf. [152 to168 N] force at the center of the pad,
and check the voltage at that time.
Standard:
VRB1 1.60V to 4.09V
3
VRB2 2.00V to 4.79V
Replace the brake potentiometer or brake pedal.
6. Tighten the screw after adjustment and mark an “I”
on the screw head with a yellow paint pen.
NOTICE!
• After performing the BRAKE OFF matching,
make sure to perform BRAKE ACT matching.
• While the DRIVE is selected on the matching
menu, the spanner indicator blinks and driving
is disabled.
• In the case of readjusting the pedal height,
readjust output of VRB1 sensor initial position
to 1.4V to 1.6V by the turn buckle and memorize
again about output of sensor.
3.16. BRAKE SWITCH ADJUSTMENT
1. Adjust brake pedal play. (Refer to PARKING BRAKE

INSPECTION AND ADJUSTMENT.)
2. Adjust brake pedal height. (Refer to BRAKE PEDAL
ADJUSTMENT.)
a
3. Check continuity of the limit switch when pedal
stroke from the brake pedal press operation start is
0.20 to 0.35 in. (5 to 9 mm)
Standard:
Not operated: OFF (∞ Ω)
Operated: ON (0 Ω)
a: Stop lamp limit switch
5 to 9 mm
(0.20 to 0.35 in)
3-86 3. CONTROLLER
4. If the standard is not met, make adjustment by

turning the adjust bolt.
a: Adjust bolt
a
3. CONTROLLER 3-87
3.17. OVER CURRENT LIMIT (OCL) MEASUREMENT

For drive circuit
1. Preparation before measurement. 3

(1) Make the fork tips contact a wall or steel pole with a
(a) rated load on the forks. Make sure to place a piece of
wood (a) between the fork tip and the wall.
(2) Turn on the SST by pressing the POWER key (a)

on the unit.
SST 979-001/158
(a)
AC + DC A measurement mode display

(3) Press the mode key (a) twice to switch to the
AC+DC A measurement mode.
(a)
3-88 3. CONTROLLER
(a) SHIFT key enabled display
(a) (4) After pressing the SHIFT key (b), press the SAMPL
key (c) to set the display update rate (d) to “SLOW”.
(d) (b)
(c)

(a)
(5) After pressing the SHIFT key (b), press the CLEAR
key (c) 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 (d).)
(b)
(c)
(d)
3. CONTROLLER 3-89
2. Measurement work
(1) Set the clamp sensor of the SST on the motor
cable.
NOTICE!
Set the clamp sensor so that the cable is 3
positioned in the center of the clamp with the
clamp sensor aligned perpendicular to the cable.
(2) Turn on the key switch and set the direction switch
to “Forward”. Gradually press the accelerator pedal to
full throttle and hold there. The SST will start
measurement automatically.
NOTICE!
• The SST starts measurement automatically as
soon as forward motion starts. Make 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

(a) approximately 20 seconds, retry the
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, the motor
current frequency in forward motion is only 10
Hz or below and current measurement cannot be
(b) obtained.
OCL Standard Value:
(c)
36V: 257 to 340 A
48V: 184 to 250 A
(b) SHIFT key
(c) PEAK/Hz key
(d) Filter setting display
(d)
3-90 3. CONTROLLER
For pump circuit

The OCL value of the pump circuit cannot be measured because of the following reason:
In the material handling system the relief valve in the control valve operates at the stroke end of each cylinder.
The OCL value for the pump circuit is set at a higher level than the current at the relief valve set pressure, as relief
occurs in the hydraulic circuit before the pump circuit current reaches the OCL value.
OCL value > Lift relief valve value

OCL Standard Value: 380 to 490 A
4. DISPLAY 4-91
4. DISPLAY
4.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2. GENERAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3. SERVICE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4
4.4. MULTI-FUNCTION DISPLAY ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.1. GENERAL
The multi-function display has various functions that indicate/notify the lift truck’s information such as lift truck speed,
the battery discharge level, and so on. The operator or administrator can set the lift truck 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. This provides various easy-to-understand
information with expressive capability.
No. Description
(1) Switch (1): Low speed setting switch / Down switch
(2) Switch (2): Power select switch / Left switch
(3) Switch (3): Time or date select switch / Right switch
(4) Switch (4): Meter mode select switch / Enter switch
(5) Multiple screen display area
(6) OPS indicator
(7) Parking brake indicator
(8) Low speed setting indicator
(9) Spanner indicator
(10) Overheat warning indicator
4-92 4. DISPLAY
4.2. GENERAL FUNCTIONS
4.2.1. GENERAL
General Function List
○: Provided
OPT: Option
Functions Remarks
Initial display Calendar watch ○
after key-ON Indication that maximum speed limiter is in active setting. ○
Indication that overspeed alarm is in active setting. ○
Indication that lifting speed limitation is in active setting. ○
Indication that active mast front tilt control is in inactive ○
setting.
Indication that turn speed control is in inactive setting. ○
Status display Operator Presence Sensor indicator ○
Parking brake indicator ○
Low speed setting (turtle) indicator ○
Spanner indicator ○
Overheat warning indicator ○
Battery discharge level indicator ○
Speedometer ○
Power select indicator ○
Power meter ○
Direction indicator ○
Mast tilt indicator ○
Maintenance indicator ○
Lifting speed limitation indicator ○
Menu lock indicator ○
Date/Time ○
Meter Key switch on hour meter ○
Lap time meter ○
Traveling hour meter ○
Material handling hour meter ○
Traveling/Material handling hour meter ○
Seat on hour meter ○
Odometer ○
Trip meter ○
Planed maintenance hour meter ○
4. DISPLAY 4-93
Functions Remarks
Warning function Over-discharge warning ○
Low remaining battery level warning ○
Overheat warning ○
Low temperature warning ○
Parking brake ON warning ○ 4
Parking brake OFF warning ○
Return to neutral warning for travel Operator Presence ○
Sensor
Return to neutral warning for material handling Operator ○
Presence Sensor
Return to neutral warning at starting ○
Diagnostic code display ○
Overspeed alarm ○
Setting function Clock set ○
Power select function ○
Travel power control level setting ○
Material handling power control level setting ○
Low speed setting ○
Maximum speed limitation setting ○
Overspeed alarm setting ○
Planned maintenance hour setting ○
Auto power off time setting ○
Second password registration for administrator ○
Menu lock setting ○
Support function PIN code entry and setting OPT With PIN Code Entry
for PIN code Profile setting OPT
entry
4-94 4. DISPLAY
Initial screen after key-on
This screen is displayed for 2 seconds after the

ignition key switch is turned on.
Display Description
SEP/ 1/2015 (TUE) Calendar watch is displayed.
Indicates if the maximum speed limiter is in active
setting.
Indicates if the overspeed alarm is in active setting.
Indicates if the lifting speed limitation is in active

setting.
Indicates if the active mast front tilt control is in

inactive setting.
Indicates if the turn speed control is in inactive setting.

4. DISPLAY 4-95
4.2.2. ADMINISTRATOR FUNCTIONS

Administrators can set the lift truck’s performance and each function.
Administrator functions are protected with a password so that the general operators cannot change these settings.
W/O PIN code entry system

4
Setting menu Setting Screen
Power Control Functions Power Mode Select*
Setting of Travel Power Control Level*
Setting of Material Handling Power Control Level*
Travel Functions Speed Setting of Low Speed*
Speed Setting of Maximum Speed Limiter
Speed Setting of Overspeed Alarm*
Vehicle Management Functions Setting of Maintenance Hour Meter
Setting of Auto Power Off Time
Setting of Administrator’s Second Password
Switching of Menu Lock
*: When menu lock setting is released, the operator can set it.
W/ PIN code entry system
Setting menu Setting Screen

PIN Code Entry Functions Registry of PINs for Operations
Change of Profile Assign
Delete of PINs for Operators
Profile Setting
Change of Initial PIN
Vehicle Management Functions Setting of Maintenance Hour Meter
Setting of Auto Power Off Time
Setting of Auto Log Off Time
Setting of Administrator’s Second Password
Switching of Menu Lock
Administrator's Password
NOTICE
• Always operate switches on the display with a fingertip. If a sharp pointed tool is used, the switch may
be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning.
4-96 4. DISPLAY
Password Entry Procedure
Step Display Operation Vehicle response

1 Press switch (2) and When pressing the
switch (4) at the same switches, a short beep
time for more than 2 sounds. After 2 seconds
seconds. another short beep
sounds.
2 Press switch (2) within 10 A short beep sounds.

seconds.

seconds.
4 Within 10 seconds, press When pressing the

switch (2) and switch (4) switches, a short beep
at the same time for more sounds, and after 2
than 2 seconds. seconds repeated short
beeps sound.
5 When the second password has been set:
Second password screen is displayed. Enter the

second password.
Other:
This screen is skipped.
6 Administrator menu screen is displayed automatically.
Administrator MENU screen
(a) W/O PIN code entry (b) W/ PIN code entry

4. DISPLAY 4-97
Icons
Icon Description Icon Description

This icon can set the drive and lift This icon can set the PIN code
power control function. entry system function. (Models
with PIN code entry system only)
4
This icon can set the travel control Returning to status screen.
function.
This icon can set the vehicle

management function.
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.
(1) (2) (3) (4)

4-98 4. DISPLAY
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.
NOTICE! : Select the return tab on the

Administrator Menu screen, and press switch (4)
(enter) to display the status screen.
Power control setting menu screen

• Power Mode Select
• Setting of Travel Power Control Level
• Setting of Material Handling Power Control Level
4. DISPLAY 4-99
Travel setting menu screen

• Speed Setting of Low Speed
• Speed Setting of Maximum Speed Limiter
• Speed Setting of Overspeed Alarm
Vehicle management setting menu screen

• Setting of Maintenance Hour Meter
• Setting of Auto Power Off Time
• Setting of Administrator’s Second Password
• Switching of Menu Lock
Return to status screen
1. Power Control Setting Menu Screen
This menu screen can set the travel and material

handling power control function.
NOTICE! : 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.
4-100 4. DISPLAY
• Power mode select screen

The power select mode (L, 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): LPH -> H -> P -> L
Switch (3): L -> P -> H -> LPH
Switch (4): Returning to power control setting menu
screen.
When the original mode is selected, all of L, P, and
H are inverted.
• Travel power control level setting screen

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.
functions.
• Material handling power control level setting screen

The material 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.

functions.
2. Travel Setting Menu Screen
This menu screen can set the travel control function.

4. DISPLAY 4-101
• 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 12 mph by 1 mph. When 4
MPH setting is “NO” in option set, it is adjustable
from 2 to 20 km/h by 1 km/h.
If the operator set the speed to more than 12 mph
(20km/h), the low speed function is disabled. In that
case “OFF” is displayed.
• Maximum speed limiter setting screen

The speed limit of the Maximum speed limitation
can be changed.
Switch (2): Setting traveling speed limit down.
Switch (3): Setting traveling speed limit up.
Switch (4): Returning to setting menu screen
It is adjustable from 2 to 12 mph by 1 mph. When
(20 km/h), the low speed function is disabled. In that
• Overspeed alarm setting screen

The speed to activate the overspeed alarm function
can be changed.
Switch (2): Setting threshold speed down.
Switch (3): Setting threshold speed up.
Switch (4): Returning to setting menu screen
It is adjustable from 3 to 12 mph by 1 mph. When
(20 km/h), the low speed function is disabled. In that
4-102 4. DISPLAY
3. Vehicle Management Setting Menu Screen
This menu screen can set the vehicle management

function.
• Maintenance hour meter setting screen

Time for maintenance hour meter can be set from
10 up to 2400 hours by 10 hours for 10 to 200 hours,
and 50 hours for 200 to 2400 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.
NOTICE! : This reset operation does not reset the
setting value and keeps it with the same value.
Press switch (2) to decrease the set time of the
maintenance hour meter function. Below 10 h would
be “OFF”.
The current value is kept, but the maintenance
indicator and the buzzer are deactivated using this
“OFF” setting.
• Auto power off time setting screen

The time that activates 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”.
4. DISPLAY 4-103
• Administrator’s second password setting screen
(1) 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 you press the switch (4) for 2 seconds or more,
the screen returns to the menu screen.
The Administrator should manage the second password so that it does not get lost.
4
If it has been lost, the service technician can clear it on the service menu.
(2) Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s second
password setting screen.
If you press the switch (4) for 2 seconds or more, the screen returns to the menu screen.
4-104 4. DISPLAY
• Menu lock setting screen

This function can limit the change of the lift truck
setting by the operator.
When the 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”
NOTICE!
• The condition to release Menu lock is varied by
the option set item, “MENULOCK SPEC”.
In the factory setting, “MENULOCK SPEC” is
preset to “A” on standard models.
MENULOCK SPEC: A
The lock release setting (“NO”) is effective until
key-OFF. (It means it is set to “YES”
automatically when the key is turned off.)
• This is not available (NOT Locked) before “hour

meter start”.
4. End Menu Screen
Switch (4): Returning to the status screen

4. DISPLAY 4-105
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 for Operators
• Change of Profile Assign
• Delete of PINs for Operators
• Profile Setting
• Change of Initial PIN
4-106 4. DISPLAY
2. 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 Maintenance Hour Meter
• Setting of Auto Power Off Time
• Setting of Auto Log Off Time
• Setting of Administrator’s Second Password
• Switching of Menu Lock
3. End Menu Screen
Switch (4): Returning to status screen

4. DISPLAY 4-107
4.3. SERVICE FUNCTIONS
4.3.1. GENERAL
In the multi-function display, aside from the general functions that an operator or an administrator normally use, the
following service functions can be used by the service staff for lift truck maintenance and specification setting. The
service functions are password protected so that the important internal data will not be damaged mistakenly by 4
wrongfully using the service functions.
Service Function List
When used
Vehicle Board
Function Description delivery replacement Others
Analyzer Displays the electrical system - - Upon lift
status and reads the error truck
information detected by abnormality
controllers.
Tuning Makes fine adjustment of - ○ As
traveling and material handling requested
functions. by customer
*2
Option set Specification Sets each lift truck option and - ○ -
setting other specifications. *1
*2,*3
Each control Enables or disables each - ○ -
function control function.
enable/disable
*2,*3
Matching Traveling Updates voltage values of - ○ ○
sensor signals under the
standard lift truck condition.
PSS *2,*3 *4,*5,*7,*8,*
9
Material
handling lever
OCV Set the current level for - ○ ○
activating activating the oil control valve.
current level
*2 *5
Tire data Makes the speedometer - ○ ○
reading appropriate.
*2 *6
4-108 4. DISPLAY
When used
Vehicle Board
Function Description delivery replacement Others
Others menu Hour meter Starts counting the hour meter, ○ ○ -
start odometer, trip meter and
maintenance hour meter.
*3
Demo mode Enables simultaneous - - Before
operation of traveling and starting the
material handling before hour meter
starting the hour meter.
To default set Initialize a set value with the - ○ When it is
default value. necessary
*2,*3
Service Sets the service second - ○ When it is
second password. necessary
password
*3
setting
Administrator’ Delete the administrator’s - ○ As
s second second password. requested
password by customer
*3
clear
LCD contrast Adjusts the contrast of the - ○ As
adjustment display screen. requested
by customer
*3
*1: These functions are used to adjust the controller and display setups to the availability of optional or
control features. They do not enable or disable the actual functioning of the optional or control features.
*2: Board: Main controller control board
*3: Board: Control board for the multi-function display
*4: When the accelerator sensor or the brake sensor is replaced, removed/installed, or the pedal height is
adjusted.
*5: When the oil control valve is replaced.
*6: When tire size is changed or tire is replaced.
*7: When the mast, tilt angle sensor, tilt cylinder, load sensor or tire angle sensor is replaced, removed /
installed or adjusted.
*8: When the attachment and fork is installed or changed.
*9: When the material handling lever angle sensor is replaced, removed / installed or adjusted.
4. DISPLAY 4-109
4.3.2. PASSWORD
NOTICE
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be
damaged.
4
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning. If the SERVICE MENU cannot be displayed after several attempts, the system may be faulty.

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

seconds.
4 Within 10 seconds, press When pressing the

switch (2) and switch (3) at switches, a short beep
the same time for more sounds, and after 2
than 2 seconds. seconds repeated short
beeps sound.
5 When the service second password has been set:
Second password screen is displayed. Input the second
password.
Other:
This screen is skipped.
6 Service function initial screen is displayed for 5 seconds.

4-110 4. DISPLAY

7 ANALYZER MENU screen is automatically displayed.
SERVICE MENU Screen

Operating Procedure
1. Enter the password on the status screen (Refer to

PASSWORD) to display the SERVICE 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.
(2) (3) (4)
ANALYZER MENU screen Reads information about the error detected by a controller
and indicates the operating state of the electric system of
the lift truck.
TUNING MENU screen Fine adjusts the settings for traveling control, material
handling control, etc.
OPTION SET MENU screen Adjusts the display and the controllers according to the
specifications of each lift truck or the control conditions
set for it.
4. DISPLAY 4-111
MATCHING MENU screen Updates the sensor output voltages and the set values
stored in the memories of the display and each controller.
OTHERS MENU screen This allows you to:

• Start each meter*.
• Switch demo mode*. 4
• Initialize the settings.
• Set a service second password.
• Clear the administrator's second password.
• Adjust the contrast of the LCD display.
END of SERVICE 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 be displayed
on the OTHERS MENU screen.
4-112 4. DISPLAY
4.3.3. ANALYZER
GENERAL
Analyzer function supports operations for inspection/investigating a 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, material handling and PSS/OPS functions, or the error information detected by the controller
can be read.
This is very useful for checking the operative condition of each function, and saving time for repairing when there is
a defect. Full utilization of the analyzer functions provides quick and easy service.
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 shows them on the display.
Each diagnostic code is displayed with its detection time as the key ON hour meter reading.
(1) DIAG MEMORY
Reads stored diagnostic codes and its detection time as the key ON hour meter and indicates them.
(2) DIAG MEMORY Quick Reverence (QR)
Displays the QR codes including the stored diagnostic codes and uses the key ON hour meter as the
detection time.
2. In/Out monitor function (I/O MONITOR)
This function displays the analog input voltage for traveling, material handling, PSS and Operator Presence
Sensor switches, sensors and actuators. The circuit or their 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 material handling and mast control switch ON/OFF states and analog input voltages from
material handling and mast control sensors.
(4) I/O STEERING
Displays the ON/OFF states of synchronized steering and the analog input voltages from respective
sensors.
(5) I/O OTHERS
Displays the analog input voltages from the battery current sensor.
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 an operation check of that function.
4. Program version display (VERSION)
Displays the program version of each controller.
NOTICE
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.
4. DISPLAY 4-113
ANALYZER SCREEN ITEM LIST
Analyzer menu screen Screen No. Display item Description

1/2 1. to 5.
1. DIAG MEMORY Indications of errors occurred
2/2 6. to 10.
1/2
2. DIAG MEMORY QR
2/2
- QR code images of errors occurred 4
Drive motor L temperature: °C
TDM
Drive motor R temperature: °C
1/6
Drive motor driver L heat sink temperature: °C
TDMDH
Drive motor driver R heat sink temperature: °C
Drive motor driver L board temperature: °C
TDMDB
Drive motor driver R board temperature: °C
2/6
Drive motor driver L condenser temperature: °C
TDMDC
Drive motor driver R condenser temperature: °C
TPM Pump motor temperature: °C
TPMDH Pump motor driver heat sink temperature: °C
3/6
TPMDB Pump motor driver board temperature: °C
3. I/O TEMP/VOLT
TPMDC Pump motor driver condenser temperature: °C
TMCB Main controller board temperature: °C
4/6 TSLLT (Not used)
TDSP Display board temperature: °C
B48V Battery voltage: V
VBKY Voltage after key switch: V
5/6
VBMBSL Solenoid power source voltage: V
VBMB Voltage after MB contactor: V
VDMDL Drive motor driver L main circuit voltage: V
6/6 VDMDR Drive motor driver R main circuit voltage: V
VPMD Pump motor driver main circuit voltage: V
4-114 4. DISPLAY

SPEED Traveling speed: km/h or mph
Accelerator sensor 1 voltage: V
VRA
Accelerator sensor 2 voltage: V
1/5
Brake sensor 1 voltage: V
VRB
Brake sensor 2 voltage: V
SWBK (Not used)
SDM Seat switch
DSF Forward switch
2/5
DSR Reverse switch
SPB Parking brake switch
SH Lifting height switch
3/5 SPLF Load sensor voltage: V (MPa display)
4. I/O TRAVELING SPEED Traveling speed: km/h or mph
Drive motor L rpm: rpm
SPDDML
[Target rpm]: rpm
4/5
Drive motor R rpm: rpm
SPDDMR
[Target rpm]: rpm
Drive motor L rotation sensor 1 voltage: V
SSDL
Drive motor L rotation sensor 2 voltage: V
Drive motor R rotation sensor 1 voltage: V
SSDR
Drive motor R rotation sensor 2 voltage: V
5/5
Drive motor L current sensor 1 voltage: V
CSDL
Drive motor L current sensor 2 voltage: V
Drive motor R current sensor 1 voltage: V
CSDR
Drive motor R current sensor 2 voltage: V
4. DISPLAY 4-115

SLUL Unload solenoid
SLLL Lift lowering lock solenoid
SLTFL Tilt forward lock solenoid
SLTBL Tilt backward lock solenoid
1/8
SHS Lift knob switch 4
STK Tilt knob switch
SDM Seat switch
SHL (Not used)
VRTA Tilt angle sensor voltage: V
SPLF Load sensor voltage: V (MPa display)
2/8
SH Lifting height switch
VRH (Not used)
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
5. I/O M.HANDLING CSPM
Pump motor driver current sensor 2 voltage: V
5/8
Lift lever angle sensor 1 voltage: V
VRL
6/8 SLTBL Tilt backward lock solenoid
SWTF Tilt forward switch
SWTR Tilt backward switch
7/8 Attachment (1) lever angle sensor 1 voltage: V
VRA1
Attachment (1) lever angle sensor 2 voltage: V
VRA2
4-116 4. DISPLAY

5/8
VRL
6/8 SLTBL Tilt backward lock solenoid
Conventional Lever
Models SWTF Tilt forward switch
SWTR Tilt backward switch
VRA1
VRA2
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
Fingertip Control Lever Tilt lever angle sensor 2 voltage: V
Models SLUL Unload solenoid
CSA1 Attachment (1) proportional valve solenoid current:

7/8
A
VRA1
CSA2 Attachment (2) proportional valve solenoid current:

8/8
A
VRA2
VRTRA Tire angle sensor voltage: V
SPEED Traveling speed: km/h or mph
6. I/O STEERING 1/1 Steering angle knob position actual value (target
K-POS
value), Steering synchronizer solenoid
SSTR Steering angle sensor signal
4. DISPLAY 4-117

CSBAT Battery current sensor voltage: V
7. I/O OTHERS 1/1 IPL (Not used)
DOPT (Not used)
STEERING
Steering synchronizer solenoid forced operation
SOL
4
1/3 LIFT LWR SOL Lift lowering lock solenoid forced operation
TILT SOL Tilt forward solenoid forced operation
TILT BWD SOL Tilt backward solenoid forced operation
8. ACTIVE TEST
UNLOAD SOL Unload solenoid forced operation
FAN1 Cooling fan for controller forced operation
2/3
FAN2 Cooling fan for motor forced operation
ACC OUT1 (Not used)
3/3 ACC OUT2 Accessory output 2 forced operation
DISPLAY Display program version
1/2 MAIN C/R Main controller program version
CAN BRIDGE CAN Bridge program version
9. VERSION
DM DRIVER L Drive motor driver L program version
2/2 DM DRIVER R Drive motor driver R program version
PM DRIVER Pump motor driver program version
ANALYZER MENU screen

Operating Procedure
Enter the password on the status screen (Refer to

PASSWORD) to display the service function initial
screen. After 5 seconds, the ANALYZER MENU screen is
automatically displayed.
4-118 4. DISPLAY
“1. DIAG MEMORY”

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

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

Switch (4): To “I/O OTHERS” screen
“8. ACTIVE TEST”
Switch (4): To “ACTIVE TEST” screen
“9. VERSION”
Switch (4): To “VERSION” screen
4. DISPLAY 4-119
Diagnostic Memory Function (DIAG MEMORY)

The controller stores up to 10 error codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these error codes and indicates them on the display.
Diagnostic Memory (1) (DIAG MEMORY)
Reads stored diagnostic codes and their detection time as the key ON hour meter and displays them.
Operating Procedure 4
PASSWORD) to display the service function initial screen.
After 5 seconds, the ANALYZER MENU screen is
2. Check that “1. DIAG MEMORY” is selected on the

screen, and press switch (4) to display “DIAG MEMORY
1/2” screen.
3. Press switch (4) on the “DIAG MEMORY 2/2” screen to

return to the ANALYZER MENU screen.
NOTICE!
• The most recent diagnostic code is displayed as 1,
followed by 2, 3 and so on to 10.
• 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.
• You cannot move directly from the DIAG MEMORY
screen to another function screen. Return to the
ANALYZER MENU screen.
• For details about the diagnostic code, refer to
section 4, Diagnostic Code List.
4-120 4. DISPLAY
“DIAG MEMORY 1/2”

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

Displays diagnostic codes 6 to 10.
Switch (4): Returning to the ANALYZER MENU screen.
Diagnostic Memory (2) (DIAG MEMORY QR)

The DIAG MEMORY QR screen displays the QR codes including the stored diagnostic codes and its detection as
the key ON hour meter.
Operating Procedure

screen. After 5 seconds, the ANALYZER MENU
screen is automatically displayed.
4. DISPLAY 4-121
2. Press the switch (1) to select the “2. DIAG

MEMORY QR”, and press switch (4) to display the
“DIAG MEMORY QR 1/2” screen.
3. Press switch (4) on the “DIAG MEMORY QR 2/2”

screen to return to the ANALYZER MENU screen.
NOTICE!
• Read the QR code in order from the first to the
second one. If you move to the next screen
before reading the first QR code, return to the
ANALYZER MENU screen and display the first
QR code again.
• If you move to the next screen before reading
the first QR code, the second QR code does not
display.
• You cannot move directly from the DIAG
MEMORY QR screen to another function screen.
Return to the ANALYZER MENU screen.
• For details of the diagnostic code, refer to
section 4, Diagnostic Code List.
“DIAG MEMORY QR 1/2”

Displays first QR code.
Switch (4): To “DIAG MEMORY QR 2/2” screen.
4-122 4. DISPLAY
“DIAG MEMORY QR 2/2”

Displays second QR code.
Switch (4): Returning to the ANALYZER MENU
screen.
QR code
QR code is a form of a two dimensional bar-code, and it can be read by using a corresponding bar-code reader,
cell-phone, app for smartphone, and so on. The data is divided and saved in some QR codes.
If the readout system is in correspond connection mode, the divided data is automatically connected after reading
all QR codes.
Data administration becomes easy by inputting the frame number before saving the scanned data.
A table and graph can be created from the scanned data by using the spreadsheet software.
Text Data
Input the frame number where arrow indicates.
NOTICE
• Ask the manufacturers of the readout system in regard to operating and specification for the
system.
• It may be difficult to read a QR code because of the reflected light and the luminous conditions around
the lift truck.
* QR code is the registered brand of DENSO WAVE Co.Ltd.
In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage from traveling, material handling, PSS and Operator Presence
Sensor 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
4. DISPLAY 4-123
1. Display the ANALYZER MENU screen.
2. Press switch (1) to select the “3. I/O TEMP/VOLT”

and press switch (4) to display “I/O TEMP/VOLT 1/6”
screen.
3. After that, “I/O TEMP/VOLT 2/6” to “I/O TEMP/VOLT
6/6” display sequentially every time switch (4) is
pressed. Press switch (4) on “I/O TEMP/VOLT 6/6”
screen to return to the ANALYZER MENU screen.
NOTICE! : You cannot move directly from the I/O
TEMP/VOLT screen to other screens. Return to the
ANALYZER MENU screen, then move to the next
screen.
“I/O TEMP/VOLT 1/6”

TDM: Drive motor L/R temperature: °C
Temperature of the drive motor L/R is displayed.
TDMDH: Drive motor driver L/R heat sink temperature:
°C
Temperature of the drive motor driver L/R heat sink is
displayed.
Switch (4): To “I/O TEMP/VOLT 2/6” screen

TDMDB: Drive motor driver L/R board temperature: °C
Temperature of the drive motor driver L/R board is
displayed.
TDMDC: Drive motor driver L/R condenser
temperature: °C
Temperature of the drive motor driver L/R condenser is
displayed.
4-124 4. DISPLAY

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.
TPMDC: Pump motor driver condenser temperature: °C
Temperature of the pump motor driver condenser is
displayed.

TMCB: Main controller board temperature: °C
Temperature of main controller board is displayed.
TSLLT: Not used
TDSP: Display board temperature: °C
Temperature of display 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.

VDMDL: Drive motor driver L main circuit voltage: V
Voltage of drive motor driver L main circuit is displayed.
VDMDR: Drive motor driver R main circuit voltage: V
Voltage of drive motor driver R 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
4. DISPLAY 4-125
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 “4. I/O TRAVELING”

and press the switch (4) to display the “I/O TRAVELING
1/5” screen.
TRAVELING screen to other screens. Return to the
screen.
4-126 4. DISPLAY
“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 1.24 V
When accelerator pedal is fully depressed: 2.00 to
4.79 V
Accelerator sensor 2
When accelerator is not operated: 0.65 to 2.31 V
When accelerator pedal is fully depressed: 2.42 to
4.79 V
VRB: Brake sensor 1 / 2 voltage: V
Displays input voltage from the brake sensor to the
controller.
Standard:
Brake sensor 1
When brake is not operated: 0.50 to 1.79 V
When brake pedal is fully depressed: 1.60 to 4.79 V
Brake sensor 2
When brake is not operated: 0.79 to 2.88 V
When brake pedal is fully depressed: 2.00 to 4.79 V
SWBK: Not used
Switch (4): To “I/O TRAVELING 2/5” screen
[BRAKE SENSOR (POTENTIOMETER)]
4. DISPLAY 4-127

SDM: Seat switch
Switch ON/OFF quality judgment by sitting on and leaving
the operator’s seat
SDM: 0 = OFF when leaving the seat
SDM: 1 = ON when sitting on the seat
DSF: Forward switch 4
DSR: Reverse switch
Switch ON/OFF quality judgment by operating the
direction lever
Standard:
Direction lever: Forward traveling position
Displayed code:
DSF: 1 (= ON)
DSR: 0 (= OFF)
Direction lever: Neutral position
Displayed code:
DSF: 0 (= OFF)
DSR: 0 (= OFF)
Direction lever: Reverse traveling position
Displayed code:
DSF: 0 (= OFF)
DSR: 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)

SH: Lifting height switch
Judges the quality of the switch ON/OFF by raising and

lowering the fork.
Height Display SH1 SH2-1 SH2-2

Switch Switch Switch
Low lifting 100 1 (=ON) 0 (=OFF) 0 (=OFF)
height
High lifting 010 0 (=OFF) 1 (=ON) 0 (=OFF)
height
SH1 SH2-1 SH2-2
4-128 4. DISPLAY
SPLF: Load sensor voltage: V (MPa)

Displays input voltage from the load sensor to the
controller, and detected pressure.
Standard at no load: 0.50 to 4.49 V
Voltage increases as load increases.

SPDDML: Drive motor L rpm [target]: rpm
SPDDMR: Drive motor R rpm [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 lift
truck.
The number of revolutions of the drive motor increases
with an increase in the traveling speed.

SSDL: Drive motor L rotation sensor 1 / 2 voltage: V
SSDR: Drive motor R rotation sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor
rotation sensors.
Standard:
When motor is stopped:
Constant, either 0.30 to 0.70V or 0.90 to 1.40V
When motor is rotating:
Variable between approx. 0.30V and 1.40V
CSDL: Drive motor L current sensor 1 / 2 voltage: V
CSDR: Drive motor R current sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor
current sensors.
Standard:
Standard value when the lift truck is stopped:
Approx. 2.50V
Standard value when the lift truck is traveling:
Approx. 0.40 to 4.50V
4. DISPLAY 4-129
In/Out Monitor (3) (I/O M.HANDLING)

Displays the material handling and mast control switch ON/OFF states and analog input voltages from material
handling and mast control sensors.
Operating Procedure
2. Press switch (1) to select “5. I/O M.HANDLING” and

press switch (4) to display the “I/O M.HANDLING 1/8”
screen.
M.HANDLING screen to other screens. Return to the
screen.
“I/O M.HANDLING 1/8”

SLUL: Unload solenoid
(Conventional Lever)
Displays output signal to the unload solenoid.
SLLL: Lift lowering lock solenoid
Displays output signal to the lift lowering lock solenoid.
SLTFL: Tilt forward lock solenoid
Displays output signal to the tilt forward lock solenoid.
SLTBL: Tilt backward lock solenoid
Displays output signal to the tilt backward lock solenoid.
4-130 4. DISPLAY
Seat condition Sitting on seat
Lift lever Tilt lever
Not Forward Backward Leaving

Lever condition operated Raising Lowering tilt tilt seat
Conventional Lever 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)
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
SLTBL 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF)
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
Fingertip Control SLUL - - - - - -
Lever SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
SLTBL - - - - - -
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
SHS: Lift knob switch

Switch ON/OFF quality judgment by operating the lift knob
switch.
SHS: 0 = OFF
SHS: 1 = ON
STK: Tilt knob 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

VRTA: Tilt angle sensor voltage: V
Displays input voltage from the tilt angle sensor to the
controller.
Standard with mast in the vertical position: 1.27 to
3.99V
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: not used
4. DISPLAY 4-131

SPDPM: Pump motor rpm [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.
Switch (4): To “I/O M.HANDLING 4/8” screen 4

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 0.30 to 0.70V
or 0.90 to 1.40V
When motor is rotating: Variable between approx.
0.30V and 1.40V
CSPM: Pump motor driver current sensor 1 / 2 voltage: V
Displays the voltage from the pump motor driver current
sensor 1 / 2.
Standard:
Do not operate the material handling lever or the
steering, and keep the direction lever in the neutral
position: Approx. 2.50V
In a case other than above: 0.40 to 4.50V
4-132 4. DISPLAY

Conventional Lever SLUL: Unload solenoid
See “I/O M.HANDLING 1/8”
SLLL: Lift lowering lock solenoid
CSL: Lift proportional valve solenoid current: A
(Fingertip Control Lever)
Displays the current from the lift proportional valve
solenoid.
Standard:
Lever pull position: 0.25 to 0.95A
Fingertip Control Lever Lever push position: 0.25 to 0.95A
Lever neutral position: 0.00A
The current increases according to the amount of operation
of the lift lever.
VRL: Lift lever angle sensor 1 / 2 voltage: V
Displays input voltage from lift lever angle sensor 1 / 2 to
the controller.
Standard:
Lift lever angle sensor 1
Lever pull position: 0.30 to 2.87V
Lever push position: 1.65 to 4.50V
Lever neutral position: 1.65 to 2.87V
The voltage increases during lever backward operation,
and it decreases during lever forward operation.
Standard:
Lift lever angle sensor 2
The voltage decreases during lever backward operation,
and it increases during lever forward operation.
4. DISPLAY 4-133

Conventional Lever CST: Tilt proportional valve solenoid current: A
Displays the current from the tilt proportional valve
solenoid.
Standard:
Lever pull position: 0.35 to 0.85 A
Lever push position: 0.35 to 0.85 A 4
Lever neutral position: 0.00 A
of 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.
Fingertip Control Lever
Standard:
Tilt lever angle sensor 1
while it decreases during lever forward operation.
Standard:
Tilt lever angle sensor 2
“I/O M.HANDLING 6/8” Lever pull position: 0.30 to 2.75V
SLUL: Unload solenoid Lever push position: 1.78 to 4.50V
See “I/O M.HANDLING 1/8” Lever neutral position: 1.78 to 2.75V
SLTFL: Tilt forward lock solenoid The input voltage decreases during lever backward
operation, while it increases during lever forward operation.
SLTBL: Tilt backward lock solenoid
SWTF: Tilt forward switch
Switch ON/OFF quality judgment by
operating the tilt forward switch.
SWTR: Tilt backward switch
Switch ON/OFF quality judgment by
operating the tilt backward switch.
Standard:
Tilt lever: Forward tilt position
Displayed code:
SWTF: 1 (= ON)
SWTR: 0 (= OFF)
Tilt lever: Neutral position
SWTF: 0 (= OFF)
SWTR: 0 (= OFF)
Tilt lever: Reverse tilt position
SWTF: 0 (= OFF)
SWTR: 1 (= ON)
4-134 4. DISPLAY
(Conventional Lever) “I/O M.HANDLING 7/8”

CSA1: Attachment (1) proportional valve solenoid
current: A
Displays the current from the attachment (1) proportional
valve solenoid.
Standard:
Lever push position: 0.35 to 0.85A
(Fingertip Control Lever) of the attachment (1) lever.
VRA1: Attachment (1) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment 1 lever angle
sensor 1 / 2 to the controller.
Standard:
Attachment 1 lever angle sensor 1
Lever pull position: neutral voltage to 4.50V
Lever push position: 0.30 to neutral voltage
Standard:
Lever pull position: 0.30 to neutral voltage
Lever push position: neutral voltage to 4.50V
The input voltage decreases during lever backward
operation, and it increases during lever forward operation.
4. DISPLAY 4-135
(Conventional Lever) “I/O M.HANDLING 8/8”

CSA2: Attachment (2) proportional valve solenoid
current: A
Displays the current from the attachment (2) proportional 4
valve solenoid.
Standard:
Lever push position: 0.35 to 0.85A
(Fingertip Control Lever) of the attachment (2) lever.
VRA2: Attachment (2) lever angle sensor 1 / 2 voltage: V
Displays input voltage from the attachment (2) lever angle
sensor 1 / 2 to the controller.
Standard:
Standard:
The input voltage decreases during lever backward
operation, and it increases during lever forward operation.
4-136 4. DISPLAY
In/Out Monitor (4) (I/O STEERING)

Displays the ON/OFF states of synchronized steering and the analog input voltages from respective sensors.
Operating Procedure
2. Press switch (1) to select the “6. I/O STEERING” and

press switch (4) to display the “I/O STEERING 1/1”
screen.
STEERING screen to other screens. Return to the
screen.
4. DISPLAY 4-137
“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 the straight ahead
position:
2.11 to 2.81V 4
The input voltage increases when you turn the steering
right, while it decreases when you turn the steering left.
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
Lift truck without synchronized steering:

K-POS: ---- = Always
Lift truck with synchronized steering:
159 One rotation (360°) of the steering wheel is divided by
0 160, and the value is set to “80” when the knob is in the
1 position as indicated in the illustration.
Clockwise turn of the steering wheel: Increase in value
80 Counterclockwise turn of the steering wheel: Decrease in
value
Steering synchronizer solenoid:
Lift truck without synchronized steering:
K-POS: ---- = Always
Arrow indicates the standard position Lift truck with synchronized steering:
0 = OFF non-energized state (Position compensation
disabled)
1 = ON energized state (Position compensation enabled)
4-138 4. DISPLAY
SSTR: Steering angle sensor signal

0 = OFF
1 = ON
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 (center) position.
SS1 SS2 SSC
In/Out Monitor (5) (I/O OTHERS)

Displays the analog input voltages from battery current sensor.
Operating Procedure
2. Press switch (1) to select “7. I/O OTHERS” and press

switch (4) to display “I/O OTHERS 1/1” screen.
OTHER screen to other screens. Return to the
screen.
4. DISPLAY 4-139
“I/O OTHERS 1/1”

CSBAT: Battery current sensor voltage: V
Display input voltage from the battery current sensor to
the controller.
Standard value when the lift truck is stopped:
Approx. 2.50V
(when material handling lever, steering wheel, and 4
forward/backward switch are in neutral)
Other than the above: 2.30 to 2.70V
Active Test (ACTIVE TEST)

In active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in
order to permit an operation check of that function.
Active Test Item List
Selection item
Content of
Item Description Signal operation Signal Content of operation
STEERING Steering synchronizer OFF Tires move ON Tire do not move
SOL*1 solenoid forced operation match
LIFT LWR Lift lowering lock solenoid OFF Lowering not ON Lowering possible
SOL forced operation possible
TILT SOL Tilt forward solenoid OFF Forward tilt not ON Forward tilt possible
forced operation possible
TILT BWD Tilt backward solenoid OFF Backward tilt ON Backward tilt not
SOL forced operation possible possible
UNLOAD SOL Unload solenoid forced OFF Material handling ON Material handling
operation operation possible operation not possible
(Except lowering)*2
FAN1 Cooling fan for controller OFF Fan stops ON Fan rotates
forced operation
FAN2*3 Cooling fan for motor OFF Fan stops ON Fan rotates
forced operation
ACC OUT1 Not used OFF - ON -
ACC OUT2*4 Accessory output 2 forced OFF Back buzzer stop ON Back buzzer sound
operation Motion alarm stop Motion alarm sound
*1: With synchronized steering only.

*2: Depending on the attachment, 3rd to 5th way operation may be possible.
It may slowly tilt forward according to load condition, but this is not a fault.
*3: With cooling fan for motor only.
*4: With motion alarm or Forward/Reverse Pedal option only.
• On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item.
4-140 4. DISPLAY
• If the selected item is forcibly turned off or on by pressing switch (2) or (3), and it is switched over to another item
by pressing switch (1), forced operation is canceled (and switches over to normal operation).
• The operation guidance in connection with switches (2) and (3) indicates whether an item is forcibly operated or
not. (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
Operating procedure
2. Press switch (1) to select the “8. ACTIVE TEST” and

press switch (4) to display the “ACTIVE TEST” 1/3 screen.
4. DISPLAY 4-141
“ACTIVE TEST 1/3”

STEERING SOL: Steering synchronizer solenoid forced
operation
Slowly turn the steering wheel, and check the difference of
the rear tire movement.
ON (By-pass open): Tires do not move much
OFF (By-pass close): Tires move (normal operation) 4
LIFT LWR SOL: Lift lowering lock solenoid forced
operation
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 forward solenoid forced operation
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
TILT BWD SOL: Tilt backward solenoid forced operation
Check the quality of mast backward tilt operation by
backward tilt operation.
ON (Solenoid ON): Backward tilt possible
OFF (Solenoid OFF): Backward 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
4-142 4. DISPLAY

UNLOAD SOL: Unload valve solenoid forced operation
Check the quality by material handling operation.
ON (Solenoid ON):
Material handling operation not possible (Except lowering)
OFF (Solenoid OFF):
Material handling operation possible.
FAN1: Cooling fan for controller forced operation
Used to check the operation state of the cooling fan for the
controller both visually and through the display.
ON: Fan rotates
OFF: Fan stops
FAN2: Cooling fan for motor forced operation
Used to check the operation state of the cooling fan for the
motor both visually and through the display.
ON: Fan rotates
OFF: Fan stops
ACC OUT1: Not used
Switch (1): Selecting the next item on the “ACTIVE TEST
2/3” screen
Switch (4): To “ACTIVE TEST 3/3” screen
ACC OUT2: Accessory output 2 forced operation
Used to check if the motion alarm and the back buzzer
work normally.
ON: Motion alarm and back buzzer sound
OFF: Motion alarm and back buzzer stop
4. DISPLAY 4-143
Program Version display (VERSION)

Displays program version of each controller.
Operating Procedure
2. Press switch (1) to select “9. VERSION” and press

switch (4) to display the “VERSION 1/2” screen.
Press 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.
NOTICE! You cannot move directly from the VERSION
screen to another screen. Return to the ANALYZER
MENU screen, then move to the next screen.
“VERSION 1/2”
DISPLAY: Program version of the multi-function display
MAIN C/R: Program version of the main controller
CAN BRIDGE: Program version of the CAN bridge
Switch (4): To “VERSION 2/2” screen
“VERSION 2/2”
DM DRIVER L: Program version of the drive motor driver L
DM DRIVER R: Program version of the drive motor driver R
PM DRIVER: Program version of the pump motor driver
4-144 4. DISPLAY
4.3.4. TUNING
This feature performs fine adjustment of traveling and material 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 have 75 items (included spare items)
Tuning Item List
Level (●: Initial setting value)

Menu No. Item 1 2 3 4 5 6 7 8
TUNE 1 Activation timing of low battery Fast Slow Disabled
GEN capacity warning and battery ●
over-discharge warning
2 Battery charge indicator Slow ● Fast
calibration No.1 decrease decrease
3 Battery charge indicator Sensitive ● Insensitive
calibration No.2
4 Motor torque when the battery Power ● Power
discharge has proceeded. Down Keep
5 Not used - ● -
6 Acceleration pedal sensitivity Insensitive ● Sensitive
7 Acceleration torque Weak ● Strong
8 Acceleration soft-start Slow ● Quick
9 Regenerative braking torque Weak ● Strong
at accelerator-off
10 Regenerative braking Slow ● Quick
soft-start at accelerator-off
11 Acceleration torque at Weak ● Strong
switch-back
12 Acceleration soft-start at Slow ● Quick
switch-back
13 Regenerative braking torque Weak ● Strong
at switch-back
14 Regenerative braking Slow ● Quick
soft-start at switch-back
15 Regenerative braking soft-stop Slow ● Quick
at switch-back
16 Accelerator traction torque Weak ● Strong
17 Accelerator and brake traction Weak Strong
torque
●
18 Rollback speed when the Slow Fast
traveling direction is opposite ●
to the direction lever.
19 Rollback speed when the Slow Fast
traveling direction is the same ●
as the direction lever.
4. DISPLAY 4-145
Level (●: Initial setting value)

Menu No. Item 1 2 3 4 5 6 7 8
TUNE 20 The time of simultaneously Short ● Long No limit
GEN operable accelerator and
brake (OPT)
21 Stop time before rollback* Short Long
● 4
22 Maximum speed limitation Slow Fast
during backward traveling ●
23 Low speed setting during Slow Fast
backward traveling ●
24 Not used - ● -
25 Regenerative braking soft-stop Slow ● Quick
at brake on
26 Pump motor output during lift Slow Fast
up operation ●
27 Pump motor output during tilt Slow ● Fast
forward and backward
operation
28 Pump motor output during the Slow ● Fast
attachment (1) lever push and
pull operation
29 Pump motor output during the Slow ● Fast
attachment (2) lever push and
pull operation
30 Not used - ● -
31 Not used - ● -
32 Not used - ● -
33 Not used - -
●
34 Not used - ● -
35 Tilt forward angle to limit lift up Small ● Large Disabled
speed in low lift position
*: The stop time of the lift truck becomes longer on a sloping road if you increase the setting level. Set the
parking brake if you leave the seat.
4-146 4. DISPLAY
Low battery capacity warning and battery over-discharge warning
[%] 1 2 3 4 5 6 7 8
50
60 (a)
(b)
70
80
90
100
(c)
(a) Battery warning (b) Battery indicator blinks (c) No warning

Over-discharge warning
Ten segments of the battery indicator blink
4. DISPLAY 4-147
○: Available
-: NOT available
Lever Level (●: Initial setting value)
OPT 4
Menu No. Item STD * 1 2 3 4 5 6 7 8
LIFT START Play at the beginning of - ○ Wide ● Narrow
DOWN lift lever down operation
INCH Inching speed during lift - ○ Slow ● Fast
down operation
MAX Maximum speed during - ○ Slow ● Fast
lift down operation
ACC Acceleration speed during - ○ Weak ● Strong
lift down operation
DEC Deceleration speed - ○ Weak ● Strong
during lift down operation
LIFT START Play at the beginning of - ○ Wide ● Narrow
UP lift up operation
INCH Inching speed during lift ○ ○ Slow ● Fast
up operation
lift up operation
ACC Acceleration speed during ○ ○ Weak ● Strong
lift up operation
DEC Deceleration speed ○ ○ Weak ● Strong
during lift up operation
TILT START Play at the beginning of - ○ Wide ● Narrow
FWD tilt forward operation
INCH Inching speed during tilt - ○ Slow ● Fast
forward operation
tilt forward operation
tilt forward operation
during tilt forward
operation
4-148 4. DISPLAY
OPT
Menu No. Item STD * 1 2 3 4 5 6 7 8
TILT START Play at the beginning of - ○ Wide ● Narrow
BWD tilt backward operation
INCH Inching speed during tilt - ○ Slow ● Fast
backward operation
tilt backward operation
tilt backward operation
during tilt backward
operation
ATT1 START Play at the beginning of - ○ Wide ● Narrow
PUSH the attachment (1) lever
push operation
INCH Inching speed during the ○ ○ Slow ● Fast
attachment (1) lever push
operation
the attachment (1) lever
push operation
push operation
during the attachment (1)
lever push operation
PULL the attachment (1) lever
pull operation
attachment (1) lever pull
operation
pull operation
pull operation
lever pull operation
4. DISPLAY 4-149
OPT
Menu No. Item STD * 1 2 3 4 5 6 7 8
PUSH the attachment (2) lever
push operation
INCH Inching speed during the ○ ○ Slow ● Fast 4
attachment (2) lever push
operation
push operation
push operation
PULL the attachment (2) lever
pull operation
attachment (2) lever pull
operation
pull operation
pull operation
* Fingertip Control Lever
TUNING MENU Screen

Operating Procedure
4-150 4. DISPLAY
2. By default, the SERVICE MENU screen is displayed

with the [ANL] tab selected. On this screen, press switch
(3) and select the [TUN] tab.
NOTICE! : The number of tuning menu items displayed
varies according to the number of spools of the
Fingertip Control Lever.
“1. GENERAL”
Switch (1): Switching selection to the next item.
Switch (2): To ANALYZER MENU
Switch (3): To OPTION SET MENU
Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER”
“3. TILT LEVER”
“4. ATT1 LEVER”
“5. ATT2 LEVER”
GENERAL (TUNING GENERAL)

Sets tuning levels for traveling and material handling.
Operating Procedure
4. DISPLAY 4-151
1. Display the TUNING MENU screen.
2. Check that “1. GENERAL” is selected on the

screen, and press switch (4) to display the TUNING
LEVEL setting screen.
NOTICE! : You cannot move directly from the
GENERAL setting screen to another screen. Return
to the TUNING MENU screen, then move to the
next screen.
“TUNE GEN.”
Switch (1): Switching selection to the next item
Switch (2): Tuning level down
Switch (3): Tuning level up
Switch (4): Switching to the next screen

Switch (4): Returning to the TUNING MENU screen
4-152 4. DISPLAY
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 switch (4) to display the TUNING LEVEL

setting screen.
NOTICE! : You cannot move directly from the LIFT
LEVER setting screen to other screens. Return to
the TUNING MENU screen, then move to the next
screen.
“LIFT DOWN”
“LIFT UP”
4. DISPLAY 4-153
TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever.
Operating Procedure
1. Display the TUNING MENU screen and press
switch (1), select the “3. TILT LEVER”.

setting screen.
NOTICE! : You cannot move directly from the TILT
LEVER setting screen to the screen of the other
items. Return to the TUNING MENU screen once,
then move to the screen for each time.
“TILT FWD”
“TILT BWD”
4-154 4. DISPLAY
ATT1 LEVER (TUNING ATT1 LEVER)

Sets tuning levels for the ATT1 lever.
Operating Procedure

switch (1). Select the “4. ATT1 LEVER”.

setting screen.
NOTICE! : You cannot move directly from the ATT1
LEVER setting screen to others screens. Return to
screen.
“ATT1 PUSH”
“ATT1 PULL”
4. DISPLAY 4-155
ATT2 LEVER (TUNING ATT2 LEVER)

Sets tuning levels for the ATT2 lever.
Operating Procedure
switch (1). Select the “5. ATT2 LEVER”.

setting screen.
NOTICE! : You cannot move directly from the ATT2
LEVER setting screen to other screens. Return to
screen.
“ATT2 PUSH”
“ATT2 PULL”
4-156 4. DISPLAY
4.3.5. OPTION SET
NOTICE
• 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 lift truck. It does not enable or disable itself.
• If the main controller or multi-function display is replaced, it is necessary to reset it according to the lift
truck specification.
Option Set Item List

Switching settings
Setting Setting
Indication Description Indication content Indication content
MPH* Setting the traveling speed YES mph NO km/h
display unit
DATE TYPE* Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
36V* Setting the battery voltage YES 36V NO 48V
between 36V and 48V
B-TYPE* Adjust the charge indicator A1: US Domestic / A2: Export / B1: Japan / B2: Maintenance
calculation Free
H MODE LOCK Setting to enable/disable YES Enabled NO Disabled
the H mode lock
MENULOCK Setting the mode of the A Unlock (“NO”) B Unlock (“NO”)
SPEC* menu lock release effective till effective till set
key-OFF “YES”
ACCEL & BRK* Setting the traction A accelerator B brake priority
limitation mode when priority
operating the accelerator
and the brake
simultaneously
[YFS specification A The output of B The motor
(E34A)only] the drive motor output gradually
Both A/B are given priority stops just after stops after the
to an accelerator the restriction restriction
activates. activates.
Drive motor output setting
after the accelerator and
brakes simultaneous
operation time progress set
by tuning No. 20.
HOLD TRQ Drive motor output setting A The drive B The drive motor
MODE after the pushing operation. motor output output stops
gradually just after the
stops after the operation.
operation.
COASTING Inactive setting of the YES Inactive NO Active (Default)
RUN regenerative braking with
the accelerator pedal off
4. DISPLAY 4-157
Switching settings
Setting Setting
OCV WAY* Setting the number of ways 2/3/4/5
for the oil control valve
“5” is no used this model.
D ACT ATT1* Double action ATT1 A: Disable / B: Enable PUSH / C: Enable PULL / D: Enable
4
Both
D ACT ATT2* Double action ATT2 A: Disable / B: Enable PUSH / C: Enable PULL / D: Enable
Both
D ACT ATT3 Reserved A/B/C/D
BUZZER SPEC* Setting for the mode of the A: Except US / B: Not in use / C: US
buzzer sound when the
Operator Presence Sensor
and Return-to-neutral
operate
SEAT BUZZER Setting to enable/disable YES Enabled NO Disabled
the buzzer sound when the
seat switch is off
PKB BUZZER Setting to enable/disable YES Enabled NO Disabled
the parking brake off
warning
SPD ALM2 Setting to enable/disable YES Enabled NO Disabled
the overspeed alarm 2
WHEEL IND Reserved A/B/C
POWER Setting display mode of the YES Enabled NO Disabled
METER power meter
ASC W/LOAD Setting to enable/disable YES Enabled NO Disabled
the auto speed control
MODE Setting to enable/disable S Enabled A Disabled
the traveling speed limit of
auto speed control
CURVE CONT Setting to enable/disable YES Enabled NO Disabled
the turn speed control with
load and height sensing
D-LIM MODE Setting the traction A Traction B Traction
limitation mode at restrictions restrictions
over-discharge warning regardless of according to
discharge level discharge level
P-LIM MODE Setting the material A Lift interrupt B Lift interrupt
handling limitation mode at while traveling
over-discharge warning
T FWD LIMIT Setting to enable/disable YES Enabled NO Disabled
the active mast front tilt
angle control
T BWD LEVEL Setting to enable/disable YES Enabled NO Disabled
the backward tilt automatic
leveling control
4-158 4. DISPLAY
Switching settings
Setting Setting
T F-SPD LIM Setting to enable/disable YES Enabled NO Disabled
the forward tilt speed limit
control
L UP-SPD LIM Setting to enable/disable YES Enabled NO Disabled
the lifting speed limitation
with mast forward-tilted
KNOB CONT* Setting to enable/disable YES Enabled NO Disabled
the steering knob
synchronizer
POWER KEEP Setting to enable/disable YES Enabled NO Disabled
the power keep control
H-SELECTOR Reserved YES - NO -
MOTION ALM Setting the directions of the F: Forward / R: Reverse (Default) / F&R: Forward and
motion alarm Reverse / OFF
DIR-SW/MVT* Setting the mode of the D: Direction / MVT: Speed Detection / D&MVT: Direction and
motion alarm Speed Detection / D/MVT: Direction or Speed Detection
STOP LAMP Reserved A - B -
D-REC Setting to enable/disable YES Enabled NO Disabled
the iWAREHOUSE CAN
communications
*: These are set according to the lift truck specification at the time of shipment.
OPTION SET MENU Screen

Operating Procedure
4. DISPLAY 4-159

with the [ANL] tab selected. On this screen, press
switch (3) to select the [OPT] tab.
3. Check that “1. OPTION SET” is selected on the

screen, and press switch (4) to display the OPTION
SET screen.
Switch (3): To MATCHING MENU
witch (4): To OPTION SET screen
WARNING! : You cannot move directly from the
OPTION SET screen to other screens. Return to the
OPTION SET MENU screen, then move to the next
screen.
“OPTION SET” Screen 1

Switch (2): Switching the selected Option Set item to
the option on the left
the option on the right

4-160 4. DISPLAY




4. DISPLAY 4-161

Switch (4): Switching to the next screen 4

Switch (4): Returning to the OPTION SET MENU
screen
4-162 4. DISPLAY
4.3.6. MATCHING
GENERAL
Each function is controlled by using the sensors and each signal voltage at standard lift truck conditions stored in
the controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a sensor at standard
lift truck condition) is required when performing maintenance on a section or replacing parts related to the sensor.
For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accelerator and
brake fully released, accelerator and brake 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 lift truck condition) is necessary.
The controller stores the values of these functions at the time of shipment; Tilt angle, Load and tire angle sensors
used for PSS functions, signal voltage values under the mast vertical, no load, tire straight, and lift truck horizontal.
When servicing or replacing these sensors, matching (updating the sensor signal voltage value in the standard lift
truck condition) is necessary. Also, matching is needed for the tilt angle sensor when the lift truck posture has
changed excessively, and for the load sensor when the load under no load condition (no load on forks) is changed
because of addition or removal of any attachment or fork, replacement of mast, or change of fork length.
Each lever angle sensor for material handling lever function is controlled based on the memory of the 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 lift truck condition) is
necessary.
The oil control valve (OCV) for Fingertip Control Lever models activating current level is set at the factory according
to each oil control valve and stored in the memory of the main controller. Therefore, when relevant service or part
replacement is performed, matching must be done.
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 the “Tire Data List”.
Matching Items and Prerequisite for Implementation
1. DRIVE
Prerequisite for
No. Indication Description implementation
1 ACCEL OFF Accelerator sensor output value with fully released *1, *2
accelerator position to the controller.
2 ACCEL ON Accelerator sensor output value with fully stepped *1, *2
3 BRAKE OFF Brake sensor output value with fully released brake *1, *16
position to the controller.
4 BRAKE ACT Brake sensor output value at the start point of wet-brake *1, *16
activation to the controller.
2. PSS
Prerequisite for
1 TILT LEVEL Tilt angle sensor output value with the forks in the *1, *3, *4, *7, *8, *9,
horizontal position to the controller. *17
2 TILT FWD LIMIT Tilt angle sensor output value at the mast vertical position *1, *3, *4, *5, *7, *8,
and the load sensor output value without load to the *9
controller.
4. DISPLAY 4-163
Prerequisite for
3 TIRE POSITION Tire angle sensor output value while the lift truck is *1, *6, *17
traveling straight to the controller.
4 MAST TYPE The mast type is stored *8, *14, *17
3. LEVER 4
Prerequisite for
1 LEVER 1 Lift lever angle sensor output value in the lift lever neutral *1, *10, *17
position is stored in the controller.
2 LEVER 2 *18 Tilt lever angle sensor output value in the tilt lever neutral *1, *11, *17
3 LEVER 3 Attachment (1) lever angle sensor output value in the *1, *12, *17
attachment (1) lever neutral position is stored in the
controller.
4 LEVER 4 Attachment (2) lever angle sensor output value in the *1, *13, *17
controller.
4. OCV *18
Prerequisite for
1 A01 Oil control valve A1 activating current level *1, *17
A02 Oil control valve A2 activating current level *1, *17
2 B01 Oil control valve B1 activating current level *1, *17
B02 Oil control valve B2 activating current level *1, *17
5. TIRE DATA
Prerequisite for
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 replacing tilt angle sensor
*4: When length change or replacement of tilt angle sensor rod
*5: When removing/installing or replacing load sensor

4-164 4. DISPLAY
*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
*16: When removing/installing or replacing brake sensor
*17: When replacing oil control valve
*18: Fingertip Control Lever models only

4. DISPLAY 4-165
MATCHING MENU Screen

Operating Procedure

PASSWORD section) to display the service function
initial screen. After 5 seconds, the ANALYZER MENU
4

with the [ANL] tab selected. On this screen, press the
switch (3) and select the [MAT] tab.
“1. DRIVE”
Switch (1): Switching selection to next item.
Switch (3): To OTHERS MENU
Switch (4): To MATCHING DRIVE screen
“2. PSS”
NOTICE! PSS and SAS are interchangeable terms
Switch (4): To MATCHING PSS screen
“3. LEVER”
Switch (3): To OTHER MENUS
Switch (4): To MATCHING LEVER screen
“4. OCV”
Switch (4): To MATCHING OCV screen
“5. TIRE DATA”
Switch (4): To TIRE DATA screen
4-166 4. DISPLAY
DRIVE (MATCHING DRIVE)

Matching is performed for traveling function.
Operating Procedure
1. Display the MATCHING MENU screen.
NOTICE! PSS and SAS are interchangeable terms.
2. Check that “1.DRIVE” is selected on the screen, and

press the switch (4) to display “ACCEL OFF” screen.
NOTICE! : You cannot move directly from each
matching set screen of “DRIVE” to other matching set
screens. Return to the MATCHING MENU screen, then
move to the next screen.
CAUTION! : Make sure that the Spanner indicator on

the display is blinking. During drive matching, the
Spanner indicator blinks, informing you that the lift
truck will not run even if the accelerator pedal is
depressed.
“ACCEL OFF” Screen

Memorize accelerator sensor signals with the pedal fully
released.
Values in the bracket ( ) are currently stored values.
Values outside the bracket ( ) are current lift truck
condition values.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): To “ACCEL ON” screen
If matching is performed, “OK” is indicated on the display.
Lift truck condition
• All parts related to the accelerator pedal should be
formally mounted.
• The accelerator pedal should be fully released.
4. DISPLAY 4-167
“ACCEL ON” Screen

Memorize accelerator sensor signals with the pedal fully
stepped on.
condition values.
Switch (1): Pressing this for more than 2 seconds will 4
perform matching.
Switch (4): To “BRAKE OFF” screen
• All parts related to the accelerator pedal should be
formally mounted.
• The accelerator pedal should be fully stepped on.
• On models with the Forward/Reverse Pedal option, the
forward direction side of the accelerator pedal should be
stepped on.
“BRAKE OFF” Screen
Memorize brake sensor signals with the pedal fully
released.
condition values.
perform matching.
Switch (4): To “BRAKE ACT” screen
• All parts related to the brake pedal should be formally
mounted and adjusted.
Moreover, the parking brake should be in the released
(not applied) position.
• The brake pedal should be fully released.
“BRAKE ACT” Screen
Memorize brake sensor signals at the start point of the
wet-brake activation.
condition values.
perform matching.
Switch (4): To MATCHING MENU screen
4-168 4. DISPLAY

• All parts related to the brake pedal should be formally
mounted and adjusted.
a Moreover, the parking brake should be in the released
(not applied) position.
• The brake pedal should be stepped on perpendicularly
b with the force of 36.0 ± 1.8 lbf. [160 ± 8 N] at the center
of the pad.
Use the push-pull gage for measurement.
c
a: 36.0 ± 1.8 lbf. [160 ± 8 N]
d b: Full release point
c: Start point of the wet-brake
d: Full stroke
PSS (MATCHING PSS)

Matching is performed for PSS function.
Operating Procedure
1. Display the MATCHING MENU screen and press switch

(1), select the “2. PSS (SAS)”.
2. Press switch (4) to display “TILT LEVEL” screen.

matching set screen of “PSS” to other matching set
NOTICE! In standard lift truck condition, if the value in
the bracket ( ) and the value outside the bracket ( ) are
different, matching is required.
4. DISPLAY 4-169
“TILT LEVEL” Screen

Values outside the bracket ( ) are current lift truck condition
values.
perform matching.
Switch (4): To “TILT FWD LIMIT” screen 4

TT/QM
• This procedure should be done with all equipment,
including forks or attachments, mounted as specified.
• The lift truck should be with no load and on level ground.
• For TT/QM mast: The rear lift cylinders should be raised
to a height of approximately 3.93 in. (100 mm).
100 mm
(3.93 in)
• The mast should be adjusted to the base position by

tilting only forward.
Tilt the mast backward enough and adjust again, when
the mast is tilted beyond the desired position.
• In special cases when the execution of “the other
procedure” is specified, the mast should be lifted to the
top and the hydraulic oil control valve should be
relieved.
“TILT FWD LIMIT” Screen

Values outside the bracket ( ) are the current lift truck
condition values.
perform matching.
Switch (4): To “TIRE POSITION” screen
4-170 4. DISPLAY

TT/QM • This procedure should be done with all equipment,
including forks or attachments, mounted as specified.
• The lift truck should be with no load and on the level
ground.
• For TT/QM mast: The rear lift cylinders should be raised
to a height of approximately 3.93 in. (100 mm).
100 mm
(3.93 in)
• The mast should be adjusted to the base position by

tilting only forward.
Tilt the mast backward enough and adjust again, when
the mast is tilted beyond the desired position.
• In special case that the execution of “the other
procedure” is specified, the mast should be lifted to the
top and the hydraulic oil control valve should be
relieved.
“TIRE POSITION” Screen

values.
perform matching.
Switch (4): To “MAST TYPE” screen
• This procedure should be done with all equipment,
including forks or attachments, and mounted as
specified.
However, it is acceptable to do this procedure in a
condition of no forks, but only for the fork-less
specification.
• Lift truck should be with no load, and on the level
ground.
• Forks or attachments should be lowered as low as
possible so that the lift truck direction can be checked
easily.
• The mast should be approximately vertical to the
ground. (The visual observation is acceptable.)
• The tire angle should be adjusted to the straight
position.
4. DISPLAY 4-171
“MAST TYPE” Screen

Mast type setting screen
Used to select the type of mast that is mounted.
Switch (2): Switching in the following sequence:
“-” (unspecified) → QM → TT
Switch (3): Switching in the following sequence:
TT → QM → “-” (unspecified) 4
Switch (4): Returning to MATCHING MENU screen.
NOTICE! The mast type on your lift truck might not show on the display. Use the table below to select the
correct mast type.
Display Equivalent / Interchangeable mast types
V TN
SV –
FSV TT
FV TF
FSW TT
FW –
QFV QM
LEVER (MATCHING LEVER)

Matching is performed for material handling lever.
Operating Procedure
1. Display the MATCHING MENU screen and press the

switch (1). Select the “3. LEVER”.
2. Press switch (4) to display the “LEVER1” screen.

matching set screen of “LEVER” to other matching set
4-172 4. DISPLAY
“LEVER1” Screen
values.
perform matching.
Switch (4): To “LEVER2” screen
After matching is performed, operate the lever to push side
and pull side at full position.
• Inputting data for the oil control valve into the main
controller should be completed.
• All the material handling levers should be in the neutral
positions.
• Lift trucks with the Fingertip Control Lever option should
have the battery hood closed, and the armrest should be
horizontal. (A visual observation is acceptable.)
“LEVER2” Screen
Conventional Lever Values in the bracket ( ) are currently stored values.
values.
perform matching.
Switch (4): To “LEVER3” screen
Fingertip Control Lever controller should be completed.
• All the material handling levers should be in the neutral
positions.
4. DISPLAY 4-173
“LEVER3” Screen
values.
perform matching.
Switch (4): To “LEVER4” screen 4
• All the material handling levers should be at the neutral
positions.
NOTICE! : “Lever3” screen will be displayed according
to the number of ways being set.
“LEVER4” Screen
values.
perform matching.
Switch (4): To MATCHING MENU screen
• All the material handling levers should be at the neutral
positions.
NOTICE! : “Lever4” screen will be displayed according
to the number of ways being set.
4-174 4. DISPLAY
TIRE DATA
Used to set the tire data.
The tire data is set according to the type of mounted tires before shipment from the factory. However, if the type or
size of drive tire is changed, the tire data should be set again according to the “Tire Data List”.
Operating Procedure
1. Display the MATCHING MENU screen and press switch

(1), select the “5. TIRE DATA”.
2. Press switch (4) to display the “TIRE DATA” screen.
“TIRE DATA” Screen

Switch (2): Setting tire data smaller
Switch (3): Setting tire data larger
Switch (4): Returning to the MATCHING MENU screen.
Tire Data List
Applicable model Tire size Tire type Tire data

All models 18X7X12.1/8 Smooth Cushion 245
Cushion non-marking 246
Lug Cushion non-marking 248
4. DISPLAY 4-175
4.3.7. OTHERS MENU
NOTICE
After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be displayed on
the “OTHERS MENU”.
4
Operating Procedure
4-176 4. DISPLAY

switch (3) and select the [etc.] tab.
“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
“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
HOUR METER START (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 material handling operation during traveling.
• Enables the parking brake reminder function.
• Enables all functions of the PIN code entry system (option).
4. DISPLAY 4-177
NOTICE
• This option does not clear the PIN code authentication data 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 started.
Operating Procedure 4
PASSWORD section) to display the service function
initial screen. After 5 seconds, the ANALYZER MENU

3. Check that “1. METER START” is selected on the

screen, and press switch (4) to display the “METER
START” screen.
NOTICE! :
• After completing the hour meter start setting,
“METER START” and “DEMO MODE” will not be
displayed on the “OTHERS MENU”.
• Pay attention so H mode lock is maintained as
the former state of hour meter start.
The hour meter start screen always displays the
H mode lock condition.
4-178 4. DISPLAY
“METER START” screen

Hour meter start procedure
1. Press switch (2) for more than 2 seconds to display
the right arrow (guidance) on the screen.
2. While pressing switch (2), if you press switch (3),

inverted NO on the screen turns to inverted YES, and
the setting is completed.
3. Press switch (4) to return to the SERVICE MENU

screen.
4. DISPLAY 4-179
NOTICE! : On completion of the hour meter start

operation, the hourglass icon on the key ON hour
meter blinks to indicate that the hour meter has
started to count up.
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
PIN code entry system (OPT) Authentication function Authentication Authentication
possible only for possible by simply
registered pressing the log-in
authentication switch
numbers
Registration, change or Enabled Disabled
deletion of authentication
number
NOTICE
• Even after the demo mode has been disabled, the data recorded and the settings made during the demo
mode are all retained.
• After the start of the hour meter, no settings can be made in the demo mode.
4-180 4. DISPLAY
Operating Procedure

with the [ANL] tab selected. On this screen, press the
3. Press switch (1) to check that “2. DEMO MODE” is

selected.
4. Press switch (4) to display the “DEMO MODE” screen.
NOTICE!
• After the hour meter start operation completes,
“METER START” and “DEMO MODE” items of other
service function menus will not be displayed.
• When “YES” is selected, H mode lock becomes NO
automatically. The demo mode screen always
displays the H mode lock condition.
• When demo mode is changed from “YES” to “NO”,
H mode lock becomes YES automatically.
“DEMO MODE” screen

Switch (2): Setting from YES
Switch (3): Setting from NO
Switch (4): Return to OTHERS MENU screen
4. DISPLAY 4-181
NOTICE! : During demo mode, “DEMO” is displayed in

the key on hour meter screen.
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 setting
• Power select function (LPH)
• Travel power control level setting, material handling power control level setting
• Low speed setting
• Maximum speed limitation setting
• Overspeed alarm setting
• Tuning level
• Auto power OFF time
NOTICE
This does not apply to data dependent on each individual lift truck, such as Option Set data, various
matching data, load meter setting data and tire constant data.
Operating Procedure

4-182 4. DISPLAY

Before hour meter start

3. Press switch (1) to check that “3. TO DEFAULT
SET” is selected.
4. Press switch (4) to display “TO DEFAULT SET”
screen.
After hour meter start
3. Check that “1. TO DEFAULT SET” is selected on the
screen, and press switch (4) to display “TO DEFAULT
SET” screen.
“TO DEFAULT SET” Screen

Default set procedure
1. Press switch (2) and select “YES”.
4. DISPLAY 4-183
2. To initialize the settings, press and hold down switch

(1) for more than 2 seconds.
3. When the settings are reset to the default values,
the progress is displayed as a bar.
4. When reset is completed, “OK” is displayed.
NOTICE!
• When the Default Set operation is in progress,
do not turn off the key switch or disconnect the
4
battery plug.
• You can return to another service function menu
by pressing switch (4), except when the Default
Set operation is in progress.
SERVICE SECOND PASSWORD SETTING (MASK PASSWORD)

This menu item is used to set or clear a service second password.
You can enter any four-digit number as a service second password, using the 4 switches on the multi-function
display.
If you set a service second password, you will be prompted to enter the second password after you enter the ordinary
password necessary to display the SERVICE FUNCTION screen. You can move to the SERVICE FUNCTION
screen only when the passwords you entered coincide with the registered passwords.
No service second password has been set by default.
NOTICE
• Set the service second password only if it is necessary.
• When the service second password is missing, it is necessary to replace the multi-function display.
• The distributor or dealer must manage the service second password organizationally to avoid losing the
service second password and making the service functions unusable.
• Clear the service second password when the lift truck is out of your service such as lift truck resale.
4-184 4. DISPLAY
Operating Procedure
PASSWORD) to display the service function. After 5
seconds, the ANALYZER MENU screen is


3. Press switch (1) to check that “4. MASK
PASSWORD” is selected.
4. Press switch (4) to display the “MASK PASSWORD”
screen.
3. Press switch (1), to check that “2. MASK
PASSWORD” is selected.
4. Press switch (4) to display the “MASK PASSWORD”
screen.
4. DISPLAY 4-185
“MASK PASSWORD” Screen

Service second password set
1. When you enter a four-digit number, “SET” appears
in the lower left corner of the screen informing you that
you are ready to save it as a password.
2. Press and hold down switch (1) for more than 2
seconds to save the password. After the password has 4
been saved, “OK” appears.
NOTICE!
• A 4-digit number needs to be entered in order for
it to be accepted as a password.
• If you press and hold down switch (4) for more
than 2 seconds, the number you entered
becomes invalid and you return to the OTHERS
MENU screen.
Service second password clear

If you press and hold down 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.
NOTICE! : The service second password can be
cleared only when no digit has been entered (when
every box is [ ■ ]).
4-186 4. DISPLAY
ADMINISTRATOR'S SECOND PASSWORD CLEAR (MANAGER PASS CLR)

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



3. Press switch (1) to check that “5. MANAGER PASS
CLR” is selected.
4. Press switch (4) to display “MANAGER PASS CLR”
screen.
3. Press switch (1), to check that “3. MANAGER PASS
CLR” is selected.
4. Press switch (4) to display the “MANAGER PASS
CLR” screen.
4. DISPLAY 4-187
“MANAGER PASS CLR” Screen

Administrator's second password clear procedure
If you press and hold down switch (1) for more than 2
seconds, the administrator's second password is
deleted and “OK” appears on the completion of its
deletion.
Switch (1): Clears the password if pressed and held 4
down for more than 2 seconds.
Switch (4): Returns to OTHERS MENU screen
LCD CONTRAST ADJUSTMENT (CONTRAST)

This menu item is used to adjust the contrast of the multi-function LCD display.
Operating Procedure
1 Enter the password on the status screen (Refer

to PASSWORD) to display the service function
initial screen. After 5 seconds, the ANALYZER
MENU screen is automatically displayed.
4-188 4. DISPLAY


3. Press switch (1) to check that “6. CONTRAST” is
selected.
4. Press switch (4) to display the “CONTRAST”
screen.
3. Press switch (1), to check that “4. CONTRAST” is
selected.
4. Press switch (4) to display the “CONTRAST”
screen.
“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
Switch (4): Returns to OTHERS MENU screen
4. DISPLAY 4-189
4.4. MULTI-FUNCTION DISPLAY ASSY
a
3
a: T = 0.7 to 0.8 ft-lbf. [0.9 to 1.1 N·m]

Removal Procedure
1. Remove the battery plug.
2. Remove the instrument panel RH.
3. Remove the display from the instrument panel RH.
4-190 4. DISPLAY
2
a
a: T = 0.5 to 0.6 ft-lbf. [0.6 to 0.8 N·m]

1. Remove the rear cover.
2. Remove the circuit plate.
3. Remove the display ASSY.
4. Remove the switch plate.
4. DISPLAY 4-191
PIN CODE ENTRY SYSTEM (WITH 10 KEY PAD)

General
Only operators who have registered PINs (Personal Identification Number) can activate the lift truck with this
feature. This can help avoid use by uncertified persons.
This system has ten different lift truck settings called “PROFILE” and each PIN can be assigned to one profile.
Administrators can use this feature to limit various lift truck performances for safety management and to fit the lift
truck settings to each operator’s preferences. 4
Caution:This system is not an anti-theft system.
Key pad
Basic specifications
1. PIN for operators
A maximum of 100 PINs can be registered.
PINs consist of 4 to 8 digits. The system distinguishes “30588” as a different code than “030588”.
2. Initial PIN
The system has one non-erasable “initial PIN” for emergencies.
The default initial PIN is “99999999” and can be changed to any PIN with 8 digits.
It is not recommended to keep using the initial “99999999” PIN for security reasons. The administrator should
change it and manage the new number so it is not lost.
3. Profile
Administrators can register ten profiles (#0 to #9) to the lift truck settings.
Each registered PIN can be assigned to one profile out of ten profiles.
Items that can be set in each profile, and the difference from the models without this option are shown in the
following table.
No. Item Models with PIN Code Entry System Models without PIN Code Entry System
Each profile has the setting value respectively. A lift truck has only one setting value.
1 Low-speed setting Administrators can change this on the profile Operator can change this on the operator’s
settings menu. menu.
Maximum speed
2 Administrators can change this on the profile Administrators can change this on the
limiter
settings menu. administrator’s menu.
3 Overspeed alarm Administrators can change this on the profile Operator can change this on the operator’s
settings menu. menu.
A lift truck has a set of various tuning parameters.
Service technicians can change them on the A lift truck has a set of various tuning
4 Tuning masked menu. Each profile has certain tuning parameters. Service technicians can change
parameters respectively. Administrators can them on the masked menu.
change them on the profile settings menu,
The set of tuning items in the profiles is a subset of the lift truck tuning parameters in the masked menu. The lift
truck performance can be adjusted by this profile as well as the tuning parameters in the mask menu. The range of
4-192 4. DISPLAY
this tuning item in the profile is limited in a certain range on the basis of current setting value of the lift truck tuning
parameters as follows.
The tuning setting is determined based on the current setting of the lift truck tuning parameter. Even though the
tuning item isn’t changed, the lift truck performance will change when the lift truck tuning parameter is changed.
Tuning items in the profile and relations with their base lift truck tuning items are shown in the following table.
Based lift
Level (*: Default setting) truck tuning Remarks
Menu No. Item item
1 2 3 4 5 6 7 8
GENERAL
D-01 Acceleration torque Weak * Strong
No.7
Regenerative braking torque at GENERAL
DRIVE D-02 Weak * Strong
accelerator off No.9 All models
TUNE
Acceleration and regenerative GENERAL
D-03 Weak * Strong
braking torque at switch-back No.11, No.13
D-04 Do not use — * — —
Inching speed during lift down LIFT DOWN
LD-01 Slow * Fast
operation INCH
Acceleration and deceleration LIFT DOWN
LD-02 Week * Strong
LIFT speed during lift down operation ACC,DEC
LEVER Inching speed during lift up LIFT UP
LU-01 Slow * Fast
operation INCH
Acceleration and deceleration LIFT UP
LU-02 Week * Strong
speed during lift up operation ACC,DEC Fingertip
Inching speed during tilt forward TILT FWD control
TF-01 Slow * Fast models
operation INCH
only
Acceleration and deceleration
TILT FWD
TF-02 speed during tilt forward Week * Strong
ACC, DEC
TILT operation
LEVER Inching speed during tilt TILT BWD
TB-01 Slow * Fast
backward operation INCH
TILT BWD
TB-02 speed during tilt backward Week * Strong
ACC, DEC
operation
4. DISPLAY 4-193
Based lift
Level (*: Default setting) truck tuning Remarks
Menu No. Item item
1 2 3 4 5 6 7 8
Inching speed during the
ATT1 PUSH
PS-01 attachment (2) lever push Slow * Fast
INCH
operation
ATT1
ATT1 PUSH
4
PS-02 speed during the attachment (2) Week * Strong
LEVER ACC, DEC
ATT1 PULL
PL-01 attachment (2) lever pull Slow * Fast
INCH
operation
Fingertip
ATT2 PUSH control
PS-01 attachment (1) lever push Slow * Fast
INCH models
operation
only
ATT2 PUSH
PS-02 speed during the attachment (1) Week * Strong
ACC, DEC
ATT 2 lever push operation
LEVER Inching speed during the
ATT2 PULL
PL-01 attachment (1) lever pull Slow * Fast
INCH
operation
ATT2 PULL
PL-02 speed during the attachment (1) Week * Strong
ACC, DEC
System configuration
Key pad
4-194 4. DISPLAY
Name of each component
Key pad
Feature of each component

No. Name Feature
The key pad installed on the instrument panel is used to enter the PIN, log in,
1 Key pad
and log off.
The multi-function display judges if the entered PIN is certified by searching the
registered PINs in its memory.
When the entered PIN has been registered, the display sends the assigned
2 Multi-function display
profile number of the PIN to the main controller.
By using this display, administrators can register the PINS, delete them, assign
the profile number to each PIN, or set the lift truck settings of each profile.
The main controller manages “KEY-ON” of the lift truck according to the
“LOGIN/LOGOFF” input on the display.
3 Main controller
The controller loads the lift truck setting data of the instructed profile number,
and changes the behavior of the lift truck.
4. DISPLAY 4-195
Basic operations
1. Log in operation
The key pad’s red and green LEDS are off when the lift truck is not activated. The operator has to enter the
PIN and press the login switch to activate the lift truck. When any numeric key is pressed, the green LED will
light and the buzzer will sound briefly according to the key operation. This sound lets the operator know that
the input has been received.
This operation is available for models with and without the key switch, and when the key switch is ON or OFF.
4
Models without a key switch:
If the PIN entered is certified, the buzzer make two short beeps, the green LED lights, and the lift truck is
activated.
Red Green
Numerical switches
Logoff switch Login switch
When the lift truck is activated, the profile assigned by the PIN is loaded and the lift truck works to its settings.
If the entered PIN is not certified, the buzzer makes one short beep and one longer beep, and the system
returns to the log off state.
NOTICE:
• Pressing the logoff switch before completing the PIN input clears the entered numbers and returns to
the log off state.
• When the login switch is pressed with nine digits or more, the system never certifies the PIN.
• If there is no key input for over 10 seconds after the last input, the entered numbers are cleared and
the system returns to the log off state.
2. Log off operation
The operator can turn the lift truck OFF by pressing the logoff switch.
At that time, the system turns off the green LED, lights the red LED for one second, and the buzzer sounds
briefly.
Without any operations, when the timer “Auto Power Off” is out, the system returns to key-off state
automatically.
3. Protection from password attacks
The system has a protective function from password attacks.
This function works on the number of consecutive wrong PIN inputs as follows.
1 - 4: The buzzer sounds and the red LED lights for one second. New PIN input is prohibited during this period.
5 - 10: The buzzer sounds and the red LED lights for five seconds. New PIN input is prohibited during this
period.
11 - 20: The buzzer sounds and the red LED lights for one minute. New PIN input is prohibited during this
period.
After the counts have reached 20, the system goes into the lock mode.
The green and red LEDs blink simultaneously and the buzzer makes two long beeps for five seconds if an
operator enters any PIN in this mode.
Only the initial PIN input can be certified to reset this mode or disconnecting the battery.
4-196 4. DISPLAY
Before the system goes into the lock mode, the count of wrong PIN input will be cleared when a correct PIN is
entered.
NOTICE:
The counts for wrong PIN input does not increase if the logoff switch is pressed before completing the PIN
input.
4. Operation on factory setting
Only pressing the login switch can activate the lift truck with the factory setting.
The factory setting for efficient and easy log in until the lift truck is delivered to the customer.
The factory setting will be disabled once the “hour meter start” is activated when the lift truck is delivered to the
customer.
There are two preset PINs prepared for the inspection of the PIN Code Entry System. The operation of this
system can be inspected by using these two PINs on the factory setting as follows.
(1) Inspection of enabling the login
Entering “12345” or “67890” and pressing the login switch can activate the lift truck. These two PINs have
been registered as factory settings.
Both PINs enable the inspection of the numeric switch recognition as well as the operation of certification.
(2) Inspection of disabling the login
If the login switch is pressed after entering a PIN other than the above PINs and “99999999”, the lift truck
never activates even on this factory setting.
This lets you make sure that the disabling operation of the system is correct.
NOTICE:
The system cannot be returned to the factory setting once the “hour meter start” has been
activated.
4. DISPLAY 4-197
Setting functions
1. Introductions
Only the administrator can use the setting menu for “PIN Code Entry” in the multi-function display by entering
the administrator password after log in.
On models with PIN Code Entry System, the power control setting screen and the setting screen for drive
function are moved into the profile setting menu. The initial administrator’s screen differs as follows.
Initial administrator’s screen
4
with PIN Code Entry System
Switch (1) Switch (2) Switch (3) Switch (4)

The power control setting
screen and the setting screen
for drive function are moved
into the profile setting menu
when PIN Code Entry System
LPH is installed.
without PIN Code Entry System LPH
2. Registry of PINs for operators

The administrator can register a new PIN for operators on the “REGISTRY” menu.
This screen is displayed by selecting the “REGISTRY” menu by using switch (1) and switch (4) on the PIN
code entry menu.

The number of registered PINs
4-198 4. DISPLAY
The new PIN can be registered by continuing to press switch (1) “SET” for two seconds after entering the PIN.
On the PIN input screen, switch (2) can be used as a back space.
Select the profile number to be assigned to the PIN. It can be selected by using the key pad or by using switch
(2) and switch (3).
The system will finish assigning the profile number to the PIN by selecting switch (1) for two seconds.
Backspace key The number of registered PINs increase
Switch (1) Switch (2) Switch (3) Switch (4) Profile number
being assigned
After a new PIN registration has been completed, press switch (1). This adds the PIN and changes the screen
to the registry screen again.The administrator can continue to register PINs.
If switch (4) is pressed, the screen returns to the menu screen.
Return to menu screen

4. DISPLAY 4-199
3. Change of assigned profile

The administrator can change the assignment of the profile number to registered PINs on the PROFILE
CHANGE menu.
This screen is displayed by selecting PROFILE CHANGE on the PIN code entry menu screen.
Assigned profile

Registered PINs
The PIN to change the assignment of the Profile number can be selected by using switch (1). By entering the
PIN with the key pad directly, the administrator can narrow down the list of available PINs.
After selecting the PIN, go back to the profile assignment screen by pressing switch (4).
The profile number can be changed by using the key pad or by using switch (2) and (3).
4-200 4. DISPLAY
The system will complete assigning the profile number to the PIN by pressing switch (1), for two seconds.
Switch (1) Switch (2) Switch (3) Switch
The back space key can help correct
4. Delete PINs for operators

The administrator can delete any registered PIN for operators on the DELETE menu, except the initial PIN.
This screen is displayed by selecting the DELETE menu using switch (1)and switch (4) on the PIN code entry
menu.
(1) Deletion of a selected PIN
A PIN can be selected by using switch (1). The administrator can narrow down the candidates of PINs
and select the PIN to be deleted by directly entering the PIN on the key pad.
4. DISPLAY 4-201
The screen changes to the waiting screen by pressing switch (4).

The system will delete the selected PIN when switch (1), “CLR”, is pressed for two seconds.
The back space key can help correct PINs
(2) Deletion of all PINs

All PINs for operators, except the initial PIN, can be deleted at one time.
Select “ALL CLEAR” using switch (1). Select switch (4) changes the screen to the waiting screen to
delete all PINs.
The system will delete all PINs, except the initial PIN, when switch (1), “CLR”, is pressed for two seconds.
4-202 4. DISPLAY
5. Profile setting
The administrator can set various parameters of each profile on the “PROFILE SETTING” menu. This screen
is displayed by selecting “PROFILE SETTING” using switch (1) and switch (4) in the PIN code entry menu.
(1) Selecting a profile number to edit
Select a profile number to edit by using switch (2) and switch (3) in the “PROFILE SETTING” menu.
The screen changes to the profile edit menu screen by pressing switch (1).
The screen returns to the PIN code entry setting menu by selecting switch (4) before selecting switch (1).
4. DISPLAY 4-203
The load handling tab is only

displayed on fingertip control lever
models Screen for standard
lever models
LPH LPH
LPH LPH
Profile number to edit
(2) Power control setting

The Administrator can edit the power control setting of the selected profile number.
The power control setting menu is the initial screen after selecting the profile number to edit. Pressed
switch (2) and switch (3) to return to this menu from other menus.
NOTICE:
H mode cannot be selected in any of the following three power control settings when “H mode
lock” is set to “YES”.
Power mode:
The initial power mode after login can be set to L, P, H, and the original mode.
Select “POWER MODE” to display the menu by using switch (1) and switch (4).
Press switch (2) and switch (3) to change the power mode.
When the original mode is selected, L, P, and H are all highlighted.
Operators can change the power mode during the operation even through the initial power mode is
selected.
Administrators can prohibit operators from changing the power mode by suing the “menu-lock” menu.
display section of this manual for “menu-lock” instructions.
4-204 4. DISPLAY
When the “menu-lock” is activated, operators cannot change the power mode. Refer to the multi-function
LPH LPH
LPH
Drive power:
The drive power in the original mode can be set for five levels.
Select “DRIVE POWER” to display the menu by using switch (1) and switch (4).
Press switch (2) and switch (3) to change the drive power.
LPH
LPH
Lift power:
The lift power of the original mode can be set up from five levels
The screen is displayed by selecting the Menu, “LIFT POWER” by using switch (1) and switch (4).
Pressing switch (2) and switch (3) can change the lift power.
LPH
LPH
(3) Travel setting

The administrator can edit the travel setting for each selected profile number.
4. DISPLAY 4-205
The travel setting menu screen can be selected by using switch (2) and switch (3) after the profile number
is selected.
Low-speed setting:
The limit speed can be changed while the low-speed setting function is activated.
On models without the PIN Code Entry System, operators can also change this value on the operator’s
menu.
On models with the PIN Code Entry System, this is the only screen to change the low-speed setting. In
other words, only the administrator can change this setting. 4
Select “LOW SPEED” to display the menu by using switch (1) and switch (4).
Press switch (2) to decrease the limit speed and press switch (3) to increase it.
The adjustable range of this setting is from 2 to 30 mph by 1 mph (2 to 50 km/h by 1km/h).
Maximum speed limiter:

Use this setting to change the limit speed of the maximum speed limiter.
On both models, with and without PIN Code Entry System, only the administrator can set the settings.
Select “SPEED LIMIT” to display the menu by using switch (1) and switch (4).
Press switch (2) to decrease the limit speed, and press switch (3) to increase it.
The adjustable range of this setting if from 2 to 30 mph by 1 mph (2 to 50 km/h by 1km/h).
Overspeed alarm:
Use this setting to activate the overspeed alarm function.
On models without the PIN Code Entry System, operators can change this on the operator’s menu. On
models with the PIN Code Entry System, use this screen to change this setting. In other words, only an
administrator can change this setting.
Select “SPEED ALARM” to display the menu by using switch (1) and switch (4).
Press switch (2) to decrease the speed, and press switch (3) to increases it.
4-206 4. DISPLAY
The adjustable range of this setting if from 3 to 30 mph by 1 mph (5 to 50 km/h by 1km/h).
Tuning for drive function:

Four items for drive function can be tuned.
Select “DRIVE TUNE” to display menu by using switch (1) and switch (4).
In the “DRIVE TUNE” screen, the tuning item can be selected by pressing switch (1).
Press switch (2) to decrease the tuning value of the selected item, and press switch (3) to increase it.
(4) Load handling function setting (fingertip control models only)

The administrator can edit the setting of the load handling function for the selected profile number.
This setting screen can be selected by using switch (2) and switch (3) after the profile number is selected.
Lift lever tuning: Two items can be tuned for lowering and lift operations.
4. DISPLAY 4-207
Select “LIFT LEVER” to display the menu by using switch (1) and switch (4).
Select “NEXT” to display the lift-up screen by pressing switch (4).
The tuning item can be selected by pressing switch (1) in each screen.
Tilt lever tuning:

Two items can be tuned for both, tilt forward and tilt backward, operations.
Select “TILT LEVER” to display the menu by using switch (1) and switch (4).
Select “NEXT” to display the tilt backward operation by pressing switch (4).
Select the tuning item by pressing switch (1) in each screen.
4-208 4. DISPLAY
Attachment 1 lever tuning:

Two items can be tuned for both, attachment 1 push and attachment 1 pull, operations.
Select “ATT1 LEVER” to display the screen for attachment 1 push operation by using switch (1) and
switch (4).
Select “NEXT” to display the screen for attachment 1 pull operation by pressing switch (4).
Attachment 2 lever tuning:

Two items can be tuned for both, attachment 2 push and attachment 2 pull operations, on models with
four-way oil control valve.
Select “ATT2 LEVER” to display the screen for attachment 2 push operation by using switch (1) and
switch (4).
Select “NEXT” to display the screen for attachment 2 pull operation by pressing switch (4).
4. DISPLAY 4-209
6. Change of initial PIN

The administrator can change the non-erasable initial PIN.
Select “INITIAL PIN” to display the menu by using switch (1) and switch (4).
Using the key pad to enter a new PIN. Switch (2) can be used as a “Back Space”.
After 8 digits have been entered, “SET” is displayed above switch (1). Press switch (1) to “SET” the entered
PIN. The screen displays a reconfirmation message.
Press switch (1) for two seconds sets the new initial PIN. Press switch (4) to cancel the initial PIN change
before completing this set-up.
4-210 4. DISPLAY

Current initial PIN
the back space key

Change of initial PIN can be canceled by pressing
can help correct PINS
switch (4) before it has been completed.
7. Demo mode with key pad

Before the “hour meter start” has not been activated, all of the setting functions in the system have been
disabled.
Demo mode is recommended if a temporary demonstration of all of the functions of the PIN Code Entry
System is required. This mode can be set up in the masked-function on the multi-function display with key pad.
All of the registered PINs and profile data entered during “DEMO MODE” returns to inactive when the “hour
meter start” is activated. When the lift truck is take out of demo mode, all of the “H mode” settings in all of the
profiles will be overwritten to “P mode” because “H MODE LOCK” becomes effective automatically.
When “DEMO MODE” becomes activated again, all of the PINs and profile data will be resumed except for the
settings that were overwritten from H mode to P mode as stated previously.
5. TROUBLESHOOTING 5-211
5. TROUBLESHOOTING
5.1. BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
5.2. SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.3. DIAGNOSIS CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.4. WHEN ERROR CODE IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . 229
5.5. WHEN NO ERROR CODE IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . 706 5
5.1. BEFORE TROUBLESHOOTING
5.1.1. 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.
5-212 5. TROUBLESHOOTING
5.1.2. 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 Ω or less
NOTICE!
• Measure while lightly shaking the wire harness up
and down and sideways.
• Open circuit at the wire harness occurs rarely
partway through a lift truck wiring but mostly at
connectors. Inspect especially the sensor connec-
tors with sufficient care.
Short circuit check

2. Measure the resistance between the corresponding
connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or above
NOTICE! : Measure while lightly shaking the wire
harness up and down and sideways.
3. Measure the resistance between a terminal

corresponding to the connector terminal and N1.
Always inspect the connectors at both ends.
Standard: 1 MΩ or above
NOTICE! : The wiring may short-circuit due to pinching
by the body or defective clamping.
Visual and contact pressure checks

2. Visually inspect that there is neither rust nor foreign matter
trapped at connector terminals.
3. 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.
5
4. 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.
NOTICE! : Even if there is rust or foreign matter trapped at
the terminal, or the contact pressure between male and
female terminals is low, abnormal contact condition may
be changed to normal by disconnecting and reconnecting
the connector. In that case, repeat connector connection
and disconnection several times. If defect is perceived even
once, terminal contact may be defective.
5.2. SST
Use SSTs for quick, accurate troubleshooting of the 4460 series electrical system.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect connection,
careful operation is necessary.
SST No. SST name
979-001/160 (SST) Shorting harness
(for CN91 connector)
979-001/161 (SST2) Shorting harness
(for CN6, CN19, CN26,CN52,CN53,CN54, CN55, CN56, CN86, CN97,
CN101, CN102, CN115, CN119, CN120, CN121, CN122,CN123,
CN126, CN129, CN130, CN138 and CN163 connectors)
CAUTION
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
connected, various boards may be damaged.
5.3. DIAGNOSIS CODE LIST
Indication: Diagnosis code will be indicated on the display when lift truck error occurs.
Memory: Use this indicated diagnosis code that can be checked on the display when using the service
function DIAG MEMORY.
Indicator:
Spanner
Overheat warning (O/H)
Detection
Indication Memory Indicator Error mode Symptom Page
ECU
Drive motor Drive motor driver
O/H
DCR A001 driver (LH) power-circuit Travel stops. 230
lighting
(RH) abnormality
Pump motor driver Load handling stops.
O/H Pump motor
PCR A002 power-circuit Steering becomes 235
lighting driver
abnormality stiff.
Load handling and
Spanner Main Main controller high
A101 A101 travel stops. Steering 239
blinking controller voltage
becomes stiff.
Spanner Drive motor Drive motor driver LH Travel speed
A102 A102 241
blinking driver (LH) high voltage becomes slow.
Spanner Drive motor Drive motor driver Travel speed
A103 A103 243
blinking driver (RH) RH high voltage becomes slow.
Load handling stops.
Spanner Pump motor Pump motor driver
A104 A104 Steering becomes 245
blinking driver high voltage
stiff.
Main controller
O/H Main Travel speed
C/R A201 overheating 247
lighting controller becomes slow.
abnormality
Drive motor driver
Drive motor circuit board / the
O/H
DCR A202 driver (LH) condenser Travel stops 249
lighting
(RH) overheating
abnormality.
Pump motor driver
circuit board / the Load handling stops.
O/H Pump motor
PCR A203 condenser Steering becomes 254
lighting driver
overheating stiff.
abnormality
Load handling and
Spanner Main Battery connection
blinking controller incorrect
becomes stiff.
Spanner Main Seat switch short
A501 A501 OPS function invalid. 260
blinking controller abnormality
Spanner Main Tilt lever switch short
A603 A603 Tilt stops. 262
Detection
ECU
Load handling and
Spanner Main F1 fuse open
becomes stiff.
Load handling and
Spanner Main F6 fuse open
becomes stiff.
F7 fuse / solenoid
A902 A902
Spanner Main
power supply line
Material handling
270
5
blinking controller disabled.
open abnormality
Main controller
Spanner Main temperature sensor Travel speed
AA01 AA01 272
blinking controller (open/short) becomes slow.
abnormality
Reduced maximum
Spanner Drive motor board temperature
AA02 AA02 speed. Acceleration 273
blinking driver (LH) sensor (open/short)
slows.
abnormality
Drive motor driver
RH board Reduced maximum
Spanner Drive motor
AA03 AA03 temperature sensor speed. Acceleration 274
blinking driver (RH)
(open/short) slows.
abnormality
Pump motor driver
Spanner Pump motor board temperature
AA04 AA04 Lift speed is limited. 275
blinking driver sensor (open/short)
abnormality
Spanner Main Cooling fan Travel speed
AB01 AB01 276
blinking controller overcurrent becomes slow.
Load handling and
Spanner Main Motor driver power
AC01 AC01 travel stops. Steering 279
blinking controller delivery abnormality
becomes stiff.
Drive motor driver LH Travel speed
Spanner Main to Main controller: becomes slow.
AD01 AD01 282
blinking controller communication Knob position
abnormality synchronizer stops.
Drive motor driver LH Travel speed
Spanner Main to Main controller: becomes slow.
AD02 AD02 283
blinking controller communication Knob position
Drive motor driver Travel speed
RH to Main becomes slow.
Spanner Main
AD03 AD03 controller: 293
blinking controller Knob position
communication
Drive motor driver Travel speed
RH to Main becomes slow.
Spanner Main
AD04 AD04 controller: 294
blinking controller Knob position
communication
Detection
ECU
Pump motor driver to
Spanner Main Main controller:
AD05 AD05 Steering becomes 298
blinking controller communication
stiff.
abnormality
Pump motor driver to
Spanner Main Main controller:
AD06 AD06 Steering becomes 299
blinking controller communication
stiff.
abnormality
Load handling and
Spanner Main Main controller CPU
AF01 AF01 travel stops. Steering 303
blinking controller error
becomes stiff.
Load handling and
becomes stiff.
Load handling and
becomes stiff.
Load handling and
becomes stiff.
Spanner Main Main controller CPU Various control
AF05 AF05 307
blinking controller error operations not stable.
AF06 AF06 308
AF07 AF07 309
AF08 AF08 310
Spanner Drive motor Travel speed
C002 C002 power-circuit 311
blinking driver (LH) becomes slow.
abnormality
Drive motor driver
C004 C004 RH power-circuit 314
blinking driver (RH) becomes slow.
abnormality
C101 C101 current sensor 317
neutral voltage error
C102 C102 current sensor over 318
current abnormality
Drive motor driver
C103 C103 RH current sensor 321
neutral voltage error
Drive motor driver
Spanner Drive motor RH current sensor Travel speed
C104 C104 322
blinking driver (RH) over current becomes slow.
abnormality
Drive motor Drive motor Reduced maximum
O/H
DM C201 driver (LH) overheating speed. Acceleration 325
lighting
(RH) abnormality slows.
Detection
ECU
Drive motor LH
Reduced maximum
Spanner Drive motor temperature sensor
C202 C202 speed. Acceleration 327
blinking driver (LH) (open/short)
slows.
abnormality
Drive motor RH
Reduced maximum
Spanner Drive motor temperature sensor
C203 C203 speed. Acceleration 329
blinking driver (RH) (open/short)
slows. 5
abnormality
power-circuit Reduced maximum
Spanner Drive motor
C301 C301 temperature sensor speed. Acceleration 331
blinking driver (LH)
(open/short) slows.
abnormality
Drive motor driver
RH power-circuit Reduced maximum
Spanner Drive motor
C302 C302 temperature sensor speed. Acceleration 332
(open/short) slows.
abnormality
Accelerator Displays error code,
Spanner Main
C401 C401 potentiometer POT1 but able to operate 333
blinking controller
open abnormality correctly.
Accelerator Displays error code,
Spanner Main
C402 C402 potentiometer POT2 but able to operate 336
blinking controller
open abnormality correctly.
Accelerator
Displays error code,
Spanner Main potentiometer
C403 C403 but able to operate 339
blinking controller POT1VCC short
correctly.
circuit abnormality
Accelerator
C404 C404 but able to operate 342
blinking controller POT2VCC short
correctly.
circuit abnormality
Accelerator
Spanner Main
C405 C405 potentiometer offset Travel stops. 345
blinking controller
abnormality
Accelerator
Spanner Main potentiometer Accelerator play
C406 C406 348
blinking controller matching value increases and
abnormality
Brake potentiometer Displays error code,
Spanner Main
C501 C501 POT1 open but able to operate 350
blinking controller
abnormality correctly.
Spanner Main
C502 C502 POT2 open but able to operate 353
blinking controller
Spanner Main
C503 C503 POT1VCC short but able to operate 356
blinking controller
circuit abnormality correctly.
Detection
ECU
Spanner Main
C504 C504 POT2VCC short but able to operate 359
blinking controller
circuit abnormality correctly.
Brake potentiometer Reduced maximum
Spanner Main
C505 C505 matching value speed. Acceleration 362
blinking controller
abnormality slows.
Spanner Main Brake potentiometer
C506 C506 Travel stops. 365
blinking controller matching value error.
Drive motor LH
C801 C801 rotation sensor open 367
abnormality
Drive motor LH
C802 C802 rotation sensor short 371
abnormality
Drive motor RH
C803 C803 rotation sensor open 375
abnormality
Drive motor RH
C804 C804 rotation sensor short 379
abnormality
Load handling and
Spanner Main MB contactor open
CB01 CB01 travel stops. Steering 383
becomes stiff.
Spanner Main MB contactor short
CB02 CB02 but able to operate 387
correctly.
MB contactor (coil Load handling and
Spanner Main
CB03 CB03 side) open travel stops. Steering 389
blinking controller
abnormality becomes stiff.
MB contactor Load handling and
Spanner Main
CB04 CB04 traveling circuit travel stops. Steering 392
blinking controller
MB contactor (coil Load handling and
Spanner Main
CB05 CB05 side) short travel stops. Steering 394
blinking controller
CC01 CC01 397
blinking driver (LH) CPU abnormality becomes slow.
CC02 CC02 398
CC03 CC03 399
CC04 CC04 400
Spanner Drive motor Drive motor driver LH
CC06 CC06 but able to operate 401
blinking driver (LH) CPU abnormality
correctly.
CD01 CD01 402
blinking driver (RH) RH CPU abnormality becomes slow.
Detection
ECU
CD02 CD02 403
CD03 CD03 404
CD04 CD04 405
Displays error code, 5
Spanner Drive motor Drive motor driver
CD06 CD06 but able to operate 406
blinking driver (RH) RH CPU abnormality
correctly.
Spanner Pump motor
E002 E002 power-circuit Steering becomes 407
blinking driver
abnormality stiff.
Spanner Pump motor
E101 E101 current sensor Steering becomes 410
blinking driver
neutral voltage error stiff.
Spanner Pump motor
E102 E102 current sensor over Steering becomes 411
blinking driver
current error stiff.
Pump motor
O/H Pump motor
PM E201 overheating Lift speed is limited. 414
lighting driver
abnormality
Pump motor
Spanner Pump motor temperature sensor
E202 E202 Lift speed is limited. 418
blinking driver (open/short)
abnormality
Pump motor driver
power-circuit
Spanner Pump motor
E301 E301 temperature sensor Lift speed is limited. 420
blinking driver
(open/short)
abnormality
Pump motor rotation Load handling stops.
Spanner Pump motor
E801 E801 sensor open Steering becomes 421
blinking driver
abnormality stiff.
Pump motor rotation Load handling stops.
Spanner Pump motor
E802 E802 sensor short Steering becomes 424
blinking driver
abnormality stiff.
EC01 EC01 Steering becomes 427
blinking driver CPU abnormality
stiff.
stiff.
stiff.
stiff.
Detection
ECU
EC06 EC06 but able to operate 431
correctly.
Communication line Displays error code.
Spanner Main
EE01 EE01 abnormality: Display The function is 432
blinking controller
to main controller partially disabled.
Spanner Main
EE02 EE02 abnormality: Display The function is 433
blinking controller
to main controller partially disabled.
Spanner abnormality between
F101 F101 Display The function is 434
blinking main controller and
display partially disabled.
Spanner abnormality between
F102 F102 Display The function is 435
blinking main controller and
display partially disabled.
Travel and load
handling cannot be
Spanner performed
F401 F401 Display Display CPU defect 438
blinking simultaneously. Does
not recognize PIN
code entry.
Travel and load
handling cannot be
Spanner performed
not recognize PIN
code entry.
Travel and load
handling cannot be
Spanner performed
not recognize PIN
code entry.
Spanner
F404 F404 Display Display CPU defect Display only. 441
blinking
Spanner Display function not
blinking stable.
Spanner Various control
blinking operations not stable.
Power meter function
Battery current
Spanner Main disabled. Battery
FB01 FB01 sensor neutral 446
blinking controller state of charge
voltage error
increasing incorrectly.
Detection
ECU
Power meter function
Spanner Main Battery current disabled. Battery
FB02 FB02 449
blinking controller sensor overcurrent state of charge
increasing incorrectly.
Power supply circuit
Spanner Main
FF01 FF01 for display over Display turns off. 452
blinking controller
current
Steering sensor Steering becomes
5
Spanner Main
FF02 FF02 power-supply circuit stiff. Knob position 453
blinking controller
over current synchronizer stops.
Drive motor driver Displays error code,
Spanner Drive motor
3201 3201 (LH): controller ID but able to operate 455
blinking driver (LH)
Drive motor driver Displays error code,
Spanner Drive motor
3202 3202 (RH): controller ID but able to operate 456
Pump motor driver: Displays error code,
Spanner Pump motor
3203 3203 controller ID but able to operate 457
blinking driver
Main controller to
3301 3301 458
blinking driver (LH) (LH): communication becomes slow.
abnormality
Main controller to
3302 3302 461
blinking driver (RH) (RH): communication becomes slow.
abnormality
Main controller to
Spanner Pump motor Pump motor driver:
3303 3303 Steering becomes 464
blinking driver communication
stiff.
abnormality
Partial limitation of
mast control function.
Spanner Main Load sensor open travel control function.
6101 6101 467
blinking controller abnormality Partial limitation of
height and load
sensing swing speed
control function.
Spanner Main Load sensor short travel control function.
6102 6102 470
blinking controller abnormality Partial limitation of
height and load
sensing swing speed
control function.
Spanner Main Tilt angle sensor Partial limitation of
6201 6201 472
blinking controller open abnormality mast control function.
Spanner Main Tilt angle sensor Partial limitation of
6202 6202 474
blinking controller short abnormality mast control function.
Detection
ECU
Tilt switch forward /
Spanner Main backward tilt switch Partial limitation of
6301 6301 476
blinking controller simultaneously short mast control function.
abnormality
Tilt switch forward tilt
Spanner Main Partial limitation of
6302 6302 switch continuously 478
blinking controller mast control function.
short abnormality
Tilt switch backward
Spanner Main tilt switch Partial limitation of
6303 6303 479
blinking controller continuously short mast control function.
abnormality
Spanner Main Lift lock solenoid
6401 6401 Lift lowering stops. 480
blinking controller open abnormality
Spanner Main Lift lock solenoid
6402 6402 Lift lowering stops. 483
blinking controller short abnormality
Lift lock solenoid Lift lowering may
Spanner Main
6403 6403 drive circuit operate while OPS is 486
blinking controller
abnormality operating.
Lift lock solenoid Lift lowering may
Spanner Main
6404 6404 (open / short) operate while OPS is 489
blinking controller
Spanner Main Tilt solenoid open
6501 6501 Forward tilt stops. 493
Spanner Main Tilt solenoid short
6502 6502 Forward tilt stops. 496
Tilt solenoid: Tilt forward may
Spanner Main
6503 6503 traveling circuit operate while OPS is 499
blinking controller
Tilt forward may
Spanner Main Tilt solenoid (open /
6504 6504 operate while OPS is 502
blinking controller short) abnormality
operating.
Outside matching
Spanner Main Partial limitation of
6601 6601 value range for tilt 506
blinking controller mast control function.
angle error
Lifting height switch
Spanner Main travel control function.
6701 6701 open / short 508
blinking controller Partial limitation of
abnormality
height and load
sensing swing speed
control function.
Backward lock
Spanner Main
6901 6901 solenoid open Backward tilt stops. 513
blinking controller
abnormality
Backward lock
Spanner Main
6902 6902 solenoid short Backward tilt stops. 516
blinking controller
abnormality
Detection
ECU
Backward lock Tilt backward may
Spanner Main
6903 6903 solenoid drive circuit operate while OPS is 519
blinking controller
Backward lock Tilt backward may
Spanner Main
6904 6904 solenoid (open / operate while OPS is 522
blinking controller
short) abnormality operating.
Travel speed
Spanner Main Tire angle sensor becomes slow. Knob
5
7101 7101 526
blinking controller open abnormality position synchronizer
stops.
Travel speed
Spanner Main Tire angle sensor becomes slow. Knob
7102 7102 528
blinking controller short abnormality position synchronizer
stops.
Tire angle sensor
Spanner Main Knob position
7103 7103 anchoring 530
blinking controller synchronizer stops.
abnormality
Knob position
Tire angle sensor synchronizer stops.
Spanner Main
7201 7201 anchoring 533
blinking controller Steering becomes a
abnormality
little stiff.
Knob position
Steering-wheel angle
Spanner Main synchronizer stops.
7202 7202 sensor SS2 open 537
blinking controller Steering becomes a
abnormality
little stiff.
Steering-wheel angle
7203 7203 sensor SSC open 541
abnormality
Steering-wheel angle Knob position
Spanner Main sensor: sensor synchronizer stops.
7204 7204 544
blinking controller power source open Steering becomes a
abnormality little stiff.
Steering knob
Spanner Main position synchronizer Knob position
7301 7301 547
blinking controller solenoid open synchronizer stops.
abnormality
Steering knob
7302 7302 550
blinking controller solenoid short synchronizer stops.
abnormality
Steering knob
position synchronizer
7303 7303 solenoid 553
power-circuit
abnormality
Steering knob
7304 7304 556
blinking controller solenoid (open / synchronizer stops.
short) abnormality
Detection
ECU
Travel speed
Tire angle matching:
Spanner Main becomes slow. Knob
7401 7401 matching value 560
blinking controller position synchronizer
abnormality
stops.
Lift lever
Spanner Main Lifting and lowering
H101 H101 potentiometer open 562
blinking controller stops.
abnormality
Lift lever
H102 H102 potentiometer short 565
abnormality
Lift lever
potentiometer:
H103 H103 sensor output 567
declination
abnormality
Lift lever
Spanner Main potentiometer neutral Lifting and lowering
H104 H104 570
blinking controller abnormality stops.
CAUTION
Lift lever
Spanner Main potentiometer Lifting and lowering
H105 H105 572
blinking controller matching value stops.
abnormality
Tilt lever
Spanner Main Forward and
H201 H201 potentiometer open 574
blinking controller backward tilt stops.
abnormality
Tilt lever
H202 H202 potentiometer short 576
abnormality
Tilt lever
potentiometer:
H203 H203 sensor output 578
declination
abnormality
Tilt lever
Spanner Main Material handling
H204 H204 potentiometer neutral 581
error abnormality
Tilt lever
Spanner Main potentiometer Forward and
H205 H205 583
blinking controller matching value backward tilt stops.
abnormality
Attachment 1 lever
Spanner Main
H301 H301 potentiometer open Attachment 1 stops. 585
blinking controller
abnormality
Attachment 1 lever
Spanner Main
H302 H302 potentiometer short Attachment 1 stops. 587
blinking controller
abnormality
Detection
ECU
Attachment 1 lever
potentiometer:
Spanner Main
H303 H303 sensor output Attachment 1 stops. 589
blinking controller
declination
abnormality
Attachment 1 lever
blinking controller disabled. 5
abnormality
Attachment 1 lever
H305 H305 Attachment 1 stops. 594
blinking controller matching value
abnormality
Attachment 2 lever
Spanner Main
H401 H401 potentiometer open Attachment 2 stops. 596
blinking controller
abnormality
Attachment 2 lever
Spanner Main
H402 H402 potentiometer short Attachment 2 stops. 598
blinking controller
abnormality
Attachment 2 lever
potentiometer:
Spanner Main
H403 H403 sensor output Attachment 2 stops. 600
blinking controller
declination
abnormality
Attachment 2 lever
abnormality
Attachment 2 lever
H405 H405 Attachment 2 stops. 605
blinking controller matching value
abnormality
Lift proportional valve
Spanner Main solenoid open
H501 H501 Lift stops. 607
blinking controller abnormality (lever
pull side)
Spanner Main solenoid short
H502 H502 Lift stops. 610
pull side)
H503 H503 Lowering stops. 613
push side)
H504 H504 Lowering stops. 616
push side)
H505 H505 solenoid drive circuit 619
abnormality
Detection
ECU
H506 H506 solenoid (open / 622
short) abnormality
Tilt proportional valve
H601 H601 Backward tilt stops. 626
pull side)
H602 H602 Backward tilt stops. 629
pull side)
H603 H603 Forward tilt stops. 632
push side)
H604 H604 Forward tilt stops. 635
push side)
H605 H605 solenoid drive circuit 638
abnormality
H606 H606 solenoid (open / 641
short) abnormality
Attachment 1
proportional valve
Spanner Main
H701 H701 solenoid open Attachment 1 stops. 645
blinking controller
abnormality (lever
pull side)
Attachment 1
proportional valve
Spanner Main
H702 H702 solenoid short Attachment 1 stops. 648
blinking controller
abnormality (lever
pull side)
Attachment 1
proportional valve
Spanner Main
blinking controller
abnormality (lever
push side)
Attachment 1
proportional valve
Spanner Main
blinking controller
abnormality (lever
push side)
Attachment 1
Spanner Main proportional valve Material handling
H705 H705 657
blinking controller solenoid: traveling disabled.
circuit abnormality
Detection
ECU
Attachment 1
H706 H706 660
blinking controller solenoid (open / disabled.
short) abnormality
Attachment 2
proportional valve
Spanner Main
blinking controller 5
abnormality (lever
pull side)
Attachment 2
proportional valve
Spanner Main
blinking controller
abnormality (lever
pull side)
Attachment 2
proportional valve
Spanner Main
blinking controller
abnormality (lever
push side)
Attachment 2
proportional valve
Spanner Main
blinking controller
abnormality (lever
push side)
Attachment 2
H805 H805 676
blinking controller solenoid: traveling disabled.
circuit abnormality
Attachment 2
H806 H806 679
blinking controller solenoid (open / disabled.
short) abnormality
Proportional valve
Spanner Main solenoid power Material handling
HB01 HB01 683
blinking controller supply: RY1 contact disabled.
open abnormality
HB02 HB02 solenoid load-short 686
abnormality
Proportional valve
Spanner Main solenoid power Material handling
HB03 HB03 689
blinking controller supply: RY1 over disabled.
current abnormality
Lift or tilt backwards
Spanner Main Unload solenoid
HC01 HC01 may operate while 691
blinking controller open abnormality
OPS is operating.
Lift or tilt backwards
Spanner Main Unload solenoid
HC02 HC02 may operate while 694
blinking controller short abnormality
OPS is operating.
Detection
ECU
Unload solenoid Load operations other
Spanner Main
HC03 HC03 drive circuit than lower may not 697
blinking controller
abnormality operate.
Unload solenoid Lift or tilt backwards
Spanner Main
HC04 HC04 (open / short) may operate while 700
blinking controller
abnormality OPS is operating.
Drive motor Reduced maximum
COLD O/H Drive motor driver
- driver (LH) speed. Acceleration 704
DCR lighting * low temperature
(RH) slows.
Reduced maximum
COLD O/H Pump motor Pump motor driver
- speed. Acceleration 705
PCR lighting * driver low temperature
slows.
* The Multi-function display shows only each portion and does not indicate O/H light.
5.4. WHEN ERROR CODE IS DISPLAYED
5
Error Code: A001

Failure mode: Drive motor driver power-circuit abnormality
CAUTION
• If AB01 occurs at the same time, perform troubleshooting for AB01 first.
• Disconnect the battery plug and check if the power cable or motor cables are loose.
• Do not leave the lift truck standing in a hot place.
Probable cause
• The power cable or a motor cable is loose
• Connector contact defect
• Harness defect
• Cooling fan clogging
• Cooling fan defect
• Overheating (continuous overload operation)
• Drive motor driver LH defect
• Drive motor driver RH defect
• Main controller defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller CN250-27 CN250-28
F52
CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Drive motor driver LH Drive motor driver RH
Temperature sensor Temperature sensor
STEP1
Apply the cooling fan by using Active Test, and check the rotary
condition.
[ANL] ACTIVE TEST 2/3
FAN1: OFF → ON
Judgment
Result Procedure
Not running Go to step 5
Running Go to step 2
STEP2
Inspection:
Reconfirm the error.
Turn the key switch ON and check that the error occurs.
Judgment
Result Procedure
“DCR” occurs. Go to step 3 5
“DCR” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “DCR”
goes away and the lift truck can be operated as usual.
Continuously running the lift truck in an overloaded
condition will cause this error. Limit running the lift truck in
an overloaded condition.
STEP3
Inspection:
Check the temperature and reconfirm the error.
Drive motor driver power-circuit temperature LH/RH
[ANL] I/O TEMP/VOLT 1/6 TDMDH
Record the temperature of the drive motor driver power-circuit.
Turn off the key switch and leave the lift truck for approximately
fifteen minutes. Then turn the key switch ON and check that the
error occurs.
Judgment
Result Procedure
“DCR” occurs. Go to step 4
STEP4
Inspection:
Reconfirm the temperature
Drive motor driver power-circuit temperature LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDMDH
Check the drive motor driver power-circuit temperature and

compare it to the recorded value.
Judgment
Result Procedure
All temperatures have lowered by 41°F Go to step 3
(5°C) or more.
Drive motor power-circuit board Drive motor driver LH defect
temperature LH has not lowered by 41°F
(5°C) or more.
Drive motor power-circuit board Drive motor driver RH defect
temperature RH has not lowered by 41°F
(5°C) or more.
STEP5
Turn off the key switch and disconnect the battery plug.
Check the inside of connector CN112, 113 and the crimped
portion of the wire to see whether it has a defect or not by visual
confirmation. Refer to BEFORE TROUBLESHOOTING.
After connecting the connector, connect the battery plug and turn
the key switch ON. Then apply the cooling fan by using Active
Test, and check the rotary condition.
FAN1: OFF → ON
Judgment
Result Procedure
Running Connector contact defect
STEP6
Inspection: Harness
Disconnect the CN102, CN104, CN112 and CN113 connectors
and check the harnesses.
[Inspection procedure and standard]

CN102 Inspect for continuity and short circuiting of the
harness.
1 2 3 4 5 6 7 CN112 Perform this check with the battery plug and the
8 9 10 11 12 13 14 15 16 17 18 19 CN102, CN104, CN112 and CN113 connectors
20 21 22 23 24 25 26 27 1 2 disconnected, and visually check inside the connector
28 29 30 31 32 33 34 35 and the crimped portion of its wire for defects.
Refer to BEFORE TROUBLESHOOTING. 5
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Portion to be inspected Standard:

CN102-1 to CN112-2 Continuity
CN102-1 to CN104-3 No continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7
Inspection: Cooling fan

Disconnect the battery plug, then connect the CN102, CN104,
CN112 and CN113 connectors. Reconnect the battery plug and
turn the key switch ON.
condition.
FAN1: OFF → ON
Judgment
Result Procedure
Result Procedure
Not running Cooling fan defect
After replacing the cooling fan, if the fan is not running by
applying the cooling fan by using Active Test, it is possible
there is another defect. Replace the main controller.
Error Code: A002

Failure mode: Pump motor driver power-circuit abnormality
CAUTION
5
Probable cause
• Harness defect
• Pump motor driver defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
F52
CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Pump motor driver
Temperature sensor
STEP1
condition.
FAN1: OFF → ON
Judgment
Result Procedure
STEP2
Inspection:
Reconfirm the error
Turn the key switch ON and check that the error occurs.
Judgment
Result Procedure
“PCR” occurs. Go to step 3
“PCR” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “PCR”
STEP3
Inspection:
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Record the temperature of the pump motor driver power-circuit.
fifteen minutes. Then turn on the key switch and check that the
error occurs.
Judgment
Result Procedure
STEP4
Inspection:
Reconfirm the temperature
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Check the pump motor driver power-circuit temperature and
compare to the recorded value.
Judgment
Result Procedure
It has lowered by 41°F (5°C) or more. Go to step 3
Result Procedure
It has not lowered by 41°F (5°C) or more. Pump motor driver defect
STEP5
Check the inside of connector CN112,113 and the crimped portion
of the wire whether it has a defect or not by visual confirmation.
Refer to BEFORE TROUBLESHOOTING.
5
on the key switch. Then apply the cooling fan by using Active Test,
and check the rotary condition.
FAN1: OFF → ON
Judgment
Result Procedure
STEP6
Inspection: Harness

harness.
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Measurement terminals Standard:

Measurement terminals Standard:

Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7

turn on the key switch.
condition.
FAN1: OFF → ON
Judgment
Result Procedure
After replacing the cooling fan, if the fan is not running by
applying the cooling fan by using Active Test, it is possible
there is another defect. Replace the main controller.
Error Code: A101

Failure mode: Main controller high voltage
CAUTION
• If CB01,CB03 or CB05 occurs at same time as A101, perform troubleshooting for CB01,CB03 or CB05
first.
5
Probable cause
• Battery defect
• Out of battery electrolyte
• Battery plug defect
• Battery overvoltage
• The battery plug was disconnected during traveling / load handling
Related portion
MB
P2 P3 CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
Main
controller
N1
STEP1
Turn off the key switch and disconnect the battery plug, then leave
for 2 minutes.
Reconnect the battery plug and turn on the key switch to confirm
the error.
Judgment
Result Procedure
A101 error occurs. Go to step 3
A301 error occurs. Perform troubleshooting for A301.
A101, A301 error does not occur. Go to step 2
STEP2
Check if the battery plug was disconnected during traveling or load

handling.
Judgment
Result Procedure
YES Do not disconnect the battery plug during traveling or load
handling.
NO Check the battery.
STEP3
Inspection: Battery voltage check

1. Turn the key switch OFF and disconnect the battery plug.
2. Measure the voltage between both ends of the battery plug with
a circuit tester.
Judgment
Result Procedure
64V or more Check the battery.
Less than 64V Main controller defect.
Error Code: A102

Failure mode: Drive motor driver LH high voltage
CAUTION
• If CB01, CB03, or CB05 occurs at same time as A102, perform troubleshooting for CB01, CB03, or CB05
first.
5
Probable cause
• Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver LH
STEP1
for 2 minutes.
the error.
Judgment
Result Procedure
STEP2

handling.
Judgment
Result Procedure
handling.
STEP3

a circuit tester.
Judgment
Result Procedure
Less than 64V Drive motor driver LH defect.
Error Code: A103

Failure mode: Drive motor driver RH high voltage
CAUTION
first.
5
Probable cause
• Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver RH
STEP1
for 2 minutes.
the error.
Judgment
Result Procedure
STEP2

handling.
Judgment
Result Procedure
handling.
STEP3

a circuit tester.
Judgment
Result Procedure
Less than 64V Drive motor driver RH defect.
Error Code: A104

Failure mode: Pump motor driver high voltage
CAUTION
first.
5
Probable cause
• Battery defect
Related portion
MB
P1 F1 P4
Pump motor
driver
STEP1
for 2 minutes.
the error.
Judgment
Result Procedure
STEP2

handling.
Judgment
Result Procedure
handling.
STEP3

a circuit tester.
Judgment
Result Procedure
Less than 64V Pump motor driver defect.
Error Code: A201

Failure mode: Main controller overheating abnormality
CAUTION
Probable cause 5
• Temperature sensor defect (Main controller defect)
Related portion
Main controller
Temperature sensor
STEP1
Inspection:
Turn on the key switch and check that error occurs.
Judgment
Result Procedure
“C/R” occurs. Go to step 2
“C/R” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “C/R”
goes away and the truck can be operated as usual.
STEP2
Inspection:
Check the main controller board temperature and reconfirm the
error.
[ANL] I/O TEMP/VOLT 4/6 TMCB
Record the main controller board temperature.
Turn off the key switch and leave the truck for approximately thirty
minutes. Then turn on the key switch and check that error occurs.
Judgment
Result Procedure
“C/R” occurs. Go to step 3
“C/R” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “C/R”
STEP3
Inspection:
Reconfirm the main controller board temperature.
[ANL] I/O TEMP/VOLT 4/6 TMCB
Check the main controller board temperature and compare it to
the recorded value.
Judgment
Result Procedure
It has not lowered by 41°F (5°C) or more. Temperature sensor defect (Main controller defect).
Error Code: A202

Failure mode: Drive motor driver circuit board / the condenser overheating abnormality.
CAUTION
5
Probable cause
• Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
F52
CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Drive motor driver LH Drive motor driver RH
Temperature sensor Temperature sensor Temperature sensor Temperature sensor

(Circuit board) (Condenser) (Circuit board) (Condenser)
STEP1
condition.
FAN1: OFF → ON
Judgment
Result Procedure
STEP2
Inspection:
Turn on the key switch and check that error occurs.
Judgment
Result Procedure
STEP3
Inspection:
?Drive motor driver circuit board temperature LH/RH
?Drive motor driver condenser temperature LH/RH
[ANL] I/O TEMP/VOLT 2/6
TDMDB: TDMDC
Record the temperature of the drive motor driver circuit board and
drive motor driver condenser.
Turn off the key switch and leave the truck for approximately thirty
minutes. Then turn on the key switch and check that error occurs.
Judgment
Result Procedure
STEP4
Inspection:
Reconfirm the temperature.
?Drive motor driver circuit board temperature LH/RH
?Drive motor driver condenser temperature LH/RH
TDMDB: TDMDC
Check the temperature of the drive motor driver circuit board and
drive motor driver condenser. Then compare to the recorded
value.
Judgment
Result Procedure
(5°C) or more.
Either drive motor driver circuit board Drive motor driver LH defect.
temperature, (drive motor driver)
5
condenser LH or both have lowered by
41°F (5°C) or more.
Either drive motor driver circuit board Drive motor driver RH defect.
temperature, (drive motor driver)
condenser RH or both have lowered by
41°F (5°C) or more.
STEP5
Check the inside of connector CN112,113 and the crimped portion
of the wire to see whether it has a defect or not by visual
FAN1: OFF → ON
Judgment
Result Procedure
Running Connector contact defect.
STEP6
Inspection: Harness

harness.
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7

condition.
FAN1: OFF → ON
Judgment
Result Procedure
Result Procedure
Not running Cooling fan defect.
If after replacing the cooling fan it does not run when using
Active Test, it is possible there is another defect. Replace the
main controller.
5
Error Code: A203

Failure mode: Pump motor driver circuit board / the condenser overheating abnormality.
CAUTION
Probable cause
• Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
F52
CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Pump motor driver
Temperature sensor Temperature sensor

(Circuit board) (Condenser)
STEP1
condition.
FAN1: OFF → ON
Judgment
Result Procedure
STEP2
Inspection:
Turn on the key switch and check the error occurs.
Judgment
Result Procedure
“PCR” occurs. Go to step 3 5
STEP3
Inspection:
TPMDB: TPMDC
Record the temperature of the pump motor driver circuit board and
pump motor driver condenser.
thirty minutes. Then turn on the key switch and check that the error
occurs.
Judgment
Result Procedure
STEP4
Inspection:
Reconfirm the temperature.
TPMDB: TPMDC
Check the temperature of the pump motor driver circuit board and
pump motor driver condenser. Then compare it to the recorded
value.
Judgment
Result Procedure
(5°C) or more.
Either the pump motor driver circuit board Pump motor driver defect.
temperature, (pump motor driver)
condenser or both have lowered by 41°F
(5°C) or more.
STEP5
Check the inside of connector CN112, 113 and the crimped
FAN1: OFF → ON
Judgment
Result Procedure
STEP6
Inspection: Harness

harness.
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7

condition.
FAN1: OFF → ON
Judgment
Result Procedure
Result Procedure
Not running Cooling fan defect.
main controller.
Error Code: A301

Failure mode: Battery connection incorrect
Probable cause
• Battery plug connection defect
• Battery connection incorrect
• Battery defect
5
Related portion
Emergency switch (OPT)

CN176-1 (41, SWE+) CN176-2 (41, SWE-)
P1 CN250-49 F5
CN250-50 (41) CN104-1 (41, B48V)
Main
controller
BATTERY Emergency switch Less
N1
STEP1
Reconnect the battery plug correctly and turn on the key switch.
Judgment
Result Procedure
A301 error does not occur. Battery plug connector defect or battery plug not connected
correctly.
STEP2

a circuit tester.
Judgment
Result Procedure
Less than 64V Main controller defect.
Error Code: A501

Failure mode: Seat switch short abnormality
Probable cause
• Seat switch defect
• Harness defect
Related portion
CN102-10 (51, LS-) CN44-1
Main Seat swtich

controller
CN104-18 (67, SDM) CN44-2
STEP1
Inspection:
Check of the seat switch condition.
Turn off the key switch and disconnect the battery plug,
disconnect the CN44 connector, and visually check the inside of
the connector and the crimped portion of its wire for defects. Refer
to BEFORE TROUBLESHOOTING.
Connect the connector, connect the battery plug, and then turn on
the key switch without sitting in the seat.
[ANL] I/O M.HANDLING 1/8 SDM
Judgment
Result Procedure
“0” occurs. Connector contact defect.
“1” occurs. Go to step 2
STEP2
Inspection:
Check of the seat switch condition.
Disconnect the CN44 connector, connect the battery plug, and
[ANL] I/O M.HANDLING 1/8 SDM
Judgment
Result Procedure
“0” occurs. Seat switch defect.
“1” occurs. Go to step 3
STEP3
Inspection: Harness
5
Disconnect the CN102, CN104 and CN44 connectors and check
the harnesses.

harness.
1 2 3 4 5 6 7
Perform this check with the battery plug and the
8 9 10 11 12 13 14 15 16 17 18 19 CN102, CN104 and CN44 connectors disconnected,
20 21 22 23 24 25 26 27 and visually check inside the connector and the
28 29 30 31 32 33 34 35 CN44 crimped portion of its wire for defects.
1 2
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

CN102-10 (51) to CN44-1 (51) Continuity
CN44-1 (51) to CN44-2 (67) No continuity
Judgment
Result Procedure
NG Harness defect.
OK Main controller defect.
Error Code: A603

Failure mode: Tilt lever switch short abnormality
CAUTION
• This error may occur if the battery plug is connected and you turn on the key switch while the tilt lever
is being operated. But if the error does not occur after stopping the tilt lever operation, it is normal.
Probable cause
• The battery plug is connected while the tilt lever is being operated
• Tilt lever switch defect
• Tilt lever switch installation defect
• Harness defect
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2
STEP1
Connector contact inspection:

After disconnecting the CN89 connector, check the inside of the
connector and the crimped portion of the wire to see whether it has
a defect or not by visual confirmation. Refer to BEFORE
TROUBLESHOOTING.
Connect the CN89 connector, connect the battery plug.
Turn on the key switch to see if an error occurs.
Judgment
Result Procedure
A603 error does not occur. Connector contact defect.
STEP2
Inspection: Tilt switch

Disconnect the CN89 connector.

Reconnect the battery plug and turn on the key switch.
Check if an error occurs.
Judgment
Result Procedure
A603 error does not occur. Tilt lever switch defect.
Tilt lever switch installation defect.
5
STEP3
Inspection: Harness
Disconnect the CN89 and CN102 connectors and check the
harnesses for continuity.

CN89 harness.
1 2 3 4 5 6 7
Perform this check with the battery plug and the CN89
8 9 10 11 12 13 14 15 16 17 18 19 1 2 and CN102 connectors disconnected, and visually
20 21 22 23 24 25 26 27 3 4 check inside the connector and the crimped portion of
28 29 30 31 32 33 34 35 its wire for defects.

Judgment
Result Procedure
NG Harness defect.
Error Code: A801

Failure mode: F1 fuse open abnormality
CAUTION
• If CB01, CB03, CB05, A802 or A902 occurs, perform troubleshooting with priority given to CB01, CB03,
CB05, A802 or A902.
Probable cause
• Tightening the terminal defect
• Motor driver defect
• F1 fuse installation defect
• F1 fuse defect
• Cable defect
Related portion
F6
CN250-51 CN250-52 (44)
MB F1 P4
P3
Battery CN104-2 (44, VBMB)
N1
Drive motor drive Main
circuit (LH) controller
Drive motor drive

circuit (RH)
Pump motor drive

circuit
STEP1
Inspection of tightening the terminal:

Visually check each terminal for loose bolts (positive terminal,
negative terminal, P4 terminal and N1 terminal of each motor
driver).
Connect the battery plug and turn on the key switch to confirm the
error.
Judgment
Result Procedure
Result Procedure
A801 error does not occur. Tighten the loose terminal.
STEP2
Check the voltage of the power supply for the motor driver:
Connect the battery plug, and turn on the key switch, then
measure the voltage between the positive and negative terminals 5
of the motor driver (LH)
Turn off the key switch, and disconnect the battery plug, then
visually check if there is any abnormality of the copper bar for
connecting positive terminal and negative terminal. (e.g. break,
crack and so on)
Judgment
Result Procedure
0V Go to step 3
[48V battery]: Approx. 48V, [36V battery]: All motor driver defect.
Approx. 36V
STEP3
F1 fuse installation check:

Check the mounting of the F1 fuse to see if it has a defect or not
by visual confirmation.
error.
Judgment
Result Procedure
A801 error does not occur. F1 fuse installation defect.
STEP4
Inspection: F1 fuse
After removing the F1 fuse, measure the resistance at both ends
of the fuse.
*: Motor driver defect
remove the copper bar for connecting the positive terminal of the
motor driver.
Measure the resistance between the positive terminal and the

negative terminal of the motor driver.
When using the analog tester, apply the black probe for positive
terminal and red probe for negative terminal.
Motor drivers are defective if the resistance measured is 10 Ω or
less.
Judgment
Result Procedure
0Ω Motor driver defect. *
∞Ω F1 fuse defect
or motor driver defect, or short between P4 and N1.
Error Code: A802

Failure mode: F6 fuse open abnormality
CAUTION
• If CB01, CB03 or CB05 occurs, perform troubleshooting with priority given to CB01, CB03 or CB05.
Probable cause 5
• F6 fuse defect
• F6 fuse box defect
• Harness defect
Related portion
F6
CN250-51 CN250-52 (44)
MB F1 P4
P3
N1
CN102-3 (19, VBMBSL) Main
CN102-4 (19, VBMBSL) controller
STEP1

After disconnecting the CN104 connector and F6 fuse, check the
inside of the connector and the crimped portion of the wire to see
whether it has a defect or not by visual confirmation. Refer to
BEFORE TROUBLESHOOTING.
Connect the CN104 connector and F6 fuse, connect the battery
plug.
Judgment
Result Procedure
STEP2
VBMBSL voltage inspection:

[ANL] I/O TEMP/VOLT 5/6 VBMBSL
Judgment
Result Procedure
25V or more Go to step 3
Less than 25V Perform CB-1 troubleshooting.
STEP3
Check fuse installation:

Visual confirm if the F6 fuse is mounted correctly.
Judgment
Result Procedure
A802 error does not occur. F6 fuse installation defect.
STEP4
Inspection: F6 fuse
of the fuse.
Judgment
Result Procedure
0Ω Go to step 5
∞Ω F6 fuse defect.
After replacing F6 fuse, go to STEP 6.
STEP5
Inspection: Fuse box

Connect the F6 fuse, and disconnect the connector of the F6 fuse
box.
Measure the resistance for both ends of the connector for the F6
fuse box.
Judgment
Result Procedure
0Ω Go to step 6
∞Ω F6 fuse box defect.
STEP6 5
Inspection: Harness
If you disconnected the F6 fuse box connector in the former step,
reconnect it.
Disconnect the CN104 connector and the F6 fuse and check the
harnesses.

harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
CN104 connector and F6 fuse disconnected, and
26 27 28 29 30 31 visually check inside the connector and the crimped
portion of its wire for defects.
CN250
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60

CN250-52 (44, fuse side) to P3 Continuity
CN104-2 (44) to N1 No continuity
Judgment
Result Procedure
NG Harness defect.
Error Code: A902

Failure mode: F7 fuse / solenoid power supply line open abnormality
Probable cause
• Harness defect
Related portion
MB
CN102-3 (19, VBMBSL)
P3 CN102-4 (19, VBMBSL)
Main
controller
CN250-51 CN250-52 (44)
F6
N1
STEP1

TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
VBMB voltage inspection:

[ANL] I/O TEMP/VOLT 5/6 VBMB
Judgment
Result Procedure
Less than 25V Perform CB-1 troubleshooting.
STEP3
Inspection: Harness
Disconnect the CN102 connector and check the harnesses.

Inspect for continuity and short circuiting of the
CN102 harness.
5
1 2 3 4 5 6 7 CN102 connector disconnected, and visually check
8 9 10 11 12 13 14 15 16 17 18 19 inside the connector and the crimped portion of its wire
for defects.
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN102-3 (19) to P3 Continuity
Judgment
Result Procedure
NG Harness defect.
Error Code: AA01

Failure mode: Main controller temperature sensor (open/short) abnormality
CAUTION
• If AA01 occurs, the Main controller is defective. Replace it.
Probable cause
Related portion
Main controller
Temperature sensor
Error Code: AA02

Failure mode: Drive motor driver LH board temperature sensor (open/short) abnormality
CAUTION
• If AA02 occurs, the drive motor driver circuit is defective. Replace it.
Probable cause 5
Related portion
Temperature sensor
Error Code: AA03

Failure mode: Drive motor driver RH board temperature sensor (open/short) abnormality
CAUTION
• If AA03 occurs, the drive motor driver circuit is defective. Replace it.
Probable cause
Related portion
Temperature sensor
Error Code: AA04

Failure mode: Pump motor driver board temperature sensor (open/short) abnormality
CAUTION
• If AA04 occurs, the pump motor driver circuit is defective. Replace it.
Probable cause 5
Related portion
Pump motor driver
Temperature sensor
Error Code: AB01

Failure mode: Cooling fan overcurrent
CAUTION
• When checking if AB01 error occurs, wait 100 seconds after turning on the FAN1, FAN2 by using Active
Test.
(It takes 100 second to confirm the error AB01)
Probable cause
• Motor driver cooling fan 1 defect
• Motor driver cooling fan 2 defect
• Motor cooling fan defect
• Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Cooling fan 2
Main CN104-3 (1, CBAT+) CN113-1
F52
CN102-2 (99, FANDC2) CN112-2
CN104-1 (41, B48V) Cooling fan 1

CN112-1
CN250-25 CN250-26
+ F51
CN118-2
Motor fan
CN118-1
CN250-29 CN250-30
F53
STEP1
Inspection:
Check the inside of connector CN112, CN113, CN118 and the
crimped portion of the wire to see whether it has a defect or not by
visual confirmation. Refer to BEFORE TROUBLESHOOTING.
and check if an error occurs.
FAN1: OFF → ON
FAN2: OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Connector contact defect
AB01 error occurs. Go to step 2
STEP2
Inspection: Cooling fan circuit

5
After disconnect the CN112, CN113, CN118 connector, connect
the battery plug and turn on the key switch. Then apply the cooling
fan by using Active Test, and check if an error occurs.
FAN1: OFF → ON
FAN2: OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Go to step 3
AB01 error occurs. Go to step 5
STEP3
Inspection: Motor driver cooling fan 1

After connecting CN113 and disconnecting the CN112, CN118
connector, connect the battery plug and turn on the key switch.
Then apply the cooling fan by using Active Test, and check if an
error occurs.
FAN1: OFF → ON
FAN2: OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Go to step 4
AB01 error occurs. Motor driver cooling fan 1 defect.
STEP4
Inspection: Motor driver cooling fan 2

After connecting CN112 and disconnecting the CN113, CN118
connector, connect the battery plug and turn on the key switch.
Then apply the cooling fan by using Active Test, and check if an
error occurs.

FAN1: OFF → ON
FAN2: OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Motor cooling fan defect
AB01 error occurs. Motor driver cooling fan 2 defect
STEP5
Inspection: Harness
Disconnect the CN102, CN104, CN112, CN113, CN118
connectors and check the harnesses.

harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 CN102, CN104, CN112, CN113, CN118 connectors
20 21 22 23 24 25 26 27 disconnected, and visually check inside the
28 29 30 31 32 33 34 35 connectors and the crimped portion of their wires for
defects.
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
Error Code: AC01

Failure mode: Motor driver power delivery abnormality
Probable cause
• Harness defect
5
Related portion
+
Drive motor
CN109-8 (42) driver LH
MB
P2 P4 +
Drive motor
CN110-8 (42) driver RH
+ F1
+
N1 Pump motor
CN111-8 (42) driver
-
CN103-4 (42, KYSAT)
Main
CN250-49 CN250-50 (41) CN104-1 (41, B48V) controller
F5 CN101-4 (41, VBBT)
STEP1
Inspection: Harness
Disconnect the CN101, CN103, CN104, CN109, CN110, CN111
connectors and check the harness.

harness.
1 2 3 4 5 6
CN109
Perform the continuity check of CN103 to CN109,
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 CN110, CN111 connectors with the battery plug and
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 the CN101, CN103, CN104, CN109, CN110, CN111
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35 connectors disconnected, and visually check inside
the connectors and the crimped portion of their wires
for defects.
Inspect for continuity between the harness and N1.
CN110 CN111 Refer to BEFORE TROUBLESHOOTING.
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23

CN103-4 (42) to CN109-8(42) Continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 2
STEP2
Inspection: Main controller

Disconnect the CN109, CN110, CN111 connectors, then connect
the CN101, CN103, CN104 connectors.
error.
Judgment
Result Procedure
AC01 error occurs. Main controller defect
AC01 error does not occur. Go to step 3
STEP3
Inspection: Drive motor driver LH

Disconnect the CN110, CN111 connectors, then connect the
CN101, CN103, CN104, and CN109 connectors.
error.
Judgment
Result Procedure
AC01 error occurs or not. Go to step 4
STEP4
Inspection: Drive motor driver RH

error.
Judgment
Result Procedure
AC01 error occurs or not. Go to step 5
STEP5
Inspection: Pump motor driver

5
error.
Judgment
Result Procedure
AC01 error occurs at STEP 3 Drive motor driver LH defect
AC01 error occurs at STEP 4 Drive motor driver RH defect
AC01 error occurs at STEP 5 Pump motor driver defect
Error Code: AD01

Failure mode: Drive motor driver LH to Main controller: communication abnormality
CAUTION
• If AC01 occurs at the same time, perform troubleshooting for AC01 first.
• If AD02 occurs at the same time, perform troubleshooting for AD02 first.
Probable cause
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
disconnect the CN103, CN109 connectors, and visually check
inside the connector and the crimped portion of its wire for defects.
on the key switch to confirm the error.
Judgment
Result Procedure
AD01 or AD02 error occurs. Perform troubleshooting for AD02
AD01 or AD02 error does not occur. Connector contact defect
Error Code: AD02

Failure mode: Drive motor driver LH to Main controller: communication abnormality
CAUTION
Probable cause 5
• Wrong motor driver type
• Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
Main controller CN109-7
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN70-16 CN111-17 (145, CAN1H)
Display CN70-15 CN111-16 (146, CAN1L)
Pump motor
CN111-6 (152, SETP1) driver
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
Turn off the key switch and disconnect the battery plug. Check if
the part number of the motor driver is correct.
Make sure that an incorrect model motor driver was not installed if
the motor driver was recently replaced.
Judgment
Result Procedure
Wrong part number Wrong motor driver type
Correct part number Go to step 2
STEP2
Turn off the key switch, disconnect the battery plug, disconnect
the CN103, CN104, CN109, CN110, CN111, CN70 connectors,
and visually check inside the connector and the crimped portion of
its wire for defects. Refer to BEFORE TROUBLESHOOTING.
Check if the connector is connected correctly, especially if the
motor driver has just been replaced.
Check the status LED on the controller. This would tell you if the
keystart voltage is present.
Judgment
Result Procedure
(1) No error code “with AD” Connector contact defect
(2) Any of the following items occur: Go to step 8
• AD01 or AD02 error occurs.
The other cases of (1) and (2) Go to step 3
STEP3
Inspection:
Reconfirm the occurred error.
Reconfirm the error at STEP2.
Judgment
Result Procedure
AD02 error occurs. Go to step 4
Record the error code (starting form “AD”)
AD02 error does not occur. Perform the troubleshooting of the occurred error
STEP4
Inspection:
1. Confirm the identification of drive motor driver LH.
Disconnect the CN110 and CN111 connectors.
Reconnect the battery plug and turn on the key switch. Record the
occurred error.
2. Check the harness
Connect the CN110, CN111 connectors, and disconnect the
CN103, CN109 connectors.
Inspect the harness by the error recorded at STEP4.
[Inspection procedure and standard] 5

CN103 1. Check if the connector plug CN109 is wired
correctly. The connector plug could be connected to
the wrong controller.
1 2 3 4 5 6
CN109
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 2. Inspect for continuity and short circuiting of the
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 harness.
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35

CN103, CN109 connectors disconnected, and visually
check inside the connector and the crimped portion of
its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
*1: Perform if “AD-4 error does not occur and AD-6 error occurs” or “AD-4 error occurs and AD-6 error does not
occur”.
*2: Perform if “AD-4 and AD-6 error occur”.
Portion to be inspected Standard: Remarks

CN109-7 to CN109-23 No continuity *1
CN109-7 to N2 No continuity *1
CN103-4 to CN109-8 Continuity *2
Judgment
Result Procedure
NG Go to step 5
Harness defect
OK Go to step 5
Drive motor driver LH defect
STEP5
Confirm the error recorded at STEP3.

Judgment
Result Procedure
Only AD02 error occurs. Replace the defective portion in STEP4.
AD02 and AD04 error occur. Go to step 6
STEP6
Inspection:
1. Confirm the identification of drive motor driver RH.
occurred error.
2. Inspect harness

CN103 1. Check with disconnecting the drive motor driver LH
and pump motor driver to confirm if drive motor driver
RH is not operated as drive motor driver LH or pump
1 2 3 4 5 6
CN110 motor driver.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35 harness.

its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
*1: Perform if “AD02 error does not occur and AD06 error occurs” or “AD02 error occurs and AD06 error does not
occur”.
*2: Perform if “AD02 and AD06 error occur”.

Judgment
Result Procedure
NG Harness defect
In addition to the harness, replace the defective portion in
STEP4.
OK Drive motor driver RH defect
In addition to drive motor driver RH, replace the defective
portion in STEP4. 5
STEP7
Inspection:
1. Confirm the identification of pump motor driver
occurred error.
2. Inspect harness

CN103 1. Check with disconnecting the drive motor driver LH
and RH to confirm if pump motor driver is not operated
as drive motor driver LH or RH.
1 2 3 4 5 6
CN111
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 harness.
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35

check inside the connectors and the crimped portion of
their wires for defects. Refer to BEFORE
TROUBLESHOOTING.
*1: Perform if “AD02 error does not occur and AD04 error occurs” or “AD02 error occurs and AD04 error does not
occur”.
*2: Perform if “AD02 and AD04 error occur”.


Judgment
Result Procedure
NG Harness defect
In addition to the harness, replace the defective portion in
STEP 4.
OK Pump motor driver defect
In addition to pump motor driver, replace the defective
portion in STEP 4.
STEP8
Inspection: Harness
Disconnect the CN103, CN104, CN109, CN110, CN111 and
CN70 connectors and check the harnesses.

harness.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 Perform this check with the battery plug and the
CN103
CN103, CN104, CN109, CN110, CN111 and CN70
CN110 connectors disconnected, and visually check inside
1 2 3 4 5 6 the connectors and the crimped portion of their wires
1 2 3 4 5 6 7 8 for defects. Refer to BEFORE TROUBLESHOOTING.
7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
CN111
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23


Judgment
Result Procedure
NG Harness defect
OK Go to step 9
5
STEP9
Inspection: Check the voltage of the main controller power supply.

Connect the CN103, CN104, CN70 connectors, and disconnect
the CN109, CN110, CN111 connectors.
Reconnect the battery plug and turn on the key switch. Check the
voltage of the power supply for the motor driver.
Check the voltage between CN109-8 and N2.
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
Judgment
Result Procedure
Less than 15V Main controller defect
STEP10

the CN110, CN111 connectors.
voltage of the power supply for the motor driver and check if an
error occurs.

Check with the drive motor driver RH and pump motor
CN110 driver disconnected, and the main controller and drive
motor driver LH connected.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Check the voltage by using the disconnected drive
16 17 18 19 20 21 22 23
motor driver RH harness.
Judgment
Result Procedure
Voltage: less than 15V Go to step 11
Record the result
Voltage: 15V or more AD02 error occurs Go to step 11
Record the result
Voltage: 15V or more AD02 error does not Go to step 11
occur Record the result
STEP11

power supply voltage for the motor driver and check if an error
occurs.

Check with the drive motor driver LH and pump motor
CN109 driver disconnected, and the main controller and drive
motor driver RH connected.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
motor driver LH harness.
Judgment
Result Procedure
Record the result
Record the result
Result Procedure
STEP12

Connect the CN103, CN104, CN111 connectors, and disconnect 5
voltage of the power supply for the motor driver and check if an
error occurs.

Check with the drive motor driver LH and RH
CN109 disconnected, and the main controller and the pump
motor driver connected.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
motor driver LH harness.
Judgment
Result Procedure
Record the result
Record the result
STEP13
Confirm the STEP10, 11, 12

Judgment
Result Procedure
Any voltage: less than 15V Defect for inspection item of less than 15V (Drive motor
driver LH, Drive motor driver RH, Pump motor driver)
All voltage: 15V or more All error occurs Main controller defect
If the symptom persists after replacing the main controller,
there are other problems. Replace the drive motor driver LH,
drive motor driver RH, and pump motor driver.
Result Procedure
All voltage: 15V or more At least one error Defect for inspection item of the occurred error (Drive motor
is not displayed driver LH, Drive motor driver RH, Pump motor driver)
Error Code: AD03

Failure mode: Drive motor driver RH to Main controller: communication abnormality
CAUTION
• If AD01 or AD02 occurs at the same time, perform troubleshooting for AD02 first.
5
Probable cause
Related portion
CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
disconnect the CN103, CN110 connectors, and visually check
inside the connector and the crimped portion of its wire for defects.
After connecting the connectors, connect the battery plug and turn
Judgment
Result Procedure
Error Code: AD04

Failure mode: Drive motor driver RH to Main controller: communication abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN111-17 (145, CAN1H)
CN111-16 (146, CAN1L)
Pump motor
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
check if the part number of the motor driver is correct.
Judgment
Result Procedure
STEP2
Turn off the key switch, disconnect the battery plug, disconnect
the CN110 connector, and visually check inside the connector and 5
the crimped portion of its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
AD03 or AD04 error occurs. Go to step 3
STEP3
Inspection:
Confirm the identification of drive motor driver RH.
Reconnect the battery plug and turn on the key switch. Confirm the
occurred error.
Check if the connector plug CN109 is wired correctly. The
connector plug could be connected to the wrong controller.
Judgment
Result Procedure
AD02 or AD06 error occur. Go to step 4
STEP4
Inspection: Harness
Disconnect the CN110 connector and check the harness.

CN110 harness.

9 10 11 12 13 14 15
CN110 connector disconnected. Visually check inside
16 17 18 19 20 21 22 23
the connector and the crimped portion of its wire for
defects.

CN110-7 (150) to CN110-23 Continuity
CN110-6 to N2 (N2) No continuity
Judgment
Result Procedure
NG Harness defect
STEP5
Inspection: Harness
Disconnect the CN103, CN110 connectors and check the
harnesses.

harness.
1 2 3 4 5 6
CN110
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 CN103, CN110 connectors disconnected. Visually
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 check inside the connectors and the crimped portion of
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35 their wires for defects.

Judgment
Result Procedure
NG Harness defect
5
Error Code: AD05

Failure mode: Pump motor driver to Main controller: communication abnormality
CAUTION
Probable cause
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L)
Pump motor
driver
Main controller CN111-6 (152, SETP1)
CN103-5 (N2, N2) CN111-23 (152, SETP-)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
disconnect the CN103, CN111 connectors. Visually check inside
the connectors and the crimped portion of their wires for defects.
Judgment
Result Procedure
Error Code: AD06

Failure mode: Pump motor driver to Main controller: communication abnormality
CAUTION
5
Probable cause
• Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN111-17 (145, CAN1H)
CN111-16 (146, CAN1L)
Pump motor
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
Turn off the key switch, and disconnect the battery plug. Check if
the part number of the motor driver is correct.
Judgment
Result Procedure
STEP2
disconnect the CN111 connector. Visually check inside the
connector and the crimped portion of its wire for defects. Refer to
Judgment
Result Procedure
STEP3
Inspection:
Confirm the identification of pump motor driver
Reconnect the battery plug and turn on the key switch. Confirm the
occurred error.
Check if the connector plug CN109 is wired correctly. The
connector plug could be connected to the wrong controller.
Judgment
Result Procedure
AD02 and AD04 errors occur Go to step 5
STEP4
Inspection: Harness
Disconnect the CN111 connector and check the harness.

CN111 harness.

9 10 11 12 13 14 15
CN111 connectors disconnected. Visually check inside
16 17 18 19 20 21 22 23
the connector and the crimped portion of its wire for
defects.

CN111-7 to N2 (N2) No continuity
Judgment
Result Procedure
NG Harness defect
STEP5
Inspection: Harness
harnesses.

harnesses.
1 2 3 4 5 6
CN111
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 CN103, CN111 connectors disconnected, and visually
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 check inside the connectors and the crimped portion of
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35 its wire for defects.

Judgment
Result Procedure
NG Harness defect
Error Code: AF01

Failure mode: Main controller CPU error
CAUTION
• If AF01 occurs, the Main controller is defective. Replace it.
Probable cause 5
Related portion
Main controller
Error Code: AF02

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF03

CAUTION
Probable cause 5
Related portion
Main controller
Error Code: AF04

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF05

CAUTION
Probable cause 5
Related portion
Main controller
Error Code: AF06

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF07

CAUTION
Probable cause 5
Related portion
Main controller
Error Code: AF08

CAUTION
Probable cause
Related portion
Main controller
Error Code: C002

Failure mode: Drive motor driver LH power-circuit abnormality
CAUTION
• If CB03 occurs at the same time, perform troubleshooting for CB03 first.
• Jack up the lift truck until the drive wheels leave the ground and support the frame with wooden blocks
before you start troubleshooting.
5
Probable cause
• Drive motor cable tightening is defective
• Drive motor LH defect
• Drive motor cable defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off the key switch and disconnect the battery plug. Visually
check the fastened and crimped portions of the motor cables for
defects. Refer to BEFORE TROUBLESHOOTING.
Connect the drive motor cables, connect the battery plug, and
then turn on the key switch.
Operate the direction lever forward or backward, and check for
errors.
Judgment
Result Procedure
C002 error occurs. Go to step 2
Record the occurred error code.
C002 error does not occur. Drive motor cable tightening is defective
STEP2

Return the direction lever to neutral, turn off the key switch, and
disconnect the battery plug.
Disconnect the three motor cables from the drive motor driver LH
and isolate them. Make sure the disconnected terminals are not
touching.
Connect the battery plug and turn on the key switch to check if
C002 error occurs.
Judgment
Result Procedure
C002 error does not occur. Go to step 3
C002 error occurs. Drive motor driver LH defect
STEP3
Inspection: Drive motor cable

Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection
Check each drive motor cable for its continuity and short.
disconnect the three motor cables, visually check each terminal
and the crimped portion and coating of each cable for defects, and
then check the P7, P8 and P9 cables.

Both ends of P7 cable Continuity
P7 cable and P8 cable No continuity
Judgment
Result Procedure
OK (E002 does not occur at the same time Go to step 4
on STEP1)
OK (E002 occurs at the same time on Go to step 5
STEP1)
NG Drive motor cable defect
STEP4
Inspection: Drive motor driver

Replace the drive motor driver LH with the pump motor driver.

errors. (Ignore the error codes 3201 and 3203.)
Judgment
Result Procedure
C002 error occurs. Drive motor LH defect
E002 error occurs. Drive motor driver LH defect
If the error code changes to E002, replace the drive motor 5
driver.
STEP5
Inspection: Drive motor

Check the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
OK Drive motor driver LH defect
Error Code: C004

Failure mode: Drive motor driver RH power-circuit abnormality
CAUTION
Probable cause
• Drive motor cable tightening is defective
• Drive motor RH defect
• Drive motor cable defect
Related portion
P71
U
Drive motor P81

V Drive motor RH
driver RH
P91
W
STEP1
check the fastened and crimped portions of the motor cables for
errors.
Judgment
Result Procedure
C004 error does not occur. Drive motor cable tightening is defective
STEP2

Disconnect the three motor cables from the drive motor driver RH
and isolate them. Make sure the disconnected terminals are not
touching.
Connect the battery plug and turn on the key switch to check if
C004 error occurs.
Judgment
Result Procedure
C004 error does not occur. Go to step 3 5
C004 error occurs. Drive motor driver RH defect
STEP3
Inspection: Drive motor cable

Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection
Check each drive motor cable for continuity and shorts.
disconnect the three motor cables, visually check each terminal
then check the P71, P81, and P91 cables.

Judgment
Result Procedure
on STEP1)
STEP1)
NG Drive motor cable defect
STEP4

Replace the drive motor driver RH with the pump motor driver.

Judgment
Result Procedure
C004 error occurs. Drive motor RH defect
E002 error occurs. Drive motor driver RH defect
If the error code changes to E002, replace the drive motor
driver.
STEP5
Inspection: Drive motor

Check the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C101

Failure mode: Drive motor driver LH current sensor neutral voltage error
CAUTION
• If C101 occurs, the drive motor driver LH is defective. Replace it.
Probable cause 5
Related portion
Current sensor
Error Code: C102

Failure mode: Drive motor driver LH current sensor over current abnormality
CAUTION
• If C801 or C802 occurs at the same time as C102, perform troubleshooting for C801 or C802 first.
Probable cause
• Drive motor LH cable tightening is defective
• Drive motor LH defect
• Drive motor LH cable defect
• Drive motor LH rotation sensor defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off / on the key switch, and check if C002 error occurs.
Judgment
Result Procedure
C002 error occurs. Perform troubleshooting for C002
STEP2
check the assembled and crimped portions of the motor cables for
Sit in the seat and perform a direction lever operation (forward or
backward), checking for errors with pushing the accelerator pedal.
Judgment
Result Procedure
C102 error does not occur. Drive motor LH cable is loose
STEP3
Inspection: Drive motor cable LH

5
Inspect with the drive motor cable (drive side and motor side)
disconnected.
Disconnect the three motor cables. Visually check each terminal
then check the P7, P8, and P9 cables.

Judgment
Result Procedure
on STEP2)
STEP2)
NG Drive motor LH cable defect
STEP4

(Ignore the error codes 3201 and 3203.)
Judgment
Result Procedure
C102 error occurs. Drive motor LH defect
E102 error occurs. Drive motor driver LH defect
driver.
STEP5
Inspection: Drive motor LH

Turn off the key switch, disconnect the battery plug, and inspect
the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
Error Code: C103

Failure mode: Drive motor driver RH current sensor neutral voltage error
CAUTION
• If C103 occurs, the drive motor driver RH is defective. Replace it.
Probable cause 5
Related portion
Current sensor
Error Code: C104

Failure mode: Drive motor driver RH current sensor over current abnormality
CAUTION
• If C803 or C804 occurs at the same time as C104, perform troubleshooting for C803 or C804 first.
Probable cause
• Drive motor RH cable tightening is defective
• Drive motor RH defect
• Drive motor RH cable defect
• Drive motor RH rotation sensor defect
Related portion
P71
U
Drive motor P81

V Drive motor RH
driver RH
P91
W
STEP1
Turn off / on the key switch, and check if C004 error occurs.
Judgment
Result Procedure
C004 error occurs. Perform troubleshooting for C004
STEP2
Turn off the key switch and disconnect the battery plug, visually
check the assembled and crimped portions of the motor cables for
Judgment
Result Procedure
C104 error does not occur. Drive motor RH cable tightening is defective
STEP3
Inspection: Drive motor cable RH

5
Inspect with the drive motor cable (drive side and motor side)
disconnected.
Disconnect the three motor cables. Visually check each terminal

Judgment
Result Procedure
on STEP2)
STEP2)
NG Drive motor RH cable defect
STEP4

Judgment
Result Procedure
C104 error occurs. Drive motor RH defect
E102 error occurs. Drive motor driver RH defect
driver.
STEP5
Inspection: Drive motor RH

Turn off the key switch, disconnect the battery plug, and inspect
the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C201

Failure mode: Drive motor overheating abnormality
CAUTION
Probable cause 5
Related portion
CN109-9 (86, STDML+) CN121-2

Drive motor driver Temperature sensor
LH (Drive motor LH)
CN109-10 (87, STDML) CN121-1
CN110-9 (84, STDMR+) CN52-2

RH (Drive motor RH)
CN110-10 (85, STDMR) CN52-1
STEP1
Inspection:
Reconfirm the displayed error.
Turn on the key switch and check if the error occurs.
Judgment
Result Procedure
“DM” occurs. Go to step 2
“DM” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “DM” goes
away and the lift truck can be operated as usual. Continuously
running the lift truck in an overloaded condition will cause this
error. Limit running the lift truck in an overloaded condition.
STEP2
Inspection:
Confirm the temperature of the drive motor and reconfirm the
error.
?Temperature of drive motor LH/RH
[ANL] I/O TEMP/VOLT 1/6?TDM

Record the temperature of the drive motor.
thirty minutes. Then turn on the key switch and check if the error
occurs.
Judgment
Result Procedure
“DM” occurs. Go to step 3
“DM” does not occur. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “DM” goes
STEP3
Inspection:
Reconfirm the temperature of drive motor.
*Temperature of drive motor LH/RH
[ANL] I/O TEMP/VOLT 1/6 TDM
Check the temperature of drive motor and compare to the
recorded value.
Judgment
Result Procedure
(5°C) or more.
Temperature of drive motor LH has not C202 Perform troubleshooting from STEP2.
lowered by 41°F (5°C) or more.
Temperature of drive motor RH has not C203 Perform troubleshooting from STEP2.
lowered by 41°F (5°C) or more.
Error Code: C202

Failure mode: Drive motor LH temperature sensor (open/short) abnormality
Probable cause
• Drive motor LH temperature sensor defect
• Drive motor LH temperature sensor harness defect
5
Related portion
CN109-9 (86, STDML+) CN121-2

LH (Drive motor LH)
CN109-10 (87, STDML) CN121-1
STEP1
Disconnect the battery plug and visually check inside the CN121
Judgment
Result Procedure
C202 error does not occur. Connector contact defect
STEP2
Inspection:
Temperature sensor individual inspection.
Disconnect the CN121 connector, and perform the temperature
sensor individual inspection.

Carry out temperature sensor individual inspection.
CN121 Measure the temperature sensor resistance between
CN121-2 and CN121-1 (sensor side of CN121)
2 1
Standard: Approx. 245 Ω to 600 kΩ
* The resistance changes depending on the temperature. So refer to the below table about rough standard value.
Temperature sensor
resistance (between CN121-2
Temperature and CN121-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
100°C Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor LH temperature sensor defect
STEP3
Inspection: Harness
harnesses.

CN109 CN121 Inspect for continuity and short circuiting of the
harness.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2
CN109 and CN121 connectors disconnected, and
visually check inside the connector and the crimped
portion of its wire for defects with disconnecting SST.
*1: It is OK to connect CN121-1 to CN121-2 through SST2 (979-001/161) and check if there is continuity between
CN109-9 and CN109-10.

CN121-1 to CN121-2 No continuity ?
Judgment
Result Procedure
NG Drive motor LH temperature sensor harness defect
Error Code: C203

Failure mode: Drive motor RH temperature sensor (open/short) abnormality
Probable cause
• Drive motor RH temperature sensor defect
• Drive motor RH temperature sensor harness defect
5
Related portion
CN110-9 (84, STDMR+) CN52-2

RH (Drive motor RH)
CN110-10 (85, STDMR) CN52-1
STEP1
Disconnect the battery plug, and visually check inside the CN52
Judgment
Result Procedure
STEP2
Inspection:
Temperature sensor individual inspection.
Disconnect the CN52 connector and perform the temperature
sensor individual inspection.

CN52 Carry out temperature sensor individual inspection.
Measure the temperature sensor resistance between
2 1
Standard: Approx. 245 to 600 kΩ
* The resistance changes depending on temperature. So refer to the below table about rough standard value.
Temperature sensor
68°F (20°C) Approx. 13 kΩ
176°F (80°C) Approx. 1.75 kΩ
212°F (100°C) Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor RH temperature sensor defect
STEP3
Inspection: Harness
harnesses.

harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2
CN110 and CN52 connectors disconnected, and
visually check inside the connector and the crimped
portion of its wire for defects with disconnecting SST.
CN110-9 and CN110-10.

Judgment
Result Procedure
NG Drive motor RH temperature sensor harness defect
Error Code: C301

Failure mode: Drive motor driver LH power-circuit temperature sensor (open/short)
abnormality
CAUTION
• If C301 occurs, the drive motor driver LH is defective. Replace it.
5
Probable cause
Related portion
Temperature sensor
Error Code: C302

Failure mode: Drive motor driver RH power-circuit temperature sensor (open/short)
abnormality
CAUTION
• If C302 occurs, the drive motor driver RH is defective. Replace it.
Probable cause
Related portion
Temperature sensor
Error Code: C401

Failure mode: Accelerator potentiometer POT1 open abnormality
CAUTION
• Make sure to perform Matching after removal and inspection of the accelerator potentiometer.
Probable cause 5
• Harness defect
• Accelerator sensor defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN101-22 (50, VRA-) CN26-6 Accelerator
Main controller CN101-26 (55, VRA2+) CN26-1 sensor
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
After disconnecting the CN26 connector, check the inside of
connector and the crimped portion of wire whether it has a defect
or not by visual confirmation. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Accelerator sensor

Disconnect the CN26 connector and check the accelerator sensor
resistance.

Inspect accelerator sensor resistance.
CN26
Turn off the key switch and disconnect the battery
6 5 4 3 2 1 plug, disconnect the CN26 connector, visually check
each terminal and the crimped portion and coating of
each cable for defects. Refer to BEFORE
TROUBLESHOOTING.
Check resistance on both ends of the sensor

connector. Confirm the value changes when the
sensor is operating.
CN26-4(52) to CN26-6(50)

CN26-5 (53) to CN26-6 (50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to step 3
STEP3
Inspection: Harness
Disconnect the CN101, CN102, CN26 connectors and check
continuity of the harness.

CN101 Inspect for continuity of the harness.

1 2 3 4 5 6 7
CN101, CN102, and CN26 connectors disconnected,
8 9 10 11 12 13 14 15 16 17 and visually check inside the connector and the
18 19 20 21 22 23 24 25 26 27 crimped portion of its wire for defects.
28 29 30 31 32 33 34 Refer to BEFORE TROUBLESHOOTING.
CN26
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-27 and CN102-30.

CN101-27 (53) to CN26-5 Continuity *1
CN26-4 (52) to CN26-6 (50) No continuity 5
Judgment
Result Procedure
NG Harness defect
Error Code: C402

Failure mode: Accelerator potentiometer POT2 open abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN26
TROUBLESHOOTING.
5
CN26-3(54) to CN26-2(51)

CN26-1 (55) to CN26-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 and visually check inside the connector and the
18 19 20 21 22 23 24 25 26 27 crimped portion of its wire for defects.
CN26
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-26 and CN102-32.

Judgment
Result Procedure
NG Harness defect
Error Code: C403

Failure mode: Accelerator potentiometer POT1VCC short circuit abnormality
CAUTION
Probable cause 5
• Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN26
TROUBLESHOOTING.

CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)

CN26-5 (53) to CN26-6 (50) 1.8 to 3.5 kΩ
CN26-1 (55) to CN26-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness
continuity of the harnesses.

CN101 Inspect for continuity of the harnesses.

1 2 3 4 5 6 7
CN101, CN102, and CN26 connectors disconnected.
8 9 10 11 12 13 14 15 16 17 Visually check inside the connectors and the crimped
18 19 20 21 22 23 24 25 26 27 portion of their wires for defects.
CN26
5
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-22 and CN102-30.

Judgment
Result Procedure
NG Harness defect
Error Code: C404

Failure mode: Accelerator potentiometer POT2VCC short circuit abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN26
TROUBLESHOOTING.
5
CN26-3(54) to CN26-2(51)

CN26-1 (55) to CN26-2 (51) 1.8 to 3.5 k Ω
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27 portion of its wire for defects.
CN26
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-32 and CN102-32.

Judgment
Result Procedure
NG Harness defect
Error Code: C405

Failure mode: Accelerator potentiometer offset abnormality
CAUTION
Probable cause 5
• Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
connector and the crimped portion of wire whether it has a defect
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN26
TROUBLESHOOTING.

CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)

CN26-5 (53) to CN26-6 (50) 1.8 to 3.5 kΩ
CN26-1 (55) to CN26-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 and visually check inside the connectors and the
18 19 20 21 22 23 24 25 26 27 crimped portion of the wires for defects.
CN26
5
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
It is OK to connect the following portion by using SST2 (979-001/161) and check if there is continuity between
CN101 and CN102.
Portions to connect SST2 / Continuity check point
*1: CN26-5 to CN26-4 / CN101-27 to CN102-30
*2: CN26-6 to CN26-3 / CN101-22 to CN102-30
*3: CN26-1 to CN26-3 / CN101-26 to CN102-32
*4: CN26-2 to CN26-3 / CN101-32 to CN102-32

Judgment
Result Procedure
NG Harness defect
Error Code: C406

Failure mode: Accelerator potentiometer matching value abnormality
CAUTION
• If C401, C402, C403, C404, C405 occurs, give priority to troubleshooting for C401, C402, C403, C404,
C405.
Probable cause
• Accelerator potentiometer matching defect
• Accelerator potentiometer assembly defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
Perform the accelerator potentiometer matching.

(Refer to MATCHING)
Judgment
Result Procedure
NG matching Go to step 2
OK matching Go to step 3
STEP2
Check the accelerator potentiometer voltage.

Accelerator sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRA
Check if the voltage of the accelerator is within the standard range
of the table below when the accelerator is not operated and when
the accelerator is fully depressed.
Position of accelerator pedal sensor 1 sensor 2

When accelerator is not operated 0.40V to 1.24V 0.65V to 2.31V
Position of accelerator pedal sensor 1 sensor 2

During maximum pressing of accelerator 2.00V to 4.79V 2.42V to 4.79V
Judgment
Result Procedure
Within standard range Main controller defect
Outside standard range Go to step 3
Accelerator potentiometer assembly defect 5
Perform the matching after reassembly.
STEP3
Turn off the key switch and disconnect the battery plug. Connect
the battery plug again after 30 seconds and turn on the key switch.
Judgment
Result Procedure
C406 error occurs. Main controller defect
C406 error does not occur. Accelerator potentiometer matching defect
Use as it is.
Error Code: C501

Failure mode: Brake potentiometer POT1 open abnormality
CAUTION
• Make sure to perform Matching after removal and inspection of the brake potentiometer.
Probable cause
• Harness defect
• Brake potentiometer defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
Main controller CN101-33 (74, VRB2+) CN6-1 potentiometer
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Brake potentiometer

Disconnect the CN6 connector and check the brake potentiometer
resistance.

Inspect brake potentiometer resistance.
CN6
Turn off the key switch, disconnect the battery plug,
6 5 4 3 2 1 and disconnect the CN6 connector. Visually check
TROUBLESHOOTING.
5
Check resistance on both ends of the potentiometer. Confirm the
value changes when the potentiometer is operating.
CN6-4(71) to CN6-6(50)

CN6-5 (72) to CN6-6 (50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Brake potentiometer defect
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 Visually check inside the connector and the crimped
CN6
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-34 and CN102-33.

Judgment
Result Procedure
NG Harness defect
Error Code: C502

Failure mode: Brake potentiometer POT2 open abnormality
CAUTION
Probable cause 5
• Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
Disconnect the CN6 connector. Check the inside of the connector
and the crimped portion of the wire to see whether it has a defect
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN6
each cable for defects. Refer toBEFORE
TROUBLESHOOTING.
Check resistance on both ends of the potentiometer.

Confirm the value changes when the potentiometer is
operating.
CN6-3(73) to CN6-2(51)

CN6-1 (74) to CN6-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
CN6
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-33 and CN102-25.

CN6-3 (73) to CN6-6 (50) No continuity 5
Judgment
Result Procedure
NG Harness defect
Error Code: C503

Failure mode: Brake potentiometer POT1VCC short circuit abnormality
CAUTION
• If C505 occurs at the same time, perform troubleshooting for C505 first.
Probable cause
• Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN6
TROUBLESHOOTING.
5
operating.
CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)

CN6-5 (72) to CN6-6 (50) 1.8 to 3.5 kΩ
CN6-1 (74) to CN6-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
CN6
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-22 and CN102-33.

Judgment
Result Procedure
NG Harness defect
Error Code: C504

Failure mode: Brake potentiometer POT2VCC short circuit abnormality
CAUTION
• Make sure to perform Matching after removal and inspection of the accelerator brake potentiometer.
Probable cause 5
• Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
After disconnecting the CN6 connector, visually confirm whether
the inside of the connector and the crimped portion of the wire has
a defect or not. Refer to BEFORE TROUBLESHOOTING.
Connect the CN6 connector and the battery plug.
Judgment
Result Procedure
STEP2

resistance.

CN6
TROUBLESHOOTING.

operating.
CN6-3(73) to CN6-2(51)

CN6-1 (74) to CN6-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
CN6
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-32 and CN102-25.

Judgment 5
Result Procedure
NG Harness defect
Error Code: C505

Failure mode: Brake potentiometer offset abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

resistance.

CN6
Turn off the key switch, disconnect the battery plug
TROUBLESHOOTING.
5
operating.
CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)

CN6-5 (72) to CN6-6 (50) 1.8 to 3.5 kΩ
CN6-1 (74) to CN6-2 (51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness


1 2 3 4 5 6 7
CN6
CN102 1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
It is OK to connect the following portion by using SST2 (979-001/161) and check if there is continuity between
CN101 and CN102.
???Portions to connect SST2 / Continuity check point
*1: CN6-5 to CN6-4 / CN101-34 to CN102-33
*2: CN6-6 to CN6-4 / CN101-22 to CN102-33
*3: CN6-1 to CN6-3 / CN101-33 to CN102-25
*4: CN6-2 to CN6-3 / CN101-32 to CN102-25

Judgment
Result Procedure
NG Harness defect
Error Code: C506

Failure mode: Brake potentiometer matching value abnormality
CAUTION
• If C501, C502, C503, C504, C505 occurs, give priority to troubleshooting for C501, C502, C503, C504,
C505.
5
Probable cause
• Brake potentiometer matching value defect
• Brake potentiometer assembly defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
Perform matching of the brake potentiometer.

(Refer to page MATCHING)
Judgment
Result Procedure
STEP2
Check the brake potentiometer voltage.

Brake sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRB
Confirm the range is within the value of the following table with the
brake operated and the difference is 0.45V or more compared to
the matching voltage with the brake released.
Brake pedal height sensor 1 sensor 2

When the brake is released 0.50V to 1.79V 0.79V to 2.88V
Brake pedal height sensor 1 sensor 2

When at the start point of brake activation 1.60V to 4.09V 2.00V to 4.79V
Judgment
Result Procedure
Within standard range Main controller defect.
Outside standard range Go to step 3
Brake potentiometer assembly defect.
Perform the matching after reassembly.
STEP3
Judgment
Result Procedure
C506 error occurs. Main controller defect
C506 error does not occur. Brake potentiometer matching value defect
Use as it is.
Error Code: C801

Failure mode: Drive motor LH rotation sensor open abnormality
CAUTION
5
Probable cause
• Drive motor LH rotation sensor 1/2 harness defect
• Drive motor LH rotation sensor 1 defect
• Drive motor LH rotation sensor 1/2 defect
Related portion
CN109-15 (78, SSDL+) CN202-1 CN122-2

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1
Disconnect the battery plug, and visually check inside the

connector between CN109, CN122, CN123 and CN202 and the
crimped portion of its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Harness

the harnesses.

CN109 CN122 CN123 Inspect for continuity and short circuiting of the
harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2
CN109, CN122 and CN123 connectors disconnected.
Visually check inside the connector and the crimped
*1: It is OK to connect CN122-1 to CN122-2 (CN109 side) through SST2 (979-001/161) and check if there is conti-
nuity between CN109-15 and CN109-14.
Measurement terminals Standard: Remarks

Judgment
Result Procedure
OK Go to step 3
NG Drive motor LH rotation sensor 1/2 harness defect
Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3

Connect the CN109 connector, then connect the battery plug and
turn on the key switch. CN122 and CN123 connectors are still
disconnected.
Measure the voltage between CN122-2 and N1, and between

CN123-2 and N1.
CN122 CN123
1 2 1 2
Judgment 5
Result Procedure
12 ~ 16V Go to step 4
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection:
Check the error code
Connect between CN122-1 and CN122-2, and between CN123-1
and CN123-2 by using SST2. Connector CN109 is connected.
CN122 CN123
1 2 1 2
Connect the battery plug and turn on the key switch to confirm that
the error occurs.
Judgment
Result Procedure
C802 error occurs Go to step 5
C801 error occurs, or error does not occur Drive motor driver LH defect
STEP5

Disconnect the SST2, and measure the resistance between
CN122-1 (CN109 side) and N1, and between CN123-2 (CN109
side) and N1 with CN109 connected and CN122, CN123

disconnected.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx. 100 Ω Go to step 6
Either resistance is not Approx. 100 Ω Drive motor driver LH defect
STEP6
Inspection: Drive motor LH rotation sensor

Reconnect the CN122 and CN123 connector.
Connect the battery plug, turn on the key switch, and wait for the
C801 error to occur.
?Drive motor LH rotation sensor: sensor 1 / sensor 2
[ANL] I/O TRAVELING 5/5?SSDL
Judgment
Result Procedure
Drive motor LH rotation sensor 1 voltage: 0.3 or less Drive motor LH rotation sensor 1 defect
Drive motor LH rotation sensor 2 voltage: 0.4 to 1.9
Drive motor LH rotation sensor 1 voltage: 0.4 to 1.9 Drive motor LH rotation sensor 2 defect
Drive motor LH rotation sensor 2 voltage: 0.3 or less
Drive motor LH rotation sensor 1 voltage: 0.3 or less Drive motor LH rotation sensor 1/2 defect
Drive motor LH rotation sensor 2 voltage: 0.3 or less
Error Code: C802

Failure mode: Drive motor LH rotation sensor short abnormality
CAUTION
5
Probable cause
• Drive motor LH rotation sensor 1/2 harness defect
• Drive motor LH rotation sensor 1/2 defect
Related portion
CN109-15 (78, SSDL+) CN202-1 CN122-2

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1

connector between CN109, CN122, CN123 and CN202 and the
crimped portion of its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Harness

the harnesses.

harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2

Judgment
Result Procedure
OK Go to step 3
NG Drive motor LH rotation sensor 1/2 harness defect
Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3

turn on the key switch with CN122 and CN123 connectors
disconnected.

CN123-2 and N1.
CN122 CN123
1 2 1 2
Judgment 5
Result Procedure
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection:
disconnected. Check what error occurred.
Judgment
Result Procedure
C802 error occurs, or error does not occur Drive motor driver LH defect
STEP5

Measure the resistance between CN122-1 (CN109 side) and N1,
and between CN123-2 (CN109 side) and N1 with CN109
connected and CN122, CN123 disconnected.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx.100 Ω Go to step 6
Either resistance is not Approx.100 Ω Drive motor driver LH defect
STEP6
Inspection: Drive motor LH rotation sensor

?Drive motor LH rotation sensor: sensor 1 / sensor 2
[ANL] I/O TRAVELING 5/5?SSDL
Judgment
Result Procedure
Drive motor LH rotation sensor 1 voltage: 2.0 or more Drive motor LH rotation sensor 1 defect
Drive motor LH rotation sensor 2 voltage: 0.4 to 1.9
Drive motor LH rotation sensor 1 voltage: 0.4 to 1.9 Drive motor LH rotation sensor 2 defect
Drive motor LH rotation sensor 2 voltage: 2.0 or more
Drive motor LH rotation sensor 1 voltage: 2.0 or more Drive motor LH rotation sensor 1/2 defect
Drive motor LH rotation sensor 2 voltage: 2.0 or more
Error Code: C803

Failure mode: Drive motor RH rotation sensor open abnormality
CAUTION
5
Probable cause
• Drive motor RH rotation sensor 1/2 harness defect
• Drive motor RH rotation sensor 1 defect
• Drive motor RH rotation sensor 1/2 defect
Related portion
CN110-15 (75, SSDR+) CN202-3 CN53-2

CN203-3 CN202-4 Drive motor RH
P4
+ rotation
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotation
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1
Disconnect the battery plug. Visually check inside the connector

between CN110, CN53, CN54 and CN202 and the crimped
portion of its wire for defects. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2
Visually check inside the connectors and the crimped
CN110-15 and CN110-14.
CN110-15 and CN110-13.

Judgment
Result Procedure
OK Go to step 3
NG Drive motor RH rotation sensor 1/2 harness defect
Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3

disconnected.
CN54-2 and N1.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection:
5
Connect between CN53-1 and CN53-2, and between CN54-1 and
CN54-2 by using SST2 with CN110 connected and CN53, CN54
disconnected.
the error occurs.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
C803 error occurs, or error does not occur Drive motor driver RH defect
STEP5

Disconnect the SST2, and measure the resistance between
CN53-1 (CN110 side) and N1, and between CN54-1 (CN110 side)
and N1 with CN110 connected and CN53, CN54 disconnected.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection: Drive motor RH rotation sensor

?Drive motor RH rotation sensor: sensor 1 / sensor 2
[ANL] I/O TRAVELING 5/5?SSDR
Judgment
Result Procedure
Drive motor RH rotation sensor 1 voltage: 0.3 or less Drive motor RH rotation sensor 1 defect
Drive motor RH rotation sensor 2 voltage: 0.4 to 1.9
Drive motor RH rotation sensor 1 voltage: 0.4 to 1.9 Drive motor RH rotation sensor 2 defect
Drive motor RH rotation sensor 2 voltage: 0.3 or less
Drive motor RH rotation sensor 1 voltage: 0.3 or less Drive motor RH rotation sensor 1/2 defect
Drive motor RH rotation sensor 2 voltage: 0.3 or less
Error Code: C804

Failure mode: Drive motor RH rotation sensor short abnormality
CAUTION
5
Probable cause
• Drive motor RH rotation sensor 1/2 harness defect
• Drive motor RH rotation sensor 1/2 defect
Related portion
CN110-15 (75, SSDR+) CN202-3 CN53-2

CN203-3 CN202-4 Drive motor RH
P4
+ rotarion
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotarion
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1

betweenCN110, CN53, CN54 and CN202 and the crimped portion
of its wire for defects. Refer to BEFORE TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2
CN110-15 and CN110-14.
CN110-15 and CN110-13.

Judgment
Result Procedure
OK Go to step 3
NG Drive motor RH rotation sensor 1/2 harness defect
Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3

disconnected.
CN54-2 and N1.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
12 to 16V Go to step 4
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection:
5
disconnected. And check what error occurred.
Judgment
Result Procedure
C804 error occurs, or error does not occur Drive motor driver RH defect
STEP5

Measure the resistance between CN53-1 (CN110 side) and N1,
and between CN54-1 (CN110 side) and N1 with CN110
connected and CN53, CN54 disconnected.
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection: Drive motor RH rotation sensor

• Drive motor RH rotation sensor: sensor 1 / sensor 2
[ANL] I/O TRAVELING 5/5 SSDR
Judgment
Result Procedure
Drive motor RH rotation sensor 1 voltage: 2.0 or more Drive motor RH rotation sensor 1 defect
Drive motor RH rotation sensor 2 voltage: 0.4 to 1.9
Drive motor RH rotation sensor 1 voltage: 0.4 to 1.9 Drive motor RH rotation sensor 2 defect
Drive motor RH rotation sensor 2 voltage: 2.0 or more
Drive motor RH rotation sensor 1 voltage: 2.0 or more Drive motor RH rotation sensor 1/2 defect
Drive motor RH rotation sensor 2 voltage: 2.0 or more
Error Code: CB01

Failure mode: MB contactor open abnormality
CAUTION
• If CB03 or CB05 occurs, perform troubleshooting for that first.
Probable cause 5
• MB contactor defect
• Harness defect
• F6 fuse defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-2 (1, CBAT+) CN104-3 (1, CBAT+)
STEP1

After disconnecting the F5 and F6 fuses, visually confirm whether
Connect the F5, F6 fuse, connect the battery plug.
Judgment
Result Procedure
CB01 error occurs. Go to step 2
Result Procedure
CB01 error does not occur. Connector contact defect
STEP2
Check the operation of MB contactor:

Check if the MB contactor activates when turn on the key switch.
Judgment
Result Procedure
OK Go to step 4
NG Go to step 3
STEP3
Check the contact of MB contactor:

check activation of the MB contactor (contamination, freeze and
so on).
Judgment
Result Procedure
OK Perform troubleshooting for CB03.
NG MB contactor defect
Use as it is after repairing NG items.
STEP4
Inspection: F6 fuse
Remove F6 fuse and measure the resistance across it.
Judgment
Result Procedure
0Ω Go to step 5
After replacing F6 fuse, go to STEP 6
STEP5

Connect the F6 fuse, and disconnect the connector of fuse box.
Measure the resistance for both ends of F6 fuse box.
Judgment
Result Procedure
0Ω Go to step 6
∞Ω F6 fuse box defect
STEP6
5
Inspection: Harness
Disconnect the CN102 and CN104 connectors and F6 fuse and
check the harnesses for continuity.

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
Perform this check with the battery plug, the CN102
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 and CN104 connectors, and F6 fuse disconnected.
28 29 30 31 32 33 34 35 26 27 28 29 30 31 Visually check inside the connectors and the crimped
CN250
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60

CN250-52 (fuse side) to P3 Continuity
CN250-52 (fuse side) to N1 No continuity
Judgment
Result Procedure
OK Go to step 7
NG Harness defect
STEP7
Voltage inspection
After connecting the connectors, connect the battery plug, and
Measure both ends of the contactor for voltage (contact side).
Refer to the following figure, and measure both ends of the
contactor for voltage (contact side).
P2
P3
P4
P1
Judgment
Result Procedure
30V or more MB contactor defect
Error Code: CB02

Failure mode: MB contactor short abnormality
CAUTION
• If AD05, AD06, E101, E102, E002, E801, E802, EC01, EC02 or EC03 occurs at the same time as CB02,
perform troubleshooting for AD05, AD06, E101, E102, E002, E801, E802, EC01, EC02 or EC03 first.
• If CB02 error occurs, an electric charge remains in the pump motor and drive motor driver after the
battery plug is disconnected. Measure the voltage between P4 and N1 and start operation after it has 5
lowered below 3 volts.
Probable cause
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1
Reconnect the battery plug and turn on the key switch. Wait 5
seconds or more.
Turn the key switch off for 5 seconds, and then turn the key switch
on and check if the error occurs.
Judgment
Result Procedure
CB02 error does not occur. No abnormality.Use truck as it is.
STEP2
Check if the MB contactor opens when you turn off the key switch.
Judgment
Result Procedure
The contactor opens Go to step 3
The contactor does not open. Go to step 4
STEP3
Inspection:
Voltage inspection
Turn off key switch and disconnect the battery plug. Connect the
battery plug again and turn on the key switch.
Turn off the key switch and wait 5 seconds or more, then measure
the voltage between P4 and N1.
Judgment
Result Procedure
15V or more Pump motor driver defect
STEP4
Inspection: MB contactor
Measure the voltage between P4 and N1 of the contactor to see
that it is 3V or less.
Visually check the conditions of the contacts of the MB contactor.
Judgment
Result Procedure
The contactor does not open. MB contactor defect
The contactor opens Perform troubleshooting for CB03.
Error Code: CB03

Failure mode: MB contactor (coil side) open abnormality
Probable cause
• Harness defect
5
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: MB contactor coil

Disconnect the CN136 connector and measure the resistance of

the MB contactor coil.

Check the resistance of the MB contactor coil.
CN136
1
2 3

CN136-1 to CN136-2 STD spec.: 15 to 30 Ω
(Approx. 20 Ω: 20°C)
Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness
harnesses.

CN104 harnesses.
CN136 Perform this check with the battery plug and the
1 2 3 4 5 6 7
CN104, CN136 connectors disconnected. Visually
8 9 10 11 12 13 14 15 16 17 1
18 19 20 21 22 23 24 25 2 3
its wire for defects.
26 27 28 29 30 31 Refer to BEFORE TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
5
Error Code: CB04

Failure mode: MB contactor drive circuit abnormality
Probable cause
• Harness defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

TROUBLESHOOTING.
Judgment
Result Procedure
STEP2



CN136
1
2 3
5

Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness
harnesses.

CN136 harnesses.
1
2 3 CN104, CN136 connectors disconnected. Visually

CN136-1 (2) to P1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: CB05

Failure mode: MB contactor (coil side) short abnormality
Probable cause
• Harness defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

TROUBLESHOOTING.
Judgment
Result Procedure
STEP2


CN136
1
2 3
Portion to be inspected Standard: 5

Judgment
Result Procedure
OK Go to step 3
STEP3
Inspection: Harness
harnesses.

CN104 harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1
18 19 20 21 22 23 24 25 2 3
26 27 28 29 30 31 Refer to BEFORE TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect.
Error Code: CC01

Failure mode: Drive motor driver LH CPU abnormality
CAUTION
• If CC01 occurs, the drive motor driver LH is defective. Replace it.
Probable cause 5
Related portion

Error Code: CC02

CAUTION
Probable cause
Related portion

Error Code: CC03

CAUTION
Probable cause 5
Related portion

Error Code: CC04

CAUTION
Probable cause
Related portion

Error Code: CC06

CAUTION
Probable cause 5
Related portion

Error Code: CD01

Failure mode: Drive motor driver RH CPU abnormality
CAUTION
• If CD01 occurs, the drive motor driver RH is defective. Replace it.
Probable cause
Related portion

Error Code: CD02

CAUTION
Probable cause 5
Related portion

Error Code: CD03

CAUTION
Probable cause
Related portion

Error Code: CD04

CAUTION
Probable cause 5
Related portion

Error Code: CD06

CAUTION
Probable cause
Related portion

Error Code: E002

Failure mode: Pump motor driver power-circuit abnormality
CAUTION
• If E002 error occurs, electric charge remains in the pump motor and drive motor driver after the battery
plug is disconnected. Measure the voltage between P4 and N1 and start operation after it has lowered
below 3V. 5
Probable cause
• Pump motor cable tightening is defective
• Pump motor defect
• Pump motor cable defect
Related portion
P14
U
Pump motor P15

V Pump motor
driver
P16
W
STEP1
check the fastened and crimped portions of the pump motor
cables for defects. Refer to BEFORE TROUBLESHOOTING.
Connect the pump motor cables, connect the battery plug, and
errors.
Judgment
Result Procedure
E002 error occurs. Go to step 2
E002 error does not occur. Pump motor cable tightening is defective
STEP2

Disconnect the three motor cables from the pump motor driver and
isolate them. Make sure the disconnected terminals are not
touching.
Operate the direction lever forward or backward and check if error
E002 occurs.
Judgment
Result Procedure
E002 error does not occur. Go to step 3
E002 error occurs. Pump motor driver defect
STEP3
Inspection: Pump motor cable

Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for continuity and shorts.
Turn off the key switch, disconnect the battery plug and
disconnect the pump motor cables. Visually check each terminal

P14 cable to P15 cable No continuity
Judgment
Result Procedure
OK (C002 does not occur at the same time on STEP1) Go to step 4
OK (C002 occurs at the same time on STEP1) Go to step 5
NG Pump motor cable defect
STEP4

Replace the pump motor driver with the drive motor driver LH.
Judgment
5
Result Procedure
C002 error occurs. Pump motor driver defect
If the error code changes to E002, replace the pump motor
driver.
E002 error occurs. Pump motor defect
STEP5
Inspection: Pump motor

Check the pump motor.
Judgment
Result Procedure
NG Pump motor defect
Error Code: E101

Failure mode: Pump motor driver current sensor neutral voltage error
CAUTION
• If E101 occurs, the pump motor driver circuit is defective. Replace it.
Probable cause
Related portion
Pump motor driver
Current sensor
Error Code: E102

Failure mode: Pump motor driver current sensor over current error
CAUTION
below 3V.
5
Probable cause
• Pump motor cable tightening is defective
• Pump motor defect
• Pump motor cable defect
Related portion
P14
U
Pump motor P15

V Pump motor
driver
P16
W
STEP1
Judgment
Turn the key switch off and on, operate the direction lever forward or backward, and check if E002 error occurs.
Result Procedure
E002 error does not occur. Go to step 2
E002 error occurs. Perform troubleshooting for E002.
STEP2
check the assembled and crimped portions of the pump motor
cables for defects. Refer to BEFORE TROUBLESHOOTING.
Connect the pump motor cables, connect the battery plug, and
errors.
Judgment
Result Procedure
E102 error does not occur. Pump motor cable tightening is defective
STEP3
Inspection: Pump motor cable

Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for continuity and shorts.
Turn off the key switch, disconnect the battery plug, and
disconnect the pump motor cables. Visually check each terminal

Judgment
Result Procedure
OK (C102 does not occur at the same time on Go to step 4
STEP 2)
OK (C102 occurs at the same time on STEP 2) Go to step 5
NG Pump motor cable defect
STEP4

Replace the pump motor driver with the drive motor driver LH.
Judgment
Result Procedure
C102 error occurs. Pump motor driver defect
If the error code changes to E102, replace the pump motor
driver.
E102 error occurs. Pump motor defect
STEP5 5
Inspection: Pump motor
Check the pump motor.
Judgment
Result Procedure
NG Pump motor defect
Error Code: E201

Failure mode: Pump motor overheating abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN111-9 (88, STPM+) CN55-2

Temperature sensor
Pump motor driver (Pump motor)
CN111-10 (89, STPM) CN55-1
CN102-2 (99, FANDC2) CN118-2
Main controller Motor fan

CN104-3 (1, CBAT+) CN118-1
CN250-29 CN250-30
F53
STEP1
condition.
FAN2: OFF → ON
* If the cooling fan is not working correctly, start troubleshooting
from STEP2.
Judgment
Result Procedure
STEP2
Inspection:
Reconfirm the error
Turn the key switch ON and check the error that is displayed.
Judgment
Result Procedure
A “PM” is displayed. Go to step 3 5
No “PM” is displayed. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “PM” goes
STEP3
Inspection:
Confirm the temperature of the pump motor and recheck the error
*Pump motor temperature
[ANL] I/O TEMP/VOLT 3/6 TPM
Record the temperature of the pump motor.
thirty minutes. Turn the key switch ON and check the error
displayed.
Judgment
Result Procedure
An “PM” is displayed. Go to step 4
No “PM” is displayed. Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “PM” goes
STEP4
Inspection:
Recheck the temperature of the pump motor.
*Pump motor temperature
[ANL] I/O TEMP/VOLT 3/6 TPM
Check the pump motor temperature, and compare it to the
recorded value.
Judgment
Result Procedure
It has not lowered by 41°F (5°C) or more. E202 Perform troubleshooting from STEP2.
STEP5
Inspection:
Inspect harness
the harnesses.
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN118
CN104 2 1
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
OK Go to step 6
STEP6
Inspection:
Inspect cooling fan.
turn the key switch ON.
condition.
5
FAN2: OFF → ON
Judgment
Result Procedure
main controller.
Error Code: E202

Failure mode: Pump motor temperature sensor (open/short) abnormality
Probable cause
• Pump motor temperature sensor defect
• Pump motor temperature sensor harness defect
Related portion
CN111-9 (88, STPM+) CN55-2

Pump motor driver Temperature sensor
(Pump motor)
CN111-10 (89, STPM) CN55-1
STEP1
Disconnect the battery plug and visually check inside the

connector between CN55 and the crimped portion of its wire for
Judgment
Result Procedure
E202 error does not occur. Connector contact defect
STEP2
Inspection:
Pump motor temperature sensor individual inspection
Disconnect the CN55 connector and perform the sensor individual
inspection.

Carry out temperature sensor individual inspection.
CN55
Measure the temperature sensor resistance between
2 1
Standard: Approx. 245 Ω to 600 kΩ
* The resistance is changed depending on the temperature. Refer to the table below for the rough standard value.
Temperature sensor
68°F (20°C) Approx. 13 kΩ
176°F (80°C) Approx. 1.75 kΩ
212°F (100°C) Approx. 1 kΩ
Judgment 5
Result Procedure
OK Go to step 3
NG Pump motor temperature sensor defect
STEP3
Inspection: Harness
harnesses.

CN111 CN55 harnesses.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 Perform this check with the battery plug and the
16 17 18 19 20 21 22 23 CN111, and CN55 connectors disconnected. Visually
its wire for defects with disconnecting SST.
CN111-9 and CN111-10.

Judgment
Result Procedure
NG Pump motor temperature sensor harness defect
Error Code: E301

Failure mode: Pump motor driver power-circuit temperature sensor (open/short)
abnormality
CAUTION
• If E301 occurs, the pump motor driver circuit is defective. Replace it.
Probable cause
Related portion
Pump motor driver
Temperature sensor
Error Code: E801

Failure mode: Pump motor rotation sensor open abnormality
CAUTION
below 3V.
5
Probable cause
• Pump motor rotation sensor harness defect
• Pump motor rotation sensor defect
Related portion
P4
+
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1

connector between CN56 and CN111 and the crimped portion of
Judgment
Result Procedure
STEP2
Inspection: Harness
harnesses.

1 2 3 4 5 6 7 8
its wire for defects with the SST disconnected.
CN111-15 and CN111-14.

Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3

Connect the CN111 connector. Connect the battery plug and turn
on the key switch with the CN56 connector disconnected.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection:

Connect SST2 between CN56-1 and CN56-2 on the CN111 side
with CN56 connector disconnected.
the error occurs.
CN56
5
1 2
Judgment
Result Procedure
E801 error occurs, or error does not occur. Pump motor driver defect
STEP5

Disconnect SST2, and measure the resistance between CN56-1
(CN111 side) and N2 with CN56 connector disconnected.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: E802

Failure mode: Pump motor rotation sensor short abnormality
CAUTION
below 3V.
Probable cause
• Pump motor rotation sensor harness defect
• Pump motor rotation sensor defect
Related portion
P4
+
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1

connector between CN56 and CN111 and the crimped portion of
Judgment
Result Procedure
STEP2
Inspection: Harness
harnesses.

1 2 3 4 5 6 7 8
its wire for defects with the SST disconnected.
CN111-15 and CN111-14.

Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3

Connect the CN111 connector. Connect the battery plug and turn
on the key switch with the CN56 connector disconnected.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection:
Connect the battery plug and turn on the key switch with
disconnecting CN56 connector. And check the occurred error.
Judgment
Result Procedure
E802 error occurs, or error does not occur. Pump motor driver defect
STEP5

Measure the resistance between CN56-1 (CN111 side) and N2
with the CN56 connector disconnected.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: EC01

Failure mode: Pump motor driver CPU abnormality
CAUTION
• If EC01 occurs, the pump motor driver circuit is defective. Replace it.
Probable cause 5
Related portion
Pump motor driver

Error Code: EC02

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC03

CAUTION
Probable cause 5
Related portion
Pump motor driver

Error Code: EC04

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC06

CAUTION
Probable cause 5
Related portion
Pump motor driver

Error Code: EE01

Failure mode: Communication line abnormality: Display to main controller
CAUTION
• The display was not communicating with the main controller. Communication to the display has
recovered. Use it as is.
Probable cause
• Display defect
Related portion
CN103-11 (145, CAN1H) CN70-16
Main controller Display

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:

Check if error F101 or F102 is occurring at display.
Judgment
Result Procedure
F101 or F102 occur Troubleshooting for F101, F102
No occurrence Display or main controller defect
Error Code: EE02

Failure mode: Communication line abnormality: Display to main controller
CAUTION
• The display was not communicating with the main controller. Communication to the display has
recovered. Use it as is.
5
Probable cause
• Display defect
Related portion
CN103-11 (145, CAN1H) CN70-16

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:

Check if error F101 or F102 is occurring at display.
Judgment
Result Procedure
F101 or F102 occur Troubleshooting for F101, F102
No occurrence Display or main controller defect
Error Code: F101

Failure mode: Communication line abnormality between main controller and display
Probable cause
Related portion
CN103-3 (14, DGND) CN70-4

CN103-14 (16, D7V) CN70-5
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15
STEP1
Inspection: Reconfirm the error.

between CN103 and CN70 and the crimped portion of its wire for
the key switch ON to confirm the error.
Judgment
Result Procedure
F101 or F102 occurs Perform troubleshooting for F102.
F101 and F102 does not occur Connector contact defect
Use the lift truck as it is.
Error Code: F102

Failure mode: Communication line abnormality between main controller and display
Probable cause
• Harness defect
• Display defect
5
Related portion
CN103-3 (14, DGND) CN70-4

CN103-14 (16, D7V) CN70-5
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15
CN103-5 CN103-4
(N2, N2) (42, KYSAT)
CN109-8
CN109-17 Drive motor
driver LH
CN109-16
CN110-8
CN110-17 Drive motor
driver RH
CN110-16
CN111-8
CN111-17 Pump motor
driver
CN111-16
STEP1
CN103 and CN70 and the crimped portion of its wire for defects.
Judgment
Result Procedure
F102 error occurs. Go to step 2
F102 error does not occur. Connector contact defect
STEP2
Inspection: Harness
harnesses.

harnesses.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN103-11 to CN70-16 Continuity (Approx. 0 Ω)
CN103-12 to CN70-15 Continuity (Approx. 0 Ω)
CN70-15 to CN70-16 No continuity (Except 0 Ω)
Judgment
Result Procedure
NG Harness defect
OK Go to step 3
STEP3
After connecting CN70 and CN103 connectors, connect the
battery plug and turn on the key switch. Check the drive and
material handling operations of the lift truck.
Judgment
Result Procedure
The traveling and load handling operation Display defect
can be performed. If the symptom persists after replacement of the display,
there are other problems. Replace the main controller.
The traveling and load handling operation Main controller defect
cannot be performed. If the symptom persists after replacement of the main
controller, there are other problems. Replace the display. 5
Error Code: F401

Failure mode: Display CPU defect
CAUTION
• If F401 occurs, the display is defective. Replace it.
Probable cause
• Display defect
Related portion
Display
Error Code: F402

CAUTION
Probable cause 5
• Display defect
Related portion
Display
Error Code: F403

CAUTION
Probable cause
• Display defect
Related portion
Display
Error Code: F404

CAUTION
Probable cause 5
• Display defect
Related portion
Display
Error Code: F405

CAUTION
Probable cause
• Display defect
Related portion
Display
Error Code: F406

CAUTION
Probable cause 5
• Display defect
Related portion
Display
Error Code: F407

CAUTION
Probable cause
• Display defect
Related portion
Display
Error Code: F408

CAUTION
Probable cause 5
• Display defect
Related portion
Display
Error Code: FB01

Failure mode: Battery current sensor neutral voltage error
CAUTION
• If the symptom persists after replacement of the current sensor, there are other problems. Replace the
Main controller.
Probable cause
• Harness defect
• Battery current sensor defect
Related portion
Contactor panel
CN104-10 (303, CSBAT+) CN138-1
Main CN102-24 (304, CSBAT) CN138-3

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
Disconnect the CN138 connector. Check the inside of the
TROUBLESHOOTING.
Judgment
Result Procedure
FB01 error occurs. Go to step 2
FB01 error does not occur. Connector contact defect
STEP2
Inspection: Harness
the harnesses.

Check the harnesses.
CN102
1 2 3 4 5 6 7 CN102, CN104 and CN138 connectors disconnected.
8 9 10 11 12 13 14 15 16 17 18 19 portion of its wire for defects. (Note: Inspect with the
20 21 22 23 24 25 26 27 SST disconnected.)
28 29 30 31 32 33 34 35
CN138 5
1 2 3
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
*1: Connect CN138-1 and CN138-3 on the harness side through SST2 (979-001/161) and check if there is continuity
between CN104-10 and CN102-24.

CN104-10 (303) to CN138-1 (303) Continuity *1
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Inspection: Battery current sensor

Check the value of battery current sensor using the Analyzer
menu.
[ANL] I/O OTHERS 1/1 CSBAT
Judgment
Result Procedure
Approx. 0.00 Go to step 4
Except 0.00 Main controller defect
STEP4

Disconnect CN138 and connect CN138-1 to CN138-3 on the
harness side through SST2 (979-001/161).
Check the value of the battery current sensor using the Analyzer
menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FB02

Failure mode: Battery current sensor overcurrent
Probable cause
• Harness defect
• Battery current sensor defect
5
Related portion
Contactor panel
CN104-10 (303, CSBAT+) CN138-1
Main CN102-24 (304, CSBAT) CN138-3

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
Disconnect the CN138 connector. Check the inside of the
TROUBLESHOOTING.
Judgment
Result Procedure
FB02 error occurs. Go to step 2
FB02 error does not occur. Connector contact defect
STEP2
Inspection: Harness
the harnesses.

Check the harnesses.
CN102

8 9 10 11 12 13 14 15 16 17 18 19 Visually check inside the connector and the crimped
20 21 22 23 24 25 26 27 portion of its wire for defects. (Note: Inspect with the
28 29 30 31 32 33 34 35
SST disconnected.)
CN138
1 2
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
menu.
Judgment
Result Procedure
Approx. 0.00 Go to step 4
STEP4

5
Disconnect CN138 and connect CN138-1 to CN138-3 on the
harness side through SST2 (979-001/161).
menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FF01

Failure mode: Power supply circuit for display over current
CAUTION
• When FF01 error occurs, error codes cannot be checked on the display. Perform inspection and repair
while conducting troubleshooting at where no error is detected.
Probable cause
• Display defect
• Harness defect
Related portion
CN103-14 (16, D7V) CN70-5
CN103-3 (14, DGND) CN70-4
STEP1
Turn off the key switch and disconnect the battery plug. Check the
inside of connectors CN103 and CN70 and the crimped portion of
the wire to see whether it has a defect or not by visual
on the key switch to confirm the display.
Judgment
Result Procedure
Screen is displayed and FF-1 error does Connector contact defect
not occur.
Screen is not displayed. Go to step 2
STEP2
Perform inspection and repair while conducting troubleshooting at

when no error code is displayed.
Troubleshooting at WHEN NO ERROR CODE IS DISPLAYED.
[Classification of Control], errors related to power source and
[Phenomenon occurs on lift truck] are not indicated on the display
while the lift truck runs.
Error Code: FF02

Failure mode: Steering sensor power-supply circuit over current
Probable cause
• Steering sensor defect
• Harness defect
5
Related portion
CN103-13 (311, SSTR+) CN19-1
Main controller Steering sensor
CN103-6 (51, LS-) CN19-2
STEP1
Disconnect the battery plug. Visually check inside connector

CN19 and the crimped portion of its wire for defects. Refer to
on the key switch to confirm the display.
Judgment
Result Procedure
FF02 error occurs. Go to step 2
FF02 error does not occur. Connector contact defect
STEP2
Inspection:
Steering sensor power supply inspection.
Measure the voltage between the CN19-1 and CN19-2 connectors
on the harness side.

Inspect the steering sensor power supply.
CN19
1 2
and disconnect the CN19 connector. Visually check
3 4 5 6 each terminal and the crimped portion and coating of
TROUBLESHOOTING.

CN19-1 (311) to CN19-2 (51) Approx. 15V
Judgment
Result Procedure
NG Go to step 3
OK Steering sensor defect
STEP3
Inspection: Harness
harnesses.

CN103 Inspect for continuity and short circuiting of each
harness.
CN19
1 2 3 4 5 6
1 2
7 8 9 10 11 12 13 14 15 16 and CN103 connectors disconnected. Visually check
3 4 5 6 inside the connector and the crimped portion of its wire
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 for defects.

Judgment
Result Procedure
NG Harness defect
Error Code: 3201

Failure mode: Drive motor driver (LH): controller ID abnormality
CAUTION
• When a pump motor driver or drive motor driver (RH) is being used as a driver motor driver (LH) a 3201
error always occurs. This is not an abnormality. This will occur at first power up of the controller replace-
ment.
• If AD03, AD04 or AD05, AD06 occurs, perform troubleshooting for that first. 5
Probable cause
• Drive motor driver (LH) defect
Related portion
CN109-6 CN110-6
NC NC
Drive motor CN109-7 Drive motor CN110-7 (150, SETDR1)
driver LH NC driver RH
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1

After disconnecting the CN109, CN110, CN111 connector, check
the inside of the connector and the crimped portion of wire to see
Connect the CN109, CN110, CN111 connector, connect the
battery plug.
Judgment
Result Procedure
3201 error occurs. Drive motor driver (LH) defect
3201 error does not occur. Connector contact defect
Error Code: 3202

Failure mode: Drive motor driver (RH): controller ID abnormality
CAUTION
• When a new motor driver, a pump motor driver, or a drive motor driver (LH) is installed as a driver motor
driver (RH), the 3202 error always occurs. This is not an abnormality. This will occur at first power up of
the controller replacement.
• If AD01, AD02 or AD05, AD06 occurs, perform troubleshooting for that first.
Probable cause
• Drive motor driver (RH) defect
Related portion
CN109-6 CN110-6
NC NC
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1

After disconnecting the CN109, CN110, CN111 connector,
visually confirm whether the inside of the connector and the
crimped portion of the wire has a defect or not. Refer to BEFORE
TROUBLESHOOTING.
battery plug.
Judgment
Result Procedure
3202 error occurs. Drive motor driver (RH) defect
Error Code: 3203

Failure mode: Pump motor driver: controller ID abnormality
CAUTION
• When a new motor driver, drive motor driver (LH), or (RH) is being used as a pump motor driver, a 3201
error always occurs. This is not an abnormality. This will occur at first power up of the controller replace-
ment.
• If AD01, AD02 or AD03, AD04 occurs, perform troubleshooting for that first. 5
Probable cause
Related portion
CN109-6 CN110-6
NC NC
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1

After disconnecting the CN109, CN110, CN111 connector,
TROUBLESHOOTING.
battery plug.
Judgment
Result Procedure
3203 error occurs. Pump motor driver defect
Error Code: 3301

Failure mode: Main controller to Drive motor driver (LH): communication abnormality
CAUTION
• If AD01 or AD02 occurs, perform troubleshooting for AD01 or AD02 first.
Probable cause
• Harness defect
• Drive motor driver (LH) defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1

After disconnecting the CN103, CN104 and CN109 connector,
TROUBLESHOOTING.
Connect the CN103, CN104 and CN109 connector, connect the
battery plug.
Especially if the drive motor driver (LH) has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
3301 error occurs. Go to step 2
STEP2
Inspection: Harness
the harnesses for continuity.

5
1 2 3 4 5 6
CN103, CN104, CN109 connectors disconnected.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 Visually confirm whether the inside of the connector
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 and the crimped portion of the wire has a defect or not.
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35 Refer to BEFORE TROUBLESHOOTING.

CN103-4 (42) to CN103-5 (N2) No continuity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3

Turn off the key switch, and after connecting CN103, CN104,
CN109 connectors, turn on the key switch.
Judgment
Result Procedure
STEP4
Inspection: Motor driver

the error occurs.
Judgment
Result Procedure
3303 error occurs. Drive motor driver (LH) defect
The motor driver that is drive motor driver (LH) before
replacement is defective.
3301 error occurs. Main controller defect
Error Code: 3302

Failure mode: Main controller to Drive motor driver (RH): communication abnormality
CAUTION
Probable cause 5
• Harness defect
• Drive motor driver (RH) defect
Related portion
CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1

After disconnecting the CN103, CN104, CN110 connectors,
TROUBLESHOOTING.
Connect the CN103, CN104, CN110 connectors, connect the
battery plug.
Especially if the drive motor driver (RH) has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
STEP2
Inspection: Harness

1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 Visually confirm whether the inside of the connector
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15 and the crimped portion of the wire has a defect or not.
16 17 18 19 20 21 22 23

Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3

Judgment
Result Procedure
STEP4

the error occurs.
Judgment
5
Result Procedure
3303 error occurs. Drive motor driver (RH) defect
The motor driver that is drive motor driver (RH) before
replacement is defective.
Error Code: 3303

Failure mode: Main controller to Pump motor driver: communication abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H) Pump motor
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L) driver
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1

After disconnecting the CN103, CN104, CN111 connectors,
TROUBLESHOOTING.
Connect the CN103, CN104, CN111 connectors, connect the
battery plug.
Judgment
Result Procedure
STEP2
Inspect harness:
and check the harnesses for continuity.

5
CN103
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 CN103, CN104, CN109, CN111 connectors
1 2 3 4 5 6 disconnected. Visually check inside the connectors
7 8 9 10 11 12 13 14 15 16 and the crimped portion of their wires for defects.
CN111 Refer to BEFORE TROUBLESHOOTING.
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3

Judgment
Result Procedure
STEP4

the error occurs.
Judgment
Result Procedure
3301 error occurs. Pump motor driver defect
If the error code changes to 3301, replace the pump motor
driver.
Error Code: 6101

Failure mode: Load sensor open abnormality
Probable cause
• Harness defect
• Load sensor defect
5
Related portion
CN104-12 (58, SPLF+) CN91-1
Main controller CN103-29 (59, SPLF) CN91-2

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1

Judgment
Result Procedure
STEP2
Inspection: Load sensor

Disconnect the CN91 connector and connect CN91-1 to CN91-2
on the harness side through SST (979-001/160).
error.
CN91
Judgment
Result Procedure
6102 error occurs. Load sensor defect
6102 error does not occur. Go to step 3
STEP3
Inspection: Harness
Disconnect the CN91, CN101, CN103, CN104 connectors check

CN101 CN103 Inspect for continuity of the harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6
Perform this check with the battery plug and the CN91,
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
Visually confirm whether the inside of the connector
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 and the crimped portion of the wire has a defect or not.
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35
CN104 CN91
1 2 3 4 5 6 7 1
8 9 10 11 12 13 14 15 16 17 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31 3

Judgment
Result Procedure
NG Harness defect
5
Error Code: 6102

Failure mode: Load sensor short abnormality
Probable cause
• Load sensor defect
• Harness defect
Related portion
CN104-12 (58, SPLF+) CN91-1
Main controller CN103-29 (59, SPLF) CN91-2

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1

Judgment
Result Procedure
STEP2
Inspection: Load sensor

Judgment
Result Procedure
6101 error occurs. Load sensor defect
STEP3
Inspection: Harness
Disconnect the CN91, CN101, CN103 and CN104 connectors and

Inspect for continuity of the harnesses.
CN101 CN91 5
1 2 3 4 5 6 7 1 CN101, CN103, CN104 connectors disconnected.
2 portion of their wires for defects.
18 19 20 21 22 23 24 25 26 27

Judgment
Result Procedure
NG Harness defect
Error Code: 6201

Failure mode: Tilt angle sensor open abnormality
Probable cause
• Tilt angle sensor defect
• Harness defect
Related portion
CN101-20 (57, VRTA+) CN86-1
Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor
CN101-32 (51, POT-) CN86-3
STEP1

After disconnecting the CN86 connector, check inside the
connector and the crimped portion of its wires for defects or by
Judgment
Result Procedure
STEP2
Inspection: Tilt angle sensor

on the harness side through SST2 (979-001/161).
error.
CN86
1 2 3
Judgment
Result Procedure
6202 error occurs. Tilt angle sensor defect
STEP3
Inspection: Harness
5


1 2 3 4 5 6 7
CN101, CN103 connectors disconnected, Visually
8 9 10 11 12 13 14 15 16 17 check inside the connectors and the crimped portion of
18 19 20 21 22 23 24 25 26 27 their wires for defects.
28 29 30 31 32 33 34
1 2 3
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
*: It is OK to connect CN86-1 to CN86-2 through SST2 (979-001/161) and check if there is continuity between
CN101-20 and CN102-17.

CN101-20 (57) to CN86-1 (57) * Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 6202

Failure mode: Tilt angle sensor short abnormality
Probable cause
• Tilt angle sensor defect
• Harness defect
Related portion
CN101-20 (57, VRTA+) CN86-1
Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor
CN101-32 (51, POT-) CN86-3
STEP1

Judgment
Result Procedure
STEP2
Inspection: Tilt angle sensor

error.
Judgment
Result Procedure
6201 error occurs. Tilt angle sensor defect
STEP3
Inspection: Harness

5
1 2 3 4 5 6 7 Perform this check with the battery plug and the CN86,
CN101connectors disconnected, Visually check inside
8 9 10 11 12 13 14 15 16 17 the connectors and the crimped portion of their wires
18 19 20 21 22 23 24 25 26 27 for defects.
CN86
CN103 1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN103-17 and CN101-32.

Judgment
Result Procedure
NG Harness defect
Error Code: 6301

Failure mode: Tilt switch forward / backward tilt switch simultaneously short abnormality
Probable cause
• Harness defect
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1

Judgment
Result Procedure
A603 error does not occur. Go to step 2
A603 error occurs. Go to troubleshooting for A603
STEP2
Inspection: Tilt lever switch

Operate the tilt lever in either direction to confirm 6301 error.
Judgment
Result Procedure
6301 error does not occur. The forward and backward tilt lever switches turned ON at
the same time in the past.(Check the adjustment of each
switch installation)
STEP3
Inspection: Harness
Disconnect the CN89 and CN102 connectors and check the main

CN89 harnesses. 5
1 2
and CN102 connectors disconnected. Visually confirm
3 4 whether the inside of the connector and the crimped
portion of the wire has a defect or not.

Judgment
Result Procedure
OK Tilt lever switch installation defect.
Tilt lever switch defect
NG Harness defect
Error Code: 6302

Failure mode: Tilt switch forward tilt switch continuously short abnormality
Probable cause
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1

Judgment
Result Procedure
A603 error occurs. To troubleshooting for A603
STEP2

Check the status of the switches when the tilt lever is operated in
the forward direction and returned to the center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTF
Judgment
Result Procedure
“0” occurs after operation repeated many Detect the error for operating in forward direction over 2
times. minutes.Use as it is.
“1” occurs after operation repeated several Tilt lever switch installation defect.
times. Tilt lever switch defect
Error Code: 6303

Failure mode: Tilt switch backward tilt switch continuously short abnormality
Probable cause
• Tilt lever switch installation defect.
Related portion
5
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1

Judgment
Result Procedure
A603 error occurs. Go to troubleshooting for A603
STEP2

Check the status of the switches when the tilt lever is operated in
the backward direction and returned to the center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTR
Judgment
Result Procedure
“0” occurs after the operation is repeated Detect the error for operating in a backward direction for over
several times. 2 minutes.Use as it is.
“1” occurs after the operation is repeated Tilt lever switch installation defect.
several times. Tilt lever switch defect
Error Code: 6401

Failure mode: Lift lock solenoid open abnormality
CAUTION
• If 6403 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given to
6403.
• If A902 occurs at same time, perform troubleshooting for A902 first.
• Replace CN88-6 with CN88-5 when troubleshooting a lift truck with the Fingertip Control Lever option.
Probable cause
• Lift lock solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
inside of connector CN88 and the crimped portion of the wires for
After connecting CN88, connect the battery plug and turn on the
key switch to confirm the error.
Judgment
Result Procedure
6404 error occurs. Perform troubleshooting for 6404.
STEP2
Apply the lift solenoid by using Active Test, and check if an error
occurs.
LIFT LWR SOL: OFF to ON
Judgment
Result Procedure 5
STEP3
Inspection: Lift lock solenoid individual inspection

Disconnect the CN88 connector, and check the resistance of the
lift lock solenoid.

Check the resistance of lift lock solenoid.
CN88
plug. Disconnect the CN88 connector. Visually check
4 3 2 1 inside the connectors and the crimped portion of their
wires for defects. Refer to BEFORE
8 7 6 5 TROUBLESHOOTING.

CN88-2 to CN88-6 Approx. 10 Ω
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN102, CN103, CN104 and CN88
connectors, then check the harnesses.

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
CN101, CN102, CN103, CN104, CN88 connectors
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
disconnected. Visually check inside the connectors
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 and the crimped portion of their wires for defects.
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*1: Connect the CN88 connector and measure the resistance between CN101-1(3) and CN102-16(4). It is OK if this
resistance is approx.10 Ω.

CN101-1 (3) to CN88-2 (477) Continuously *1
CN102-16 (4) to CN88-6 Continuously *1
Judgment
Result Procedure
NG Harness defect
Error Code: 6402

Failure mode: Lift lock solenoid short abnormality
CAUTION
6403.
5
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Disconnect the CN88 connector. Visually check inside the
connectors and the crimped portion of their wires for defects.
Judgment
Result Procedure
STEP2
Apply the lift solenoid by using Active Test, and check if an error
occurs.
LIFT LWR SOL: OFF to ON
Judgment
Result Procedure
STEP3

Disconnect the CN88 connector, and check the resistance of lift
lock solenoid.

CN88
4 3 2 1 inside the connector and the crimped portion of its

CN88-2 (477) to CN88-6 (4) Approx. 10 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN102 and CN88 connectors, then check
the harnesses.

CN88 harnesses.
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 CN101, CN102, CN88 connectors disconnected.
20 21 22 23 24 25 26 27 Visually check inside the connectors and the crimped
5 6 7 8
28 29 30 31 32 33 34 35 portion of their wires for defects. Refer to BEFORE
TROUBLESHOOTING. 5

Judgment
Result Procedure
NG Harness defect
Error Code: 6403

Failure mode: Lift lock solenoid drive circuit abnormality
CAUTION
Probable cause
• Harness defect
• F73 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Lift lock solenoid

lift lock solenoid.

Check the resistance of the lift lock solenoid.
CN88

CN88-2 (477) to CN88-6 (4) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2 5
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 plug. Disconnect the CN101, CN102 and CN88
18 19 20 21 22 23 24 25 26 27 CN88 connectors. Visually check inside the connectors and
28 29 30 31 32 33 34 the crimped portion of their wires for defects. Refer to
1 2 3 4
CN102
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Main controller defect. Go to step 3
OK Main controller defect.Go to step 3
STEP3
Inspection: F73 fuse

After removing F73 fuse, measure the resistance for both ends of
F73 fuse.
Judgment
Result Procedure
Replace the F73 fuse with the defective portion in the former
step.
0Ω Replace the defective portion in the former step.
Error Code: 6404

Failure mode: Lift lock solenoid (open / short) abnormality
CAUTION
6403.
• Replace CN88-6 with CN88-5 when troubleshooting a lift truck with the Fingertip Control Lever option. 5
Probable cause
• F73 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Disconnect the CN88 connector. Visually check inside the
connector and the crimped portion of its wires for defects. Refer to
Judgment
Result Procedure
6404 error does not occur. Connector contact defect.
STEP2
Inspection: Check the mounting state of F73 fuse

Visually confirm if the F73 fuse has no defect.
After connecting the fuse, connect the battery plug and turn on the
Judgment
Result Procedure
6404 error does not occur. F73 fuse installation defect
STEP3
Inspection: F73 fuse individual inspection

F73 fuse.
Judgment
Result Procedure
∞Ω F73 fuse defect.
After replacing F73 fuse, go to STEP5.
0Ω Go to step 4
STEP4
Inspection: F73 fuse box

Connect the F73 fuse, and disconnect the connector of F73 fuse
box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

lift lock solenoid.

CN88
5

CN88-2 (477) to CN88-6 (4) Approx. 10 Ω
Judgment
Result Procedure
If replacing the F73 fuse in the former step, perform STEP6.
OK Go to step 6
STEP6
Inspection: Harness
Disconnect the CN101, CN102, CN103 and CN88 connectors,
then check the harnesses.

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
CN101, CN102, CN103, CN88 connectors
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*1: If the former step is OK, connect the CN88 connector and measure the resistance between CN101-1(3) and
CN102-16(4). It is OK if this resistance is approx.10 Ω.

CN88-2 (477) to CN88-6 (4) No continuity *1
Judgment
Result Procedure
NG Harness defect
Error Code: 6501

Failure mode: Tilt solenoid open abnormality
CAUTION
6503.
• Replace CN88-7 with CN88-6 when troubleshooting a lift truck with the Fingertip Control Lever option. 5
Probable cause
• Tilt solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
inside of connector CN88 and the crimped portion of the wire to
see whether it has a defect or not by visual confirmation. Refer to
key switch to the confirm error.
Judgment
Result Procedure
STEP2
Apply the tilt solenoid by using Active Test, and check if an error
occurs.
TILT SOL: OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Tilt solenoid individual inspection

tilt solenoid.

Check the resistance of tilt solenoid.
CN88

CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
Inspection: Harness

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*: Connect the CN88 connector and measure the resistance between CN101-2 and CN102-19. It is OK if this resis-
tance is approx.10 Ω.

CN101-2 (6) to CN88-3 (479) Continuity *
Judgment
Result Procedure
NG Harness defect
Error Code: 6502

Failure mode: Tilt solenoid short abnormality
CAUTION
6503.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the tilt solenoid by using Active Test, and check if an error
occurs.
TILT SOL: OFF to ON
Judgment
Result Procedure 5
STEP3

Disconnect the CN88 connector, and check the resistance of tilt
solenoid.

CN88

CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN102 and CN88 connectors, then check the
harnesses.

CN88 harnesses.
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 CN102, CN88 connectors disconnected. Visually
20 21 22 23 24 25 26 27 check inside the connectors and the crimped portion of
5 6 7 8
28 29 30 31 32 33 34 35 their wires for defects. Refer to BEFORE
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: 6503

Failure mode: Tilt solenoid drive circuit abnormality
CAUTION
Probable cause 5
• Harness defect
• F74 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Tilt solenoid

Disconnect the CN88 connector, and check the resistance of tilt
solenoid.

CN88

CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
NG Go to step 2
Tilt solenoid defect
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 CN101, CN102, CN88 connectors disconnected.
18 19 20 21 22 23 24 25 26 27 CN88 Visually check inside the connectors and the crimped
28 29 30 31 32 33 34 portion of their wires for defects. Refer to BEFORE
TROUBLESHOOTING.
1 2 3 4
CN102
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Main controller defect. Go to step 3
OK Main controller defect. Go to step 3
STEP3

F74 fuse.
Judgment
Result Procedure 5
step.
Error Code: 6504

Failure mode: Tilt solenoid (open / short) abnormality
CAUTION
6503.
Probable cause
• F74 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2

Check the mounting F74 fuse to see whether it has a defect or not
by visual confirmation.
Judgment 5
Result Procedure
6504 error does not occur. F74 fuse installation defect.
STEP3

After removing the F74 fuse, measure the resistance for both ends
of the F74 fuse.
Judgment
Result Procedure
After replacing F74 fuse, go to STEP5
0Ω Go to step 4
STEP4

Connect the F74 fuse, and disconnect the connector of the F74
fuse box.
fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

tilt solenoid.

Check the resistance of the tilt solenoid.
CN88

CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
OK Go to step 6
STEP6
Inspection: Harness

harness.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*: In case of the OK in the former step, connect the CN88 connector and measure the resistance between CN101-2
and CN102-19. It is OK if this resistance is approx.10 Ω.

CN88-3 (479) to CN88-7 (7) No continuity *
Judgment 5
Result Procedure
NG Harness defect
Error Code: 6601

Failure mode: Outside matching value range for tilt angle sensor
Probable cause
• Tilt sensor matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching of the tilt horizontal angle and the forward tilt
angle. (Refer to “Matching” of Display section)
Judgment
Result Procedure
STEP2
Tilt sensor voltage inspection:

Check the tilt sensor voltage.
?Tilt sensor voltage inspection:
[ANL] I/O M.HANDRING 2/8 VRTA
Position of tilt angle Voltage

When horizontal position 1.27V to 3.99V
Judgment
Result Procedure
Outside standard value Go to step 3
Tilt sensor assembly defect.
After reassemble, perform matching and STEP3.

Within standard value Main controller defect
STEP3
Check the error:

After 30 seconds, reconnect the battery plug and turn on the key
switch.
Judgment
Result Procedure 5
6601 error does not occur. Tilt sensor matching defect
Use as it is.
Error Code: 6701

Failure mode: Lifting height switch open / short abnormality
Probable cause
• Harness defect
• Lifting height switch defect
Related portion
CN90
CN104-22 (90, SH1) 3 3 CN92-2
Main controller CN103-24 (91, SH2-1) 2 2 CN92-3
CN103-6 (51, LS-) 1 1 CN92-1

Lifting height
switch
STEP1

Turn off the key switch and disconnect the battery plug at the lift
trucks lowermost position.
Disconnect the CN90, CN92 connectors. Visually check inside the
connectors of CN90 and CN92, and the crimped portion of the wire
for defects. Refer to BEFORE TROUBLESHOOTING.
Connect the CN90 and CN92 connectors, connect the battery
plug.
When the lifting height switch arm is released, check if an error
occurs.
In case of being height switch in the truck, lifting height switch arm
is released, check if an error occurs.
Judgment
Result Procedure
STEP2
Inspection: Harness
Turn off the key switch and disconnect the battery plug while
keeping the condition (height) under the occurred error.
Error Code: 6502

Failure mode: Tilt solenoid short abnormality
CAUTION
6503.
5
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
Disconnect the CN90 connector and check the height switch for
continuity.

Check the harness for continuity.
CN90
3 2 1 connector disconnected. Visually check inside the
connector and the crimped portion of its wires for
defects.
Give attention to the inspection contents. These are different standards for the condition of the height switch lever.
Portion to be
Height switch lever condition inspected Standard
Pushed (low height) CN90-1(51) to Continuity
CN90-2(90)
Pushed (low height) CN90-1(51) to No continuity
CN90-3(91)
Pushed (low height) CN90-2(90) to No continuity
CN90-3(91)
Released (high height) CN90-1(51) to No continuity
CN90-2(90)
Released (high height) CN90-1(51) to Continuity
CN90-3(91)
Released (high height) CN90-2(90) to No continuity
CN90-3(91)
Judgment
Result Procedure
OK Go to step 3
NG Go to step 4
STEP3
Inspection: Harness

Inspect for continuity of the harness.
CN103
1 2 3 4 5 6 CN102, CN103 and CN104 connectors disconnected.
7 8 9 10 11 12 13 14 15 16
portion of their wires for defects.
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN90 5
CN104 1 2 3
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Portion to be inspected Standard

Judgment
Result Procedure
NG Harness defect
STEP4
Inspection: Lifting height switch

Turn off the key switch and disconnect the battery plug while
keeping the condition (height) under the occurred error.
Disconnect the CN92 connector and check the height switch for
continuity.

Check the switch for continuity.
CN92
3 2 1 connector disconnected. Visually check inside the
connector and the crimped portion of its wires for
defects.
Give attention to the inspection contents. These are different standards for the condition of the height switch lever.
Portion to be
Height switch lever condition inspected Standard
Pushed (low height) CN92-1 (51) to Continuity
CN92-2 (90)
Pushed (low height) CN92-1 (51) to No continuity
CN92-3 (91)
Pushed (low height) CN92-2 (90) to No continuity
CN92-3 (91)
Released (high height) CN92-1 (51) to No continuity
CN92-2 (90)
Released (high height) CN92-1 (51) to Continuity
CN92-3 (91)
Released (high height) CN92-2 (90) to No continuity
CN92-3 (91)
Judgment
Result Procedure
OK Harness defect
NG Lifting height switch defect
Error Code: 6901

Failure mode: Backward lock solenoid open abnormality
CAUTION
6903.
5
Probable cause
• Backward lock solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid by using Active Test, and check
if an error occurs.
TILT BWD SOL: OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Backward lock solenoid individual inspection

backward lock solenoid.

Check the resistance of backward lock solenoid.
CN88

CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness

harness.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
tance is approx.10 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: 6902

Failure mode: Backward lock solenoid short abnormality
CAUTION
6903.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid by using Active Test, and check
if an error occurs.
TILT BWD SOL: OFF to ON
Judgment
Result Procedure
STEP3

5
Disconnect the CN88 connector, and check the resistance of

CN88

CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN88 harnesses.
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 CN102, CN88 connectors disconnected. Visually
20 21 22 23 24 25 26 27 check inside the connectors and the crimped portion of
5 6 7 8
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: 6903

Failure mode: Backward lock solenoid drive circuit abnormality
Probable cause
• Harness defect
• F75 fuse defect
5
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1


CN88

CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Go to step 2
Backward lock solenoid defect
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 Perform this check with the battery plug and the

18 19 20 21 22 23 24 25 26 27 CN88 CN101, CN102, CN88 connectors disconnected.
28 29 30 31 32 33 34 Visually check inside the connectors and the crimped
portion of their wires for defects. Refer to BEFORE
CN102
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Main controller defect.Go to step 3
STEP3

F75 fuse.
Judgment
Result Procedure
step.
5
Error Code: 6904

Failure mode: Backward lock solenoid (open / short) abnormality
CAUTION
6903.
Probable cause
• F75 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2

Visually confirm if the mounting of F75 fuse is defective.
Judgment
5
Result Procedure
STEP3

the F75 fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4

fuse box.
fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5


CN88

CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect.
OK Go to step 6
STEP6
Inspection: Harness
then check the harness.

harness.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*: If the former step is OK, connect the CN88 connector and measure the resistance between CN101-2 and
CN102-18. It is OK if this resistance is approx.10 Ω.

Judgment 5
Result Procedure
NG Harness defect
Error Code: 7101

Failure mode: Tire angle sensor open abnormality
Probable cause
• Tire angle sensor defect
• Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3
Main controller CN102-31 (317, VRTRA) CN97-2 Tire angle

sensor
CN102-26 (51, POT-) CN97-1
STEP1
Connector inspection
Visually check inside the connector of CN97, and the crimped
portion of the wire for defects. Refer to BEFORE
TROUBLESHOOTING.
After connecting the CN97 connector, connect the battery plug
and turn key switch ON to confirm the error.
Judgment
Result Procedure
7101 errors. Go to step 2
STEtP2
Inspection: Tire angle sensor

Disconnect the CN97 connector, and connect between CN97-3
and CN97-2 with SST2 (979-001/161).
error code.
CN97
1 2 3
Judgment
Result Procedure
7102 error occurs. Tire angle sensor defect.
STEP3
Inspection: Harness
5
Disconnect the CN101, CN102, and CN97 connectors. Inspect
harnesses with SST disconnected.

CN101
harnesses.
Turn off the key switch and disconnect the battery plug
1 2 3 4 5 6 7 and the CN101, CN102 and CN97 connectors. With
SST disconnected, visually check inside each
8 9 10 11 12 13 14 15 16 17
connector and the crimped portion of each wire for
18 19 20 21 22 23 24 25 26 27 defects.
28 29 30 31 32 33 34 CN97 Refer to BEFORE TROUBLESHOOTING.
1 2 3
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: 7102

Failure mode: Tire angle sensor short abnormality
Probable cause
• Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
TROUBLESHOOTING.
and turn the key switch ON to confirm the error.
Judgment
Result Procedure
STEP2
Inspection: Harness
the harnesses.

CN101
harnesses.
1 2 3 4 5 6 7 and the CN101, CN102 and CN97 connectors.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN97
5
1 2 3
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3

Disconnect the CN97 connector, then connect the CN101 and
CN102 connectors.
??Check the error code.
Judgment
Result Procedure
7102 error occurs. Main controller defect.
7101 error occurs. Tire angle sensor defect.
Error Code: 7103

Failure mode: Tire angle sensor anchoring abnormality
Probable cause
• Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
TROUBLESHOOTING.
and turn on the key switch to confirm the error by turning the
steering wheel.
Judgment
Result Procedure
7103 error does not occur. Connector contact defect.
STEP2

CN102 connectors.
Reconnect the battery plug and turn on the key switch, and check
the error code.
Judgment
Result Procedure
STEP3
Tire angle sensor inspection

CN102 connectors. Connect between CN97-3 and CN97-2 on the
harness side with SST2 connected.
Reconnect the battery plug and turn on the key switch, and check
the error code.
5
CN97
1 2 3
Judgment
Result Procedure
7102 error occurs. Tire angle sensor defect
STEP4
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7 and the CN101, CN102 and CN97 connectors.
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN97
1 2 3
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: 7201

Failure mode: Steering-wheel angle sensor SS1 open abnormality
Probable cause
• Harness defect
• Steering angle sensor defect
5
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
Main controller CN104-31 (313, SSTR2) CN19-4
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1

Turn on the key switch, and check if an error occurs with turning
the steering wheel.
Judgment
Result Procedure
STEP2
Inspection: Steering angle sensor

Check the condition of the sensor when operating the steering
wheel.
[ANL] I/O STEERING 1/1 SSTR
Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to step 3
STEP3

CN19
1 2
3 4 5 6

Check the condition of the sensor when operating the steering
wheel.
Judgment
Result Procedure
1** (* represents either 0 or 1.) Steering angle sensor defect
STEP4
Inspection: Harness
Disconnect the CN19, CN101, CN103, CN104 connectors and

Inspect for continuity of the harness.
CN104
CN19 Perform this check with the battery plug and the CN19,
1 2 3 4 5 6 7 CN101, CN103, CN104 connectors disconnected.
1 2 Visually confirm whether the inside of the connector
8 9 10 11 12 13 14 15 16 17
3 4 5 6 and the crimped portion of the wire has a defect or not.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
STEP5

5
Check the condition of the sensor while operating the steering
wheel.
Judgment
Result Procedure
0** (* represents either 0 or 1.) Steering angle sensor defect
STEP6
Inspection: Harness
check the harnesses for their continuity.

CN104
1 2 Visually check inside the connector and the crimped
8 9 10 11 12 13 14 15 16 17
3 4 5 6 portion of its wire for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
Error Code: 7202

Failure mode: Steering-wheel angle sensor SS2 open abnormality
Probable cause
• Harness defect
5
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1

Turn on the key switch, and check if the error occurs with turning
the steering wheel.
Judgment
Result Procedure
STEP2

wheel.
Judgment
Result Procedure
*0* (* represents either 0 or 1.) Go to step 3
STEP3

CN19
1 2
3 4 5 6

wheel.
Judgment
Result Procedure
*1* (* represents either 0 or 1.) Steering angle sensor defect
STEP4
Inspection: Harness

CN104
1 2 Visually check inside the connectors and the crimped
8 9 10 11 12 13 14 15 16 17
3 4 5 6 portion of their wires for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
STEP5

5
Check the condition of the sensor with operating the steering
wheel.
Judgment
Result Procedure
STEP6
Inspection: Harness

CN104
1 2 Visually check inside the connectors and the crimped
8 9 10 11 12 13 14 15 16 17
3 4 5 6 portion of their wires for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
Error Code: 7203

Failure mode: Steering-wheel angle sensor SSC open abnormality
Probable cause
• Harness defect
5
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1

After disconnecting the CN19 connector, visually check inside the
connector and the crimped portion of its wires for defects. Refer to
Turn on the key switch, and check if an error occurs while turning
the steering wheel (over one revolution).
Judgment
Result Procedure
STEP2

wheel.
Judgment
Result Procedure
STEP3

wheel.
Judgment
Result Procedure
STEP4
Inspection: Harness

CN104
1 2 Visually check inside the connector and the crimped
8 9 10 11 12 13 14 15 16 17
3 4 5 6 portion of its wire for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
STEP5

wheel.
[ANL] I/O STEERING 1/1 SSTR 5
Judgment
Result Procedure
STEP6
Inspection: Harness

CN104
1 2 3 4 5 6 7 CN101, CN103, CN104 and CN19 connectors
1 2 disconnected. Visually check inside the connector and
8 9 10 11 12 13 14 15 16 17
3 4 5 6 the crimped portion of its wire for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
Error Code: 7204

Failure mode: Steering-wheel angle sensor: sensor power source open abnormality
CAUTION
• Turning the steering angle sensor without turning the steering wheel may cause error code 7204 to be
set.
Probable cause
• Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1

Turn on the key switch, and turn the steering wheel to see if an
error occurs. (If the steering wheel cannot be turned easily,
perform this check with the direction switch in the Forward or
Reverse position.)
Judgment
Result Procedure
STEP2
Check of sensor supply voltage:


Check the supply voltage to the sensor.
CN19-1 to CN19-2.
Judgment
Result Procedure
Approx. 0V Go to step 3
Approx. 15V Go to step 4
5
STEP3
Inspection: Harness

1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 Visually check inside the connector and the crimped
20 21 22 23 24 25 26 27 portion of its wire for defects.
28 29 30 31 32 33 34 35
1 2
CN103 3 4 5 6
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
STEP4
Reconnect the CN19 connector.
Perform troubleshooting for 7201 (SSTR1).
Perform troubleshooting for 7202 (SSTR2).
Error Code: 7301

Failure mode: Steering knob position synchronizer solenoid open abnormality
CAUTION
7303.
5
Probable cause
• Steering knob position synchronizer solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
Steering knob CN98-2 (485) CN102-14 (330,SLS-)
N1 position
syncohonizer CN98-1 (330) CN103-5 (N2, N2)
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Connect the CN98 connector. Connect the battery plug.
Judgment
Result Procedure
STEP2

Using Active Test, forcibly turn on the output of the steering knob
position synchronizer solenoid to see if an error occurs.
STEERING SOL: OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Steering knob position synchronizer solenoid

steering knob position synchronizer solenoid.

Inspect the solenoid resistance.
CN98
2 1 connector disconnected. Visually confirm whether the
inside of the connector and the crimped portion of the
wire has a defect or not.

CN98-2 (329) to CN98-1 (329) between 7 and 17 Ω (approx.
10 Ω at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
connectors and check the harnesses for their continuity.

CN102
1 2 disconnected. Visually confirm whether the inside of
8 9 10 11 12 13 14 15 16 17 18 19 the connector and the crimped portion of the wire has
20 21 22 23 24 25 26 27 a defect or not.
28 29 30 31 32 33 34 35 Refer to BEFORE TROUBLESHOOTING. 5
*: In case of the OK in the steering knob position synchronizer solenoid, connect the CN98 connector and measure
the resistance between CN102-7 and CN102-14. It is OK if this resistance is between 7 and 17 Ω (approx. 10 Ω at
20°C).

Judgment
Result Procedure
NG Harness defect
Error Code: 7302

Failure mode: Steering knob position synchronizer solenoid short abnormality
CAUTION
7303.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Judgment
Result Procedure
STEP2

Using Active Test, forcibly turn on the output of the steering knob
position synchronizer solenoid to see if an error occurs.
STEERING SOL: OFF to ON
Judgment
5
Result Procedure
STEP3


CN98
2 1 connector disconnected. visually confirm whether the

CN98-2 (329) to CN98-1 (330) Between 7 and 17 Ω (approx.
10 Ω at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4
Inspection: Harness

CN98
1 2
Visually confirm whether the inside of the connector
and the crimped portion of the wire has a defect or not.

Judgment
Result Procedure
NG Harness defect
Error Code: 7303

Failure mode: Steering knob position synchronizer solenoid power-circuit abnormality
Probable cause
• Harness defect
• F71 fuse defect
5
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1


CN98

CN98-2(329) to CN98-1(330) between 7 and 17 Ω (approx.
10 Ω at 20°C)
Judgment
Result Procedure
NG Go to step 2
Steering knob position synchronizer solenoid defect
OK Go to step 2
STEP2
Inspection: Harness

CN102
8 9 10 11 12 13 14 15 16 17 18 19 the connectors and the crimped portion of their wires
20 21 22 23 24 25 26 27 have a defect or not.

Judgment
Result Procedure
NG Harness and main controller defect.Go to step 3
STEP3

the F71 fuse.
Judgment
Result Procedure
step.
5
Error Code: 7304

Failure mode: Steering knob position synchronizer solenoid (open / short) abnormality
CAUTION
7303.
Probable cause
• F71 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Judgment
Result Procedure
STEP2
5
Check fuse installation:
Visually confirm if the mounting of F71 fuse is defective.
Judgment
Result Procedure
STEP3

After removing the F71 fuse, measure the resistance for both ends
of the F71 fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4

fuse box.
fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5


CN98

CN98-2 (329) to CN98-1 (330) between 7 and 17 Ω (approx.
10 Ω at 20°C)
Judgment
Result Procedure
If replacing the F71 fuse in the former step, perform the
STEP6.
OK Go to step 6
STEP6
Inspection: Harness

CN102
8 9 10 11 12 13 14 15 16 17 18 19 the connector and the crimped portion of the wire has
20 21 22 23 24 25 26 27 a defect or not.
tance is between 7 and 17 Ω (approx. 10 Ω at 20°C).

CN102-7 (329) to CN102-14 (330) * No continuity
Judgment 5
Result Procedure
NG Harness defect
Error Code: 7401

Failure mode: Tire angle matching: matching value abnormality
CAUTION
• If 7101, 7102, 7103 occurs, give priority to troubleshooting for 7101, 7102, 7103. After that, perform the
following.
Probable cause
• Tire angle matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform tire angle matching. (Refer to “Matching” of Display
section)
Judgment
Result Procedure
STEP2
Tire angle sensor voltage inspection:

Check the tire angle sensor voltage.
[ANL] I/O STEERING 1/1 VRTRA
Tire angle position Voltage

When straight running condition 2.11V to 2.81V
Judgment
Result Procedure
Tire angle sensor assembly defect. After reassemble,
perform matching and STEP3.
STEP3 5
Check the error:
switch.
Judgment
Result Procedure
7401 error does not occur. Tire angle matching defect
Error Code: H101

Failure mode: Lift lever potentiometer open abnormality
CAUTION
• Make sure to perform matching if the lever was removed and inspected.
• Replace CN115 with CN162 when troubleshooting a lift truck with the Fingertip Control Lever option.
Probable cause
• Harness defect
• Lift lever potentiometer defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
Main controller Lift lever
CN103-18 (21, VRL2) CN115-2 potentiometer
CN102-26 (51, POT-) CN115-1
STEP1
After disconnecting the CN115 connector. Visually check inside
the connector and the crimped portion of its wires for defects.
Turn on the key switch to check that the error occurs.
Judgment
Result Procedure
H101 error does not occur. Connector contact defect
H101 error occurs. Go to step 2
STEP2
Inspection: Lift lever potentiometer

Connect between CN115-3 and CN115-4 on the harness side with

SST2 connected.
CN115
1 2 3 4
the error occurs.
5
Judgment
Result Procedure
H102 error does not occur. Go to step 4
STEP3

SST2 connected.
the error occurs.
CN115
1 2 3 4
Judgment
Result Procedure
H102 error occurs. Lift lever potentiometer defect
STEP4
Inspection: Harness


1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27 portion of their wires for defects.
28 29 30 31 32 33 34
1 2 3 4
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN101-25(28) to CN115-4 Continuity
CN115-3(20) to CN115-1(51) No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: H102

Failure mode: Lift lever potentiometer short abnormality
CAUTION
5
Probable cause
• Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
After disconnecting the CN115 connector, visually confirm
whether the inside of the connector and the crimped portion of the
wire has a defect or not. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

the error occurs.
Judgment
Result Procedure
STEP3
Inspection: Harness

CN102
1 2 3 4 5 6 7 CN102, CN103, and CN115 connectors disconnected.
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H103

Failure mode: Lift lever potentiometer: sensor output declination abnormality
CAUTION
5
Probable cause
• Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

the error occurs.
Judgment
Result Procedure
STEP3
Inspection: Harness
and check the harnesses for continuity.

CN101

8 9 10 11 12 13 14 15 16 17 disconnected. Visually check inside the connectors
and the crimped portion of their wires for defects.
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN115
CN103 1 2 3 4
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
STEP4

SST2 connected.
the error occurs. 5
CN115
1 2 3 4
Judgment
Result Procedure
STEP5

SST2 connected.
the error occurs.
CN115
1 2 3 4
Judgment
Result Procedure
Error Code: H104

Failure mode: Lift lever potentiometer neutral abnormality
CAUTION
• H104 error occurs if the key switch is turned on while operating lift lever.
Probable cause
• Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

Check if the lift lever potentiometer is installed correctly.
the error occurs.
Perform matching the lift lever potentiometer. (Refer to
MATCHING)
Judgment
Result Procedure
NG matching Lift lever potentiometer defect
OK matching Lift lever potentiometer assembly defect
5
Error Code: H105

Failure mode: Lift lever potentiometer matching value abnormality
CAUTION
• If H101, H102, H103, H104 occurs, give priority to troubleshooting for H101, H102, H103, H104.
Probable cause
• Lift lever potentiometer matching value defect
• Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
Perform matching the lift lever potentiometer.

(Refer to MATCHING)
Judgment
Result Procedure
STEP2
Check the lift lever potentiometer voltage.

Lift lever angle sensor (1/2) voltage
[ANL] I/O M. HANDLING 5/8 VRL
In case of uppermost / lowermost, make sure to confirm the range
is within the following table and the difference of the sensor neutral
matching voltage is over 0.79V.
Standard Lever spec. Fingertip Control Lever spec.

Position of lift lever
sensor 1 sensor 2 sensor 1 sensor 2
Neutral 1.65 ~ 2.87V 1.52 ~ 3.01V 1.78 ~ 2.75V 1.78 ~ 2.75V
Standard Lever spec. Fingertip Control Lever spec.

Position of lift lever
sensor 1 sensor 2 sensor 1 sensor 2
When Uppermost position 0.30 ~ 2.87V 1.52 ~ 4.50V 1.78 ~ 4.50V 0.30 ~ 2.75V
When Lowermost position 1.65 ~ 4.50V 0.30 ~ 3.01V 0.30 ~ 2.75V 1.78 ~ 4.50V
Judgment
Result Procedure
5
Lift lever potentiometer assembly defect
Perform the matching after reassemble.
STEP3
Judgment
Result Procedure
H105 error does not occur. Lift lever potentiometer matching value defect
Use as it is.
H105 error occurs. Main controller defect
Error Code: H201

Failure mode: Tilt lever potentiometer open abnormality
CAUTION
Probable cause
• Harness defect
• Tilt lever potentiometer defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
Main controller Tilt lever
CN102-22 (23, VRT2) CN163-2 (23) potentiometer
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection: Tilt lever potentiometer

Replace CN163 with CN162 (connector of tilt lever potentiometer
and lift lever potentiometer).
error code.
H104, H204 can be ignored.
Judgment
Result Procedure
H101 error occurs. Tilt lever potentiometer defect
STEP3
Inspection: Harness
5
Disconnect the CN101, CN102 and CN163 connector, then check
the harnesses.

CN101
harnesses.
1 2 3 4 5 6 7 Perform this check with the battery plug and the

18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN163 TROUBLESHOOTING.
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
*: It is OK “to connect CN163-3 to CN163-4 through SST2 (979-001/161) and check if there is continuity between
CN101-28 and CN102-23,” and “to connect CN163-2 to CN163-4 through SST2 (979-001/161) and check if there
is continuity between CN101-28 and CN102-22.”
Portions to be checked Standard:

Judgment
Result Procedure
NG Harness defect
Error Code: H202

Failure mode: Tilt lever potentiometer short abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Replace CN163 with CN162 (connector of tilt lever potentiometer
and left lever potentiometer).
error code.
Judgment
Result Procedure
H102 error occurs. Tilt lever potentiometer defect.
STEP3
Inspection: Harness
5
harnesses.

CN101
harnesses.

8 9 10 11 12 13 14 15 16 17 CN102, CN163 connectors disconnected. Visually
18 19 20 21 22 23 24 25 26 27
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-28.

Judgment
Result Procedure
NG Harness defect
Error Code: H203

Failure mode: Tilt lever potentiometer: sensor output declination abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

the error occurs.
Judgment
Result Procedure
STEP3
Inspection: Harness
5

CN101

18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN163
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
STEP4

SST2 connected.
the error occurs.
CN163
1 2 3 4
Judgment
Result Procedure
STEP5
Check the tilt lever potentiometer

SST2 connected.
the error occurs.
CN163
1 2 3 4
Judgment
Result Procedure
H202 error occurs. Tilt lever potentiometer defect.
Error Code: H204

Failure mode: Tilt lever potentiometer neutral error abnormality
CAUTION
• H204 error occurs if the key switch is turned on while operating tilt lever.
5
Probable cause
• Tilt lever potentiometer assembly defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Check if the tilt lever potentiometer is installed correctly.
Perform matching the tilt lever potentiometer. (Refer to “Matching”
of Display section)
Judgment
Result Procedure
NG matching Tilt lever potentiometer defect.
OK matching Tilt lever potentiometer assembly defect.
Error Code: H205

Failure mode: Tilt lever potentiometer matching value abnormality
Probable cause
• Tilt lever potentiometer matching defect
Related portion
5
Main controller
STEP1
MATCHING:
Perform matching of the tilt lever. (Refer to “Matching” of Display
section)
Judgment
Result Procedure
STEP2
Tilt lever potentiometer voltage inspection:

Check the tilt lever voltage.
?Tilt lever potentiometer voltage
[ANL] I/O M.HANDRING 6/8 VRT
Position of tilt lever sensor 1 sensor 2

When neutral position 1.78V to 2.75V 1.78V to 2.75V
Judgment
Result Procedure
Tilt lever assembly defect. After reassembly, perform
matching and STEP 3.
Within standard value Main controller defect.
STEP3
Check the error:

switch.
Judgment
Result Procedure
H205 error does not occur. Tilt lever potentiometer matching defect
Use as it is.
Error Code: H301

Failure mode: Attachment 1 lever potentiometer open abnormality
CAUTION
• Replace CN119 with CN164, and CN115 with CN162, when troubleshooting a lift truck with the Fingertip
Control Lever option.
5
Probable cause
• Harness defect
• Attachment 1 lever potentiometer defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-21 (24, VRA11) CN119-3 (24) Attachment 1
Main controller lever
CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection: Attachment 1 lever potentiometer

Replace CN119 with CN115 (connector of attachment lever 1
potentiometer and lift lever potentiometer).
error code.

Judgment
Result Procedure
H101 error occurs. Attachment 1 lever potentiometer defect
STEP3
Inspection: Harness
Disconnect the CN101, CN102 and CN119 connectors, then
check the harnesses.

CN101
harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN119
TROUBLESHOOTING.
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-29 and CN102-21”, and “to connect CN119-2 to CN119-4 through SST2 (979-001/161) and check if there
is continuity between CN101-29 and CN102-20”.

Judgment
Result Procedure
NG Harness defect
Error Code: H302

Failure mode: Attachment 1 lever potentiometer short abnormality
CAUTION
5
Probable cause
• Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2

error code.
Judgment
Result Procedure
STEP3
Inspection: Harness
harnesses.

CN101
harnesses.

18 19 20 21 22 23 24 25 26 27
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-29.

CN102-26(51) to CN119-1(51) Continuity *
Judgment
Result Procedure
NG Harness defect
Error Code: H303

Failure mode: Attachment 1 lever potentiometer: sensor output declination abnormality
CAUTION
5
Probable cause
• Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Inspection: Attachment 1 potentiometer

the error occurs.
Judgment
Result Procedure
STEP3
Inspection: Harness

CN101

18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN119
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
STEP4
Inspection: Attachment 1 potentiometer

SST2 (979-001/161) connected.
the error occurs. 5
CN119
1 2 3 4
Judgment
Result Procedure
STEP5

the error occurs.
CN119
1 2 3 4
Judgment
Result Procedure
Error Code: H304

Failure mode: Attachment 1 lever potentiometer neutral abnormality
CAUTION
• H304 error occurs if the key switch is turned ON while operating attachment 1 lever.
Probable cause
• Attachment 1 lever potentiometer assembly defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Check if the attachment 1 lever potentiometer is installed
correctly.
Perform matching the attachment 1 lever potentiometer. (Refer to
“Matching” of Display section)
Judgment
Result Procedure
NG matching Attachment 1 lever potentiometer defect
OK matching Attachment 1 lever potentiometer assembly defect
5
Error Code: H305

Failure mode: Attachment 1 lever potentiometer matching value abnormality
Probable cause
• Attachment 1 lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching the attachment 1 lever.
(Refer to “Matching” of Display section)
Judgment
Result Procedure
STEP2
Attachment 1 lever potentiometer voltage inspection:

Check the attachment 1 lever voltage.
Attachment 1 lever potentiometer voltage.
[ANL] I/O M.HANDRING 7/8 VRA1
Position of attachment 1 lever sensor 1 sensor 2
When the neutral position (Standard Lever spec.) 1.65V to 2.87V 1.52V to 3.01V
When the neutral position 1.78V to 2.75V 1.78V to 2.75V
(Fingertip Control Lever spec.)
Judgment
Result Procedure
Attachment 1 lever assembly defect. After reassembly,
perform matching and STEP 3.
STEP3
Check the error:

switch.
Judgment
Result Procedure 5
H305 error does not occur. Attachment 1 lever potentiometer matching defect
Use as it is.
Error Code: H401

Failure mode: Attachment 2 lever potentiometer open abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2

error code.
Judgment
Result Procedure
STEP3
Inspection: Harness
5
Disconnect the CN101, CN102 and CN120 connectors, then

CN101
harnesses.

18 19 20 21 22 23 24 25 26 27
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-30 and CN102-29,” and “to connect CN120-2 to CN120-4 through SST2 (979-001/161) and check if there
is continuity between CN101-30 and CN102-28.”

Judgment
Result Procedure
NG Harness defect
Error Code: H402

Failure mode: Attachment 2 lever potentiometer short abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2

error code.
Judgment
Result Procedure
STEP3
Inspection: Harness
5
harnesses.

CN101
harnesses.

18 19 20 21 22 23 24 25 26 27
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-30.

Judgment
Result Procedure
NG Harness defect
Error Code: H403

Failure mode: Attachment 2 lever potentiometer: sensor output declination abnormality
CAUTION
Probable cause
• Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STtEP1
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

the error occurs.
Judgment
Result Procedure
STEP3
Inspection: Harness
5

CN101

18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN120
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
STEP4

the error occurs.
CN120
1 2 3 4
Judgment
Result Procedure
STEP5

the error occurs.
CN120
1 2 3 4
Judgment
Result Procedure
Error Code: H404

Failure mode: Attachment 2 lever potentiometer neutral abnormality
CAUTION
• H404 error occurs if the key switch is turned on or the emergency stop button is released using operating
attachment 2 lever.
• Replace CN120 with CN165 when troubleshooting a lift truck with the Fingertip Control Lever option. 5
Probable cause
• Attachment 2 lever potentiometer assembly defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Check if the attachment 2 lever potentiometer is installed
correctly.
Perform matching the attachment 2 lever potentiometer. (Refer to
“Matching” of Display section)
Judgment
Result Procedure
NG matching Attachment 2 lever potentiometer defect
OK matching Attachment 2 lever potentiometer assembly defect
Error Code: H405

Failure mode: Attachment 2 lever potentiometer matching value abnormality
Probable cause
• Attachment 2 lever potentiometer matching defect
Related portion
5
Main controller
STEP1
MATCHING:
Perform matching the attachment 2 lever. (Refer to “Matching” of
Display section)
Judgment
Result Procedure
STEP2
Attachment 2 lever potentiometer voltage inspection:

Check the attachment 2 lever voltage.
Attachment 2 lever potentiometer voltage.
[ANL] I/O M.HANDRING 8/8 VRA2
Position of attachment 2 lever sensor 1 sensor 2
When the neutral position (Standard Lever spec.) 1.65V to 2.87V 1.52V to 3.01V
When the neutral position
1.78V to 2.75V 1.78V to 2.75V
(Fingertip Control Lever spec.)
Judgment
Result Procedure
Attachment 2 lever assembly defect. After reassemble,
perform matching and STEP 3.
STEP3
Check the error:

switch.
Judgment
Result Procedure
H405 error does not occur. Attachment 2 lever potentiometer matching defect
Use as it is.
Error Code: H501

Failure mode: Lift proportional valve solenoid open abnormality (lever pull side)
CAUTION
• If H505 also occurs, disconnect the battery plug at once. Perform troubleshooting with priority given to
H505.
• If HB01 or HB03 occurs at the same time, perform troubleshooting for HB01, HB03 first.
5
Probable cause
• Lift proportional valve solenoid (PULL) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
CN127-1 (19,VBMBSL) CN127-7 (17,SOLCOM) CN102-5 (17,SOLCOM)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

Lift PULL controller
solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
solenoid CN104-4 (N2, N2)
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
H506 error occurs. Perform troubleshooting for H506.
STEP2
Operate the pull side of lift lever more than 1 second to check if an
error occurs.
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PULL) individual

inspection
Disconnect the CN78 connector, and check the resistance of lift
proportional valve solenoid (PULL).

Check the resistance of lift proportional valve solenoid
CN78 (PULL).

4 3 2 1 plug. Disconnect the CN78 connector. Visually check
inside the connectors and the crimped portion of their
8 7 6 5 wires for defects. Refer to BEFORE
TROUBLESHOOTING.

CN78-5 (481) to CN78-1 (10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness

the harnesses.

harnesses.
1 2 3 4 5 6 7
18 19 20 21 22 23 24 25 26 27 CN78 Visually check inside the connectors and the crimped 5
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
*1: Connect the CN78 connector and measure the resistance between CN101-5(9) and CN101-17(10). It is OK if
this resistance is approx.8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H502

Failure mode: Lift proportional valve solenoid short abnormality (lever pull side)
CAUTION
H505.
Probable cause
• Lift proportional valve solenoid (PULL) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Disconnect the CN78 connector. Visually check each terminal and
the crimped portion and coating of each cable for defects. Refer to
Judgment
Result Procedure
STEP2
Operate the pull side of lift lever more than 1 second to check if an
error occurs. 5
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PULL) individual

inspection
lift proportional valve solenoid (PULL).

CN78 (PULL).

8 7 6 5 each cable for defects. Refer to BEFORE
TROUBLESHOOTING.

CN78-5(481) to CN78-1(10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness

harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34 their wires for defects. Refer to BEFORE
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H503

Failure mode: Lift proportional valve solenoid open abnormality (lever push side)
CAUTION
H505.
5
Probable cause
• Lift proportional valve solenoid (PUSH) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of the lift lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PUSH) individual

inspection
Disconnect the CN87 connector. Check the resistance of lift

proportional valve solenoid (PUSH).

CN87 (PUSH).

4 3 2 1 plug, disconnect the CN87 connector, and visually
check inside each connector and the crimped portion
8 7 6 5 of each wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN87-5 (481) to CN87-1 (11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
the harnesses.

harnesses.
5
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
*1: Connect the CN87 connector and measure the resistance between CN101-5(9) and CN101-16(11). It is OK if
this resistance is approx. 8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H504

Failure mode: Lift proportional valve solenoid short abnormality (lever push side)
CAUTION
H505.
Probable cause
• Lift proportional valve solenoid (PUSH) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Disconnect the CN87 connector. Visually check inside each
connector and the crimped portion of each wire for defects. Refer
to BEFORE TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Operate the push side of lift lever more than 1 second to check if
an error occurs. 5
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PUSH) individual

inspection
Disconnect the CN87 connector. Check the resistance of the lift
proportional valve solenoid (PUSH).

CN87 (PUSH).

4 3 2 1 plug. Disconnect the CN87 connector, and visually
TROUBLESHOOTING.

CN87-5 (481) to CN87-1 (11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness

harnesses.

CN87 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H505

Failure mode: Lift proportional valve solenoid drive circuit abnormality
Probable cause
• Lift proportional valve solenoid defect
• Harness defect
• F76 fuse defect
5
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Lift proportional valve solenoid individual inspection

Disconnect the CN78 and CN87 connectors, and check the
resistance of the lift proportional valve solenoid.

CN78 CN87 Check the resistance of lift proportional valve solenoid.

4 3 2 1 4 3 2 1 plug. Disconnect the CN78 and CN87 connectors.
Visually check each terminal and the crimped portion
8 7 6 5 8 7 6 5 and coating of each cable for defects. Refer to

CN78-5 (481) to CN78-1 (10) Approx. 8 Ω
CN87-5 (481) to CN87-1 (11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid defect
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27 check inside the connectors and the crimped portion of
5 6 7 8
TROUBLESHOOTING.
CN87
1 2 3 4
5 6 7 8

Judgment
Result Procedure
NG Harness defect
Main controller defect
Go to step 3
Go to step 3
5
STEP3

F76 fuse.
Judgment
Result Procedure
step.
Error Code: H506

Failure mode: Lift proportional valve solenoid (open / short) abnormality
CAUTION
• If H505 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given to
H505.
• If HB01, HB02, or HB03 occurs at the same time, perform troubleshooting for HB01, HB02, HB03 first.
Probable cause
• F76 fuse defect
• Lift proportional valve solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and the
CN78 and CN87 connectors. Check the inside of connectors
CN78 and CN87, and the crimped portion of their wires to see
After connecting CN78 and CN87, connect the battery plug and
turn on the key switch to confirm the error.
Judgment
Result Procedure
STEP2 5
Check the mounting F76 fuse it has defect or not by visual

confirmation.
After connecting fuse, connect the battery plug and turn on the key
switch to confirm the error.
Judgment
Result Procedure
H506 error does not occur. F76 fuse installation defect
STEP3
Inspection: F76 fuse individual inspection

1. Turn off the key switch and disconnect the battery plug.
2. After removing F76 fuse, measure the resistance for both ends
of F76 fuse.
Judgment
Result Procedure
After replacing fuse, go to STEP5
0Ω Go to step 4
STEP4

box.

Judgment
Result Procedure
0Ω Go to step 5
STEP5
Inspection: Lift proportional valve solenoid individual inspection


resistance of the lift proportional valve solenoid.

CN78 CN87 Check the resistance of lift proportional valve solenoid.

4 3 2 1 4 3 2 1 plug. Disconnect the CN78 and CN87 connectors.
Visually check each terminal and the crimped portion
8 7 6 5 8 7 6 5 and coating of each cable for defects. Refer to

CN78-5 (481) to CN78-1 (10) Approx. 8 Ω
CN87-5 (481) to CN87-1 (11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
Inspection: Harness
Disconnect the CN101, CN103, CN78, and CN87 connectors,

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 CN101, CN103, CN78, CN87 connectors
5 6 7 8
28 29 30 31 32 33 34 and the crimped portion of their wires for defects.
CN103
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*1: In case of the OK in the former step, connect the CN78 connector and measure the resistance between
CN101-5(9)and CN101-17(10). It is OK if this resistance is approx. 8 Ω.
*2: In case of the OK in the former step, connect the CN87 connector and measure the resistance between
CN101-5(9)and CN101-16(11). It is OK if this resistance is approx. 8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H601

Failure mode: Tilt proportional valve solenoid open abnormality (lever pull side)
CAUTION
• If H605 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given to
H605.
Probable cause
• Tilt proportional valve solenoid (PULL) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

Tilt PULL controller
solenoid CN78-2 (33) CN101-13 (34,STPS-)
CN87-6 (482) CN103-5 (N2, N2)

Tilt PUSH CN104-4 (N2, N2)
solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78 connector. Check the inside of connector CN78 and the
Judgment
Result Procedure
STEP2
Operate the pull side of the tilt lever for more than 1 second to
check if an error occurs. 5
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PULL) individual

inspection
tilt proportional valve solenoid (PULL).

Check the resistance of the tilt proportional valve
CN78 solenoid (PULL).

TROUBLESHOOTING.

CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness

the harnesses.

harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
tance is approx. 8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H602

Failure mode: Tilt proportional valve solenoid short abnormality (lever pull side)
CAUTION
H605.
5
Probable cause
• Tilt proportional valve solenoid (PULL) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the pull side of the tilt lever for more than 1 second to
check if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PULL) individual

inspection
tilt proportional valve solenoid (PULL).

CN78 solenoid (PULL).

4 3 2 1 plug, disconnect the CN78 connector. Visually check
TROUBLESHOOTING.

CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
5
1 2 3 4 Perform this check with the battery plug and the
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8 check inside the connectors and the crimped portion of
28 29 30 31 32 33 34
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H603

Failure mode: Tilt proportional valve solenoid open abnormality (lever push side)
CAUTION
H605.
Probable cause
• Tilt proportional valve solenoid (PUSH) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and CN87
connector. Check the inside of connector CN87 and the crimped
Judgment
Result Procedure
STEP2
Operate the push side of the tilt lever for more than 1 second to
check if an error occurs. 5
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PUSH) individual

inspection
tilt proportional valve solenoid (PUSH).

CN87 solenoid (PUSH).

4 3 2 1 plug, disconnect the CN87 connectors, and visually
TROUBLESHOOTING.

CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H604

Failure mode: Tilt proportional valve solenoid short abnormality (lever push side)
CAUTION
H605.
5
Probable cause
• Tilt proportional valve solenoid (PUSH) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of the tilt lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PUSH) individual

inspection
tilt proportional valve solenoid (PUSH).

CN87 solenoid (PUSH).

4 3 2 1 plug, disconnect the CN87 connector, and visually
8 7 6 5 each wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN87 harnesses.
5
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H605

Failure mode: Tilt proportional valve solenoid drive circuit abnormality
Probable cause
• Tilt proportional valve solenoid defect
• Harness defect
• F77 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Tilt proportional valve solenoid individual inspection

resistance of the tilt proportional valve solenoid.

CN78 CN87 Check the resistance of the tilt proportional valve
solenoid.
4 3 2 1 4 3 2 1 Turn off the key switch and disconnect the battery

plug. Disconnect the CN78 and CN87 connectors,
8 7 6 5 8 7 6 5 visually check each terminal and the crimped portion
and coating of each cable for defects. Refer to

CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid defect 5
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
5 6 7 8
TROUBLESHOOTING.
CN87
1 2 3 4
5 6 7 8

Judgment
Result Procedure
NG Harness defect
Go to step 3
Go to step 3
STEP3

F77 fuse.
Judgment
Result Procedure
step.
Error Code: H606

Failure mode: Tilt proportional valve solenoid (open / short) abnormality
CAUTION
H605.
5
Probable cause
• F77 fuse defect
• Tilt proportional valve solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and CN78,
CN87 connectors. Check the inside of connectors CN78, CN87
and the crimped portion of their wires to see whether they have a
defect or not by visual confirmation. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

Check the mounting F77 fuse it has defect or not by visual confirm.
Judgment
Result Procedure
STEP3
F77 fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4
box.
Measure the resistance for both ends of the connector for F77 fuse
box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5
Inspection: Tilt proportional valve solenoid individual inspection

tilt proportional valve solenoid.

CN78 CN87 Check the resistance of the tilt proportional valve
solenoid. 5

plug, disconnect the CN78, CN87 connectors, and
8 7 6 5 8 7 6 5 visually check inside each connector and the crimped
portion of each wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
Inspection: Harness

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
5 6 7 8
CN103
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*1: In case of the OK in the former step, connect the CN78 connector and measure the resistance between CN101-6
and CN101-12. It is OK if this resistance is approx. 8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H701

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever pull side)
CAUTION
H705.
5
Probable cause
• Attachment 1 proportional valve solenoid (PULL) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

Attachment 1 controller
PULL
solenoid CN78-3 (36) CN101-11 (37,SA1PS-)
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and
disconnect the CN78 connector. Check the inside of connector
CN78 and the crimped portion of the wire to see whether it has a
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Operate the pull side of attachment 1 lever more than 1 second to

Judgment
Result Procedure
STEP3
Inspection: Attachment 1 proportional valve solenoid (PULL)

individual inspection
attachment 1 proportional valve solenoid (PULL).

Check the resistance of attachment 1 proportional
CN78 valve solenoid (PULL).

TROUBLESHOOTING.

CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness

the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H702

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever pull
side)
CAUTION
H705.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
disconnect the CN78 connector. Check the inside of connector
CN78 and the crimped portion of the wire to see whether it has a
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2
Operate the pull side of attachment 1 lever for more than 1 second
to check if an error occurs. 5
Judgment
Result Procedure
STEP3



TROUBLESHOOTING.

CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness

harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H703

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever push
side)
CAUTION
H705.
• If HB01 or HB03 occurs at the same time, perform troubleshooting for HB01, HB03 first. 5
Probable cause
• Attachment 1 proportional valve solenoid (PUSH) defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
C87 connector. Check the inside of connector CN87 and the
Judgment
Result Procedure
STEP2
Operate the push side of the attachment 1 lever for more than 1
second to check if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Attachment 1 proportional valve solenoid (PUSH)

attachment 1 proportional valve solenoid (PUSH).

Check the resistance of the attachment 1 proportional
CN87 valve solenoid (PUSH).

inside each connector and the crimped portion of each
8 7 6 5 wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness

the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H704

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever push
side)
CAUTION
H705.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
Result Procedure
STEP2
Operate the push side of the attachment 1 lever for more than 1
Judgment
5
Result Procedure
STEP3



inside the connector and the crimped portion of each
TROUBLESHOOTING.

CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN87 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H705

Failure mode: Attachment 1 proportional valve solenoid drive circuit abnormality
Probable cause
• Attachment 1 proportional valve solenoid defect
• Harness defect
• F78 fuse defect
5
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Attachment 1 proportional valve solenoid individual

inspection
resistance of the attachment 1 proportional valve solenoid.

CN78 CN87 Check the resistance of the attachment 1 proportional
valve solenoid.

plug. Disconnect the CN78 and CN87 connectors.
8 7 6 5 8 7 6 5 Visually check each terminal and the crimped portion

CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid defect
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
5 6 7 8
TROUBLESHOOTING.
CN87
1 2 3 4
5 6 7 8

Judgment
Result Procedure
NG Harness defect
Go to step 3
Go to step 3
5
STEP3

F78 fuse.
Judgment
Result Procedure
step.
Error Code: H706

Failure mode: Attachment 1 proportional valve solenoid (open / short) abnormality
CAUTION
H705.
Probable cause
• F78 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78 and CN87 connectors. Check the inside of connectors
CN78 and CN87 and the crimped portion of the wires to see
whether they have a defect or not by visual confirmation. Refer to
Judgment
Result Procedure
STEP2

5
Check the mounting of the F78 fuse to see whether it has a defect
or not by visual confirmation.
Judgment
Result Procedure
STEP3
F78 fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4
box.
box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

inspection
Disconnect the CN78, CN87 connectors, and check the resistance
of the attachment 1 proportional valve solenoid.

CN78 CN87 Check the resistance of the attachment 1 proportional
valve solenoid.

plug. Disconnect the CN78, CN87 connectors. Visually
8 7 6 5 8 7 6 5 check inside each connector and the crimped portion
of each wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
If replacing the F78 fuse in the former step, perform STEP 6.
OK Go to step 6
STEP6
Inspection: Harness

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
5 6 7 8
CN103
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H801

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever pull side)
CAUTION
H805.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
Result Procedure
STEP2
Operate the pull side of the attachment 2 lever for more than 1
Judgment
5
Result Procedure
STEP3


Check the resistance of the attachment 2 proportional

TROUBLESHOOTING.

CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H802

Failure mode: Attachment 2 proportional valve solenoid short abnormality (lever pull
side)
CAUTION
H805.
5
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
Result Procedure
STEP2
Operate the pull side of attachment 2 lever more than 1 second to

Judgment
Result Procedure
STEP3



TROUBLESHOOTING.

CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
TROUBLESHOOTING. 5

Judgment
Result Procedure
NG Harness defect
Error Code: H803

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever push
side)
CAUTION
H805.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of attachment 2 lever more than 1 second

to check if an error occurs. 5
Judgment
Result Procedure
STEP3



inside each connector and the crimped portion of each
TROUBLESHOOTING.

CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN103, and CN87 connectors, then check

the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN103
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Error Code: H804

Failure mode: Attachment 2 proportional valve solenoid short abnormality
(lever push side)
CAUTION
H805.
5
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of attachment 2 lever more than 1 second

to check if an error occurs.
Judgment
Result Procedure
STEP3



the terminal and the crimped portion and coating of
TROUBLESHOOTING.

CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness

harnesses.

CN87 harnesses.
1 2 3 4 5 6 7
1 2 3 4
18 19 20 21 22 23 24 25 26 27
5 6 7 8
check inside the connectors and the crimped portion of 5
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: H805

Failure mode: Attachment 2 proportional valve solenoid drive circuit abnormality
Probable cause
• Harness defect
• F79 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

inspection
resistance of attachment 2 proportional valve solenoid.

CN78 CN87 Check the resistance of attachment 2 proportional
valve solenoid.

plug. Disconnect the CN78 and CN87 connector.
8 7 6 5 8 7 6 5 Visually check each terminal and the crimped portion

CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 2 proportional valve solenoid defect 5
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
5 6 7 8
TROUBLESHOOTING.
CN87
1 2 3 4
5 6 7 8

Judgment
Result Procedure
NG Harness defect
Go to step 3
Go to step 3
STEP3

F79 fuse.
Judgment
Result Procedure
step.
Error Code: H806

Failure mode: Attachment 2 proportional valve solenoid (open / short) abnormality
CAUTION
H805.
5
Probable cause
• F79 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
and CN87 connectors. Check the inside of connectors CN78,
CN87 and the crimped portion of their wires to see whether they
have a defect or not by visual confirmation. Refer to BEFORE
TROUBLESHOOTING.
Judgment
Result Procedure
STEP2

Visually confirm the mounting of F79 fuse is correct.
Judgment
Result Procedure
H806 error turn on the key switch. F79 fuse installation defect
STEP3
of the fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4
fuse box.
Measure the resistance at both ends of the connector for F79 fuse
box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

inspection
resistance of attachment 2 proportional valve solenoid.

CN78 CN87 Check the resistance of attachment 2 proportional 5
valve solenoid.
4 3 2 1 4 3 2 1 Turn off the key switch. Disconnect the battery plug,

and disconnect the CN78 and CN87 connectors.
8 7 6 5 8 7 6 5 Visually check inside each connector and the crimped
portion of each wire for defects. Refer to BEFORE
TROUBLESHOOTING.

CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 6
STEP6
Inspection: Harness
Disconnect the CN101, CN103, CN78 and CN87 connectors, then

CN78 harnesses.
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 CN101, CN103, CN78, and CN87 connectors
18 19 20 21 22 23 24 25 26 27 disconnected. Visually check inside the connector and
5 6 7 8
28 29 30 31 32 33 34 the crimped portion of its wire for defects. Refer to
CN103
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*1: If the former step is OK, connect the CN78 connector and measure the resistance between CN101-5 and
CN101-14. It is OK if this resistance is approx. 8 Ω.
*2: If the former step is OK, connect the CN87 connector and measure the resistance between CN101-5 and

Judgment
Result Procedure
NG Harness defect
Error Code: HB01

Failure mode: Proportional valve solenoid power supply: RY1 contact open abnormality
Probable cause
• Harness defect
• RY1 defect
5
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
Lift PULL CN78-5 (481)
solenoid CN78-1 (10) CN101-17 (10,SLPL-)
SLPL CN101-16 (11,SLPS-)
Lift PUSH CN87-5 (481)
solenoid CN87-1 (11)
SLPS
F79
CN250-48 (484) CN250-47 (9)
Attachment 2 CN78-8 (484)
PULL CN78-4 (39) CN101-14 (39,SA2PL-) Main
solenoid CN101-15 (40,SA2PS-) controller
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
Attachment 1 CN78-7 (483) CN101-10 (36,SA1PL-)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
Attachment 1 CN87-7 (483) CN104-4 (N2, N2)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HB01 error does not occur. Connector contact defect
HB01 error occurs. Go to step 2
STEP2
Inspection: Harness

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN127
28 29 30 31 32 33 34
1 2 3 4 5 6 7
CN102
1 2 3 4 5 6 7 CN137
8 9 10 11 12 13 14 15 16 17 18 19
1
20 21 22 23 24 25 26 27
2 3
28 29 30 31 32 33 34 35
Inspect for continuity and short circuiting of the harnesses.
CN102, CN127, CN137 connectors disconnected. Visually
check inside the connectors and the crimped portion of their
wires for defects. Refer to BEFORE TROUBLESHOOTING.


Judgment
Result Procedure
NG Harness defect
OK RY1 defect 5
If the symptom persists after replacement of the relay, there
are other problems. Replace the Main controller.
Error Code: HB02

Failure mode: Proportional valve solenoid load-short abnormality
Probable cause
• Harness defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
CN127, CN78, and CN87 connectors. Check the inside of
connector CN127, CN78, and CN87 and the crimped portion of
their wires to see whether they have a defect or not by visual
After connecting CN127, CN78 and CN87, connect the battery
plug and turn on the key switch to confirm the error.
Judgment 5
Result Procedure
STEP2
Inspection: Harness
Disconnect the CN101, CN102, CN103, CN104, CN78, and CN87
connectors, then check the harnesses.

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
CN101, CN102, CN103, CN104, CN78, and CN87
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
connectors disconnected. Visually check inside the
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 connectors and the crimped portion of their wires for
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Portions to be checked Standard


Judgment
Result Procedure
NG Harness defect
Error Code: HB03

Failure mode: Proportional valve solenoid power supply: RY1 over current abnormality
Probable cause
• Harness defect
• RY1 defect
5
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Inspection: Harness
harnesses.

CN127 harnesses.

TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
OK RY1 defect
If the symptom persists after replacement of the relay, there
are other problems. Replace the Main controller.
Error Code: HC01

Failure mode: Unload solenoid open abnormality
CAUTION
• If HC03 also occurs, disconnect the battery plug at once. Perform troubleshooting with priority given to
HC03.
• If A902 occurs at the same time, perform troubleshooting for A902 first.
5
Probable cause
• Unload solenoid defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HC04 error occurs. Perform troubleshooting for HC04.
HC04 error does not occur. Go to step 2
STEP2
Apply the unload solenoid by using Active Test, and check if an

error occurs.
UNLOAD SOL: OFF to ON
Judgment
Result Procedure
HC01 error does not occur. Connector contact defect
HC01 error occurs. Go to step 3
STEP3
Inspection: Unload solenoid individual inspection

unload solenoid.

CN88 Check the resistance of unload solenoid.
Turn off the key switch, disconnect the battery plug, and
4 3 2 1 disconnect the CN88 connector. Visually check each terminal
and the crimped portion and coating of each cable for defects.
8 7 6 5 Refer to BEFORE TROUBLESHOOTING.

CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
NG Unload solenoid defect
OK Go to step 4
STEP4
Inspection: Harness

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
CN101, CN102, CN103, and CN88 connectors
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*: Connect the CN88 connector and measure the resistance between CN101-1 and CN102-17. It is OK if this
resistance is approx.10 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: HC02

Failure mode: Unload solenoid short abnormality
CAUTION
HC03.
Probable cause
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HC04 error occurs. Perform troubleshooting for HC04.
HC04 error does not occur. Go to step 2
STEP2
Apply the unload solenoid by using Active Test, and check if an

error occurs.

UNLOAD SOL: OFF to ON
Judgment
Result Procedure
5
STEP3

unload solenoid.

Check the resistance of the unload solenoid.
CN88

CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN88 harnesses.
1 2 3 4 5 6 7
1 2 3 4 Perform this check with the battery plug and the
8 9 10 11 12 13 14 15 16 17 18 19
CN102 and CN88 connectors disconnected. Visually
20 21 22 23 24 25 26 27
5 6 7 8 check inside the connectors and the crimped portion of
TROUBLESHOOTING.

Judgment
Result Procedure
NG Harness defect
Error Code: HC03

Failure mode: Unload solenoid drive circuit abnormality
Probable cause
• Harness defect
• F72 fuse defect
5
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

unload solenoid.

Check the resistance of unload solenoid.
CN88

CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
NG Go to step 2
Unload solenoid defect
OK Go to step 2
STEP2
Inspection: Harness
the harnesses.

harnesses.
1 2 3 4 5 6 7
TROUBLESHOOTING.
1 2 3 4
CN102
5 6 7 8
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

Judgment
Result Procedure
NG Harness defect
Go to step 3
Go to step 3
STEP3

After removing F72 fuse, measure the resistance at both ends of
the fuse.
Judgment
Result Procedure 5
step.
Error Code: HC04

Failure mode: Unload solenoid (open / short) abnormality
CAUTION
HC03.
• If A902 occurs at the same time, perform troubleshooting for A902 first.
Probable cause
• F72 fuse defect
• Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2

Check to see if the F72 fuse is mounted correctly. Visually confirm
if it has a defect or not.
Judgment 5
Result Procedure
HC04 error does not occur. F72 fuse installation defect
STEP3
After removing F72 fuse, measure the resistance at both ends of
the fuse.
Judgment
Result Procedure
0Ω Go to step 4
STEP4
box.
box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5


unload solenoid.

Check the resistance of unload solenoid.
CN88

CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
OK Go to step 6
STEP6
Inspection: Harness

harnesses.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 CN101, CN102, CN103, CN88 connectors
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 disconnected. Visually check inside the connectors
and the crimped portion of their wires for defects.
CN103 CN88
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
*: If the former step is OK, connect the CN88 connector and measure the resistance between CN101-1 and

Judgment 5
Result Procedure
NG Harness defect
Error Code: SAFETY MONITOR DRIVE MOTOR

Failure mode: Drive motor driver low temperature
If caution indicator occurs, turn on the key switch, and

leave 20 to 30 minutes at normal temperature (23 to
104°F [0 to 40°C]).
Error Code: SAFETY MONITOR PUMP MOTOR

Failure mode: Pump motor driver low temperature
If caution indicator occurs, turn on the key switch, and

leave 20 to 30 minutes at normal temperature (23 to
104°F [0 to 40°C]).
5
5.5. WHEN NO ERROR CODE IS DISPLAYED

Probable causes of problems for which no error code is displayed.
If an error code is displayed or the spanner indicator blinks, make sure to perform checks with priority given to it.
Control Failed portions and Action and

systems Symptom failure modes How to check remedies
Power-supply Although the key Battery Check the battery • Charge the
related control switch or ten-key : Low voltage voltage. Battery
operation is turned : Battery plug is
on, power is not disconnected.
supplied.
Key switch main body - • Check the
(The multi-function switch, and
: Open failure
screen does not replace it if
appear, and the lift Key switch harness
necessary
truck does not move, : Wire breakage, short
• Check the
either.) circuit or leakage
harness and
(harness, connector or
repair or
F5 fuse)
replace it if
necessary.
• Replace the F5
fuse.
Numeric keypad - • Check the
harness (with PIN harness and
code entry) repair or
: Open failure replace it if
necessary.
Power-supply Although the key Numeric keypad main Check the operation of • Replace the
related control switch or ten-key body (with PIN code each switch. numeric
operation is turned entry) : Check if a response keypad.
on, power is not : Switch failure (lighting of LED or
supplied. sounding of buzzer) is
(The multi-function given only to a
screen does not particular switch.
appear, and the lift If there are two types of
truck does not move, switches: switch to
either.) which a response is
given and switch to
which no response is
given in the
combination of (1, 2
and 3), (4, 5 and 6), (7,
8 and 9) or (OFF, 0 and
ON), it is certain that
there is a defective
switch.
Multi-function display Using the Administrator • Register PIN
(with PIN code entry) menu, check if PIN has using the
: PIN not registered been registered. Administrator
menu.

Power-supply Although the key Display power supply - • Check the
related control switch or ten-key and ground harness harness and
operation is turned (with PIN code entry) repair or
on, power is not : Wire breakage, short replace it if
supplied. circuit, leakage necessary.
(The multi-function (harness or connector) • Replace the
screen does not Multi-function display display.
appear, and the lift (with PIN code entry) • Replace the
5
truck does not move, main controller.
: Internal failure
either.)
Main controller
: Internal failure (D7V,
DGND)
Power-supply The multi-function Display power supply - • Check the
related control screen does not and ground harness harness and
appear. : Wire breakage, short repair or
(The lift truck runs circuit, leakage replace it if
normally.) (harness or connector) necessary.
Multi-function display • Replace the
display.
: Internal failure
• Replace the
Main controller
main controller.
: Internal failure
Traveling The lift truck does Warm-up operation Confirm the caution *It is not
not run (the drive with running cold indicator and warning abnormality.
motor does not protect function. tone on the display Warm-up function
rotate) or cannot run may be operated
at slope suddenly. for several
*The caution indicator
seconds when
is displayed with a
turn on the key
warning tone to alert
switch.
the customers the lift
truck is running the
warm-up operation Operate after the
(E.g. If left for a long warning tone has
time under low gone because
temperature). traveling and
handling function
can not be
operated under
warm-up function.

Traveling The lift truck does After the key switch - After the key
not run (the drive was turned on, the switch was turned
motor does not accelerator was not on, release the
rotate) or cannot run released or the accelerator and
at slope suddenly. direction switch was operate neutral for
not returned to neutral. the direction
switch once, then
operate traveling
function.
Traveling function
can not be
operated after
detecting the
accelerator
released and
neutral for the
direction switch.
Direction switch main Check the direction • Check the
body switch using Analyzer. switch, and
: Open failure : Accelerator is fully replace it if
closed. necessary
Direction switch
harness Operate the direction • Check the
switch to see if it turns harness and
: Wire breakage, short
on and off normally. repair or
circuit (harness or
replace it if
connector) (The lift truck does not
necessary.
run if the forward and
reverse switches are
turned on
simultaneously.)
Direction switch Check the operation of • Repair or
installation portions the direction switch replace the part
(Forward/Reverse (microswitch). that does not
pedal) operate
: One of the normally.
installation portions is
broken or damaged or
does not operate
normally.
Accelerator sensor Check the accelerator • Check the
main body sensor voltage using sensor and
: Internal failure Analyzer. replace it if
: Direction switch is in necessary.
Accelerator sensor
installation portion neutral. • Check the
Fully open and close harness and
: The link or the
the accelerator pedal to repair or
installation portion is
check the change in replace it if
broken or damaged.
voltage at that time. necessary.
Accelerator sensor
harness
circuit, leakage
(harness or connector)

Traveling The lift truck does Brake sensor main Check the brake • Check the
not run (the drive body sensor voltage using sensor and
motor does not : Internal failure Analyzer. replace it if
rotate) or cannot run : Direction switch is in necessary.
Brake sensor
at slope suddenly. neutral. • Check the
installation portion:
The link or the Fully open and close harness and
installation portion is the brake pedal to repair or
broken or damaged. check the change in replace it if 5
Brake sensor harness
circuit, leakage
Brake fully closed / Check the matching • Perform
operational point value on the Matching matching
matching value screen. again.
: No agreement with
the lift truck state
Tire angle sensor main Check the sensor • Check the
body voltage using Analyzer. sensor and
: Internal failure : Direction switch is in replace it if
neutral. necessary.
Tire angle sensor
installation Fully close the • Check the
accelerator pedal and harness and
: The installation
operate steering wheel repair or
portion is broken or
to check the change in replace it if
damaged.
Tire angle sensor
harness
circuit, leakage
Tire angle sensor Check the matching • Perform
straight running value on the Matching matching
: No agreement with
Brake Check the brake and • Check the
: Dragging (internal the drive motor. brake, and
failure) : With the battery plug repair or
disconnected, the replace it if
Drive motor
parking brake released necessary.
: Seizure or dragging
and the front wheels off • Check the drive
of drive motor (internal
the ground, motor, and
failure)
rotate each tire to see if repair or
it rotates smoothly. replace it if
necessary.

Traveling The lift truck does Main body of drive Check the voltage of • Check the drive
not run (the drive motor rotation sensor the drive motor rotation motor rotation
motor does not : Internal failure sensor using Analyzer. sensor, and
rotate) or cannot run : Seated in seat, adjust or
Drive motor rotation
at slope suddenly. direction switch in replace it if
sensor installation
forward position, brake necessary.
portion
released • Check the
: Gap improperly
Operate the harness and
adjusted
accelerator and check repair or
Drive motor harness replace it if
the change in the
: Wire breakage, short rotation sensor voltage. necessary.
circuit, leakage
Drive motor drive Check the voltage of • Check the
circuit the drive motor current cable and
: Internal failure sensor using Analyzer. repair or
: Seated in seat, replace it if
Motor cables
direction switch in necessary.
forward position, brake • Replace the
circuit or leakage
released drive motor
(cable or terminal
Operate the drive circuit.
board)
accelerator and check
the change in the
current sensor voltage.
Main controller - • Replace the
: Internal failure main controller.
Load handling Load handling Warm-up operation Confirm the caution *It is not an
and power cannot be performed with running cold indicator and warning abnormality.
steering and the steering is protect function. tone on the display Warm-up function
heavy. may be operated
(The pump motor for several
*The caution indicator
does not work for seconds when you
is displayed with a
material handling turn on the key
warning tone to alert
operation, steering switch.
customers that the lift
operation and truck is running the
direction switch warm-up operation Operate after the
operation.) (e.g. If left for a long warning tone has
time under low gone because
temperature). traveling and
handling function
can not be
operated under
warm-up function.

Load handling Load handling Main body of pump Check the voltage of • Check the
and power cannot be performed motor rotation sensor the pump motor pump motor
steering and the steering is : Internal failure rotation sensor using rotation sensor,
heavy. Analyzer. and adjust or
Pump motor rotation
(The pump motor : Seated in the seat replace it if
sensor installation
does not work for necessary.
portion Operate the direction
material handling switch and check the • Check the
: Gap improperly 5
operation, steering change in the rotation harness and
adjusted
operation and sensor voltage. repair or
direction switch Pump motor harness replace it if
operation.) : Wire breakage, short necessary.
circuit, leakage
Pump motor drive Check the voltage of • Check the
circuit the pump motor current motor cables,
: Internal failure sensor using Analyzer. and repair or
: Seated in the seat replace them if
Motor cables
necessary.
: Wire breakage, short Operate the direction
switch and check the • Replace the
circuit or leakage
change in the current pump motor
(cable or terminal
sensor voltage. drive circuit.
board)
Pump - • Check the
: Seizure pump, and
repair or
Pump motor
replace it if
: Seizure necessary.
• Check the
pump motor,
and repair or
replace it if
necessary.

Load handling Only load handling Main body of load Measure the voltage of • Check the
and power cannot be handling lever the load handling lever sensor and
steering performed. potentiometer potentiometer using replace it if
(The pump motor : Internal failure Analyzer. necessary.
operates normally Installation of load : Leave the seat • Check the
during steering handling lever Tilt the load handling harness and
operation and potentiometer lever forward and repair or
direction switch backward to check the replace it if
: Installation portion is
operation.) change in voltage. necessary.
broken or damaged.
Load handling lever
potentiometer harness
circuit, leakage
Main body of tilt Check the tilt • Check the
forward/backward forward/backward switch, and
switch switch using Analyzer. replace it if
: Internal failure : Leave the seat necessary
Installation of tilt Operate the tilt lever • Check the
forward/backward forward to backward harness and
switch position to check the repair or
switch turns on and off replace it if
: Installation portion is
normally. necessary.
broken or damaged.
Tilt forward/backward
switch harness
circuit, leakage
Seat switch main body Check the seat switch • Check the seat
: Open failure using Analyzer. adjustment and
: Load handling lever in seat switch
Seat switch harness
neutral replace it if
: Wire breakage, necessary.
(harness or connector) Check if the switch
turns on and off • Check the
normally, sitting in the harness and
seat or standing beside repair or
it. replace it if
necessary.

Load handling Only load handling Oil control valve - • Check the oil
and power cannot be : Seizure of or leakage control valve,
steering performed. from the unload valve and repair or
(The pump motor replace it if
Harness of the unload
operates normally necessary.
valve solenoid
during steering Refer to the
: Wire breakage, short maintenance
operation and
circuit, leakage manual 5
direction switch
(harness or connector) “TROUBLE-
operation.)
SHOOTING” of
oil control
valve.
• Check the
unload valve
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
: Leak pump, and
repair or
Priority valve
replace it if
: Leak, seizure necessary.
• Check the
priority valve,
and repair or
replace it if
necessary.
Refer to the
maintenance
manual
“TROUBLE-
SHOOTING” of
oil control
valve.
Load handling Only lowering is Lowering lock valve If a current flows, turn • Check the
and power impossible. : Seizure (internal on the lowering lock lowering lock
steering (Other load handling damage) solenoid using Active valve, and
operations, including Test to lower the fork. repair or
raising, are replace it if
possible.) necessary.

Load handling Only forward tilting is Tilt forward lock valve: If a current flows, turn • Check the tilt
and power impossible. Seizure (internal on the tilt forward lock forward lock
steering (Other load handling damage) solenoid using Active valve, and
operations, including Test to forward the fork. repair or
backward tilting, are replace it if
Load handling Only backward tilting Tilt backward lock If a current flows, turn • Check the
and power is impossible. (Other valve on the tilt backward backward lock
steering load handling : Seizure (internal lock solenoid using valve, and
operations, including damage) Active Test to repair or
forward tilting, are backward the fork. replace it if
Load handling Not activated lift limit Lifting height switch Check the lifting height • Check the
and power function main body switch using Analyzer. switch, and
steering : High lifting height is : In ANL, replace it if
always detected. necessary
Raise and lower the lift
Lifting switch harness to its uppermost and • Check the
lowermost positions to harness and
see if the switch turns repair or
circuit (harness or
on and off normally. replace it if
connector)
necessary.
Main body of tilt angle Check the tilt angle • Check the
sensor sensor voltage sing sensor, and
: Internal damage Analyzer. adjust or
: In ANL, replace it if
Tilt angle sensor
necessary.
installation Tilt the mast to its
forward and backward • Check the
: The link or the
tilt limits to check the harness and
change in voltage. repair or
broken or damaged.
replace it if
Tilt angle sensor necessary.
harness
circuit, leakage
Display setting: Lifting Check the set value on • Setting screen
speed limitation the Option Set screen.
disabled.(OPTION
SET L UP-SPD LIM)
Display setting: Tuning Check the set value on • Setting screen
No.35 (TUNE GEN. the Tuning screen.
35)
Load handling Delay of moving Display setting Check the OCV • Adjusting of
and power load handling or the : The setting of OCV activation current value setting Adjust
steering play of load handling activation current is on the Matching activation
not in agreement with screen. current of
lever is large until
that of the lift truck turning after
moving (Fingertip setting the OCV
state.
Control Lever spec.) activation
current.

Load handling The steering is Direction switch Check the direction • Check the
and power heavy. : Open failure switch using Analyzer. switch, and
steering (The pump motor : Accelerator is fully replace it if
Direction switch
operates normally closed. necessary
harness
during material Operate the direction • Check the
: Wire breakage
handling.) switch to see if it turns harness and
on and off normally. repair or
replace it if 5
necessary.
Main body of steering Check the steering • Check the
angle sensor angle sensor using sensor and
: Internal damage Analyzer. replace it if
: Turn the steering necessary.
Installation of steering
angle sensor wheel to check the • Check the
input signal. harness and
: Cam or steering
repair or
wheel is defective.
replace it if
Steering angle sensor necessary.
harness
circuit, leakage
: Leak pump, and
repair or
Priority valve
replace it if
: Leak, seizure necessary.
PS valve • Check the
: Leak, seizure priority valve,
and repair or
replace it if
necessary.
Refer to the
maintenance
manual
“TROUBLE-
SHOOTING” of
oil control
valve.
• Check the PS
valve, and
repair or
replace it if
necessary.
Refer to the
maintenance
manual
“TROUBLE-
SHOOTING” of
steering.

Load handling The steering is Main controller - • Replace the
and power heavy. : Internal failure main controller.
steering (The pump motor
operates normally
during material
handling.)
Load handling Although ATT1 Display setting: Check the set value on • Change the
and power (ATT2) is operated, The serial number the Option Set screen. setting
steering no operation is setting is not in
performed. agreement with that of
(Pump motor is not the lift truck.
rotated at ATT (OCV WAY)
operation)
Operator Neither traveling Seat switch main body Check the seat switch • Check the
Presence Operator Presence : Short failure using Analyzer. switch, and
Sensor Sensor nor load : Direction switch in replace it if
Seat switch harness
handling Operator neutral, accelerator necessary
Presence Sensor : Short circuit (harness
pedal fully closed • Check the
operates. or connector)
Check if the switch harness and
turns on and off repair or
normally, sitting in the replace it if
seat or standing beside necessary.
it.
Operator Only traveling Drive motor drive - • Replace the
Presence Operator Presence circuit drive motor
Sensor Sensor does not : Internal failure drive circuit.
operate.

Operator Only load handling Oil control valve Check the tilt forward • Check the oil
Presence Operator Presence : Seizure of or leakage lock valve using Active control valve,
Sensor Sensor does not from tilt forward lock Test. and repair or
operate. valve : Tilt forward solenoid replace it if
forcibly turned off necessary.
(forward tilting Refer to the
harness
stopped) Tilt the fork maintenance
: Short circuit, leakage manual 5
forward to check the
operation.
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Oil control valve Check the tilt backward • Check the oil
: Seizure of or leakage lock valve using Active control valve,
from tilt backward lock Test. and repair or
valve : Tilt backward solenoid replace it if
Tilt backward solenoid
Refer to the
harness (backward tilting
maintenance
: Short circuit, leakage stopped) Tilt the fork
manual
(harness or connector) backward to check the
“TROUBLE-
operation.
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.

Operator Only load handling Oil control valve Check the lift lower • Check the oil
Presence Operator Presence : Seizure of or leakage lock valve using Active control valve,
Sensor Sensor does not from lift lower lock Test. and repair or
operate. valve : Lift lower lock replace it if
solenoid forcibly turned necessary.
Lift lock solenoid
off (lifting stopped) Refer to the
harness
Lower the lift to check maintenance
: Short circuit, leakage manual
the operation.
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Oil control valve Check the unload valve Tilt control
: Seizure or leakage using Active Test.
from unload valve : Unload solenoid
Harness of unload forcibly turned on
valve solenoid (lifting stopped) Lower
: Wire breakage, short the lift to check the
circuit, leakage operation.
Main controller -
: Internal failure
Auxiliary The backup buzzer Backup buzzer main -
equipment and smart alarm do body
not sound. : Internal damage
(Forward/Reverse Backup buzzer
Pedal option or harness
motion alarm spec.)
circuit, leakage
Auxiliary equipment -
relay main body
: Open failure
Auxiliary equipment
relay harness
circuit, leakage
Backup relay main -
body
: Open failure
Backup relay harness
circuit, leakage

Auxiliary The backup buzzer Backup buzzer main - • Check the
equipment and smart alarm do body backup buzzer
not stop sounding. : Internal damage and replace it if
(Forward/Reverse necessary.
Backup buzzer
Pedal option or harness • Check the
motion alarm spec.) harness and
: Short circuit, leakage
repair or
(harness or connector) 5
replace it if
necessary.
Auxiliary equipment - • Check the
relay main body auxiliary
: Short circuit equipment
relay and
Auxiliary equipment
replace it if
relay harness
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Backup relay main - • Check the
body backup relay
: Short circuit and replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.

Auxiliary The backup light Backup lamp or light - • Check the
equipment does not go on. main body backup light
(Forward/ Reverse : Open failure, light and replace it if
Pedal option) bulb blow-out. necessary.
Backup light harness • Check the
: Wire breakage, short harness and
circuit, leakage repair or
(harness or connector) replace it if
necessary.
: Open failure equipment
relay and
Auxiliary equipment
re-place it if
relay harness
necessary.
• Check the
circuit, leakage
harness and
repair or
replace it if
necessary.
body backup relay
: Open failure and replace it if
necessary.
• Check the
:Wire breakage, short
harness and
circuit, leakage
repair or
replace it if
necessary.

Auxiliary The backup light Backup light or lamp - • Check the
equipment does not go out. main body backup light
(Forward/ Reverse : Open failure and replace it if
Pedal option) necessary.
Backup light harness
• Check the
harness and
circuit, leakage
repair or
(harness or connector) 5
replace it if
necessary.
: Short circuit equipment
relay and
Auxiliary equipment
replace it if
relay harness
necessary.
• Check the
harness and
repair or
replace it if
necessary.
body backup relay
: Short circuit and replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Buzzer-relate Operator Presence Display setting Check the set value on • Setting screen
d control Sensor operation : Operator Presence the Option Set screen.
warning does not Sensor operation
sound. notification buzzer
disabled
(BUZZER SPEC,
SEAT BUZZER)
Display Check that the built-in • If the buzzer
: Built-in buzzer is buzzer sounds a short does not
broken. beep when the display sound, replace
switch (microswitch) is the display.
pressed.

Buzzer-relate The traveling Display setting Check the set value on • Setting screen
d control Operator Presence : Return-to-neutral the Option Set screen.
Sensor warning buzzer
return-to-neutral disabled (BUZZER
warning does not SPEC)
sound.
pressed.
Buzzer-relate The load handling Display setting Check the set value on • Setting screen
d control Operator Presence : Return-to-neutral the Option Set screen.
Sensor return-to warning buzzer
neutral warning does disabled (BUZZER
not sound. SPEC)
pressed.
Buzzer-relate The parking brake Parking brake switch Check the parking • Check the
d control release reminder main body brake switch using switch, and
does not sound. : Short circuit Analyzer. adjust or
(The switch can also replace it if
Installation of parking
be checked by necessary.
brake switch
checking if the parking • Check the
: Switch is held down.
indicator on the display harness and
Parking brake switch goes on and out.) repair or
harness replace it if
: Direction switch is in
: Short circuit (harness neutral. necessary.
or connector)
Operate the parking
brake to see if the
switch turns on and off
normally.
pressed.

Buzzer-relate When the lift truck Parking brake switch Check the parking • Check the
d control runs with the parking main body brake switch using switch, and
brake released, the : Open failure Analyzer. adjust or
parking brake (The switch can also replace it if
release reminder be checked by necessary.
brake switch
sounds. checking if the parking • Check the
: Switch is off.
Parking brake switch goes on and out.) repair or 5
: Wire breakage neutral. necessary.
Operate the parking
brake to see if the
normally.
Buzzer-relate The parking brake Display setting Check the set value on • Setting screen
d control reminder does not the Option Set screen.
sound. Parking brake switch Check the parking • Check the
main body brake switch using switch, and
: Open failure Analyzer. adjust or
(The switch can also replace it if
be checked by necessary.
brake switch
checking if the parking • Check the
: Switch is off.
Parking brake switch goes on and out.) repair or
: Wire breakage neutral. necessary.
Operate the parking
brake to see if the
normally.
Seat switch main body Check the seat switch • Check the seat
: Short failure using Analyzer. and replace it if
: Check if the switch necessary.
Seat switch harness
turns on and off • Check the
: Short circuit (harness
normally, sitting in the harness and
or connector)
seat or standing beside repair or
it. replace it if
necessary.
pressed.
Buzzer-relate The parking brake Main controller - • Replace the
d control reminder does not : Internal failure main controller.
sound.

Buzzer-relate Although the parking Parking brake switch Check the parking • Check the
d control brake is pushing, the main body brake switch using switch, and
parking brake : Short circuit Analyzer. adjust or
reminder does not replace it if
stop sounding. necessary.
brake switch : Direction switch is in
neutral. • Check the
: Switch is on.
harness and
Parking brake switch Operate the parking
repair or
harness brake to see if the
replace it if
: Short circuit (harness necessary.
normally.
or connector)
Multifunction [Diagnostic mode One of the following Check the matching • Setting screen
display indicator] matching operations is value on the Matching * If accelerator
not performed. screen. pedal fully closed
• Tire straight and fully open
Although no error
running angle matching is
code is displayed,
matching finished by simply
the spanner
indicator is left on. • Forward tilt limit performing fully
angle matching closed matching
• Tilt horizontal angle and fully open
matching matching in this
order, the setting
• Tilt no-load
will not be saved.
matching
• Mast type data
matching * If brake pedal
fully closed and
• Accelerator pedal
operating point
fully open matching
matching is
• Accelerator pedal finished by simply
fully closed performing fully
matching closed matching
• Brake pedal fully and operating
open matching point matching in
• Brake pedal fully this order, the
closed matching setting will not be
saved.
• Each load handling
lever: neutral
voltage matching
• Tire diameter data

Multifunction [Tilt indicator] Main body of tilt angle Check the tilt angle • Check the
display The correct tilt angle sensor sensor voltage using sensor, and
is not displayed. : Internal damage Analyzer. adjust or
: In ANL, replace it if
Tilt angle sensor
necessary.
The tilt indicator installation Tilt the mast to its
calculates as 0° : The link or the
when matching as installation portion is 5
horizontal angle for broken or damaged.
replace it if
no load. At tilt most Tilt angle sensor necessary.
forward / most harness
backward position, it
may be jolted out of
circuit, leakage
alignment for the
actual tilt angle. But
it is normal. Tilt angle sensor Check the matching • Perform
horizontal matching value on the Matching matching
value screen. again.
: No agreement with
A load is carried. - • The tilt indicator
calculates as 0°
when matching
as horizontal
angle for no
load. So if load
is carried, have
the potential to
display the
angle of
backward side
in spite of
making fork
horizontal level,
because tire
and mast bend
to forward side.

Multifunction [Tilt indicator] A load is carried. - • The automatic
display The tilt angle is not tilt leveling
indicated as 0° when function stops
the automatic fork at the position
leveling is finished. of the backward
side corrected
for the load in
consideration
for the bend of
tire and mast
when a load is
carried. On the
other hand, tilt
indicator
calculates as 0°
when matching
as horizontal
angle for no
load.
tilt angle may not
be indicated as 0°
depending on the
load, but it is
normal.
Turn speed The lift truck lacks Tire specification - • Check the tires
control stability during and replace
traveling. them if
: Type, diameter
(The speed limit necessary
does not activate Load sensor main Check the load sensor • Check the
easily or at all during body voltage using Analyzer. sensor and
turning.) : Internal damage : In ANL, replace it if
necessary.
Load sensor harness Raise and lower the lift
to its uppermost (relief) • Check the
and lowermost harness and
circuit, leakage
positions to check the repair or
change in the voltage. replace it if
necessary.
Load sensor no-load Check the matching • Perform
matching value value on the Matching matching
: No agreement with screen. again.
Lifting height switch Check the lifting height • Check the
main body switch using Analyzer. switch, and
: Low lifting height is : In ANL, replace it if
circuit (harness or
connector)
necessary.

Turn speed The lift truck lacks Tire angle sensor main Check the sensor • Check the
control stability during body voltage using Analyzer. sensor and
traveling. : Internal failure : Direction switch is in replace it if
(The speed limit neutral. necessary.
Tire angle sensor
does not activate installation Fully close the • Check the
easily or at all during accelerator pedal and harness and
: The installation
turning.) operate steering wheel repair or
portion is broken or 5
damaged.
Tire angle sensor
harness
circuit, leakage
: No agreement with
Main body of drive - • Check the
motor rotation sensor sensor and
: Internal failure replace it if
necessary.
Drive motor rotation
sensor harness • Check the
harness and
repair or
circuit, leakage
replace it if
necessary.
Drive motor drive
• Replace the
circuit
drive motor
: Internal failure drive circuit.
Turn speed The lift truck lacks Display setting Check the matching • Correct the
control stability during : The setting of tire value on the tire setting
traveling. diameter data is not in diameter data screen.
(The speed limit agreement with that of
does not activate the lift truck state.
easily or at all during Main controller - • Replace the
turning.) main controller.
: Internal failure

Tilt control When tilted forward Main body of tilt angle Check the tilt angle • Check the
for leveling, the fork sensor sensor voltage using sensor, and
does not stop : Internal damage Analyzer. adjust or
automatically in a : In ANL, replace it if
Tilt angle sensor
horizontal position. necessary.
(The fork tilts to its forward and backward • Check the
: The link or the
forward tilt limit tilt limits to check the harness and
without stopping in a change in voltage. repair or
broken or damaged.
horizontal position.) replace it if
harness
circuit, leakage
Tilt angle sensor Check the matching • Perform
: No agreement with
Main body of Check the automatic • Check the
automatic fork leveling fork leveling switch switch, and
switch using Analyzer. replace it if
: Open failure : Load handling lever in necessary
Mechanical detection neutral • Check the
unit of automatic fork Operate the automatic harness and
leveling switch fork leveling switch to repair or
see if it turns on and off replace it if
: Gap in detection unit
is improperly adjusted.
Automatic fork leveling
switch harness
circuit (harness or
connector)

Tilt control When tilted forward Oil control valve Check the tilt control • Check the oil
for leveling, the fork : Seizure of or leakage valve using Active Test. control valve,
does not stop from tilt forward lock : Tilt forward solenoid and repair or
automatically in a valve forcibly turned off replace it if
horizontal position. (forward tilting necessary.
Tilt solenoid harness
(The fork tilts to its stopped) Refer to the
: Short circuit, leakage maintenance
forward tilt limit Tilt the fork forward to
(harness or connector) manual 5
without stopping in a check the operation.
horizontal position.) “TROUBLE-
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.

Tilt control When the fork tilted Main body of tilt angle Check the tilt angle • Replace the
forward for leveling, sensor sensor voltage using main controller.
it does not stop : Internal damage Analyzer.
automatically in a : In ANL,
Tilt angle sensor
horizontal position.
: The link or the forward and backward
(The fork does not installation portion is tilt limits to check the
stop in a horizontal broken or damaged. change in voltage.
position.)
Tilt angle sensor
harness
circuit, leakage
: No agreement with
Load sensor main Check the load sensor • Check the
body voltage, using sensor and
: In ANL, necessary.
Load sensor harness
Raise and lower the lift • Check the
to its uppermost (relief) harness and
circuit, leakage
and lowermost repair or
positions to check the replace it if
change in the voltage. necessary.
: No agreement with screen. again.

Tilt control When the fork tilted Main controller - • Replace the
forward for leveling, : Internal failure main controller.
it does not stop
Main body of tilt angle Check the tilt angle • Check the
automatically in a
sensor sensor voltage using sensor, and
horizontal position.
: Internal damage Analyzer. adjust or
(The fork does not replace it if
Tilt angle sensor : In ANL,
stop in a horizontal necessary.
position.) installation Tilt the mast to its 5
: The link or the
broken or damaged.
replace it if
harness
circuit, leakage
: No agreement with
Load sensor main Check the load sensor • Check the
body voltage using Analyzer. sensor and
: Internal damage : In ANL, replace it if
necessary.
circuit, leakage
necessary.
screen. again.
: No agreement with
: High lifting height is : In ANL, replace it if
circuit (harness or
connector)
necessary.

Tilt control When tilted Main body of tilt angle Check the tilt angle • Check the
backward for sensor sensor voltage, using sensor, and
leveling, the fork : Internal damage the Analyzer. adjust or
does not stop : In ANL replace it if
Tilt angle sensor
automatically in a necessary.
horizontal position. • Check the
: The link or the forward and backward
(The fork tilts to its tilt limits to check the harness and
backward tilt limit change in voltage repair or
broken or damaged.
without stopping in a replace it if
horizontal position.) Tilt angle sensor necessary.
(Fingertip Control harness
Lever spec.) :Wire breakage, short
circuit, leakage
: No agreement with
Main body of Check the automatic • Check the
automatic fork leveling fork leveling switch, sensor and
switch using the Analyzer. replace it if
: Open failure : Load handling lever in necessary.
see if it turns ON and replace it if
: Gap in detection
OFF normally. necessary.
unit is incorrectly
adjusted.
switch harness
circuit (harness or
connector)
: Internal failure main controller
Tilt control When the fork is Refer to “When the - •
tilted backward for fork tilted forward for
leveling, it does not leveling, it does not
stop automatically in stop automatically in a
a horizontal position. horizontal position.
(The fork does not (The fork does not
stop in a horizontal stop in a horizontal
position.) position.)”
(Fingertip Control
Lever spec.)

Tilt control When the fork is Main body of tilt angle Check the tilt angle • Check the
tilted backward for sensor sensor voltage, using sensor, and
leveling, it does not : Internal damage the Analyzer. adjust or
replace it if
stop automatically in Tilt angle sensor : In ANL
necessary.
a horizontal position. installation Tilt the mast to its
• Check the
(The fork does not : The link or the forward and backward
harness and
stop in a horizontal installation portion is tilt limits to check the
repair or 5
position.) broken or damaged. change in voltage. replace it if
(Fingertip Control Tilt angle sensor necessary.
Lever spec.) harness
circuit, leakage
: No agreement with
Tilt control The mast backward Main body of Check the automatic • Check the
tilting speed is not automatic fork leveling fork leveling switch sensor and
limited. switch using Analyzer. replace it if
: Open failure : Load handling lever in necessary.
switch harness
circuit (harness or
connector)
: High lifting height is : In ANL, replace it if
circuit (harness or
connector)
necessary.

Tilt control The mast backward Main body of Check the automatic • Check the
tilting speed is automatic fork leveling fork leveling switch switch, and
always slow. switch using Analyzer. replace it if
: Short circuit : Load handling lever in necessary
switch harness
: Short circuit (harness
or connector)
Oil control valve Check the tilt forward • Check the oil
from tilt forward lock Test. and repair or
valve replace it if
necessary.
Tilt forward solenoid : Tilt forward solenoid
Refer to the
harness forcibly turned off
maintenance
: Short circuit, leakage manual
(harness or connector) (No backward tilting “TROUBLE-
speed limit) Tilt the fork SHOOTING” of
backward to check the oil control
operation. valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.

Tilt control The mast backward Oil control valve Check the tilt backward • Check the oil
tilting speed is lock valve using Active control valve,
always slow. Test. and repair or
: Seizure or leakage
: Tilt backward solenoid replace it if
from tilt backward lock
forcibly turned on necessary.
valve
Refer to the
Tilt backward solenoid (No backward tilting
maintenance
harness speed limit) Tilt the fork
backward to check the
manual 5
“TROUBLE-
operation.
: Wire breakage, short SHOOTING” of
circuit, leakage oil control
(harness or connector) valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Tilt control Although the load is Lifting height switch Check the lifting height • Check the
lifted high, the mast main body switch using Analyzer. switch, and
forward tilting speed : High lifting height is replace it if
is not limited. always detected. necessary
: In ANL,
Lifting switch harness • Check the
harness and
: Wire breakage, short to its uppermost and
repair or
circuit (harness or lowermost positions to
replace it if
connector) see if the switch turns
necessary.
on and off normally.
Display setting: Check the set value on • Setting screen
Forward tilting speed the Option Set screen.
setting
(T F-SPD LIM)
circuit (harness or
connector)
necessary.

Tilt control The mast forward Lifting height switch Check the lifting height • Check the
tilting speed is main body switch, using Analyzer. switch, and
always slow. : High lifting height is : In ANL, replace it if
circuit (harness or
connector)
necessary.
Oil control valve Check the tilt forward • Check the oil
from tilt forward lock Test. and repair or
valve Tilt forward solenoid replace it if
Refer to the
harness (No backward tilting
maintenance
: Short circuit, leakage speed limit) Tilt the fork
manual
(harness or connector) backward to check the
“TROUBLE-
operation.
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.
Oil control valve Check the tilt backward • Check the oil
: Seizure or leakage lock valve using Active control valve,
from tilt backward lock Test. and repair or
valve : Tilt backward solenoid replace it if
forcibly turned on necessary.
Tilt backward solenoid
Refer to the
harness (No backward tilting
maintenance
: Wire breakage, short speed limit) Tilt the fork
manual
circuit, leakage backward to check the
“TROUBLE-
(harness or connector) operation.
SHOOTING” of
oil control
valve.
• Check the
solenoid and
replace it if
necessary.
• Check the
harness and
repair or
replace it if
necessary.

Tilt control The mast forward Main controller - • Replace the
tilting speed is : Internal failure main controller.
always slow.
Knob position The knob is Tire angle sensor main Check the sensor • Check the
compensation displaced from its body voltage using Analyzer. sensor and
control normal position to a : Internal failure : Direction switch is in replace it if
(OPT) certain position. neutral. necessary.
Tire angle sensor 5
(10° or more from installation Fully close the • Check the
the straight running accelerator pedal and harness and
: The installation
position) operate steering wheel repair or
portion is broken or
damaged.
Tire angle sensor
harness
Wire breakage, short
circuit, leakage
: No agreement with
: Cam or steering
repair or
wheel is defective.
replace it if
harness
circuit, leakage
Knob position Check the knob • Check the knob
compensation valve position compensation position
main body valve using Active Test. compensation
: Leakage, seizure : Tire end valve, and
(internal damage) repair or
Forcibly turn on
replace it if
Harness of knob (bypass) and off (no
necessary.
position compensation bypass) the knob
solenoid position compensation • Check the
solenoid to check how solenoid and
the steering system replace it if
circuit, leakage
operates. necessary.
Forcibly ON... Steering • Check the
idles (light). harness and
repair or
Forcibly OFF...
replace it if
Steering does not idles
necessary.
(heavy).

Knob position The knob is The road surface is - If the road surface
compensation displaced from its inclined. is inclined to the
control normal position to a right and left, the
(OPT) certain position. knob position will
(10° or more from be different than
the straight running on a horizontal
position) surface.

Knob position The knob is Tire angle sensor main Check the sensor • Check the
compensation displaced from its body voltage using Analyzer. sensor and
control normal position. : Internal failure : Direction switch is in replace it if
(OPT) (The knob position is neutral. necessary.
Tire angle sensor
not constant during installation Fully close the • Check the
straight running.) accelerator pedal and harness and
: The installation
operate steering wheel repair or
portion is broken or 5
damaged.
Tire angle sensor
harness
circuit, leakage
: No agreement with
: Cam or steering
repair or
wheel is defective.
replace it if
harness
circuit, leakage
Knob position Check the knob • Check the knob
compensation valve position compensation position
main body valve using Active Test. compensation
: Leakage, seizure : Tire end valve, and
(internal damage) repair or
Forcibly turn on
replace it if
Harness of knob (bypass) and off (no
necessary.
position compensation bypass) the knob
solenoid position compensation • Check the
solenoid to check how solenoid and
the steering system replace it if
circuit, leakage
operates. necessary.
Forcibly ON... Steering • Check the
idles (light). harness and
repair or
Forcibly OFF...
replace it if
Steering does not idles
necessary.
(heavy).

Knob position The knob is PS cylinder system - • Check the
compensation displaced from its link is defective. cylinder, and
control normal position. : Eccentric pin or repair or
(OPT) (The knob position is kingpin is defective replace it if
not constant during necessary.
straight running.)
Traveling Speed limit applies Load sensor main Check the load sensor • Check the
control (OPT) at high lifting height body voltage using Analyzer. sensor and
despite not being : Internal damage : In ANL, replace it if
loaded necessary.
circuit, leakage
necessary.
Display setting Check the matching • Correct the
: The setting of tire value on the tire setting
diameter data is not in diameter data screen.
agreement with that of
the lift truck state.
Heavy attachment, - • In traveling
mast with a high lifting control, the
height attachment
weight and the
mast weight are
treated as part
of the load
weight,
because they
affect the
longitudinal
stability of the
lift truck. For a
very heavy
mast or an TT
or QM mast
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.

Traveling Speed limit applies Lift relief pressure - When the lift is
control (OPT) at high lifting height detected. raised to its
despite not being uppermost
loaded position, the load
sensor cannot
distinguish this
situation from a
situation in which 5
a heavy load is
carried, because,
in that situation, a
relief pressure
remains in the lift
cylinder pressure
that the load
sensor senses.
After a lift relief,
however, it
becomes possible
to perform
operation because
the relief pressure
is discharged
when the lift is
lowered even a
little.

Traveling Although a load is Load sensor main Check the load sensor • Check the
control (OPT) carried, the speed is body voltage using Analyzer. sensor and
not limited when the : Internal damage : In ANL, replace it if
lift is raised high. necessary.
circuit, leakage
necessary.
circuit (harness or
connector)
necessary.
Display setting Check the set value on • Setting screen
: Traveling control the Option Set screen.
setting disabled
Load sensing speed
restriction disabled
(ASC W/LOAD,
MODE)
agreement with that of
Traveling Although a load is Main controller - • Replace the
control (OPT) carried, the speed is : Internal failure main controller.
not limited when the
lift is raised high.
Traveling Speed limit applies Lifting height switch Check the lifting height • Check the
control (OPT) when loaded despite main body switch using Analyzer. switch, and
being at a low lifting : Low lifting height is : In ANL, replace it if
height always detected. necessary
circuit (harness or
connector)
necessary.

Traveling A limit is always Display setting Check the set value. • Setting screen
control (OPT) placed on the speed : Maximum speed limit
regardless of is set very low.
whether a load is
carried or not.
agreement with that of 5
6. MOTOR 6-747
6. MOTOR
6.1. DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747
6.2. PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757
6.1. DRIVE MOTOR

6
6.1.1. GENERAL
6-748 6. MOTOR
6.1.2. SPECIFICATIONS
Body size
Battery Nominal Rated
Diameter × Weight
Voltage Voltage Output Insulation
Type Length IP
class
(V) (V) (kW) (mm) (kg)
Three phase
36 21 4.8 φ180×261 30 20 F
AC
STD
Three phase
48 29 5.0 φ180×261 30 20 F
AC
6. MOTOR 6-749
3
c
6
d 8
b
6
a: T = 86.8 to 145 ft·lbf. [117.6 to 196.0 N·m]

b: T = 54 to 108 ft·lbf. [73 to 147 N·m]
c: T = 6.5 to 12.0 ft·lbf. [8.8 to 16.3 N·m]
d: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
6-750 6. MOTOR
Removal Procedure
1. Disconnect the battery plug.
2. Remove the mast ASSY. (Refer to MAST Section)
3. Jack up the lift truck and remove front wheels. [Point 1]
4. Drain gear oil. [Point 2]
5. Remove the tie rod.
6. Disconnect the PKB brake link and remove PKB bracket set bolt, then free PKB cable.
7. Remove the brake lever.
8. Disconnect the wiring. Tightening torque of wiring: T = 8.1 to 11 ft-lbf. [11 to 15 N·m]
9. Remove the drive motor.[Point 3]
Point Operations
[POINT 1]
Removal:
Always jack up the lift truck at the jack-up point.
Jacking up the lift truck at the other location is very
dangerous. Always support the load of jacked-up lift
truck with wooden blocks at specified points.
[POINT 2]
Installation:
(a) After installation, fill “AUTOMATIC TRANSMISSION
FLUID T-IV” to the specified level.
A = 0.39 in. (10 mm) or less (Target A = 0.20 in.)
(The amount of oil: 0.55 L [Reference])
(a) Upper limit
A (b) Lower limit
(b)
6. MOTOR 6-751
[POINT 3]
Removal:
For removal of the drive motor, place a hand pallet
truck at the drive motor bracket.
NOTICE! Do not damage crush the downside speed
sensor
Apply gasket sealant to the mating face with the drive

unit.
6-752 6. MOTOR
Front axle bar adjustment

1. AXLE BRACKET & AXLE BAR
BRACKET, FR AXLE, LH NT=151 TO 225 ft lbf

(205 to 305 N·m)
NT=54 TO 108 ft lbf

(73 to 147 N·m) BRACKET, FR AXLE, RH
25.59 to 25.62 in. (650 to 651 mm)
T=54 TO 108 ft lbf

(73 to 147 N·m)
Measurement point
OUTTER NUT INNER NUT BAR, FR AXLE
[Point]
After the drive unit is attached to the lift truck, adjust the width to 25.59 to 25.62 in. (650 to 651 mm).
6. MOTOR 6-753
2. EXTENSION BRACKET & AXLE BAR, UPPER
NT=54 TO 108 ft-lbf.

(73 to 147 N·m)
BAR, FR AXLE, UPPER
NT=118 TO 177 ft-bf.

BRACKET EXTENSION (160 to 240 N·m)
OUTTER NUT
INNER NUT
BAR, FR AXLE, UPPER BAR, FR AXLE
[Point]
1. Adjust the width with BAR, FR AXLE, then tighten BAR,FR AXLE, UPPER.
2. Either side (RH, LH) of the BAR,FR AXLE and BAR, FR AXLE, UPPER, is acceptable.
3. The end face of the bar should protrude past the end face of the nut when tightening the BAR, FR AXLE and
BAR, FR AXLE, UPPER.
4. There should be no clearance between the inner nut and the extension bracket before tightening the outer nut
when setting the BAR, FR AXLE, UPPER.
6-754 6. MOTOR
a: T = 6.9 to 10.2 ft·lbf. [9.3 to 13.9 N·m]

b: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
c: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
6. MOTOR 6-755
1. Remove the terminal.
2. Remove the end frame. [Point 1]
3. Remove the rotor ASSY. [Point 2]
4. Remove the stator ASSY. [Point 3]
5. Remove the bracket.
CAUTION 6
Make sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT 1]
Disassembly:
SST 979-001/181
[POINT 2]
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
abnormal noise or damage is observed.
Disassembly:
SST(1) 979-001/182
SST(2) 979-001/183
6-756 6. MOTOR
Reassembly:
SST 979-005/492
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: 100 MΩ or more
Inspection:
Check continuity between motor cables.
Measurement terminals: U-V, V-W, and W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of temperature
sensor connector
Standard: Approx. 13 kΩ (at 68°C [20°C])
6. MOTOR 6-757
6.2. PUMP MOTOR
6.2.1. GENERAL
Sectional plan
(a) Length (c) Speed Sensor (e) Field Core
(b) Diameter (d) Field Winding (f) Rotor

6-758 6. MOTOR
Body size
Nominal Rated Diameter ×
Voltage Output Length Weight
Insulation
(V) (kW) Type (mm) (kg) IP class
STD 22 12 Three φ180×303 36 20 F

phase
AC
6. MOTOR 6-759
7
a
3 9
11
6 5 10 6
a: T = 18 to 24 ft·lbf. [24 to 33 N·m]
Removal Procedure
1. Remove the battery ASSY.
2. Remove the toe board and tilt cover.
3. Remove the front battery cover.
4. Disconnect the pump motor wiring.[POINT 1]
5. Remove the return filter set bolt and keep the filter free.
6. Disconnect the oil pump piping (outlet hose).
7. Remove the oil pump set bolt and keep free.
8. Disconnect the inlet hose for oil pump side.
9. Remove the oil pump ASSY W/ fitting.
10. Hoist the pump motor and remove. [POINT 2]
11. Remove the insulator.
6-760 6. MOTOR
NOTICE
Apply grease to the spline section of the pump before installation.
Point Operations
[POINT 1]
Installation:
Tightening torque of wiring:
T = 8.1 to 11·ft lbf. [11 to 15 N·m]
[POINT 2]
Removal:
Loosen the set bolt of the terminal bracket and hoist
the pump motor.
Removal:
When hoisting the pump motor, make sure not to
apply excess force on the hose.
NOTICE!
• Make sure to release the hose clamp sufficiently.
• If the hose and tank pipe stick hard, do not forcefully
hoist the pump motor as it may damage the
hydraulic oil tank.
• Remove the adhesion of the hose and tank pipe.
6. MOTOR 6-761
1
a 6
d
3
5
2
a: T = 6.9 to 10.2 ft·lbf. [9.3 to 13.9 N·m]

b: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
c: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
d: T = 7.7 to 11.5 ft·lbf. [10.4 to 15.6 N·m]
1. Remove the terminal.
2. Remove the end frame. [Point 1]
3. Remove the rotor ASSY. [Point 2]
4. Remove the stator ASSY. [Point 3]
6-762 6. MOTOR
CAUTION
Make sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT 1]
Disassembly:
SST(1) 979-001/181
SST(2) 979-001/157
Reassembly:
Install the end frame and rpm sensor to the position
with the dimension A.Dimension A 0.43 to 0.50 in.
(10.8 to 12.8 mm)
[POINT 2]
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
an abnormal noise or damage is observed.
Disassembly:
SST(1) 979-001/182
SST(2) 979-001/183
6. MOTOR 6-763
Reassembly:
SST 979-005/492
6
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: 100 MΩ or more
Inspection:
Check the continuity between motor cables.
Measurement terminals: U-V, V-W, W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of temperature
sensor connector Standard:
Approx. 13 kΩ (at 68°F [20°C])
6-764 6. MOTOR
7. DRIVE UNIT AND FRONT AXLE 7-763
7. DRIVE UNIT AND FRONT AXLE

7.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
7.2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
7.3. FRONT AXLE HUB AND DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 766
7
7-764 7. DRIVE UNIT AND FRONT AXLE
7.1. GENERAL
(a) Planetary gear (d) Sun gear (g) First axis (Motor input shaft)
(b) Planetary gear shaft (e) First reduction drive gear
(c) Second axis (Front axle shaft) (f) First reduction driven gear
7.2. SPECIFICATIONS
Vehicle model All model

Item
Total reduction ratio 27.452
Tire type Tread pattern Tire size Wheel size Air pressure -
Cushion Smooth - - STD

7
Cushion Smooth 18 x 7 x 121/8
- - OPT
Non-Marking Lug
7.3. FRONT AXLE HUB AND DRIVE UNIT

S/N 10580 and Below
3
1
d
c
b
a: T = 86.8 to 145 ft·lbf. [117.6 to 196.0 N·m]

b: T = 54 to 108 ft·lbf. [73 to 147 N·m] (Refer to [POINT 4])
c: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
d: T = 73.8 to 108 ft·lbf. [100 to 146 N·m]
Removal Procedure
1. Jack up the lift truck and remove front wheels. [Point 1]
2. Drain gear oil. [Point 2]
3. Remove the drive unit ASSY. [Point 3]
4. Remove the front axle hub. [Point 4]
NOTICE
The following table: Type and quantity of gear oil
Type STD (ATF) AUTOMATIC TRANSMISSION FLUID T-IV
Cold storage type
Quantity 0.55L (0.145 US gal) / 1 Wheel
7
NOTICE
The following table: Type of grease
STD MP grease
Cold storage type
Point Operations
[POINT 1]
Removal:
Always jack up the lift truck at the jack-up point. Jacking
up the lift truck at the other location is very dangerous.
Always support the load of the jacked-up lift truck with
wooden blocks at specified points.
[POINT 2]
Installation:
(a) After installation, fill “AUTOMATIC TRANSMISSION
FLUID T-IV” to the specified level.
A = 0.39 in. (10 mm) or less (Target A = 5 mm)
(The amount of oil: 0.55 L [Reference])
Use the SST to measure the oil
A
SST 979-005/555
(a) Upper limit
(b) (b) Lower limit
[POINT 3]
Installation:
For installation, apply gasket sealant to the mating face
with the drive unit. Make sure to remove the grease on the
face.
Liquid gasket: 979-001/154
[POINT 4]
Inspection:
Install the front axle hub on the drive unit ASSY, and
measure the front axle hub breakaway torque.
(1) Install the front axle hub on the drive unit case W/front
axle bearing the SST.
SST 979-005/501
(a) Wooden Blocks
(a) (a)
(2) Install the front axle shaft, and measure the front axle
hub starting torque without installing the idle gear.
1. Select proper shim
2. Install claw washer
3. Tighten lock nut (1): T = 16.2 to 37.7 ft·lbf [21.9 to
51.1 N·m]
4. Running in (1): 10 to 60 [rpm] and 3 times or more
5. Tighten lock nut (2):T = 127 to 190 ft·lbf. [172 to 258
N·m]
6. Running in (2): 10 to 60 [rpm] and 3 times or more
Measure the value of starting force
Standard: 6.12 to 14.1 lbf. [27.2 to 62.9 N]
7. If OK for standard value, clinch lock nut.
Method when using SST (979-005/555)

1) Remove the plug from the pouring hole at the top of the
axle housing (Fig. 1).
(a) Upper limit
(b) Lower limit
(c) Pouring hole
7
Fig. 1
2) Insert the SST (the end with markings) into the pouring
hole (Fig. 2).
Point: Try to keep the direction of the SST going
forward like shown in Fig. 3.
(a) Upper limit
(b) Mark for insert end
(c) Lower limit
(d) Tip (end)
Fig. 2
(a) Front
(b) Utilize tube's curve
(c) Insert the tip at the front
Fig. 3 SST inserting direction

3) When your hand feel that the SST tip reached the wall
of the space, check whether “Mark for insert end” is at the
same level of the hole entrance (Fig. 4).
(a) “Mark for insert end” at the entrance level of the hole.
This is the measurable condition.
Fig. 4
4) Keep the condition of Fig. 4 for approximately 5
seconds, then block the other side of the SST tip opening
with your finger (Fig. 5).
5) Keep your finger on the SST tip opening. Draw out the
SST from the hole.
Fig. 5
6) Check if the oil level is between the limit lines (Fig. 6).
If the oil level is out of the correct range, adjust oil by
adding or draining oil.
After you remove the held oil in the SST tip, check the oil
level again repeating the above procedure steps 2)
through 6).
(a) Oil level
(b) Upper limit
(c) Lower limit
7) When the oil level is satisfied, close the hole by the
plug.
Fig. 6
• Clean the inside of the SST every time after using.
• When the tip of the SST makes contact with a waste
cloth, the oil will be removed (Fig. 7).
• If the inside of the SST becomes contaminated, clean it
with a cleaning spray.
Fig. 7
NOTICE
• Before using, check if the tube is damaged or dirty.
• Check that the markings on the SST are not erased.
• Do not insert the SST forcefully into the hole.
When the SST cannot be inserted, draw it out fully and insert it again.
• For an accurate oil level inspection, check the oil level 5 minutes or more after parking the lift truck.
You will not have a accurate oil level inspection if some amount of oil is still attached to the internal
components.
• Do not use strong force. The SST is made of a thin tube.
Inspection SST
7
Material: Nylon
Outside diameter: Φ3.2mm
inside diameter: Φ2mm
Length: 500mm
Color: Clear of milky white

1. Remove the idle gear bearing. [Point 1]
2. Remove the planetary gear. [Point 2]
3. Remove the axle shaft bearing and inner bearing.
4. Remove the oil seal and outer bearing. [Point 3]
5. Remove the bearing outer race. [Point 4]
6. Remove the inner bearing outer race. [Point 5]
NOTICE
Apply gear oil to the planetary gear and bearing and install them.
Point Operations
[POINT 1]
Disassembly:
Use the SST to remove the idle gear bearing.
SST 979-001/182
7
Disassembly:
Use the SST to install the idle gear bearing.SST(1)

979-001/183SST(2) 979-001/185
[POINT 2]
Reassembly:
Measure the backlash of the planetary gear, idle gear
and ring gear.
Standard: 0.2 mm (0.008 in.) or less
[POINT 3]
Reassembly:
Use the SST to install the oil seal.
SST 979-001/177
SST
[POINT 4]
Disassembly:
SST Use the SST to remove the outer bearing outer race.
SST 979-001/177
Reassembly:
Use the SST to install the outer bearing outer
SST race.SST 979-001/177
[POINT 5]
Disassembly:
Use the SST to remove the inner bearing outer race.
SST 979-001/177
SST
Reassembly:
Use the SST to install the inner bearing outer
SST race.979-001/177
8. REAR AXLE 8-775
8. REAR AXLE
8.1. REAR AXLE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776
8.2. REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
8.3. REAR AXLE CYLINDER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 788
8.4. TIRE ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
8
8-776 8. REAR AXLE
8.1. REAR AXLE ASSY
8.1.1. GENERAL
8. REAR AXLE 8-777
Tire type Tread pattern Tire size Wheel size Air pressure -
Cushion Smooth, Black 15 x 5 x 111/4 - - STD
Cushion Smooth - - OPT

non-marking
Lug
b 7
4 9
c 6
11
4
3
a: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]

b: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]
c: T = 166 to 273 ft·lbf. [265 to 370 N·m]
Removal Procedure
1. Remove the counterweight. (Refer to BODY section)
2. Jack up the lift truck. [Point 1]
8-778 8. REAR AXLE
3. Remove the hubcap, rear wheel and outer bearing. [Point 2]

4. Remove the outer bearing outer race. [Point 3]
5. Remove the inner bearing outer race. [Point 4]
6. Disconnect the piping of the power steering cylinder.
7. Remove the tire angle sensor.
8. Measure the rear axle ASSY starting force. [Point 5]
9. Loosen the rear axle set bolts.
10. Hoist the rear axle temporarily and remove the set bolts. [Point 6]
11. Remove the rear axle.
NOTICE
• When the tire angle sensor is removed and installed or replaced, perform matching. (See the PSS
section)
• Apply grease before installation.
Outer bearing Inner bearing Inside rear wheel
Type STD STSK2520-1 or Daphne grease #2U
Cold storage Esso beacon 325

spec.
Amount 11 to 15 14 to 19 55 to 67
g (lb) (0.024 to 0.033) (0.031 to 0.042) (0.12 to 0.15)
(Reference)
NOTICE
After tightening the castle nut, apply lubricant to the castle nut, cotter pin, and the tip of rear axle. (Use to
STSK2520-1, Daphne grease #2U or STSK2520-2)
Point Operations
[POINT 1]
Removal:
Jack up the lift truck at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the lift truck with wooden blocks at
specified points.
8. REAR AXLE 8-779
[POINT 2]
Inspection:
Measure the rear wheel or rear hub (OPT) starting
force.
Standard:
Cushion: 1.3 to 3.42 lbf [5.8 to 15.2 N]
Reassembly:
When installing a claw washer, position it with its edge
facing the rear axle.
(a) Face without edge. 8
(b) Face with edge.
(a)
(b)
[POINT 3]
Disassembly:
Use a copper bar to remove the outer bearing outer
race.
Reassembly:
SST(2) Use the SST to install the outer bearing outer
race.SST(1) 979-001/184SST(2) 979-001/185
SST(1)
8-780 8. REAR AXLE
[POINT 4]
Disassembly:
Use a copper bar to remove the inner bearing outer
race.
Reassembly:
SST(2) Use the SST to install the inner bearing outer race.
SST(1) 979-001/184
SST(1) SST(2) 979-001/185
[POINT 5]
Inspection:
Measure the rear axle ASSY starting force.
Standard: F = 22.5 to 45.0 lbf. [100 to 200 N]
Installation:
Check the projection of the rear axle from the lock nut.
Standard: longer than 0.3 in. (8 mm)
Installation:
When the correct value is obtained, securely stake the
lock nut. (Stake the lock nut on the top of corner)
8. REAR AXLE 8-781
[POINT 6]
Removal:
Temporarily hoist the rear axle as shown in the
illustration.
a
8
2 6
5 7
8
8
a: T = 7.4 to 14.8 ft·lbf. [10 to 20 N·m] (Reference value)
1. Remove the lock nut.
2. Remove the upper bearing.
3. Disconnect the rear axle cylinder W/ holder ASSY and rear axle ASSY.
4. Remove the lower oil seal. [Point 1]
5. Remove the lower bearing outer race. [Point 2]
8-782 8. REAR AXLE
6. Remove the upper bearing outer race. [Point 3]

7. Remove the lower bearing. [Point 4]
8. Remove the oil seal and inner bearing. [Point 5]
Point Operations
[POINT 1]
Reassembly:
SST Use the SST to install the oil seal.
SST 979-001/177
[POINT 2]
SST Disassembly:
Use the SST to remove the lower bearing outer race.
SST 979-001/182
Reassembly:
SST(2) Use the SST to install the lower bearing outer race.
SST(1) 979-005/491SST(2) 979-001/185
SST(1)
8. REAR AXLE 8-783
[POINT 3]
Disassembly:
SST Use the SST to remove the upper bearing outer race.
SST 979-001/177
Reassembly:
Use the SST to install the upper bearing outer

SST(2) race.SST(1) 979-001/184SST(2) 979-001/185 8
SST(1)
[POINT 4]
SST(1) Disassembly:
Use the SST to remove the lower bearing.
SST(1) 979-001/182
SST(2) SST(2) 979-001/183
Reassembly:
Use the SST to install the lower bearing.SST
979-001/168
SST
8-784 8. REAR AXLE
Disassembly:
SST Use the SST to remove the inner bearing.
SST 979-001/182
Reassembly:
Use the SST to install the inner bearing.
SST 979-005/490
SST
Reassembly:
SST 979-001/177
SST
8. REAR AXLE 8-785
8.2. REAR AXLE HUB
2 3
8
1
a
4
1
4
3
a: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]
Removal Procedure
1. Jack up the lift truck. [Point 1]
2. Remove the hub caps.
3. Remove the rear wheel and outer bearing. [Point 2]
4. Remove the oil seal and inner bearing. [Point 3]
NOTICE
Apply grease before installation.
8-786 8. REAR AXLE
Outer bearing Inner bearing Inside rear wheel

Type STD STSK2520-1 or Daphne grease #2U
Cold storage Esso beacon 325
spec.
Amount 11 to 15 14 to 19 55 to 67
g (lb) (0.024 to 0.033) (0.031 to 0.042) (0.12 to 0.15)
(Reference)
NOTICE
After tightening the castle nut, apply lubricant to the castle nut, cotter pin and the tip of rear axle. (Use to
STSK2520-1, Daphne grease #2U or STSK2520-2)
Point Operations
[Point 1]
Removal:
Jack up the lift truck at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the lift truck with wooden blocks at
specified points.
[Point 2]
Inspection:
Measure the rear wheel or rear hub (OPT) starting
force.
Standard:
Cushion: 1.3 to 3.42 lbf. [5.8 to 15.2 N]
Reassembly:
When installing a claw washer, position it with its edge
facing the rear axle.
(a) Face without edge
(b) Face with edge
(a)
(b)
8. REAR AXLE 8-787
[Point 3]
Disassembly:
Use the SST to remove the inner bearing.
SST 979-001/182
SST
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
8
SST
Reassembly:
SST 979-001/177
SST
8-788 8. REAR AXLE
8.3. REAR AXLE CYLINDER ASSY
a: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]

b: T = 166 to 273 ft·lbf. [265 to 370 N·m]
c: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]
Removal Procedure
1. Remove the rear axle ASSY. (Refer to REAR AXLE ASSY)
2. Remove the rear axle cylinder ASSY. [Point 1]
8. REAR AXLE 8-789
Point Operations
[Point 1]
Installation:
Adjust the installation of the steering cylinder.
1. Apply STSK 2520-1 on the rotation portion (both outside and inside) equally until it protrudes from the edge
surfaces of the top and bottom.
2. Set the blue tooth on the rack between the 2 pink teeth on the pinion.
Apply "Moly cote grease D-321RK" equally on more than 180° of area on the rack side of the pinion teeth.
3. Tighten the lock nut and caulk the lock nut in two places to ensure the starting force of the rear axle. (a) 7.4
to 14.8 ft·lbf. [10 to 20 N·m] (Reference value)
4. Tightening the torque of the frame installation: (b) 166 to 273 ft·lbf. [265 to 370 N·m]
a 8
b
8-790 8. REAR AXLE
2
1
3 5
2 1
1. Remove the steering cylinder end.
2. Remove the piston.
3. Remove the bushing.
4. Remove the rack.
5. Remove the steering torque cylinder. [Point 1]
8. REAR AXLE 8-791
NOTICE
• Apply hydraulic oil to each part before installation.
• Replace O-ring, U-packing and dust seal.
Point Operations
[Point 1]
Inspection:
Measure the steering cylinder bore.
Inside diameter standard: 2.16 in. (55.0 mm)
Wear limit: 2.179 in. (55.35 mm)
8
8-792 8. REAR AXLE
8.4. TIRE ANGLE SENSOR
a: T = 1.0 to 1.2 ft·lbf. [1.4 to 1.6 N·m]

b: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]
Removal Procedure
2. Remove the rear cover.
3. Disconnect the wiring connector.
4. Remove the tire angle sensor and joint. [Point 1]
5. Remove the tire angle sensor plate. [Point 2]
7. Remove the joint cover.
8. REAR AXLE 8-793
CAUTION
Align the tapping screw axis and the sensor plate hole straight for installation. If the screw is out of position,
replace the sensor plate with a new one.
When the tapping screw is removed, the sensor plate should be replaced with a new one.
NOTICE
• Make sure to set the tires to the straight traveling position before installing the tire angle sensor.
• Apply MP grease to the inside of the joint cover for installation.
• Perform matching when the tire angle sensor is removed, installed or replaced. (Refer to PSS section)
Point Operations
8
[Point 1]
Installation:
After positioning the sensor as shown in the illustration to
the left, rotate it by approx. 110° to align the holes.
[Point 2]
SST Installation:
Use the SST to adjust the concentricity of the rear axle
and sensor plate holes.
SST 979-005/494
(a)
(a) The tip of the SST.
1. Temporarily secure the bracket and sensor plate.
2. Securely set the tip of the SST at the hole at the top
of the rear axle shaft and position the bracket and
sensor plate.
3. Securely tighten the bracket and sensor plate bolt
and remove the SST.
Installation:
(a) Apply MP grease to the sensor plate hole of the rear axle
shaft groove.
(a) Groove part.
8-794 8. REAR AXLE
9. STEERING 9-795
9. STEERING
9.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795
9.2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796
9.3. STEERING WHEEL AND MAST JACKET . . . . . . . . . . . . . . . . . . . . . . . 797
9.4. HYDROSTATIC STEERING VALVE ASSY . . . . . . . . . . . . . . . . . . . . . . 800
9.5. RELIEF PRESSURE INSPECTION AND ADJUSTMENT . . . . . . . . . . . 809
9.1. GENERAL
9
9-796 9. STEERING
9.2. SPECIFICATIONS
Model
All Models
Item
Steering wheel diameter
11.8 (300)
in. (mm)
Steering wheel play
0.79 to 1.97 (20 to 50)
in. (mm)
Power steering type Hydrostatic steering
Discharge
3.1 [50.0]
cu-in. (in.3) [cc (cm3)]
Rated flow rate
Hydrostatic steering valve 2.6 (10)
US gal / min. (L / min.)
Relief set pressure
1624 to 1697 [11.2 to 11.7]
psi [MPa]
PS valve list
Identification mark With or without solenoid Manufacturer Type
E1 Without solenoid Danfoss OSPC50LS
E2 With solenoid OSPC50LS_EFU
(a)
E1
(a) Identification mark.

9. STEERING 9-797
9.3. STEERING WHEEL AND MAST JACKET
3
5
2
2 12
10
8
9
b 5
2 9 11
c
a: T = 26 ft·lbf. [35 N·m]

b: T = 26.0 to 39.0 ft·lbf. [35.2 to 52.8 N·m]
c: T = 22.0 to 28.6 ft·lbf. [29.8 to 38.8 N·m]
Removal Procedure
2. Remove the instrument panel. (LH, RH, CTR)
3. Remove the steering wheel.[Point 1]
4. Remove the knob for the parking brake lock release lever.
5. Remove the column covers (upper and lower).
6. Disconnect the connectors of the combination switch.
7. Remove the combination switch.
8. Remove the parking brake lock release lever.
9. Remove the return spring.
10. Remove the tilt lock mechanism and tilt steering lock release lever. [Point 2]
11. Remove the steering valve set bolts and set the steering valve free.
12. Remove the mast jacket ASSY.
9-798 9. STEERING
NOTICE
• Apply MP grease to each sliding portion of the tilt lock mechanism and tilt steering lock release lever.
• Add MP grease to the coupling between the steering shaft and steering valve.
Point Operations
[Point 1]
SST Removal:
SST 979-001/181
Installation:
Steering wheel installation procedure
1. Before removing the steering wheel, make a
positioning mark at the top of the steering shaft.
2. Apply rubber grease to the sliding portion of the
turn signal switch.
3. Install the steering wheel by referring to the posi-
tioning mark made in (1).
4. Turn the steering wheel after installation. Turning
the steering wheel will automatically position the
three pins of the turn signal switch at the pin
holes of the steering wheel.
[Point 2]
Installation:
The lever is attached in ±20° based on the part line in
the column cover.
20°
20°
9. STEERING 9-799
1
3
1. Remove the snap ring.
2. Remove the steering shaft.
3. Remove the bearing.
4. Remove the direction switch bracket.
9-800 9. STEERING
9.4. HYDROSTATIC STEERING VALVE ASSY
9.4.1. TROUBLESHOOTING
Symptom Probable cause Corrective action
The steering wheel The steering valve is defective. Replace the steering valve
cannot be rotated. ASSY.
The priority valve is defective. Replace the inlet section of

OCV.
The oil pump is defective. Replace the pump ASSY.
The piping connection is wrong. Connect the piping right.
The piping is damaged. Replace the piping ASSY.
The steering wheel is The steering valve is defective. Replace the steering valve
hard to turn. ASSY.

OCV.
The oil leaks in the steering valve, the piping or the Repair or replace the
rear axle cylinder. corresponding part.
The oil pressure does not increase. See the corrective action
below.
The steering shaft is damaged. Replace the steering shaft.
The power steering cylinder rod is bent or the piston is Repair or replace the
sticking. corresponding part.
The oil pressure does The relief valve is defective. Adjust, repair or replace the
not rise. relief valve.
The steering valve is defective. Replace the steering valve

ASSY.
The oil leaks in the power steering valve, the piping or Repair or replace the
the rear axle cylinder. corresponding part.

OCV.
The knob solenoid is defective. Replace the knob solenoid.
does not return ASSY.
correctly.
The tire was worn away. Replace the tire.
The piping is defective. Repair or replace the piping.

9. STEERING 9-801
Symptom Probable cause Corrective action
The lift truck wobbles. The steering valve is defective. Replace the steering valve
ASSY.
The tire was worn away. Replace the tire.
The steering shaft was worn away. Replace the steering shaft.
The tire moves The piping is connected in reverse. Connect the piping right.
opposite to the
steering wheel
operating direction.
The knob position is The knob solenoid is defective. Replace the knob solenoid.
out of alignment.
The oil leaks in the power steering valve, the piping or Repair or replace the
the rear axle cylinder. corresponding part.
The steering wheel The priority valve is defective. Replace the inlet section of
jams occasionally. OCV. 9
cannot stop at the ASSY.
stroke end.
9-802 9. STEERING
4 2
2 5
4
a: T = 22.0 to 28.6 ft·lbf. [29.8 to 38.8 N·m]
Removal Procedure
2. Remove the instrument panel. (LH, RH)
3. Remove the knob for the parking brake lock release lever.
4. Remove the column covers. (upper and lower)
5. Disconnect the piping.
6. Remove the steering valve ASSY.
7. Remove the fitting. [Point 1]
NOTICE
Add MP grease at the coupling between the steering shaft and steering valve.
9. STEERING 9-803
Point Operations
[Point 1]
Reassembly:
Install the fitting with the angle shown in the illustration
40° 40° to the left.
12° 40° 40°

9
5
b 5
4
3
3 3
2 4
a: T = 17.7 to 26.6 ft-lbf. [24 to 36 N·m]

b: T = 44.3 to 51.7 ft-lbf. [60 to 70 N·m]
NOTICE
Clean dirt off from ports and joints before disassembly and operate in a clean place.
9-804 9. STEERING
1. Remove the end cover.[Point 1]
2. Remove the gear wheel set, cardan shaft and distributor plate.[Point 2]
3. Remove the check valve and steel ball.[Point 3]
4. Remove the sleeve W/spool and bearing.[Point 4]
5. Remove the O-ring, kin-ring and dust seal ring.[Point 5]
6. Remove the relief valve.[Point 6]
Point Operations
[Point 1]
Disassembly:
Make a match mark across the end cover, outer gear,
and valve body.
Disassembly:
When removing each set bolts, be careful not to lose
the steel ball.
Reassembly:
• Put a steel ball in the illustrated position before
installing each set bolts.
• One out of seven set bolts is a bolt with pin. Install it
in the correct position.
9. STEERING 9-805
[Point 2]
Reassembly:
Reassemble the gear wheel set, cardan shaft and
distributor plate.
(a) Parallel
(a)
(a)
9
[Point 3]
Disassembly:
a A steel ball is placed under the pin.
Be careful so as not to lose it.
The cross-section drawing of the ball and pin is
illustrated at left.
a: Pin
b: Steel ball
b Reassembly:
Make sure to install the steel ball and pin.
9-806 9. STEERING
[Point 4]
Disassembly:
Extract the spool W/sleeve upward. Otherwise, the
spool cross pin may move during extraction to cause
sticking.
Reassembly:
Set and install the neutral position spring correctly.
Reassembly:
Pay attention to the bearing direction for installation.
(See the figure.)
a: Chamfer
b: Sleeve
Reassembly:
Place the housing with its flanged side facing down
and insert the spool W/sleeve into the housing. Set the
cross pin of the spool horizontal during insertion.
9. STEERING 9-807
[Point 5]
Reassembly:
Install the kin-ring and O-ring correctly.
a: O-ring
b: Kin-ring
For SST No. SJ150-9000-11, please inquire at the

nearest Danfoss service shop.
Reassembly:
1. Turn the steering unit until the bore is horizontal.
Guide the outer part of the assembly tool into the
bore for the spool/sleeve.
2. Apply O-ring and kin-ring with hydraulic oil and 9

place them on the tool.
3. Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide the
inner part of the tool right to the bottom.
4. Press and turn the O-ring/kin-ring into position in

the housing.
5. Draw the inner and outer parts of the assembly tool

out of the steering unit bore, leaving the guide from
the inner part in the bore.
9-808 9. STEERING
[Point 6]
Disassembly:
Do not remove the relief valve unless it is judged
defective. The valve seat cannot be removed.
Measure the screwed-in depth of the relief valve
adjusting screw before starting disassembly.
Reassembly:
Reassemble by adjusting to the screwed-in depth of
the valve spring retainer measured before
disassembly. After installing the steering valve ASSY
on the lift truck, measure the relief pressure. If it is not
within the standard range, adjust it by changing the
screwed-in depth of the retainer.
NOTICE
Wash each part with clean hydraulic oil before assembly.
9. STEERING 9-809
9.5. RELIEF PRESSURE INSPECTION AND ADJUSTMENT
Step 1 Install an oil pressure gauge.
(a) P port
• Disconnect the hose from the P port of the steering
valve, and connect the SST (adapter)
• (b) SST 979-001/170

Install the oil pressure gauge.
Plug size: PT1/8
(a)
(b)
Step 2 Turn the key switch ON, rotate the steering wheel
slowly clockwise and counterclockwise, and inspect
the relief pressure at each stroke end.
Standard: 1624 to 1697 psi [11.2 to 11.7 MPa]
Step 3 If the standard is not satisfied, remove the steering

valve and make an adjustment by turning the relief
valve adjusting screw.
9-810 9. STEERING
10. BRAKE 10-811
10. BRAKE
10.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811
10.2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 813
10.3. DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
10.4. BRAKE AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
10.5. BRAKING FORCE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . 820
10.6. BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 821
10.7. PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824
10.8. PARKING BRAKE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . 825
10.9. BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827
10.1. GENERAL
10
(a) Wheel cylinder (c) Parking cable (e) Motor (g) Brake plate
(b) Lever (d) Drive unit (f) Brake disc
10-812 10. BRAKE
Parking Brake
10. BRAKE 10-813
Master Cylinder
10
10.2. SPECIFICATIONS
Brake type Wet disc brake
Brake disk diameter 108 mm (4.25 in.)
Number of brake disk (Piece × wheel) 3×2
Cooling oil AUTOMATIC TRANSMISSION T-IV or MOBIL ATF

3309
Amount of oil (L × wheel) 0.55 × 2
Brake fluid SAE J-1703, DOT-3

10-814 10. BRAKE
10.3. DISC BRAKE
10.3.1. REMOVAL AND INSTALLATION (Outside of brake)
8
a
11
10 b
a: T = 151 to 225 ft·lbf. [205 to 305 N·m]

b: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
c: T = 73.8 to 108 ft·lbf. [100 to 146 N·m]
10. BRAKE 10-815
Removal Procedure
2. Remove mast ASSY. (Refer to mast section)
3. Jack up the lift truck and remove the front wheel.
4. Drain the gear oil.
5. Disconnect the tie rod.
6. Disconnect the PKB brake link.
7. Disconnect the wiring and piping. [Point 1]
8. Remove the reamer bolt the of drive unit bracket.
9. Remove the drive unit W/ drive motor.
10. Remove the drive unit ASSY.
11. Remove the drive motor.
10
10-816 10. BRAKE
6 1
a: T = 24.2 to 36.3 ft·lbf. [32.8 to 49.2 N·m]

b: T = 6.49 to 12.0 ft·lbf. [8.8 to 16.3 N·m]
Removal Procedure
1. Remove the brake lever.
2. Remove the wheel cylinder.
3. Remove the sun gear and first reduction gear.
4. Remove the retainer.
5. Remove the disc and plate.
6. Remove the pressure pin.
10. BRAKE 10-817
1. Install the pressure pin.[Point 1]
2. Install the brake lever.[Point 2]
3. Install the wheel cylinder.
4. Install the disc and plate.[Point 3]
5. Install the retainer.
6. Install the sun gear and first reduction gear. [Point 4]
7. Adjust the brake lever. [Point 5]
NOTICE
• After installation, perform brake pedal adjustment, air bleeding and matching.
• Do not wear cotton working gloves.
• Never wash Disc.
Point Operations
[POINT 1] 10
Installation:
Install the disc and plate with arranging each phase of the
(a)
oil through hole.
(a) D-ring
(b) Pressure pin
(c) Axle bracket
(b) NOTICE! Pay attention to the installed direction of the
pressure pin.
(c) NOTICE! Apply NPC grease spray to the D-ring when
assemble D-ring to the pressure pin and axle bracket.
NOTICE! If removing pressure pin, replace the D-ring.
[POINT 2]
Installation:
Insert the bush from the side chamfered for lever hole.
(a) Brake Lever
(b) Bush install direction
(c) Lever hole chamfering
10-818 10. BRAKE
[POINT 3]
Installation:
(a)
Install the disc and plate aligning each phase of the oil
through hole.
(a) Disc
(b) Oil through hole (6 places)
(c) Plate
(b) (c)
[POINT 4]
Installation:
1. Set the center position by holding on to the disc using
the brake lever.
2. Use the adjusting bolt to hold the disc in place.
3. After that, install the sun gear and first reduction gear.
[POINT 5]
Installation:
1. Pull the brake lever by force (F).
F = 31.5 to 33.7 lbf. [140 to 150 N]
2. Keep the lever at the “1” status, and set the adjust bolt
(a) clearance between the adjust bolt and axle bracket
“L”.
L = 0.079 to 0.091 in. (2.00 to 2.30 mm)
3. Keep the top position of the adjust bolt, and rotate

lever for running-in. Then tighten the nut.
Tighten torque T = 4.06 to 6.12 ft·lbf. [5.5 to 8.3 N·m]
A = 0.768 to 0.992 in. (19.5 to 25.2 mm)
10. BRAKE 10-819
Inspection of disc and plate
Installation:
1. Pull the brake lever by force (F).
F = 31.5 to 33.7 lbf. [140 to 150 N]
2. Keep the lever at the “1” status, and contact the

adjust bolt to the stopper.
3. If exposed portion “A” is under 0.886 in. (22.5 mm),
inspect the disc and the plate, and replace.
Limit: A = 0.886 in. (22.5 mm)
Disc thickness
Standard: 0.138 in. (3.5 mm)
Limit: 0.130 in. (3.3 mm)
Plate thickness 10
Limit: 0.071 in. (1.8 mm)
NOTICE! If disc and plate is over limit value, replace

the brake lever and pressure pin.
10-820 10. BRAKE
10.4. BRAKE AIR BLEEDING
NOTICE
Add brake fluid to the reservoir tank during air bleeding to prevent it from becoming insufficient. Perform
air bleeding with two operators.
1. Bleed air from the brake master cylinder.

• Depress the brake pedal several times to
compress the air in the piping, and hold that
state.
• Loosen the breather plug (a) to discharge air in
the piping with the brake fluid, and tighten the
plug immediately before the fluid starts to run
out.
• Repeat steps above until no air bubbles are seen
in the discharged brake fluid.
(a) 2. Bleed air from wheel cylinders RH and LH.
• Operate as described in step 1 above for both the
RH and the LH side.
3. Add brake fluid to the specified level.
• Add brake fluid through the filter provided at the
reservoir tank.
• Add brake fluid up to the staged portion in the
reservoir tank.
10.5. BRAKING FORCE INSPECTION AND ADJUSTMENT

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)
• Initial speed of braking mph (km/h): Max. speed
Braking distance ft. (m): 16.4 (5.0) or less
10. BRAKE 10-821
10.6. BRAKE MASTER CYLINDER
10
Removal Procedure
2. Remove the toe board (front and rear) and lower panel.
3. Disconnect the brake side hose from the reservoir tank and drain brake fluid.
5. Remove the push rod clevis pin.
6. Remove the brake master cylinder.
NOTICE
After installation, perform brake pedal adjustment, air bleeding, and matching of the pedal.
10-822 10. BRAKE
a: T = 38.3 to 60.8 ft·lbf. [52.0 to 82.4 N·m]
Removal Procedure
1. Turn the boot up and remove the snap ring.
2. Remove the push rod. [Point 1]
3. Remove the piston. [Point 2]
4. Remove the pin and the fluid inlet elbow.
5. Remove the outlet plug and valve.
Point Operations
[POINT 1]
Reassembly:
Temporarily set the push rod length to the illustrated
dimension, and make readjustment after installation.
10. BRAKE 10-823
Reassembly:
Apply rubber grease on the piston cup and the whole
periphery of the cup before reassembly.
10
10-824 10. BRAKE
10.7. PARKING BRAKE
2
6
a: T = 6.7 to 12.5 ft·lbf. [9.1 to 16.9 N·m]
Removal Procedure
2. Remove the tilt steering lock release lever.
3. Remove the column cover.
4. Remove the instrument panel LH.
5. Remove the lower panel.
6. Remove the parking brake release cable from the mast jacket.
7. Remove the parking brake ASSY.
10. BRAKE 10-825
10.8. PARKING BRAKE INSPECTION AND ADJUSTMENT
1. Check the parking brake cable set position.

Standard: A = 0 to 0.08 in. (0 to 2 mm)
2. Apply chassis grease on the portions indicated
by arrows.
A
Inspect and adjust the parking brake pedal oper-
ating force.
(a) For RH
(b) For LH
• Measure the operating force.
(a) (b)
• When using SST [979-500/502]
Standard: 23.2 to 26.0 lbf. [103 to 116 N]
• When using a push pull tester (a)

Push the probe of a push-pull tester 10
vertically into the center of the brake
pedal.
Standard: 54.0 to 60.7 lbf. [240 to 270 N]
• If the operating force is out of the stan-

dard range, release the parking brake
and make adjustment at the adjusting
portion.
Clockwise turn: Increases the operating

force.
Counterclockwise turn: Decreases the
(a) operating force.
10-826 10. BRAKE
RELEASE LEVER CABLE ADJUSTMENT
1. Adjust the play of the release lever (b) to 0.0 to

0.2 in. (0.0 to 5 mm) at the tip of the lever using
the release cable adjusting nut (a).
(a)
(b)
10. BRAKE 10-827
10.9. BRAKE PEDAL ADJUSTMENT
(b)
(a)
(c)
B 10
A
C
(d)
(a) Brake master cylinder (c) Push rod

(b) Stopper bolt protrusion (d) Toe board
1. Inspect brake pedal height A. (From toe board to top of pedal)

Standard: A = 132 to 137 mm (5.20 to 5.39 in.) (with pedal pad)
2. Inspect brake pedal play B.
Standard: B = 1 to 5 mm (0.04 to 0.20 in.)
If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.
3. Check the master cylinder push rod play C with the brake pedal in the above state.
Standard: C = 0.5 to 2 mm (0.02 to 0.08 in.)
4. After the adjustment, fully (at 196 N) press the brake pedal and inspect the pedal height D.
Standard: D = 77 mm (3.03 in.) or more
5. After finishing the adjustment, perform the brake matching.
10-828 10. BRAKE
11. BODY & FRAME 11-829
11. BODY & FRAME

11.1. BATTERY HOOD ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 829
11.2. COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 831
11.3. OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 833
11.4. FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 834
11.1. BATTERY HOOD ASSY
11
4 1
5
11-830 11. BODY & FRAME
Removal Procedure
2. Open the battery hood.
3. Use string to tie the battery hood ASSY W/seat ASSY to the overhead guard rear pillar.
4. Disconnect the wiring of the seat switch.
5. Disconnect the battery hood damper (on the frame side).
6. Close the battery hood.
7. Remove the battery hood hinge set bolt.
8. Remove the battery hood ASSY W/seat ASSY.
11. BODY & FRAME 11-831
11.2. COUNTERWEIGHT
7 9 5
11
5
1
8
a
a: T = 236 to 354 ft·lbf. [320 to 480 N·m]
Removal Procedure
2. Remove the rear cover (item 3).
3. Remove the draw bar (item 7). Temporarily hoist the counterweight by slinging with a wire rope.
4. Remove the counterweight set bolt (item 8).
5. Remove the counterweight (item 9). [Point 1]
NOTICE
Make sure to set the tires to the straight traveling position.
11-832 11. BODY & FRAME
Point Operations
[POINT 1]
Inspection:
Make sure to keep the counterweight balanced when
installing.
11. BODY & FRAME 11-833
11.3. OPERATOR’S SEAT
11
Removal Procedure
1. Disconnect the wiring of the seat switch.
3. Remove the operator's seat set nuts. (Be careful not to drop the operator's seat.)
4. Remove the operator's seat.
11-834 11. BODY & FRAME
11.4. FUSE REPLACEMENT

If a lamp/light does not come on or an electrical device does not function, the corresponding fuse may have blown.
Check the fuse for each device.
F1 Fuse
The F1 fuse is located on the contactor panel inside the battery hood.
F1
Fuse box
Other fuses are located in the fuse box.
1. To access the fuse box, remove the rear cover.
(1)
(1) Rear cover

2. Remove the fuse box cover and remove the fuse by clipping with the fuse clip attached to the fuse box.
11. BODY & FRAME 11-835
(3) (2)
11
(2) Fuse box cover

(3) Fuse clip
See the fuse assignment table below for the device corresponding to each fuse.
Fuse Assignment
Fuse name Capacity Corresponding device

F1 700A (36V spec.) Drive and pump circuit
600A (48V spec.)
F54 2A Horn relay
F55 2A Horn surge absorber
F58 2A Direction control switch
F56 2A Strobe light, blue light, key off head light off relay
11-836 11. BODY & FRAME
Fuse name Capacity Corresponding device

F57 2A Flasher relay
F45 2A Stop lights
F41 2A Interior light, head light rely, tail light relay, rear working lights
F43 2A Head light (left-hand)
F44 2A Head light (right-hand)
F42 2A Tail light (left- and right-hand) and clearance lights (left- and right-hand)
F5A 2A Clamp release interlock
F59 2A
F51 2A Inverter fan 1
F52 2A Inverter fan 2
F53 2A Motor fan
F71 2A Knob solenoid
F72 2A Unload solenoid
F73 2A Lift lock solenoid
F74 2A Forward tilt solenoid
F75 2A Backward tilt solenoid
F76 2A Lift solenoid
F77 2A Tilt solenoid
F78 2A Attachment 1 solenoid
F79 2A Attachment 2 solenoid
F5 10A Controller
F6 10A Controller
F81 10A DC/DC converter (front)
F82 10A DC/DC converter (rear)
F5B 2A Telematics
F5C 2A
WARNING
• Disconnect the battery plug before inspecting the fuse.
• Always replace with a fuse having the same capacity. See the SERVICE DATA section of this manual for
fuse specifications.
• If the replaced fuse blows again, ask your Raymond Sales and Service Center for an inspection.
• When the fuse is being replaced, never short between terminals with a spanner or other tools.
12. MATERIAL HANDLING SYSTEM 12-837
12. MATERIAL HANDLING SYSTEM

12.1. HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 838
12.2. REMOVAL • INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 839
12.3. NATURAL DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
12.4. NATURAL FORWARD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 841
12.5. OIL LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 842
12
12-838 12. MATERIAL HANDLING SYSTEM
12.1. HYDRAULIC CIRCUIT
6
4
5
3
8
10
11
9
12
1) Lift cylinder 4) Return filter 7) Steering valve 10) Load sensing
2) Oil control valve 5) Priority valve 8) Suction filter 11) Oil pump
3) Tilt cylinder 6) Oil tank 9) Solenoid valve 12) Pump motor

12.2. REMOVAL • INSTALLATION
12.2.1. RETURN FILTER
12
Removal Procedure
2. Remove the toe boards (front and rear) and tilt cylinder cover.
3. Disconnect hoses from the front and rear of the return filter.
4. Remove the return filter.
12.2.2. SUCTION FILTER
Removal Procedure
1. Remove the oil pump ASSY W / fitting. (Refer to Oil pump section.)
2. Remove the tank cover W / suction filter.
3. Remove the suction filter cover.
4. Remove the suction filter.
12.3. NATURAL DROP TEST

1. Set the mast vertical with the standard load on the
forks. Lift the forks 39.3 to 59.1 in. (1 to 1.5 m), and turn
the key switch to OFF.
2. Draw datum lines on the inner and outer masts, and

measure the drop in 15 minutes.
Limit: 1.77 in. (45 mm)
12
12.4. NATURAL FORWARD TEST

1. Set the mast vertical with a standard load on the forks.
Lift the forks about 19.7 in. (50 cm) and turn the key
switch OFF.
2. Measure the tilt cylinder rod extension in 15 minutes.

1 ton series: 0.6 in. (15 mm) or less
2 ton series: 0.8 in. (20 mm) or less
12.5. OIL LEAK TEST

12.5.1. LIFT CYLINDER
1. Set the mast vertical with the standard load on the
forks. Lift the forks 1 to 1.5 m (40 to 59 in.).
2. Slowly tilt the mast fully forward, and turn the key
switch to OFF.
3. After 5 minutes, disconnect the oil control valve to oil
tank hose. Place a measuring cylinder under the
elbow and measure the amount of oil leaking in one
minute.
Standard (at lift port): 0.49 in.3(8 cm3) or less
NOTICE! If the natural drop is big even though the oil
leak amount is within the standard, the lift cylinder
packing is defective.
12.5.2. TILT CYLINDER

1. Set the mast in the vertical position with standard
load on the forks. Lift the forks about 19.7 in. (50 cm)
and turn the key switch to OFF.
2. After 5 minutes, disconnect the oil control valve to oil

tank hose. Place a measuring cylinder under the
elbow and measure the amount of oil leaking in one
minute.
Standard (total for lift and tilt): 0.98 in.3(16 cm3)
or less
3. The leak amount at the tilt port is equal to the
remainder when you subtract the lock amount at the
lift port from the total leak amount of the lift and tilt
cylinder.
NOTICE! If the natural forward tilt is big even though
the oil leak amount is within the standard, either the
tilt lock valve or the tilt cylinder packing is defective.
13. MAST 13-843
13. MAST
13.1. CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 843
13.2. FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 848
13.3. QM MAST ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 849
13.4. TT MAST ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 853
13.5. LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) . . . . . . . . . . . . . . . . . . . . . . . . . 869
13.1. CHAIN
13.1.1. INSPECTION
1. Inspect the chain elongation using the following
procedure:
(a) Chain gauge
(1) Since the measurement scale differs according to
the chain type, set the corresponding scale on the
chain as illustrated.
(2) Check the chain no. of the chain to be inspected,
and check the pin center position.
If the pin center is at the arrow mark on the chain 13
gauge, it has reached the limit; replace the chain.
Chain link pitch standard

Mast Pitch Type CHAIN No. No. of links
in. (mm) measured N
TT 0.75 (19.05) BL634 50 13
QM: Front 0.625 (15.88) BL534 50 15
QM: Rear 1.0 (25.4) BL834 80 11
NOTICE
• Perform measurement without removing the chain from the lift truck.
• Inspect elongation over the entire chain length as it may be localized.
13-844 13. MAST
13.1.2. REASSEMBLY
1. Installing direction
Applicable mast and section QM: Inner mast QM: Carriage

Rough sketch
(a) (a)
Arrow indicates the back of the lift Arrow indicates outside of the lift truck.
truck. Install with the split pin directing
Install with the split pin directing backward of the lift truck.
outside the lift truck.
(a) Split pin
2. Chain adjusting nut tightening procedure

(1) Tighten nut (a), (b). T = 50.9 ft-lbf. [69.0 N·m].
However,
T = 90.7 ft-lbf. [123.0 N·m]
(b) for only QM hard lock nut.
(2) Tighten nuts (c).
(3) Attach the clamp (e) with the bolts (d).
Applicable mast QM: Front cylinder QM: Lower middle QM: Outer mast QM: Upper middle
and section mast mast
Rough sketch
(b)
(a)
13.1.3. ADJUSTMENT
1. Park the lift truck on a flat surface and set the mast in the vertical position.
2. Lower the forks to the ground, and turn the adjusting nut to eliminate any chain sag.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check that the chain is not twisted.
13. MAST 13-845
5. Check that the lifting height meets the standard.

6. In the uppermost position, check that the carriage fall-out prevention stopper at the inner mast upper beam is
not in contact with the carriage.
13.1.4. MAIN LIFT CHAIN ADJUSTMENT (TT)

1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90 cm) block under the free lift cylinder support blocks. The
main lift chain anchors are now accessible.
2. Adjust one chain to achieve the correct upright position when fully lowered.
3. Adjust the other chain to achieve equal chain tension.
4. Raise and lower the mast several times to confirm the adjustments.
(a) Chain adjusting nut

13
13.1.5. MAIN LIFT CHAIN SERVICE (TT)
WARNING
Block the intermediate upright.
1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90 cm) block under the free lift cylinder support casting,
then lower the cylinder support onto the block. The main lift chains should be slack.
2. Remove the cotter pins and pins (a) from the chain anchors (b). Remove the chains.
3. Inspect the chain anchors for cracks. Replace as required.
4. For reassembly, reverse the disassembly procedure. Adjust the chains.
13-846 13. MAST
CAUTION
If chain anchor is secured with a nylon lock nut (c), install a new lock nut when it is necessary to loosen the
chain or remove the anchor.
13.1.6. FREE LIFT CHAIN ADJUSTMENT (TT)

The free lift chains should be adjusted so that when the mast is vertical and the carriage is fully lowered, the forks
are positioned as specified in the table below.
Fork Type Distance Above Floor
Standard 2 in. (5 cm) measured from top of fork at the heel
1. Locate the threaded chain anchors on the front side of the inner upright cross member in front of both cylin-
ders. Adjust one chain to achieve the correct carriage position when fully lowered.
2. Adjust the other chain to achieve equal chain tension.
3. Raise and lower the mast several times to confirm the adjustments.
13. MAST 13-847
13.1.7. FREE LIFT CHAIN SERVICE (TT)
1. Raise the carriage enough to place a 12 in. (300

mm) block under the carriage, then lower the carriage
onto the block. The free lift chains should be slack.
WARNING! Block the carriage.
2. Remove the cotter pins and pins from the chain
anchors. Remove the chains.
3. Inspect the chain anchors for cracks. Replace as
required.
4. For reassembly, reverse the disassembly
procedure. Adjust the chains.
CAUTION! If chain anchor is secured with a nylon
lock nut, install a new lock nut when it is necessary
to loosen the chain or remove the anchor.
13
13-848 13. MAST
13.2. FORK
13.2.1. REMOVAL
1. Raise the forks to approx. 7.9 in. (20 cm) from the
ground.
2. Place a wooden block under the notched section
of the fork rail.
3. Unlock the fork by lifting the fork stopper pin, and
shift the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
13.2.2. INSTALLATION
13.2.3. INSPECTION
Inspect misalignment of the fork tip ends.

Limit: 0.39 in. (10 mm)
If the limit is exceeded, inspect individual fork bend,
looseness of fork installation, and carriage finger bar
distortion.
13. MAST 13-849
13.3. QM MAST ASSY
13.3.1. MAST ADJUSTMENT (QM)

Lift Roller Adjustment at Mast
1. Inner mast roller and middle mast lower roller clearance adjustment.
13
About the QM mast
Clearance between outer mast and lower middle mast lower roller
Clearance between lower middle mast and upper middle mast lower roller
Clearance between upper middle mast and inner mast roller
(a) Bring into contact
Position where the roller is the closest to the QM mast.
(1) Adjust the mast overlap to approx. 17.7 in. (450 mm).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and measure on the opposite
side the clearance between the roller side face and mast at the point where they are the closest.
Standard: A = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.
Shim thickness: 0.020 and 0.039 in. (0.5 and 1.0 mm)
(3) Distribute shims equally to the left and right rollers.
(4) After adjustment, check that mutual mast movement is smooth.
2. Outer mast roller (QM) and middle mast upper roller (QM) clearance adjustment.
13-850 13. MAST
About the QM mast

Clearance between lower middle mast and outer mast roller
Clearance between upper middle mast and lower middle mast upper roller
Clearance between inner mast and upper middle mast upper roller
(1) Adjust the mast overlap to approx. 17.7 in. (450 mm).
(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on the opposite
side the clearance between the roller side face and mast at the point where they are the closest.
Standard: B = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the outer mast roller shim thickness.
Shim thickness: 0.020 to 0.039 in. (0.5 to 1.0 mm)
(3) Distribute shims equally to the left and right rollers.
(4) After adjustment, check that mutual mast movement is smooth.
13. MAST 13-851
Lift and Side Roller Adjustment at the Carriage
13
(a) Lower side roller (c) Bring into contact (e) Carriage
(b) Side roller (d) Bring into contact
(1) For adjustment, raise the carriage fully in case of QM.

(2) Shift the carriage to one side to bring the lower lift roller and side roller into contact with the inner mast, and
measure on the opposite side the clearance between the roller side face and the mast at the point where they are
the closest.
Standard: C = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness. (Distribute shims equally to the left and right side
rollers.)
(3) After the inspection and adjustment in step (2) above, inspect and adjust the side rollers. Bring the side roller on
one side into contact with mast side surface, and measure on the opposite side the clearance between the side roller
and the inner mast side surface.
Standard: D = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.(Distribute shims equally to the left and right side
rollers.)
(4) After the above adjustment, check that the carriage moves smoothly along the entire length of the mast.
13-852 13. MAST
Mast Strip Adjustment

1. Mast strip clearance adjustment
QM mast (a) (b)
(c)
(d)
(e)
E
(f)
NOTICE! Image shows three of the four upright weldments
(a) Intermediate mast (c) Inner mast (e) Outer mast
(b) Upper side roller (d) Bring into contact (f) outward
(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller), measure the
clearance between the mast strip and mast.
Standard: E = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.
(3) After adjustment, check the mast for smooth movement.
13. MAST 13-853
13.4. TT MAST ASSY
13.4.1. MAST REMOVAL AND INSTALLATION

13.4.1.1. REMOVAL AND INSTALLATION (W/CARRIAGE)
13
2 a
7
5
8
b
a: T = 63 to 95 ft·lbf. (86 to 129 N·m)

b: T = 62 to 115 ft·lbf. (84 to 156 N·m)
Removal Procedure
1. Set the mast in the vertical position.
2. Remove the fork. (Refer to Cylinder section)
3. Disconnect the lifting height switch.
4. Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast
and operate the lift lever several times to release the residual pressure from the lift cylinder.)
5. Tie the carriage and outer mast tie beam with a wire rope.
6. Slightly hoist the mast.
7. Remove the tilt cylinder front pin. [Point 1]
8. Remove the mast support cap.
13-854 13. MAST
9. Remove the mast ASSY W/carriage.
NOTICE
• Apply chassis grease special to the mast support bushing and mast support cap interior surfaces. Apply
MP grease to the tilt cylinder front pin.
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or either
lift cylinder is replaced.
• Adjust the chain tension after installation.
• When the mast is replaced, perform PSS matching after installation.
Point Operations
[POINT 1]
Removal:
Make match marks to clarify the relative positions of
the front pin, stopper plate and lock bolt. Match marks,
however, are unnecessary when the mast or mast
ASSY is replaced as mast tilt angle adjustment is to be
done after replacement.
Removal:
If the fitting is stiff, use the driver for removal.
Inspection:
Measure the mast support bushing thickness.Limit:

0.039 in. (1.0 mm)
13. MAST 13-855
13.4.1.2. PARTIAL REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck with a capacity of at least five tons.
1. Turn the key switch OFF and disconnect the battery connector.
2. Remove the console and front covers.
3. Remove the forks.
4. Verify that the mast is in a vertical position.
5. Position the lift truck beneath the hoist or lift truck.
6. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist or lift truck.
7. Lift the hoist just enough to take the slack out of the chain or strap.
8. Remove the support cap and retaining bolts from the support pins.
9. Remove the tilt pin assembly retaining hardware and mast support cap. Carefully remove the pivot blocks from
each tilt cylinder clevis, allowing the tilt cylinder to rest on the brake assemblies
13.4.1.3. INSTALLATION AFTER PARTIAL REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity.
1. With the mast securely held by a strap or chain, carefully raise the mast until it is vertical.
2. Reconnect the battery connector and turn the key switch ON.
3. Apply chassis grease on the tilt pin before the mast is installed on the lift truck.
4. Slowly extend the tilt cylinders until you are able to install the cylinder front pin, stopper plate, and lock bolt
into each tilt plate.
5. Perform MAST FORWARD/BACKWARD TILT ANGLE ADJUSTMENT in the Cylinder section.
6. Apply chassis grease to the grease nipple after the mast is mounted to the lift truck.
7. Remove the lifting device and any chains/straps used to lift the mast.
8. Bleed the hydraulic system. 13
NOTICE
• Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check normal func-
tioning.
• Check the hydraulic oil level and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (Refer to “MAST FORWARD
BACKWARD TILT ANGLE ADJUSTMENT”
9. Install the forks.
13.4.1.4. COMPLETE MAST REMOVAL

NOTE: See also “Partial Removal” procedure which precedes for an alternative means of gaining access to motors
and pumps.
For this procedure, you will need a hoist or lift truck of suitable capacity.
1. Before starting complete removal, perform partial removal steps.
2. Verify that the mast is in a vertical position.
3. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist.
4. Turn the key switch OFF and disconnect the battery connector.
5. Remove the forks.
6. Lift the hoist just enough to take the slack out the chain or strap.
7. Remove the support cap and retaining hardware from the support pins.
8. Disconnect the main lift and auxiliary hoses. Be careful not to spill hydraulic fluid. Plug/cap each fitting to
prevent contamination from entering the hydraulic system.
9. Use the hoist or other lift truck to lift the mast just enough to allow it to be moved away from the tractor.
13-856 13. MAST
10. Have wood blocks positioned to support the mast off the floor.
11. Carefully lower the mast onto the support blocks with the fork carriage facing down.
(a) Mast support pin (b) Mast support cap
(c) Retaining hardware. 62?113 ft. lb. (84?156 N·m) (4PCS.)
13.4.1.5. INSTALLATION AFTER COMPLETE REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity.
1. Make sure the pivot bearings are shimmed as they were when the mast was removed.
2. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to the lifting device.
3. Slowly lift the mast up and off the wooden blocks.
4. Slowly move the mast towards the lift truck.
5. Carefully engage the mast support pin with the supports on the drive unit.
6. Place the mast support caps over both mast support pins. Install the retaining hardware in both support caps.
7. Remove C-clamps from upright flange if they were installed during mast reassembly.
8. Reconnect the mast and auxiliary hoses. Torque to correct specification.
9. Apply chassis grease to the grease nipples on the support caps.
10. Follow the procedure for “Installation after Partial Removal”.
(a) Mast support pin (b) Mast support cap
(c) Retaining hardware. 62?113 ft. lb. (84?156 N·m) (4PCS.)

13. MAST 13-857
13.4.2. ROLLER BEARING WEAR PAD ADJUSTMENT (TT)

Adjust the roller bearing wear pad spacing, at all locations, as shown.
13
(a) 0.008 to 0.016 in. (0.2 to 0.4 mm) Clearance
1. Check and adjust the gap at each of the roller bearing wear pads (12 places).
• (4) Carriage bearings
• (2) Inner Tele bearings
• (4) Outer tele bearings
• (2) Mainframe bearings
2. Set the gap (a) between the wear pads and the mast rails by adjusting the set screws.
• A 1/6th inch turn of the set screw is approximately 0.011 in. (0.30 mm) of lateral movement of the wear
pad.
3. Make sure the adjustment of the wear pads keeps the teles centered within each other (left to right).
4. Replace a wear pad if it is excessively worn.
13.4.3. MAST SKEWING

Raise the mast to full height:
• If the mast kicks to the right at full extension, the right hand main lift cylinder rod must be shimmed.
• If the mast kicks to the left at full extension, the left hand main lift cylinder rod must be shimmed.
13-858 13. MAST
1. Place a 4 x 4 x 12 in. (10 x 10 x 30 cm) wood

block between the intermediate weldment and
the outer weldment cross members. Lower the
cross member onto the block.
2. Remove the cap (a), screw (b), inner (c), and
outer (d) sleeves from the cylinder to be
adjusted. Activate the lower control to allow the
cylinder rod to retract and disengage the cross
member.
3. Install shim(s) (e) as necessary.
4. Slowly activate the lift control to allow the
cylinder rod to engage the cross member. Rein-
stall the outer and inner sleeves, screw, and cap.
Torque the screw (b) to 55 ft·lbf. (74.5 N•m).
5. Repeat steps 1 through 4 until skewing has been
removed.
13.4.4. 3-STAGE (TT) MAST SERVICE

Bubbled items in the figures correspond to steps in the associated procedure.
13.4.4.1. DISASSEMBLY
1. Remove the mast assembly from the truck.
2. Reverse the Internal Reeving Installation.
3. Remove the free lift cylinders.
4. Disconnect the free lift chains from the carriage.
5. Disconnect the auxiliary hoses from the carriage bulkheads and plug all fittings.
6. Remove the carriage by sliding it out of the bottom of the inner upright.
7. Remove the main lift chain.
8. Remove main lift chain sheave.
9. Remove fittings and hoses between the mast manifold and main lift cylinders.
10. Remove the main lift cylinders.
11. Remove the mast manifold.
12. Using an overhead hoist, turn the mast over (cross members facing down).
13. Attach an overhead hoist to the inner upright. Remove the inner upright through the top of the intermediate
upright.
14. Attach an overhead hoist to the intermediate upright and remove it through the top of the outer upright.
15. Remove bearing assemblies (if necessary).
13. MAST 13-859
(a) Intermediate Upright

(b) (a) (c)
(b) Inner Upright
(c) Outer Upright
13.4.4.2. INSPECTION
1. Inspect the wear pads for excessive wear or damage. Wear pads with visible flat spots or cracks should be
replaced.
2. Inspect the roller bearings by turning them on their shafts. Roller bearings with roughness or noticeable
restrictions to turning should be replaced.
3. Inspect the bearing roller stub shafts. If they are damaged or have cracks at the base, the upright must be
replaced or repaired.
4. Inspect the lift chains. Refer to “Mast Chain Inspection”.
5. Inspect the outer upright chain anchors.
6. Inspect the inner upright chain anchors.
13
13-860 13. MAST
13.4.4.3. REASSEMBLY
1. Install small and large roller bearing assemblies in the locations specified. Wear pads should be pushed in as
far as they can go. Set screws should be started but should not be installed far enough to start forcing the
wear pad out of the roller stud.
2. Lubricate the roller bearing surfaces on the outer, intermediate, and inner uprights.
3. Attach an overhead hoist to the intermediate upright. Install the intermediate upright through the top of the
outer upright.
4. Adjust the wear pad spacing on the roller bearings positioned on the top of the outer upright and at the bottom
of the intermediate upright. This adjustment is made by driving in the adjusting set screw. Spacing between
the wear pads and the rails should be between 0.008 and 0.016 in. (0.2 and 0.4 mm) on both sides. The inter-
mediate upright should be centered within the outer upright.
5. Attach an overhead hoist to the inner upright. Install the inner upright through the top of the intermediate
upright.
6. Adjust the wear pad spacing on the roller bearings positioned on the top of the intermediate upright and at the
bottom of the inner upright. This adjustment is made by driving in the adjusting set screw. Spacing between
the wear pads and the rails should be between 0.008 and 0.016 in. (0.2 and 0.4 mm) on both sides. The inner
upright should be centered within the intermediate upright.
7. Using an overhead hoist, turn the mast over (cross members facing up).
8. Install the mast manifold as shown.
9. Install the main lift cylinders. Refer to Main Lift Cylinder Installation - Mast on Floor.
10. Install fittings and hoses between the mast manifold and main lift cylinders as shown.
11. Install the main lift chain sheave.
12. Install the main lift chain. Refer to Main Lift Chain Service.
13. Install the carriage by sliding it into the bottom of the inner upright.
14. Adjust the wear pad spacing on the roller bearings positioned on either side of the carriage. This adjustment
is made by driving in the adjusting set screw. Spacing between the wear pads and the rails should be between
0.008 and 0.016 in. (0.2 and 0.4 mm) on both sides. The carriage should be centered within the inner upright.
15. Connect auxiliary hoses to the carriage bulkheads in the correct orientation.
16. Connect the free lift chains to the carriage. Refer to Free Lift Chain Service.
17. Install free lift cylinders. Refer to Free Lift Cylinder Installation - Mast on Floor.
18. Adjust the chains by securing the carriage at the specified dimension from the bottom of the inner upright with
C-clamps clamped on the upright flange. Adjust both chain anchors until they have equal tension with the
carriage in the correct position (minor adjustments will need to be made once the mast is upright). Leave the
carriage in this position with the C-clamps in place.
19. Route the auxiliary and lift hoses. Refer to Internal Reeving Installation.
13. MAST 13-861
13
(a) Top of outer upright (g) Wear pad adjustment set screw (On all roller
bearing assemblies)
(b) Small roller bearing assembly (h) Bottom of inner upright
(c) Mast manifold (i) Large roller bearing assembly
(d) Main lift hoses (j) 1" from bottom of carriage to bottom of inner
upright
(e) Top and bottom of intermediate upright (k) Carriage
(f) Main lift chain sheave (l) C-clamp location

13-862 13. MAST
13.4.5. CYLINDER REMOVAL AND INSTALLATION

13.4.5.1. MAIN LIFT CYLINDER REMOVAL - MAST ON FLOOR
13. MAST 13-863
1. Remove the mast from the truck. See Complete Mast Removal.
2. Lay the mast face-down on wood blocks. Block under the outer upright so the inner upright is free to move.
The integral side shift must be positioned between the blocks and free to move.
3. Disconnect the cylinder supply hoses from the cylinder inlet ports. Remove the special long fittings from the
cylinder ports and install plugs.
NOTE: Each internal fuse piston holds a compressed spring in place.
4. Remove the cap (a), screw (b), inner sleeve (c), outer sleeve (d), and shims (e) (if present).
5. Remove the two screws securing the cylinder retaining bracket.
6. Remove the cylinder retaining bolt at the bottom of the cylinder.
7. Remove main lift cylinder.
13.4.5.2. MAIN LIFT CYLINDER INSTALLATION - MAST ON FLOOR

For installation, reverse the Removal procedure. In addition:
• Torque the screw at the top of the cylinder to 55 ft. lb. (74.5 N·m).
• Bleed the system.
13
13-864 13. MAST
13.4.5.3. FREE LIFT CYLINDER REMOVAL - MAST ON FLOOR

13. MAST 13-865
1. Remove the mast from the truck. See Complete Mast Removal.
2. Lay the mast down.
3. Roll the carriage toward the center of the cylinder to slacken the chains and internal reeving hoses.
4. Disconnect the cross-over tube and fittings from the cylinders. Cap the fittings and plug the hose.
5. Remove the free lift hose assembly from the free lift chain sheave assembly (a) by removing the two bolts.
6. Remove the chain and nut from the free lift chain anchor.
7. Remove the free lift chain sheave assembly from the cylinder.
8. Remove the free lift cylinder bolts (b) connecting the cylinder to the lower mounting blocks.
9. Remove the chain anchor and remove the cylinder from the mast.
13.4.5.4. FREE LIFT CYLINDER INSTALLATION - MAST ON FLOOR

For installation, reverse the Removal procedure. Bleed the system.
13
13-866 13. MAST
13.4.5.5. FREE LIFT CYLINDER REMOVAL - MAST ON TRUCK
1. Completely lower the carriage. Remove forks or attachment. Make sure the free lift cylinder is completely
retracted. Attach an overhead hoist to the top carriage bar.
WARNING
The carriage must be supported by a block while removing the cylinder to avoid possible injury.
2) Raise the carriage to the center of the cylinder to slacken the chains and internal reeving hoses.
Block the carriage in place using a 4 x 4 x 24 in. (10 x 10 x 60 cm) wood block between the lower
carriage bar and the floor.
3. Remove the bolts connecting the cylinders to the lower mounting blocks.
13. MAST 13-867
4. Remove the free lift hose assembly.

5. Remove the chain and nut from the free lift chain anchor.
6. Remove the free lift chain sheave assembly from the cylinder.
7. Disconnect the cross-over tube and fittings from the cylinders. Cap the fittings and plug the hose.
8. Remove the chain anchors.
9. Remove the cylinder from the mast.
13.4.5.6. FREE LIFT CYLINDER INSTALLATION - MAST ON TRUCK

For installation, reverse the Removal procedure. Bleed the system.
13.4.6. INTERNAL REEVING INSTALLATION

1. Install auxiliary hoses at the carriage fittings.
2. Route auxiliary hoses over the free lift cylinder and through the hose pulley assembly. Attach hose pulley
assembly to the free lift chain sheave assembly.
3. Route auxiliary hoses down the free lift cylinder to the hose clamp. Install hose clamp components around
auxiliary hoses and bolt clamps to the cross-member. Do not tighten.
4. With carriage at its lowest position, pull slack out of the two aux hoses. Mark the hoses at the bottom of the
clamp. Pull the hoses until the distance between the line and the clamp is 1.5 ±0.5 in. (38 ±12 mm). Tighten
the clamp.
5. Route the auxiliary hoses as shown, clamping them at the positions specified with the hose clamps.
6. Attach lift hose (d) to the cross-over tube (c) between the free lift cylinders (e).
7. Clamp the free lift hose (a) and auxiliary hoses (b) into the hose clamp. Make sure the plastic clamps are
arranged as shown. Torque the screws to 50 in. lb. (6 N·m).
8. Route the free lift (a) and aux (b) hoses up to the upper hose pulley assembly. Install the hoses on the pulleys, 13
then push the pulleys into position so the shaft can engage both pulleys.
9. Assemble the upper hose clamp as shown with the hoses in the clamps, do not tighten.
10. With the mast fully collapsed, pull slack out of the lift hose and two aux hoses. Mark the hoses at the bottom
of the clamp. Pull the hoses until the distance between the line and the clamp is 1.5 ±0.5 in. (38 ±12 mm).
Tighten the clamp to hold the hoses. Torque the screws to 50 in. lb. (6 N·m).
11. Route hoses as shown over to the main lift cylinder and clamp at equal distances in 3 places on the main lift
cylinder.
12. Attach the lift hose to the mast manifold.
13. Secure the two auxiliary hoses to the fitting on the mast manifold with a cable tie.
14. Raise and lower the mast several times. Make sure the hoses track over the pulleys correctly. The hose pulley
assembly attached to the free lift cylinder should be aligned front to back. If it looks like it is twisting as the free
lift cylinder is raised, perform the following adjustment procedure:
(a) Slightly loosen the aux hose fittings at the carriage, allowing the swivel fitting to correct the twist in the
hose.
(b) Tighten the fittings and check the hose pulley assembly for alignment. If necessary, adjust the hose ends
with a slight amount of twist to improve the alignment of the hose pulley assembly.
13-868 13. MAST
13. MAST 13-869
13.5. LIFT CYLINDER ROD SHIM ADJUSTMENT

(PREVENTION OF UNEVEN LIFTING)
NOTICE
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left and
right sides due to tolerances of parts, etc.
• Perform inspection and adjustment when any of the following parts are replaced: Lift cylinder ASSY, lift
cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY and inner mast
SUB-ASSY.
• After adjustment, perform PSS matching. (See section 17.)
1. Inspection method
Slowly raise the inner mast, and observe the stopping
condition of the left and right cylinder rods at the
moment when the inner mast reaches the maximum
height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first. 13
2. Adjustment method
SST (1) Raise the inner mast, attach the SST to the outer
mast tie beam, and lower the inner mast until it comes
into contact with the
SST 979-001/174
(2) Remove the cylinder rod end set bolt on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims (a) on the cylinder rod end, and slowly
raise the cylinder rod end into the inner mast.
(5) Install the cylinder rod end set bolt.
(6) Raise the inner mast again for reinspection.
(7) Repeat the inspection and adjustment until the
number of shims is determined.
Shim thickness: 0.020 to 0.039 in.(0.5 to 1.0 mm)
13-870 13. MAST
14. CYLINDER 14-871
14. CYLINDER
14.1. REAR LIFT CYLINDER (TT•QM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 871
14.2. VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 878
14.3. FRONT LIFT CYLINDER (TT, QM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 881
14.4. TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 886
14.1. REAR LIFT CYLINDER (TT•QM)
14.1.1. GENERAL
Rear Lift Cylinder (TT)
275 PSI
14
Rear Lift Cylinder (QM)
LH
RH
14-872 14. CYLINDER
Rear Lift Cylinder (TT)
Cylinder type Single-acting type
Cylinder bore 1.77 (45)

in. (mm)
Piston rod outside diameter 1.57 (40)

in. (mm)
Piston seal type U packing
Rod seal type U packing
Others Built-in valve (LH and RH)
Rear Lift Cylinder (QM)


in. (mm)

in. (mm)
Others Built-in valve (LH)

14. CYLINDER 14-873
3 2
10
5 10
6
14
8
Removal Procedure
1. Set the mast in the vertical position and fully lower the forks.
2. Remove the lift cylinder rod end set bolt.
3. Hoist the inner mast by slinging with a wire and disconnect the end of each lift cylinder rod.[Point 1]
4. Hoist the inner mast farther so that the lift cylinder ASSY can be removed toward the front of the lift truck.
5. Support the bottom of the inner mast with wooden blocks and fix to the outer mast with string.
6. Remove the hose cover.
7. Disconnect the hose.
8. Remove the lift cylinder bottom end set bolt.
9. Remove the lift cylinder support.
10. Remove the lift cylinder ASSY.[Point 2]
14-874 14. CYLINDER
NOTICE
• Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check normal func-
tioning.
• Check the hydraulic oil level and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (Refer to “MAST FORWARD
BACKWARD TILT ANGLE ADJUSTMENT”
Point Operations
[POINT 1]
Removal:
Perform shim adjustment at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Record which cylinder the adjustment is made and
also the number of shims used.
[POINT 2]
Installation:
Temporarily fasten the cylinder support, and eliminate
any clearance between the cylinder support and outer
mast by shim (a) insertion after connecting the rod
end.
(The shim thickness should be slightly greater than the
clearance)
14. CYLINDER 14-875
(a) 2
14
a (TT): T = 180 to 200 ft·lbf. [244 to 271 N·m]

a (QM): T = 200 to 220 ft·lbf. [271 to 298 N·m]
1. Remove the valve (LH).
2. Remove the cylinder cover. [Point 1]
3. Remove the piston rod.[Point 2]
4. Remove seals on the piston side.[Point 3]
14-876 14. CYLINDER
NOTICE
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the cylinder cover on the part shown in the below illustration and reas-
semble it.
(a)
(b)
(c)
(a) 1/3 to 1/2 of circumference (b) 2 ridges (c) 2 to 3 ridges
Point Operations
[POINT 1]
Disassembly / Reassembly:
If the cylinder cover is a U-groove type, use the SST.
SST 979-001/175
[POINT 2]
Installation:
Measure the piston rod outside diameter.
Standard:
TT mast: 1.574 in. (40 mm)
QM: 45 mm (1.77 in.)
Limit:
TT mast: 1.5716 in. (39.92 mm)
QM: 1.7685 in. (44.92 mm)
Installation:
Measure the bend of the piston rod.
Limit: 0.079 in. (2.0 mm)
14. CYLINDER 14-877
Reassembly:
SST Use a cylinder rod (a) and insertion guide (SST) to
(a) reassemble the cylinder (b).
SST 979-005/504
(b)
[POINT 3]
Inspection:
Measure the lift cylinder bore.
Standard:
TT:1.77 in. (45 mm)
QM: 2.17 in. (55mm)
Limit:
TT: 1.7795 in. (45.20 mm)
QM: 2.1791 in. (55.35 mm)
14
14-878 14. CYLINDER
14.2. VALVE
QM
TT
14. CYLINDER 14-879
14.2.1. REMOVAL AND INSTALLATION for QM
7
a 3
14
a (QM): T = 43.5 to 53.9 ft·lbf. [59 to 73 N·m]
Removal Procedure
1. Remove the lift cylinder rod end set bolt.
2. Hoist the inner mast. [Point 1]
3. Remove the front hose cover and load sensor bracket.
4. Remove the lift cylinder (LH) bottom end set bolt.
5. Loosen the lift cylinder (LH) support set bolt.
6. Disconnect the hose.
7. Remove the valve.
14-880 14. CYLINDER
Point Operations
[POINT 1]
Removal:
Hoist the inner (middle) mast by slinging with wire, set
the SST on the inner (middle) mast tie beam, and
lower the inner mast until it comes into contact with the
SST.
SST 979-001/174
14. CYLINDER 14-881
14.3. FRONT LIFT CYLINDER (TT, QM)
14.3.1. GENERAL
Front Lift Cylinder (TT)
275 PSI
Front Lift Cylinder (QM)
14
14-882 14. CYLINDER
Front Lift Cylinder (TT)
in. (mm)
in. (mm)
Others Built-in valve (LH and RH)
Front Lift Cylinder (QM)

in. (mm)
Piston rod outside diameter 2.00 (50.8)
in. (mm)
Others Built-in valve

Removal Procedure
1. Remove the carriage W/ fork.
3. Remove the front lift cylinder.
NOTICE
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• Adjust the lift chain tension equally on the left and right sides.
14. CYLINDER 14-883
1. Remove the chain wheel support.
2. Remove the cylinder cover.[Point 1] 14
3. Remove the piston rod. [Point 2]
4. Remove the wear ring and U packing.
5. Remove the check valve.
6. Remove the valve from the cylinder. [Point 3]
14-884 14. CYLINDER
NOTICE
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the cylinder cover on the part shown in the below illustration to reas-
semble it.
(a)
(b)
(c)
• Fill the cylinder with the specified amount of hydraulic oil through the cylinder top opening before
installing the cylinder cover.
Filling amount: 3.66 in.3 (60 cm3)
(a) 1/3 to 1/2 of circumference

(b) 2 ridges
(c) 2 to 3 ridges
Point Operations
[POINT 1]
If the cylinder cover is a U-groove type, use the SST.
SST 979-001/175
14. CYLINDER 14-885
[POINT 2]
Installation:
Standard:
TT: 1.654 in. (42 mm)
QM: 2.00 in. (50.8 mm)
Limit:
TT: 1.650 in. (41.92 mm)
QM: 1.9969 in. (50.72 mm)
Installation:
Limit: 0.079 in. (2.0 mm)
[POINT 3]
Installation:
Standard:
TT: 1.968 in. (50 mm)
QM: 2.76 in. (70 mm)
Limit:
TT: 1.980 in. (50.3 mm)
QM: 2.7697 in. (70.35 mm)
14
14-886 14. CYLINDER
14.4. TILT CYLINDER
14.4.1. GENERAL
14.4.2. SPECIFICATION
Cylinder type Double-acting type

in. (mm)

in. (mm)

14. CYLINDER 14-887
9
8
3 7
3
14
Removal Procedure
1. Remove the toe board (front and rear) and tilt cover.
2. Remove the instrument panel.
3. Remove the fender cover and step.
4. Slightly hoist the mast.
5. Disconnect the hose. (After releasing the residual pressure in the tilt cylinder by operating the tilt lever several
strokes)
6. Disconnect the tilt angle sensor link. (RH)
7. Remove the tilt cylinder front pin.[Point 1]
8. Remove the tilt cylinder rear pin.
9. Remove the tilt cylinder ASSY.
NOTICE
• Apply MP grease to the insertion portions of the tilt cylinder front and rear pins before installation.
• After installation, slowly tilt the mast forward and backward a few times to check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform PSS matching. (Refer to PSS section.)
14-888 14. CYLINDER
Point Operations
[POINT 1]
Removal:
Make match marks to clarify the relative positions of
the front pin, stopper plate and lock bolt. Match marks,
however, are unnecessary when the mast or mast
ASSY is replaced as mast tilt angle adjustment needs
to be done after replacement.
[POINT 2]
Removal:
If the fitting is stiff, use the driver for removal.
14. CYLINDER 14-889
14
a: T = 260 ft·lbf. [353 N·m]

b: T = 322 ft·lbf. [436 N·m]
1. Remove the Fitting.
2. Loosen the rod guide. [Point 1]
3. Extract the piston rod W/piston.
4. Remove the tilt cylinder. [Point 2]
5. Remove the bushing.
6. Remove the piston.
7. Remove the rod guide.
8. Remove the piston rod. [Point 3]
14-890 14. CYLINDER
NOTICE
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the threaded portion of the rod guide before reassembly.
Point Operations
[POINT 1]
SST 979-001/175
[POINT 2]
Inspection:
Limit: 2.770 in. (70.35 mm)
Reassembly:
SST Use a cylinder rod insertion guide (SST) to
reassemble the cylinder rod (a) to the cylinder (b).
SST 979-001/176
(b)
(a)
[POINT 3]
Installation:
Limit: 1.178 in. (29.92 mm)
Installation:
Limit: 0.039 in. (1.0 mm)
14. CYLINDER 14-891
14.4.5. MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT

(ADJUSTMENT OF UNEVEN TILTING)
NOTICE
• Adjust the mast forward and backward tilt angles (uneven tilting) when the tilt cylinder and mast ASSY
are replaced or overhauled.
• After adjustment, perform PSS matching. (Refer to PSS section.)
1. Inspect the forward and backward tilt angle and uneven lifting amount.
Standard:
Mast forward tilt angle: Standard set angle -0.6° to +1.6°
Mast backward tilt angle: Standard set angle -0.8° to +0.6°
Uneven lifting amount: 1 mm (0.04 in.) or less
2. If the standard is not satisfied, adjust it.
(a)
Tilt the mast forward, loosen the nut that holds the rod, then adjust the mast tilt angle and uneven lifting by 14
adjusting the screw engagement margin between the rod and the joint. (To adjust the screw engagement mar-
gin, position a wrench to the 2-faced section on the rod and turn the rod.)
(a) Eccentric direction
CAUTION! Do not turn the rod when it is in the forward most tilt position (or the backward most tilt
position) (Turn it with the mast slightly before forward most tilt position).
3. After adjusting, tighten the nut to fix the rod.
14-892 14. CYLINDER
15. OIL PUMP 15-893
15. OIL PUMP

15.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 893
15.2. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894
15.3. DISASSEMBLY, INSPECTION AND REASSEMBLY . . . . . . . . . . . . . . . 895
15.4. TEST METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 898
15.1. GENERAL
15
Vehicle model All model
Oil pump name Single gear pump
Oil pump type SMG300A21A3H1-L726

(Shimadzu)
Drive system Direct motor drive
Delivery (at speed: 1800 rpm, pressure: L (US gal) /min 36.8 (9.72)
17.2 MPa)
Theoretical discharge cm3 (in3) /rev 21.8 (1.330)

15-894 15. OIL PUMP
15.2. REMOVAL AND INSTALLATION
6
5
a
a: T = 18 to 24 ft·lbf. [24 to 33 N·m]
Removal Procedure
2. Remove the toe board (front and rear) and tilt cover.
3. Remove the return filter set bolt and set the filter free.
4. Disconnect the pump outlet hose at the oil pump side.
5. Remove the oil pump set bolts.
6. Disconnect the pump inlet hose at the oil pump side.
7. Remove the oil pump ASSY W/ fitting.
Torque the bolts evenly to prevent pump from angling.
NOTICE
• Apply grease at the spline section of the oil pump before installation. Grease shall be MOLIWHITE TA No.
1 manufactured by Kyodo YUSHI Co. LTD. The grease should be applied heavily to the oil pump splines
(fill the grooves). This grease is not compatible with previous lubricants. Clean the spline area
thoroughly before the new grease is applied.
• Clean the flange that meets the motor before installation.
15. OIL PUMP 15-895
15.3. DISASSEMBLY, INSPECTION AND REASSEMBLY
a
5
a: T = 35.5 to 42.7 ft·lbf. [48.1 to 57.9 N·m]
15
1. Make match marks between the front cover and body.
2. Fix the mounting parts of front cover with body side up to the vice.
3. Remove the four bolts, body, back-up, figure 3 gasket and side plate. [Point 1]
4. Remove the drive gear, driven gear and side plate.[Point 2]
5. Remove the oil seal. [Point 3]
1. Put the body on the worktable with its hole for the gear up.
2. Reassemble the parts in order as the upper illustration. [Point 4]
3. Invert the assembled pump so the front cover is down and fix the mounting parts to the vice.
4. Tighten 4 bolts evenly by 35.5 to 42.7ft·bf. [48.1 to 57.9 N·m] torque.
5. Invert the assembled pump again so the front cover is up. Fix the body to the vice.
6. Remove the oil seal. [Point 5]
NOTICE
• Wash each part, blow dry with compressed air, and apply hydraulic oil before installation.
• Always use new seals for reassembly.
15-896 15. OIL PUMP
Point Operations
[POINT 1]
(b)
Inspection:
(a) The bushing inner surface should not be roughened
and should not be worn to the extent that the metal on
the rear side is visible.
Disassembly:
Since the pair of side plates, figure 3 gaskets, and
back-ups are assembled in different directions, put a
tag on each pair to distinguish where the part is used.
(a) Lubrication groove
(b) Bushing
Inspection:
The side plate surface in contact with gears should not
(a) be worn beyond the limit shown at left.
(a) Wear limit: 0.0059 in. (0.15 mm) or less
(b)
(b) Surface in contact with gears
(d) (e) (c) Groove of figure 3 gaskets
(d) Discharge port
(c) (e) Suction port
(f) (f) Erosion by cavitation around this portion
(g)
(g) Strong contact around here
Inspection:
Inspect the body inner surface for the wipe mark.
(b) (a) Standard:
(c) Wipe depth: 0.0004 to 0.0024 in. (0.010 to 0.060
mm)
(a) Wipe depth 0.0004 to 0.0024 in. (0.010 to 0.060
mm)
(b) Discharge port
(c) Suction port
(d)
(d) wipe mark
[POINT 2]
Inspection:
Check the gear side surface for wear and the tooth
flanks for roughening.
Standard:
(a) Shaft diameter limit: 0.78 in. (19.85 mm)
Tooth width limit: 1.11 in. (28.30 mm)
(a) Shaft diameter
(b) (b) Tooth width
15. OIL PUMP 15-897
Disassembly:
Make match marks on the tooth flanks of the drive and
driven gears.
(a) Drive gear
(a)
(b) Front cover
(c) (c) Driven gear
(b)
[POINT 3]
Inspection:
1. Check that there is no wear (that makes edge
rounded portion invisible) or damage at oil seal
(a) lip.
2. Check that the figure 3 gasket is not damaged.
3. Check that the O-ring is not damaged.
4. Check that seals are not swollen.
(a) Oil seal
(b)
(b) Figure 3 gasket
[POINT 4]
(a) Disassembly:
Fix the figure 3 gasket and back-up to the side plate by
using grease to prevent them from being twisted or
caught (The figure 3 gasket has a small dent for
back-up).
Reassembly: 15
Fix the drive gear and driven gear by matching each
(b) mark.
(a) Figure 3 gasket
(b) Back-up
[POINT 5]
(a) Reassembly:
Fill the dent between the main lip and dust lip of oil
seal with grease.
(a) Dust lip
(b) (b) Grease filling
(c) Main lip
(c)
15-898 15. OIL PUMP
15.4. TEST METHOD

A bench test should be conducted for strict testing, but as it is generally impossible in practical service operation,
install the oil pump on the lift truck and judge the oil pump discharge performance by operating the cylinder.
• Check that the battery charge is sufficient by observing the battery charge indicators.
• Check that the oil control valve set relief pressure is as specified. (Refer to Oil control valve section)
• Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 122 ~ 131°F (50 ~ 55°C)
and calculate the lifting speed. However, due to soft start by material handling chopper circuit, lifting speed is
2.0 ~ 3.9 fpm (10 ~ 20 mm/sec) lower than the value obtained from the table. The lifting speed can be calculated
more accurately by measuring the full stroke operation time excluding the soft start period.
The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and mast
adjustment.
The values below are based on a certain condition.
Lifting speed (reference value)

36V fpm (mm / sec)
C30S C35S
Model C30 C35 C40
Mast Mode No load Load No load Load No load Load
TF H 114 (580) 73 (370) 114 (580) 66 (335) 114 (580) 64 (325)
P 97 (495) 64 (325) 97 (495) 59 (300) 97 (495) 58 (295)
L 78 (395) 53 (270) 78 (395) 50 (255) 78 (395) 49 (250)
TT H 115 (585) 73 (370) 115 (585) 69 (350) 115 (585) 64 (325)
P 97 (495) 64 (325) 97 (495) 61 (310) 97 (495) 58 (295)
L 78 (395) 53 (270) 78 (395) 51 (260) 78 (395) 49 (250)
QM H 118 (600) 83 (420) 118 (600) 81 (410) 118 (600) 79 (400)
P 99 (505) 73 (370) 99 (505) 71 (360) 99 (505) 69 (350)
L 80 (405) 60 (305) 80 (405) 58 (295) 80 (405) 56 (285)
48V fpm (mm / sec)
C30S C35S
Model C30 C35 C40
Mod
Mast e No load Load No load Load No load Load
TF H 116 (590) 88 (445) 116 (590) 84 (425) 116 (590) 82 (415)
P 109 (555) 72 (365) 109 (555) 66 (335) 109 (555) 65 (330)
L 96 (490) 61 (310) 96 (490) 55 (280) 96 (490) 54 (275)
TT H 118 (600) 89 (450) 118 (600) 87 (440) 118 (600) 84 (425)
P 109 (555) 73 (370) 109 (555) 69 (350) 109 (555) 66 (335)
L 96 (490) 61 (310) 96 (490) 57 (290) 96 (490) 53 (270)
QM H 121 (615) 98(500) 121 (615) 95 (485)) 121 (615) 94 (475)
P 110 (560) 80 (405) 110 (560) 78 (395) 110 (560) 76 (385)
L 99 (505) 70 (355) 99 (505) 68 (345) 99 (505) 64 (325)
16. OIL CONTROL VALVE 16-899
16. OIL CONTROL VALVE

16.1. OIL CONTROL VALVE (Mechanical controlled valve) . . . . . . . . . . . . . . 900
16.2. OIL CONTROL VALVE (Solenoid controlled valve) . . . . . . . . . . . . . . . . 913
16.3. CONTROL VALVE LEVER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926
16.4. RELIEF PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 928
16.5. MANUAL DOWN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 930
16.6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 931
16
16-900 16. OIL CONTROL VALVE
16.1. OIL CONTROL VALVE (Mechanical controlled valve)
16.1.1. GENERAL
X1 X3 X4
S X2 C2
C4
P
CF
X1 T1
X4 C5
C1 C3
X2 X3
T2
LS
Inlet section (X1-X1)
(a)
(b)
(c)
(a) Priority valve (b) Relief valve (c) Unloading valve (Unloading SOL)
Lift section (X2-X2)
(b)
(a) 16
(c)
(d)
(a) Lift lock valve (Lift lock SOL) (c) Manual down valve
(b) Flow regulator valve (d) Lift spool
Tilt section (X3-X3)
(b)
(a)
(c) (e)
(d)
(a) Tilt control valve (Tilt control SOL) (c) Backward tilt switch (e) Tilt spool
(b) Backward tilt lock valve (Backward tilt lock SOL) (d) Forward tilt switch
Attachment section (X4-X4)
(a)
(a) Attachment spool

Solenoid Connector Diagram
(a)
(b)
(a) SOL (ON-OFF) (b) T-SW
16
Hydraulic Circuit Diagram
(f)
T2 LS R
(g)
(a)
P
CF
(b)
(c) (h)
(d)
S
C1
(e)
C2
C3
C4
C5
T1
(a) Unloading valve (Unloading SOL) (d) Manual down valve (g) Gauge port
(b) Relief valve (e) Tilt control valve (Tilt control SOL) (h) Flow regulator valve
(c) Lift lock valve (Lift lock SOL) (f) Priority valve
Model All model
Type Add-on type
Relief pressure Lift 2494 [17.2]

psi [MPa]
Tilt 1987 [13.7]
ATT
Flow regulator flow rate 50

L / min
ATT flow rate list
Tuning level Flow rate (L / min)
8 63
7 54
6 45
5 37
4 28
3* 20
2 16
1 13
*: Factory preset is level “3”

16
Lowering speed specification (36V / 48V)
fpm (mm / sec)
Model All model
Mast Mode No load Load
TN All 91 (460) 93 (470)
TT All 94 (480) 96 (490)
QM All 95 (485) 98 (500)

8
7
7
3
Removal Procedure
3. Remove the floor mat and rear toe board.
4. Remove the accelerator clamp set bolt and disconnect the connector of accelerator pedal.
5. Remove the front toe board.
7. Remove the instrument panel (RH).
8. Remove the wire harness bracket.
9. Disconnect the wiring.
11. Disconnect the lever rod.
12. Slightly hoist the oil control valve ASSY.
13. Remove the oil control valve ASSY W/bracket.[Point 1]
14. Remove the oil control valve ASSY.

15. Remove the fitting and load sensor. [Point 2]
NOTICE
• Apply chassis grease special to the oil control valve lever linkage.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (Refer to PSS section.)
Point Operations
[Point 1]
Removal:
For the removal of the oil control valve ASSY W/
bracket for fourth-way, use a hoist.
Installation:
• Tightening torque T = 17.7 ft·lbf. [24.0 N•m]
• For the reassembly of the oil control valve ASSY W/
[Point 2]
Installation:
Reassemble the fitting and the load sensor.
• Standard: Refer to the following table.
16
Standards
Port Application Tightening torque (ft·lbf. [N•m])
P ALL 55 to 60 [74 to 82]
S (Pressure sensor) ALL Fitting: 24 to 27 [32 to 36]

Sensor: 16 to 19 [22 to 26]
C1 ALL 41 to 46 [56 to 62]

C2 ALL 24 to 27 [32 to 36]
C3 ALL
C4 ALL
C5 ALL
C6 4 way
C7 4 way
A ALL
OUT ALL
LS ALL
PS return ALL
Oil-pressure check port ALL
T2 ALL
NOTICE
• Work in a clean location.
• Carefully handle parts. Individual parts are finished with high precision.
1. Remove the lift lock SOL and flow regulator valve. [Point 1]
2. Remove the lift spool.[Point 2]
3. Remove the tilt control SOL.[Point 3]
4. Remove the backward tilt lock SOL.[Point 4]
5. Remove the tilt limit switch and spring cover.[Point 5]
6. Remove the tilt spool.[Point 6]
7. Remove the unload SOL. [Point 7]
8. Remove the priority valve. [Point 8]
9. Remove the relief valve. [Point 9]
10. Remove the attachment valve.
11. Remove the rod bolt.
12. Remove the housing.
Inspection and Reassembly Procedure

NOTICE
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.
Point Operations
[Point 1]
Removal:
Put match marks on the solenoid to prevent installing in the
wrong position.
Installation:
Align match marks for reassembly.
Inspection:
2 3 Check the lift lock solenoid for continuity.
1 4
Measurement terminal 2 <–> 6: Continuity exists.
5 6 7 8
9.4 to 10.4 Ω (at 20°C [68°F])
Installation:
• Check for contamination and clean the filter.
• Carefully reassemble to prevent incorrect installation of
each solenoid spool, etc.
16
[Point 2]
Removal / Installation:
(b)
Remove / Install the compression spring to the lift spool.
a: SST 979-005/495
Use the SST after attaching a washer (b).
(a)
[Point 3]
2 3 Inspection:
1 4
Check the tilt solenoid for continuity.
9.4 to 10.4 Ω (at 20°C [68°F])
5 6 7 8
Installation:
Check for contamination and clean the filter.
Installation:
• Check for contamination and clean the orifice.
each solenoid spool.
[Point 4]
1
2 3
4
Inspection:
Check the backward tilt lock SOL for continuity.
5 6 9.8 to 10.8 Ω (at 20°C [68°F])
7 8
Installation:
each solenoid spool.
[Point 5]
Inspection:
Check the tilt limit switch for continuity.
2 1 Forward tilting side (measurement terminals 1 <–> 2):
No continuity when the switch is pressed.
Backward tilting side (measurement terminals 3 <–> 4):
4 3 No continuity when the switch is pressed.
Be careful not to mistake the forward and backward tilt limit
switches.
[Point 6]
Removal / Installation:
(b) Remove / Install the compression spring to the tilt spool.
a: SST 09610-10161-71
Use the SST after attaching a washer (b).
16
(a)
[Point 7]
Inspection:
1
2 3
4 Check the unload solenoid for continuity.
Measurement terminal 1 ? 5: Continuity exists.
9.4 to 10.4 Ω (at 20°C [68°F])
5 6 7 8
Installation:
[Point 8]
Installation:
Check for contamination and clean the orifice.
Installation:
16.2. OIL CONTROL VALVE (Solenoid controlled valve)
16.2.1. GENERAL
X3 X4
X2
S C2
X1
C4
P
CF
R1
T1 16
X1
C5
C1 C3
X4
X2 X3
T2
LS
(a)
(b)
(a) Priority valve (b) Relief valve
(c)
(d)
(b) (a)
(a) Proportion SOL (c) Lift lock valve (Lift lock SOL)
(b) Proportion SOL (d) Manual down valve
(c)
(b) (a)
(a) Proportional SOL (b) Proportional SOL (c) Tilt control valve (Tilt control SOL)
16
(b) (a)
(a) Proportional SOL (b) Proportional SOL

Solenoid Connector Diagram
SOL-b
SOL-a
(c)
(c) SOL (ON-OFF)

Hydraulic Circuit Diagram
(f)
T2 LS R1
CF
(a)
b1 a1
(b)
(c) S
C1
(d)
b2 a2
(e)
C2 16
C3
b3 a3
C4
C5
T1 R2
(a) Relief valve (c) Flow regulator valve (e) Tilt control valve (Tilt control SOL)
(b) Lift lock valve (Lift lock SOL) (d) Manual down valve (f) Priority valve
8
7
7
3
Removal Procedure
4. Remove the accelerator clamp set bolt and disconnect the connector of accelerator pedal.
8. Remove the wire harness bracket.
9. Disconnect the wiring.
11. Slightly hoist the oil control valve ASSY.
12. Remove the oil control valve ASSY W/bracket.[Point 1]
13. Remove the oil control valve ASSY.
14. Remove the fitting and load sensor. [Point 2]
NOTICE
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (Refer to PSS section.)
• The solenoid controlled valve starting current is set up by turning for every section.
Do not carry out position change of a wire harness and a connector.
Point Operations
[Point 1]
Removal:
For the removal of the oil control valve ASSY W/
Installation:
• Tightening torque
T = 17.7 ft-lbf. [24.0 N•m]
• For the reassembly of the oil control valve ASSY W/
[Point 2]
Installation:
Reassemble the fitting and load sensor.
• Standard: Refer to the following table.
16
Standards
Port Application Tightening torque (ft-lbf. [N•m])
P ALL 55 to 60 [74 to 82]
S (Pressure sensor) ALL Fitting: 24 to 27 [32 to 36]

Sensor: 16 to 19 [22 to 26]
C1 ALL 41 to 46 [56 to 62]
C2 ALL 24 to 27 [32 to 36]
C3 ALL
C4 ALL
C5 ALL
C6 4 way
C7 4 way
A ALL
OUT ALL
LS ALL
PS return ALL
Oil-pressure check port ALL
T2 ALL
NOTICE
• Work in a clean location.
• Carefully handle parts. Individual parts are finished with high precision.
1. Remove the lift lock SOL and flow regulator valve. [Point 1]
2. Remove the tilt control SOL.[Point 2]
3. Remove the proportional SOL (a). [Point 3]
4. Remove the proportional SOL (b). [Point 4]
5. Remove the lift spool, tilt spool and attachment spool.
6. Remove the priority valve.[Point 5]
7. Remove the relief valve. [Point 6]
8. Remove the rod bolt, and then remove the housing.
Inspection and Reassembly Procedure

NOTICE
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reassembly.
Point Operations
[Point 1]
Removal:
Put match marks on the solenoid to prevent installing
16
in the wrong position.
Installation:
Align match marks for reassembly.
Inspection:
2 Check the lift lock solenoid for continuity.
3
9.4 to 10.4 Ω (at 68°F [20°C])
6
5
Installation:
• Carefully reassemble to prevent incorrect installa-
tion of each solenoid spool, etc.
[Point 2]
2
3
Inspection:
Check the tilt solenoid for continuity.

6
5
9.4 to 10.4 Ω (at 68°F [20°C])
Installation:
Installation:
• Check for contamination and clean the orifice.
• Carefully reassemble to prevent incorrect installa-
tion of each solenoid spool.
[Point 3]
1 2 3 Inspection:
Check the proportional solenoid (a) for continuity.
5 6 7 Measurement terminal 2 <–> 6: Continuity exists.
(3way)
6.5 to 7.2 Ω (at 68°F [20°C])
[Point 4]
1 2 3 Inspection:
Check the proportional solenoid (b) for continuity.
5 6 7 Measurement terminal 2 <–> 6: Continuity exists.
(3way) 16
6.5 to 7.2 Ω (at 68°F [20°C])
[Point 5]
Installation:
Check for contamination and clean the orifice.
[Point 6]
Installation:
16.2.4. I-Q PLATE

The oil control valve installed on the lift truck requires setting of the starting current level.
The starting current is the current drawn by the oil control valve when the main spool starts to move.
By setting the starting current level, it is possible to attain a smoother load handling movement.
For the standard setting value of the starting current, refer to the I-Q plate attached on the oil control valve or the
label attached to the harness.
If there is no information about the standard setting value or if the load handling movement is not smooth after setting
with a certain setting value, decide the standard setting value as follows:
1. Set the starting current level to level 1.
2. Operate the load handling lever slowly.
3. Check the lever position when the mast or the attachment starts to move.
4. To make the play between that lever position and the neutral position smaller, raise the setting value.
5. Repeat the procedure 2 to 4.
For each of the following cases, it is necessary to change the starting current level settings.
1. When replacing the oil control valve ASSY.
2. When replacing the oil control valve sections.
3. When disassembly, cleaning, or parts replacement of the oil control valve.
4. When replacing the main controller.
Perform the setting using the display.

For detailed setting procedure, refer to the section DISPLAY for MATCHING OCV (3 OCV).
(a)
SOL-b
SOL-a 16
(b) (c)
When replacing the oil control valve as an ASSY or as a block, remove the label that is attached to the harness.
(a) Plate (b) Current level (c) SOL (ON_OFF)
NOTICE
1. If the level of the I-Q starting current was not entered correctly, it will not perform to the predetermined
level.
2. When a new lift truck is delivered or the oil control valve is replaced, make sure to record the I-Q starting
current level. The I-Q starting current level can be checked on the display, the I-Q plate, or the I-Q label.
16.3. CONTROL VALVE LEVER ASSY
10
Removal Procedure
4. Remove the accelerator clamp set bolt and disconnect the connector of the accelerator pedal.
8. Disconnect the lever rod.
9. Remove the set bolt.
10. Remove the control valve levers. [Point 1]
NOTICE
Apply molybdenum disulfide grease on the control valve lever links.
Point Operations
[Point 1]
Installation:
Check the knob switch for continuity.
16
16.4. RELIEF PRESSURE ADJUSTMENT
NOTICE
• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause high
pressure generation that may result in damage to the oil pump and other hydraulic devices.
• Before starting adjustment, check if the no-load maximum rpm is as specified.

2. Remove the lower panel and toe board.
3. Install an oil pressure gauge. [Point 1]
4. Set the adjusting screw A and adjusting sleeve B of the relief valve as described “Point Operations”. [Point 2]
5. Turn the key switch ON, and check for oil leaks and abnormal noise.
6. Install the toe board.
7. Close the battery hood.
8. Adjust the lift side relief pressure.[Point 3]
9. Adjust the tilt side relief pressure.[Point 4]
Point Operations
[Point 1]
Inspection:
Remove the oil-pressure detecting plug installed on
the left side of the oil control valve, and install the oil
(a) pressure gauge there.
Plug size: 9/16-18UNF
Fitting size: 9/16-18UNF × PF1/4
Fitting (a): 979-005/513
9/16-18 UNF
[Point 2]
(b) 1. Loosen lock nut (b). After fully tightening
(a)
adjusting screw (a) once, loosen it by 1 to 2 turns.
Loosen the lock nut (d), and position adjusting
(c) screw (c) to the following dimension.
A = 1.06 in. (27.0 mm)
A
(d)
[Point 3]
1. Set the seat switch to ON. (Operate with two
workers with one sitting on the seat.)
2. Operate the lift lever to lift the forks fully.
3. Operate the lift lever to the lifting side. Gradually
tighten adjusting sleeve B to make the oil pres-
sure in the relief state satisfy the standard in the
table on the next page, and fix the sleeve position
by tightening lock nut (d).
[Point 4]
1. Set the seat switch ON.
2. Operate the tilt lever to tilt the mast fully back-
ward.
3. Operate the tilt lever to the backward side. Grad-
ually tighten adjusting screw A to make the oil
pressure in the relief state satisfy the standard in
the table below, and fix the sleeve position by
tightening lock nut (b).
4. Tighten the lock nut and re-check the oil pres-
sure.
Standards:
Relief pressure
Lift
2494 to 2567 psi [17.2 to 17.7 MPa]
Tilt / ATT
1987 to 2059 psi [13.7 to 14.2 MPa]
16
16.5. MANUAL DOWN VALVE
(a)
(a) Manual down valve

• Tightening torque: T = 23.59 ft-lbf. [32.0 N•m]
If the forks do not lower due to a malfunction or other cause, loosen the manual down valve to lower the forks in
emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.
After making repairs, tighten it securely.
16.6. TROUBLESHOOTING
Operation Symptom Probable cause Corrective action
During steering The steering The priority valve • Check the priority valve piston. This part is
operation wheel cannot piston is stuck. removable.
be rotated • Check the priority valve piston is not damaged.
• Check the priority valve piston is not
contaminated.
The steering Priority valve piston • Check the priority valve piston is not damaged.
wheel is hard malfunction. • Check the priority valve piston is not
to rotate contaminated.
Insufficient spring • Check the priority valve spring is not broken.
force is applied by the • Check the seat surface of the spring is not worn
priority valve spring. out.
• Check the seat surface of the stopper is not
worn out.
Contamination is stuck • Check that the priority valve orifice is not
in the priority valve contaminated.
orifice (3).
16

During lift Cannot lift Relief valve main • Check the relief main plunger. This part is
operation plunger is open and removable.
stuck. • Check the relief main plunger is not damaged.
• Check the relief main plunger is not
contaminated.
The relief valve is set • Check the relief pressure.
at the wrong setting
pressure.
Manual down valve is • Check the manual down valve is tightened.
loose.
Load pressure • Not possible to inspect.
detection circuit check
valve (2) is closed and
stuck.
Lift by-pass check • Check the lift by-pass check valve and lift lock
valve (1) and the lift plunger. This part is removable.
lock plunger are • Check the lift by-pass check valve and lift lock
closed and stuck. plunger is not damaged.
• Check the lift by-pass check valve and lift lock
plunger is not contaminated.
Load check valve (12) • Check the load check valve. It is removable.
is closed and stuck. • Check the load check valve is not damaged.
• Check the load check valve is not
contaminated.
Lift spool is closed and • Check the lift spool. This part is removable.
stuck. (FINGERTIP • Check the lift spool is not damaged.
CONTROL LEVER • Check the lift spool is not contaminated.
ONLY)
Proportional SOL • Remove the tip pin of the proportional SOL and
malfunction. check the function using the lever operation.
(FINGERTIP
CONTROL LEVER
ONLY)
Proportional SOL • Check the proportional SOL spool. It is
spool (17) is closed removable.
and stuck. • Check the proportional SOL spool is not
(FINGERTIP damaged.
CONTROL LEVER • Check the proportional SOL spool is not
ONLY)
contaminated.
Contaminants are • Check for contamination in the proportional
stuck in the SOL pilot circuit.
proportional SOL pilot
circuit (18).
(FINGERTIP
CONTROL LEVER
ONLY)

During lift Lifting speed is Relief valve main • Check the relief valve main plunger is not
operation slow plunger malfunction. damaged.
• Check the relief valve main plunger is not
contaminated.
Insufficient spring • Check the relief valve main plunger spring is
force is applied by the not broken.
relief valve main • Check the seat surface of the spring is not worn
plunger spring. out.
Too small lap of relief • Check for any damage or contamination on the
main plunger. relief main plunger.
pressure.
Manual down valve is • Check the manual down valve is tightened.
loosen.
Contamination is stuck • Check for contamination in the load pressure
in the load pressure detection circuit.
detection circuit (2).
Check valve (2) • Not possible to inspect.
malfunction.
Lift by-pass check • Check the lift by-pass check valve is not
valve (1) malfunction. damaged.
• Check the lift by-pass check valve is not
contaminated.
Lift lock plunger • Check the lift lock plunger is not damaged.
malfunction. • Check the lift lock plunger is not contaminated.
Load check valve (12) • Check the load check valve is not damaged.
malfunction. • Check the load check valve is not
contaminated.
Lift spool malfunction. • Check the lift spool is not damaged. 16
(FINGERTIP • Check the lift spool is not contaminated.
CONTROL LEVER
ONLY)
(FINGERTIP
CONTROL LEVER
ONLY)
Proportional SOL • Check the proportional SOL spool is not
spool (17) damaged.
malfunction. • Check the proportional SOL spool is not
(FINGERTIP contaminated.
CONTROL LEVER
ONLY)

During lift Lifting speed is Contaminants are • Check contamination in the proportional SOL
operation slow stuck in the pilot circuit.
circuit (18).
(FINGERTIP
CONTROL LEVER
ONLY)
Contamination is • Check for contamination in the lift SOL filter.
attached to the lift
SOL filter.
Current level setting of • Check that the current level (30) on the I-Q
the I-Q plate is plate is the same as when shipped. Mask menu
incorrect. (FINGERTIP > Matching menu > OCV > A01X Check the
CONTROL LEVER value of X
ONLY)
Contamination is stuck • Check for contamination in the priority valve
into the priority valve orifice.
orifice (31).
Relief valve spring (A) • Check the relief valve spring (A).
is damaged.
malfunction. check the function with the lever operation.
(FINGERTIP
CONTROL LEVER
ONLY)
During lift Cannot lower Lift lock plunger is • Check the lift lock plunger. This part is
operation closed and stuck. removable.
• Check the lift lock plunger is not damaged.
• Check the lift lock plunger is not contaminated.
Contamination is stuck • Check for contamination in the lift lock plunger
into the lift lock orifice.
plunger orifice (5).
Lift lock SOL is closed • Check the operation sound of the lift lock SOL
and stuck. by the following procedure. *MASK MENU >
ANALYZER > ACTIVE TEST > LIFT LWR SOL >
ON - OFF (Lift lowering SOL forced operation).
Lift spool is closed and • Check the lift spool removable.
stuck. (FINGERTIP • Check the lift spool with no damage.
CONTROL LEVER • Check the lift spool without any contaminations.
ONLY)
Lowering operation • Check limit switch continuity.
detection limit switch
is damaged. ONLY
FOR
CONVENTIONAL
LEVER

During lift oper- Cannot lower Contamination is stuck • Check for contamination in the lift lock valve
ation in the lift lock valve pilot circuit.
pilot circuit (4)
(FINGERTIP
CONTROL LEVER
ONLY)
(FINGERTIP damaged.
ONLY) contaminated.
Contamination is stuck • Check for contamination in the proportional
in the proportional SOL pilot circuit.
SOL pilot circuit (20).
(FINGERTIP
CONTROL LEVER
ONLY)
SOL filter.
Unload valve (SOL) is • Check the unload SOL for broken wires.
closed and stuck. • Check the unload SOL spool is not
CONTROL LEVER
ONLY)
16

During lift Lowering Lift lock plunger • Check the lift lock plunger is not damaged.
operation speed is slow malfunction. • Check for contamination in the lift lock plunger.
Contamination is stuck • Check for contamination in the lift lock plunger
in the lift lock plunger orifice.
orifice (5).
Lift lock SOL • Check the operation sound of the lift lock SOL
malfunction. by the following procedure. *MASK MENU >
ON - OFF (Lift lowering SOL forced operation)
• Check for contamination attached to the filter.
Lift spool malfunction. • Check the lift spool is not damaged.
(FINGERTIP • Check the lift spool is not contaminated.
CONTROL LEVER
ONLY)
Contamination is stuck • Not possible to inspect.
in the lift lock valve
pilot circuit (4).
Flow regulator valve • Check the flow regulator valve is not damaged.
piston malfunction. • Check for contamination in the flow regulator
valve.
The flow regulator • Check the flow regulator valve piston spring is
valve piston spring is not broken.
applying insufficient • Check the seat surface (6) of the spring is not
spring force. worn out.
(FINGERTIP
CONTROL LEVER
ONLY)
spool (19) damaged.
CONTROL LEVER
ONLY)
circuit (20).
(FINGERTIP
CONTROL LEVER
ONLY)
SOL filter.
is damaged.

During lift Lowering Proportional SOL • Remove the tip pin of the proportional SOL and
operation speed is slow malfunction. check the function using the lever operation.
(FINGERTIP
CONTROL LEVER
ONLY)
During tilt Cannot tilt Relief valve main • Check the relief valve main plunger. This part is
operation forward plunger is open and removable.
stuck. • Check the relief valve main plunger is not
damaged.
contaminated.
pressure.
Current level setting of • Check current level (30) on the I-Q plate is the
the I-Q plate is same as when shipped. Mask menu > Matching
incorrect. (FINGERTIP menu > OCV > B01X Check the value of X.
CONTROL LEVER
ONLY)
Tilt control valve • Check the tilt control valve plunger. This part is
plunger is closed and removable.
stuck. • Check the tilt control valve plunger is not
damaged.
• Check the tilt control valve plunger is not
contaminated.
Contamination is stuck • Check for contamination in the tilt control valve
in the tilt control valve plunger orifice.
plunger orifice (7).
Tilt SOL is stuck and • Check the operational sound of the tilt SOL by
closed. moving the lever after the key switch is turned
ON. 16
• Check the operation sound of tilt SOL by the
following procedure. *MASK MENU >
ANALYZER > ACTIVE TEST > TILT SOL > ON -
OFF (Tilt SOL forced operation)
Tilt spool is closed and • Check the tilt spool. It is removable.
stuck. (FINGERTIP • Check the tilt spool is not damaged.
CONTROL LEVER • Check the tilt spool is not contaminated.
ONLY)
in the tilt control valve pilot circuit.
pilot circuit (8).

During tilt Cannot tilt Load pressure • Not possible to inspect.
operation forward detection circuit check
valve (25) is closed
and stuck.
Load check valve (13) • Check the load check valve. This part is
is closed and stuck. removable.
• Check the load check valve with no damage.
• Check the load check valve without any
contaminations.
(FINGERTIP
CONTROL LEVER
ONLY)
(FINGERTIP damaged.
ONLY) contaminated.
circuit (24).
(FINGERTIP
CONTROL LEVER
ONLY)
Contamination is • Check for contamination in the tilt SOL filter.
SOL filter.
During tilt Tilt forward Relief valve main • Check the relief valve main plunger is not
operation speed is slow plunger malfunction. damaged.
contaminated.
pressure.
Tilt control valve • Check the tilt control valve plunger is not
malfunction. damaged.
contaminated.

into the tilt control plunger orifice.
valve plunger orifice
(7).
During tilt Tilt forward Tilt SOL malfunction. • Check the operational sound of the tilt SOL by
operation speed is slow following this procedure. *MASK MENU >
• Check for contamination in the filter.
Tilt spool malfunction. • Check the tilt spool is not damaged.
(FINGERTIP • Check the tilt spool is not contaminated.
CONTROL LEVER
ONLY)
Contamination is stuck • Check for contamination are not in the tilt
in the tilt control valve control valve pilot circuit.
pilot circuit (8).
valve (25) malfunction.
contaminated.
Proportional SOL • Remove the tip pin of proportional SOL and
(FINGERTIP
CONTROL LEVER
ONLY)
Proportional SOL • Check the proportional SOL spool is not 16
spool (23) damaged.
CONTROL LEVER
ONLY)
Contaminations are • Check for contamination in the proportional
circuit (24).
(FINGERTIP
CONTROL LEVER
ONLY)
SOL filter.
Current level setting of • Check current level (30) on the I-Q plate is the
the I-Q plate is same as when shipped. Mask menu > Matching
incorrect. (FINGERTIP menu > OCV > A02X Check the value of X.
CONTROL LEVER
ONLY)

During tilt Cannot tilt Relief valve main • Check the relief valve main plunger. This part is
operation backward plunger is open and removable.
damaged.
contaminated.
pressure.
Tilt spool is closed and • Check the tilt spool. This part is removable.
stuck. • Check the tilt spool is not damaged.
CONTROL LEVER
ONLY)
and stuck.
• Check the load check valve is not damaged.
contaminated.
Proportional SOL • Remove the tip pin of the proportional SPA and
(FINGERTIP
CONTROL LEVER
ONLY)
Proportional SOL • Check the proportional SOL spool. This part is
and stuck.
• Check the proportional SOL spool is not
(FINGERTIP damaged.
CONTROL LEVER
ONLY) • Check the proportional SOL spool is not
contaminated.
Contaminations are • Check the proportional SOL pilot circuit is not
stuck in the contaminated.
circuit (22).
(FINGERTIP
CONTROL LEVER
ONLY)
attached to the tilt
SOL filter.
pilot circuit (8).

During tilt Tilt backward Relief valve main • Check the relief valve main plunger is not
operation speed is slow plunger malfunction. damaged.
contaminated.
pressure.
Tilt spool malfunction. • Check the tilt spool is not damaged.
CONTROL LEVER
ONLY)
contaminated.
(FINGERTIP
CONTROL LEVER
ONLY)
16
spool (21) damaged.
malfunction.
• Check the proportional SOL is not
CONTROL LEVER
ONLY)
circuit (22).
(FINGERTIP
CONTROL LEVER
ONLY)
attached to the tilt
SOL filter.
pilot circuit (8).

During tilt Tilt backward Current level setting • Check the current level (30) on the I-Q plate is
operation speed is slow on the I-Q plate is the same as when shipped. Mask menu >
incorrect. (FINGERTIP Matching menu > OCV > B02X Check the value
CONTROL LEVER of X.
ONLY)
Key switch is Natural drop is Lift lock plunger seat • Check the lift lock plunger seat is not damaged.
OFF large is damaged. • Check the lift lock plunger seat is not
contaminated.
Lift lock plunger is • Check the lift lock plunger. This part is
open and stuck. removable.
• Check the lift lock plunger is not damaged.
Insufficient spring • Check the lift lock plunger spring is not broken.
force is applied by the • Check the seat surface of the spring is not worn
lift lock plunger spring. out.
Lift by-pass check • Check the lift by-pass check valve seat is not
valve seat is damaged.
damaged. • Check the lift by-pass check valve seat is not
contaminated.
Lift by-pass check • Check the lift by-pass check valve plunger. This
valve plunger is open part is removable.
and stuck. • Check the lift by-pass check valve plunger is
not damaged.
• Check the lift by-pass check valve plunger is
not contaminated.
Insufficient spring • Check the lift by-pass check valve spring is not
force is applied by the broken.
lift by-pass check • Check the seat surface of the spring is not worn
valve spring. out.
Manual down valve is • Check the manual down valve is tight.
loose.
Lift lock SOL seat is • Not possible to inspect.
damaged.
Lift lock SOL is open • Check the operational sound of the lift lock SOL
and stuck. by following this procedure. *MASK MENU >

Key switch is Natural tilt Tilt control valve • Check the tilt control valve plunger seat is not
OFF forward is large plunger seat is damaged.
damaged. • Check the tilt control valve plunger seat is not
contaminated.
plunger is open and removable.
damaged.
contaminated.
Insufficient spring • Check the tilt control valve plunger spring is not
tilt control valve • Check the seat surface of the spring is not worn
Insufficient spring • Check spring force by pushing.
force is applied by the
tilt control valve check
ball spring.
Tilt SOL seat is • Not possible to inspect.
damaged.
Tilt SOL is open and • Check the operational sound of the tilt SOL by
stuck. following this procedure. *MASK MENU >
Tilt spool is open and • Check the tilt spool. This part is removable.
stuck. (FINGERTIP • Check the tilt spool is not damaged.
CONTROL LEVER
• Check the tilt spool is not contaminated.
ONLY)
16

Forward tilt Does not stop Tilt control valve • Check the tilt control valve plunger seat is not
automatic automatically plunger seat is damaged.
leveling stop damaged. • Check the tilt control valve plunger seat is not
contaminated.
damaged.
contaminated.
ball spring.
damaged.
Lift spool is open and • Check the lift spool. It is removable.
stuck. (FINGERTIP • Check the lift spool is not damaged.
CONTROL LEVER
• Check the lift spool is not contaminated.
ONLY)
Backward tilting Speed is fast Tilt control valve • Check the tilt control valve plunger is not
speed plunger malfunction. damaged.
regulation • Check the tilt control valve plunger is not
contaminated.
damaged.
contaminated.
Tilt SOL is stuck and • Check the operational sound of the tilt SOL by
closed. operating the lever after the key switch is turned
ON.
• Check the operation sound of the tilt SOL by
following this procedure. *MASK MENU >
pilot circuit (8).

During ATT ATT does not Relief valve main • Check the relief valve main plunger. This part is
operation move plunger is open and removable.
damaged.
contaminated.
pressure.
ATT spool is closed • Check the ATT spool. It is removable.
and stuck. • Check the ATT spool is not damaged.
(FINGERTIP • Check the ATT spool is not contaminated.
CONTROL LEVER
ONLY)
and stuck.
• Check the load check valve is not damaged.
contaminated.
(FINGERTIP
CONTROL LEVER
ONLY)
16
(FINGERTIP damaged.
CONTROL LEVER
ONLY)
contaminated.
circuit (29).
(FINGERTIP
CONTROL LEVER
ONLY)
During ATT ATT movement Relief valve main • Check the relief valve main plunger is not
operation is slow plunger malfunction. damaged.
contaminated.

During ATT ATT movement Too small lap of relief • Check for any damage or contamination on the
operation is slow main plunger. relief main plunger.
pressure.
ATT spool malfunction • Check the ATT spool is not damaged.
(FINGERTIP • Check the ATT spool is not contaminated.
CONTROL LEVER
ONLY)
contaminated.
(FINGERTIP
CONTROL LEVER
ONLY)
spool (28) damaged.
CONTROL LEVER
ONLY)
circuit (29).
(FINGERTIP
CONTROL LEVER
ONLY)
Current level setting • Check the current level (30) on the I-Q plate is
on the I-Q plate is the same as when shipped. Mask menu >
incorrect. (FINGERTIP Matching menu > OCV > A03X, B02X Check the
CONTROL LEVER value of X A03X--A05X, B03X--B05X for multiple
ONLY) attachment.
is damaged.
(FINGERTIP
CONTROL LEVER
ONLY)

During Operator Lifting does not Unload valve (D) is • Check the unload valve (D).
Presence stop closed and stuck.
Sensor Main spool is open • Check the main spool. This part is removable.
operation and stuck. • Check the main spool is not damaged.
(FINGERTIP
• Check the main spool is not contaminated.
CONTROL LEVER
ONLY)
(FINGERTIP
CONTROL LEVER
ONLY)
spool (17) is open and removable.
stuck. (FINGERTIP • Check the proportional SOL spool is not
CONTROL LEVER damaged.
ONLY)
contaminated.
16

During Operator Lowering does Lift lock plunger is • Check the lift lock plunger. This part is
Presence not stop open and stuck. removable.
Sensor • Check the lift lock plunger is not damaged.
operation
Lift lock SOL is open • Check the operational sound of the lift lock SOL
and stuck. by following this procedure. *MASK MENU >
Lift by-pass check • Check the lift by-pass check valve seat is not
valve seat is damaged.
damaged. • Check the lift by-pass check valve seat is not
contaminated.
Lift by-pass check • Check the lift by-pass check valve plunger. This
valve plunger is open part is removable.
and stuck. • Check the lift by-pass check valve plunger is
not damaged.
• Check the lift by-pass check valve plunger is
not contaminated.
Lift lock SOL seat is • Not possible to inspect.
damaged.
Main spool is open • Check the main spool. This part is removable.
and stuck. • Check the main spool is not damaged.
(FINGERTIP
CONTROL LEVER
ONLY)
(FINGERTIP
CONTROL LEVER
ONLY)
ONLY)
contaminated.

During Operator Tilt forward Tilt control valve • Check the tilt control valve plunger seat is not
Presence does not stop plunger seat is damaged.
Sensor damaged. • Check the tilt control valve plunger seat is not
operation contaminated.
damaged.
contaminated.
ball spring.
damaged.
Unload valve (D) is • Check the unload valve (D).
closed and stuck.
(FINGERTIP
CONTROL LEVER
ONLY) 16
(FINGERTIP
CONTROL LEVER
ONLY)
ONLY)
contaminated.

During Operator Tilt backward Unload valve (D) is • Check the unload valve (D).
Presence Sen- does not stop closed and stuck.
sor operation Main spool is open • Check the main spool. This part is removable.
(FINGERTIP
CONTROL LEVER
ONLY)
(FINGERTIP
CONTROL LEVER
ONLY)
ONLY)
contaminated.
ATT does not Unload valve (D) is • Check the unload valve (D).
stop closed and stuck.
(FINGERTIP
CONTROL LEVER
ONLY)
(FINGERTIP
CONTROL LEVER
ONLY)
ONLY)
contaminated.
General Can not Decompression valve • Check the decompression valve piston. This
material operate piston is closed and part is removable.
handling material stuck. • Check the decompression valve piston is not
operation handling damaged.
(FINGERTIP
• Check the decompression valve piston is not
CONTROL
contaminated.
LEVER ONLY)
General All handling Decompression valve • Check the decompression valve piston is not
material moves slow piston malfunction. damaged.
handling
• Check the decompression valve piston is not
operation
contaminated.
(FINGERTIP
CONTROL
LEVER ONLY)

Backward tilt Does not stop Proportional SOL • Check the proportional SOL valve piston. This
automatic automatically valve piston is open part is removable.
leveling stop and stuck. • Check the proportional SOL valve piston is not
(FINGERTIP damaged.
CONTROL
• Check the proportional SOL valve piston is not
LEVER ONLY)
contaminated.
Tilt spool is open and • Check the tilt spool. This part is removable.
stuck. • Check the tilt spool is not damaged.
• Check the tilt spool is not contaminated.
(31)
(3)
(A)
(D)
16
(A) Spring (3) Orifice
(D) Unload valve (31) Priority valve

(20)
(19)
(12)
(6)
(1)
(2)
(14)
(17)
(16)
(5)
(18)
(15)
(6)
(1) Check valve (5) Orifice (12) Load check valve (15) O-ring (17) SOL spool (19) SOL spool
(2) Check valve (6) Seat surface (14) Sleeve (16) O-ring (18) Pilot circuit (20) Pilot circuit
(24)
(23)
(13)
(25)
(25)
16
(21)
(7)
(22)
(8)
(7) Orifice (13) Load check valve (22) Pilot circuit (24) Pilot circuit
(8) Pilot circuit (21) SOL spool (23) SOL spool (25) Check valve
(29)
(28)
(27)
(26)
(28)
(29)
(26) Check valve (27) Load check valve (28) SOL spool (29) Pilot circuit
Hydraulic Circuit diagram
T2 CF LS R1
P1
(12)
b1
a1
S
(4) C1
b2
a2
16
C2
C3
b3
a3
C4
C5
T1 R2
(4) Pilot circuit (12) Load check valve

I-Q plate
(a)
(30)
(a) Plate (30) Current level

17. FINGERTIP CONTROL LEVER 17-957
17. FINGERTIP CONTROL LEVER

17.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957
17.2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 960
17.3. DISASSEMBLY, INSPECTION, AND REASSEMBLY - ARMREST ASSY . . . . 961
17.4. DISASSEMBLY, INSPECTION, AND REASSEMBLY
- DIRECTIONALSWITCH ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 963
17.1. GENERAL
FINGERTIP CONTROL LEVER
Armrest
Lift lever
Tilt lever
Direction switch
17
Lever for fixing rotation

of lever box
Automatic fork leveling switch
17-958 17. FINGERTIP CONTROL LEVER
Lift Lever-Attachment Lever
22.5 to 26° 22.5 to 26°
5 V (1)
PS1 (2)
GND (3)
PS2 (4)
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
17
17.2. REMOVAL·INSTALLATION
T = ft-lbf. (N·m)
4
5
Removal Procedure
2. Remove the counterweight.
3. Disconnect the connectors.
4. Remove the cover.
5. Remove the lever ASSY from the operator’s seat.
Removal Procedure
17.3. DISASSEMBLY·INSPECTION·REASSEMBLY -
ARMREST ASSY
T = ft-lbf (N·m)
4
T = 10.3 (14)
1
T = 26~30 (35~40) 3
5
T = 1.5~3.0 (2.0~4.0)
2 3
3
17
T = 1.5~3.0 (2.0~4.0)
1. Remove the lever for setting the rotation. [Point 1]
2. Remove the rotary damper ASSY.
3. Remove the knob for fixing the 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.
Point Operations
[Point 1]
Installation:
Install the lever for setting rotation so that the dimension
A shown in the illustration on the left becomes 0.12 to
0.24 in. (3 to 6 mm).
The A part moves 0.142 in. (3.6 mm) 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 14.6 to 22.5 lbf. (65 to 100
N).
(3) Press the armrest forward with the force of 22.5 lbf.
(100 N), and check that it does not move. If it
moves, tighten the flange nut further.
(4) Tighten nut A to the specified torque.
T = 10.3 ft-lbf. (14 N·m)
29.3 to 33.7 ft-lbf.(130 to 1050 N)
Nut A
17.4. DISASSEMBLY·INSPECTION·REASSEMBLY -
DIRECTIONAL SWITCH ASSY
y
1
1
4
4
1. Remove the lever cover.
2. Disconnect the connector. [Point 1]
3. Remove each lever ASSY and guide. [Point 2] 17
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.
NOTICE:
Perform matching when the fingertip control lever is
reassembled.
18. PSS FUNCTIONS 18-965
18. PSS FUNCTIONS

18.1. GENERAL (PSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 966
18.2. FOR REPAIR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 969
18.3. TILT ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 970
18.4. LOAD SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 971
18.5. SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 972
18.6. MAST LIFTING HEIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 973
18.7. TIRE ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 973
18.8. MATCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 974
18.9. GENERAL (Operator Presence Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . 978
18.10. CONTROL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 982
18.11. RENEWAL OF PSS CAUTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . 984
18
18-966 18. PSS FUNCTIONS
18.1. GENERAL (PSS)
18.1.1. System configuration

18.1.2. Name and Feature of Each Component

18.1.2.1. Name of Each Component
4,
No. Name No. Name
1 Height switch 10 Forward switch
2 Tilt angle sensor 11 Reverse switch
3 Tilt lever switch *1 12 Vehicle speed sensor *3
4 Tilt lever angle sensor *2 13 Tilt forward lock valve
5 Lift lever angle sensor 14 Tilt backward lock valve *1

18
6 Load sensor 15 Tilt electric proportional valve *2
7 Automatic fork leveling control switch 16 Lift lock valve
8 Tire angle sensor 17 Drive motor *4
9 Accelerator pedal angle sensor 18 Main controller
*1: With Conventional Lever (STD).

*2: With Fingertip Control Lever (OPT).
*3: The lift truck speed is detected by the motor speed sensors via the drive motor driver.
*4: The drive motor is driven by the drive motor driver.
18.1.2.2. Feature of Each Component
No. Name Feature
1 Height switch The limit switch installed on the outer mast detects the height of the inner mast.
Then it is determined whether the lift height is on the lower stage or upper stage
with respect to the specified height.
2 Tilt angle sensor The angle sensor installed on the right tilt cylinder detects the mast tilt angle by
measuring the position of the tilt cylinder considering the rear pin as axis of
rotation.
3 Tilt lever switch *3 The tilt lever switch installed on the oil control valve detects the tilting operation.
4 Lift lever angle sensor The lift lever angle sensor detects lifting operation. It is installed on the oil control
valve on standard models, and in the lever for Fingertip Control Lever models.
5 Load sensor The pressure sensor installed in the hydraulic circuit of the lift detects the load. It
is mounted on the oil control valve.
6 Automatic fork This switch that is installed on the tilt lever is used to automatically level the fork.
leveling control switch
7 Tire angle sensor The sensor installed at the center of the rotational axis of the rear axle detects
the steered angle of the tire.
8 Accelerator pedal This sensor measures the angle of depression of the accelerator pedal. The
angle sensor response to accelerator operation is limited by traveling control.
9 Forward switch The forward switch in the direction lever detects the operation to drive forward.
The direction lever is installed on the left side of the handle post or on the
armrest.
10 Reverse switch The reverse switch in the direction lever detects the operation to drive backward.
The installed location is the same as the forward switch.
11 Vehicle speed sensor The lift truck speed is detected by the motor speed sensors via the drive motor
*1 driver. The motor speed sensors are installed on the drive motor.
12 Tilt forward lock valve The solenoid installed on this valve changes the oil passage of the tilt and stops
tilt forward by switching the applied voltage from the controller.
13 Tilt backward lock The solenoid installed on this valve changes the oil passage of the tilt and stops
valve tilt backward by switching the applied voltage from the controller.
14 Lift lock valve The solenoid installed on this valve interrupts the oil passage from the lift
cylinder to the oil tank and stops the forks lowering by switching the applied
voltage from the controller.
15 Drive motor *2 The drive motor drives the front wheels of the lift truck.
17 Tilt electric Two electric proportional solenoids (forward / backward) on this valve control the
proportional valve *4 tilting angle speed and the direction by controlling the current from the controller.
18 Tilt lever angle sensor On models with Fingertip Control Lever, the tilt lever angle sensor installed in the
*4 lever detects the tilting operation.
*1: The lift truck speed is detected by the motor speed sensors via the drive motor driver.
*3: With Conventional Lever (STD).
*4: With Fingertip Control Lever (OPT).
18.2. FOR REPAIR WORK

Before starting PSS repair, make sure you fully understand the PSS functions.
CAUTION
Always disconnect the battery terminal before the inspection or servicing of electrical parts.
1. Preparation for repair work

(1) Avoid washing the lift truck as much as possible; for cleaning, blow compressed air. If washing with water
is required, avoid water jet washing. Always blow compressed air to remove water after washing.
(2) Transport the controller in a packed state, and keep it packed until installation. Never transport it in an ex-
posed state. Make sure not to drop or apply impact to the controller.
(3) If matching is required after repair, park the lift truck on a flat surface in advance.
(4) Prepare necessary tools, testers (analog tester).
2. During repair work
(1) Never use an impact wrench for removing or installing the main controller. Full care should be taken not
to drop the main controller by mistake. Avoid impact from dropping that may damage parts inside.
(2) Do not turn the key switch to ON or OFF carelessly while the sensor wiring is disconnected. Key switch
ON in this state may cause an error and the error code will be stored in the controller. Error codes cannot be
cleared. When the stored error codes exceed ten, the oldest one is cleared from the controller. Therefore nec-
essary repair information becomes unavailable.
(3) Do not drive the lift truck during matching, as PSS function is disabled.
(4) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(5) When the oil control valve lift lock unlocking bolt is loosened, always tighten it to the specified torque and
return the bolt to the original state after the end of repair.
(6) Tighten the set bolts of respective functional parts to the specified torque.
(7) No adjustment is necessary for each sensor at the time of installation, but make sure to perform matching
after the installation.
(8) When disconnecting a connector, do not pull it at the harness.
(9) When inspecting the harness, make sure to avoid damaging the connector terminals.
(10) Positioning of the low- and high-lifting heights described in the troubleshooting section are as follows.
Classification How to distinguish 18

Low lifting height Fully lowered to height with lifting height switch MH1 (Less than approx. 2 m)
High lifting height Height with lifting height switch MH2-1 (Approx. 2 m or more)
3. Emergency Action
If the mast fails to lower during lowering operation, it
(a) can be lowered manually as follows:
Loosen the manual down valve (a) gradually until the
mast starts to lower. After repair, do not forget to
re-tighten the manual down valve. If forgotten, the lift
speed becomes remarkably delayed.
Tightening torque: T = 23.59 ft-lbf. [32.0 N·m]
18.3. TILT ANGLE SENSOR
1
a
a: T = 5.8 to 13.4 ft·lbf. [7.8 to 18.2 N·m]
Removal Procedure
1. Disconnect the tilt angle sensor link.
2. Remove the toe boards (front and rear).
4. Disconnect the connector.
5. Remove the tilt angle sensor.
NOTICE
• Perform matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is adjusted
in length or replaced. (Refer to PSS section)
• For installation, apply MP grease on sliding section of the end.
• Spread thread locking compound (P/N 990-403) on screw.
• Hold both parts rigidly to avoid damaging end.
18.4. LOAD SENSOR
2
a
a (Load sensor): T = 16.2 to 19.2 ft·lbf. [22 to 26 N·m]
Removal Procedure
1. Disconnect the connector from the load sensor.
2. Remove the load sensor.
18
NOTICE
• When the load sensor is replaced, proceed with the matching procedure. (Refer to Display section)
• Do not use open type tool, in fixing pressure sensor to oil control valve. (Use box type wrench)
18.5. SPEED SENSOR
Removal Procedure
1. Remove the mast ASSY.
2. Remove the toe board.
4. Disconnect the speed sensor connector.
5. Remove the speed sensor.
18.6. MAST LIFTING HEIGHT SWITCH
a: T = 12.0 to 27.9 ft·lbf. (16.2 to 37.8 N·m)

b: T = 5.8 to 13.4 ft·lbf. (7.8 to 18.2 N·m)
Removal Procedure
1. Remove the lower cover.
2. Disconnect the connector.
3. Remove the mast lifting height switch.
The installation procedure is the reverse of the removal procedure. 18
18.7. TIRE ANGLE SENSOR

Refer to the REAR AXLE section for tire angle sensor.
18.8. MATCHING
18.8.1. GENERAL
Each function is controlled by using the sensors and each signal voltage at standard lift truck condition stored in the
controller at the time of shipment. Therefore, a MATCHING (updating of the signal voltage of a sensor at standard
lift truck 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, acceler-
ator 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 lift truck
condition) is necessary.
For the tilt angle, load and tire angle sensors used for PSS functions, the signal voltage values under the mast
vertical, no load, tire straight and lift truck horizontal are stored respectively at the time of shipment, 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 lift truck condition) is necessary. Also, matching is needed for the tilt angle
sensor when the lift truck 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.
Each lever angle sensor for material handling lever function is controlled based on the memory of signal voltage
values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or
replacing related parts, MATCHING (updating the sensor signal voltage value in the standard lift truck condition) is
necessary.
The oil control valve (OCV) for Fingertip Control Lever models activating current level, is set at the factory according
to each oil control valve and stored in the main controller memory. When relevant service or part replacement is
performed, matching must be done.
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
1 ACCEL OFF Accelerator sensor output value with fully released *1, *2
2 ACCEL ON Accelerator sensor output value with fully stepped *1, *2
3 BRAKE OFF Brake sensor output value with fully released brake *1, *16
4 BRAKE ACT Brake sensor output value at the start point of wet-brake *1, *16
activation to the controller.
2. PSS
Prerequisite for
1 TILT LEVEL Tilt angle sensor output value with fork in the horizontal *1, *3, *4, *7, *8, *9
2 TILT FWD LIMIT Tilt angle sensor output value at the mast vertical position *1, *3, *4, *5, *7, *8,
and the load sensor output value without load to the *9
controller.
Prerequisite for
3 TIRE POSITION Tire angle sensor output value while the lift truck is *1, *6
traveling straight to the controller.
4 MAST TYPE The mast type is stored *8, *14
3. LEVER
Prerequisite for
1 LEVER 1 Lift lever angle sensor output value in the lift lever neutral *1, *10
2 LEVER 2 Tilt lever angle sensor output value in the tilt lever neutral *1, *11
3 LEVER 3 Attachment (1) lever angle sensor output value in the *1, *12
controller.
4 LEVER 4 Attachment (2) lever angle sensor output value in the *1, *13
controller.
4. OCV *18
Prerequisite for
No. Indication Description
implementation
A01 Oil control valve A1 activation current level *1, *17

1
B01 Oil control valve B1 activation current level *1, *17

2
B03 Oil control valve B3 activation current level *1, *17 18
5. TIRE DATA
Prerequisite for
1 TIRE DATA The tire data according to the tire size is stored. *1, *15
Prerequisite content for implementation

*1: When replacing the main controller
*2: When removing/installing or replacing the accelerator sensor
*3: When removing/installing or replacement the tilt angle sensor
*4: When length change or replacement of the tilt angle sensor rod
*5: When removing/installing or replacing the load sensor
*6: When removing/installing or replacing the tire angle sensor or the sensor cover
*7: When installing or changing the attachment or forks
*8: When removing/installing or replacing the mast
*9: When removing/installing or replacing the tilt cylinder
*10: When replacing the lift lever angle sensor
*11: When replacing the tilt lever angle sensor
*12: When replacing the attachment (1) lever angle sensor
*13: When replacing the attachment (2) lever angle sensor
*14: When replacing the multi-function display
*15: When the tire size or the type is changed
*16: When removing/installing or replacing the brake sensor
*17: When replacing the oil control valve
*18 Fingertip Control Lever models only
18.8.2. STANDARD STATE OF VEHICLE

If the surface on which matching is to be performed is slanted, error occurs to the standard state. Select a level floor
without irregularity for matching.
NOTICE
The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the floor
inclination to be 0.5° or under. Therefore, matching on these floors is not affected. Do not perform
matching on a floor that is inclined over 0.5° for draining purpose.
[POINT 1]
TT/QM
Fork stop position with automatic leveling and
forward tilting limit position
• Set the lift truck in the following condition so as to
have the tilt angle sensor signal voltage value stored
with the mast held vertical to the floor surface: Load
sensor
No-load standard load
• Set the lift truck in the following condition so as to
100 mm have the load sensor signal voltage value stored
(3.93 in) under no-load condition:
Standard:
• This procedure should be done with all equip-
ment, including forks or attachments, mounted
as specified.
• The lift truck should be with no load on level
ground.
• For TT/QM mast: The rear lift cylinders should
be raised to a height of approximately 3.93 in.
(100 mm).
• Park the lift truck on a level surface. Position the
mast perpendicular to the floor. Press 1 for 2
seconds or more.
• In special cases that the execution of “the other
procedure” is specified, the mast should be
lifted to the top and the hydraulic oil control
valve should be relieved.
Tire straight traveling position check

Signal voltage of the tire angle sensor in tire straight
travel position is stored. Tire straight travel position is
the condition in which driving the lift truck 16 ft. (5 m)
with the steering wheel fixed causes the center of the
lift truck to stay within 2.0 in. (50 mm) to the left and
right of the line. 18
NOTICE
• Keep the forks or attachment installed on the lift truck.
• Set the mast vertical from a backward tilted position (not from the forward tilted position).
• In case of a detachable attachment, keep the attachment installed on the lift truck.
18.8.3. CAUTIONS ON MODIFYING VEHICLES

When replacing the mast
• When the mast is replaced, the mast harness has to be replaced with one suitable for the new lifting
height.
• When placing an order for a mast ASSY, check the need for sensors (lifting height switch, load sensor,
mast harness, and other PSS-replaced parts) and place an order accordingly.
• Make sure to perform matching after replacement. (Refer to Display section)
Other functional parts

• Refer to the oil control valve section for the OCV solenoid 1, 2, backward and forward tilt switch, and tilt
lever knob button.
• For the inspection of functional parts, refer to the troubleshooting section.
18.9. GENERAL (Operator Presence Sensor)
18.9.1. System Configuration
*1: With Conventional Lever (STD)

*2: With Fingertip Control Lever (OPT)
18.9.2. Name and Feature of Each Component

18.9.2.1. Name of Each Component
Conventional Lever Fingertip Control Lever
No. Name No. Name
1 Height switch 12 Tilt forward lock valve
2 Load sensor 13 Tilt backward lock valve *1
3 Seat switch 14 Lift lock valve
4 Accelerator pedal angle sensor 15 Unload valve *1
5 Forward switch 16 Lift electric proportional valve *2
6 Reverse switch 17 Tilt electric proportional valve *2 18

7 Lift lever angle sensor 18 Attachment 1 electric proportional valve *2
8 Tilt lever switch *1 19 Attachment 2 electric proportional valve *2
9 Tilt lever angle sensor *2 20 Multi-function display
10 Attachment 1 lever angle sensor 21 Drive motor
11 Attachment 2 lever angle sensor 22 Main controller
*1 Conventional Lever (STD).

*2 With Fingertip Control Lever (OPT).
18.9.2.2. Feature of Each Component

No. Name Feature
1 Height switch The limit switch installed on the outer mast detects the height of the inner
mast. Then it is determined whether the lift height is on the lower stage or
upper stage with respect to the specified height.
2 Load sensor The pressure sensor installed in the hydraulic circuit of the lift detects the
load.
It is mounted on the oil control valve.
3 Seat switch This limit switch is built into the seat, and detects the operator sitting on
the seat.
4 Accelerator pedal angle The sensor installed on the accelerator pedal unit detects the stepped-on
sensor angle of it.
5 Forward switch The forward switch in the direction lever detects the operation to drive
forward.
The direction lever is installed on the left side of the handle post or on the
armrest.
It is installed on the accelerator pedal unit on the Forward/Reverse Pedal
model.
6 Reverse switch The reverse switch in the direction lever detects the operation to drive
backward.
The installed location is same as the forward switch.
7 Lift lever angle sensor The lift lever angle sensor detects the lift operation.
On standard models it is installed on the oil control valve. On Fingertip
Control Models it is installed in the lever.
8 Tilt lever switch *1 The tilt lever switch installed on the oil control valve detects the tilt
operation.
9 Tilt lever angle sensor *2 On models with Fingertip Control Lever, the tilt lever angle sensor
installed in the lever detects the tilting operation.
10 Attachment 1 lever angle The attachment 1 lever angle sensor detects the operation of the
sensor attachment 1.
11 Attachment 2 lever angle The attachment 2 lever angle sensor detects the operation of the
sensor attachment 2.
12 Tilt forward lock valve The solenoid installed on this valve changes the oil passage of the tilt
and stops tilt forward by switching the applied voltage from the controller.
It is installed on the oil control valve.
13 Tilt backward lock valve *1 The solenoid installed on this valve changes the oil passage of the tilt
and stops tilt backward by switching the applied voltage from the
controller.
14 Lift lock valve The solenoid installed on this valve interrupts the oil passage from the lift
cylinder to the oil tank and stops forks lowering by switching the applied
voltage from the controller.
15 Unload valve *1 This valve bypasses the oil pressure, supplied from the oil pump to the
oil control valve, to the oil tank by switching of the applied voltage from
the controller.
No. Name Feature

16 Lift electric proportional Two electric proportional solenoids (lowering/lifting) on this valve control
valve *2 the lift speed and the direction, by controlling the current from the
controller.
17 Tilt electric proportional Two electric proportional solenoids (forward/backward) on this valve
valve *2 control the tilting angle speed and the direction by controlling the current
from the controller.
18 Attachment 1 electric Two electric proportional solenoids (forward/backward) on this valve
proportional valve *2 control the speed of the attachment 1 and the direction, by controlling the
current from the controller.
19 Attachment 2 electric Two electric proportional solenoids (forward/backward) on this valve
proportional valve *2 control the speed of the attachment 2 and the direction by controlling the
current from the controller.
20 Multi-function display This indicator on the multi-function display is turned on while the seat
Operator Presence Sensor switch is turned off. The onboard buzzer on the multi-function display
indicator Onboard buzzer sounds by the specified pattern when the seat switch is turned off or
“return to neutral warning” is activated.
21 Drive motor *3 In the normal operation, the drive motor drives the front wheels.
When the travel Operator Presence Sensor is activated, the drive motor
acts as the regenerative brake and reduces the freewheeling.
*1 Conventional Lever (STD).

*2 With Fingertip Control Lever (OPT).
18
18.10. CONTROL SPECIFICATION

1. Traveling Operator Presence Sensor Functions
• When the controller detects the seat switch being turned off for 2 seconds, the traveling power is interrupted
by interrupting the voltage supply to the forward and reverse drive valve with control of the forward interrupt
relay and the reverse interrupt relay.
• Travel Operator Presence Sensor is released by returning the direction lever to the neutral position and
turning on the seat switch.
Moreover, the lift truck must be returned to neutral and the accelerator pedal released, if the operator left the
seat when traveling in the forward or reverse direction.
NOTICE
Traveling Operator Presence Sensor is not a brake. Engage the parking brake all the time when leaving the
lift truck.
2. Material Handling Operator Presence Sensor System

• When the controller detects the seat switch has been turned off for 2 seconds, all the load-handling operations
are restricted by the valve control.
• On conventional lever models, the lock valve restricts lowering. The tilt control valve and tilt backward lock
valve restrict tilting. The unload valve shuts off the hydraulic oil supply and restricts lifting and attachment
operations.
• On Fingertip Control Lever models, the electric proportional valves restrict the movements of lift, tilt, and
attachments. At the same time, the lift lock valve and tilt control valve also restricts lowering and tilting.
• On conventional lever models, the hydraulic function Operator Presence Sensor has been released by turning
the lift down lever to the neutral position and turning on the seat switch.
• On Fingertip Control Lever models, the hydraulic function OPS have been released by turning all the levers
to the neutral positions and turning on the seat switch.
3. Operator Presence Sensor operation information function

• When the controller detects that the seat switch is turned off, the buzzer sounds for 1 second and the Operator
Presence Sensor indicator shows up on the display in advance of Operator Presence Sensor activation.
• If the operator notices it and is seated again within 2 seconds, the Operator Presence Sensor will not activate.
In order to know that the Operator Presence Sensor is operating, the Operator Presence Sensor indicator
stays on as long as the seat switch is turned off.
4. Return-to-neutral warning
Traveling
• Once the travel Operator Presence Sensor is activated, the buzzer sounds continuously when the seat switch
is turned on until the direction lever is returned to the neutral position and the accelerator pedal is released.
This sound informs the operator that the lift truck is still in the travel Operator Presence Sensor condition.
Hydraulic function
• On all models, once hydraulic function Operator Presence Sensor is activated, and when the seat switch is
turned on without returning all the hydraulic control levers to the neutral position, the sound informs the oper-
ator that the hydraulic function Operator Presence Sensor is not released.
5. Parking brake OFF warning

• The buzzer sounds when the operator leaves the seat with the parking brake released.
• The buzzer sounds when the operator turns off the key switch with the parking brake released.
18
18.11. RENEWAL OF PSS CAUTION LABEL

The warning instructions on the PSS caption label affixed to each truck must always agree with the PSS features
that particular model owns. You must be very strict about changing the PSS warning label when a modification is
made to your lift truck that changes the PSS system.
Notice that the caution label must be changes in the following cases:
The selective function of the mast Function or Turn Control was switched to either Validation or Invalidation.*
(*See Option Set for the switching method.)
1. Case of Switching “Mast Function” or “Turn Control” Valid / Invalid.”
(1) (2)
Valid Invalid
(1) (2)
(1) (2)
Valid Invalid
(3) (4)
Valid Invalid
(3) (4)
(3) (4)
Valid Invalid
Label (1) has the following PSS features: Label (2) has the following PSS features:
• Turn speed control “VALID”. • Turn speed control “INVALID”.
• Mast tilt forward angle control “VALID”. • Mast tilt forward angle control “VALID”.
Label (3) has the following PSS features: Label (4) has the following PSS features:
• Turn speed control “VALID”. • Turn speed control “INVALID”.
• Mast tilt forward angle control “INVALID”. • Mast tilt forward angle control “INVALID”.
2. Case of Mast Installation for Mast-Less Spec. models.

When you install a mast to a mast-less model, make sure the specification features with the mast assembled.
Take note that the correct caution label must be chosen to be affixed to the lift truck.
The correct label can be found from the labels numbered (1) - (4) in the illustration.
19. APPENDIX 19-985
19. APPENDIX
18.1. SST LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 985
18.2. SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 988
18.3. CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 993
18.4. CONNECTOR DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1006
19.1. SST LIST
Section
Illustration Part No. Part Name 2 3 4 6 7 8 9 10 13 14 16
979-001/157 Puller B set О
extension
tool
979-001/164 Reamer bolt О

remover
979-005/490 Transmission О
and transfer
bearing
replacer
979-005/491 Front axle О
hub inner
bearing
replacer
979-001/168 Front axle О 19
bearing
replacer
979-005/492 Steering О
warm bearing
replacer
979-001/170 Puller О
979-005/502 Tool, parking О

brake
19-986 19. APPENDIX
Section
979-005/494 Tire angle О
sensor set
tool
979-005/495 Oil control О

valve spring
remover and
replacer
979-001/174 Inner mast О О

stopper
979-001/175 Cylinder cap О

remover and
replacer
979-001/173 Deep socket О
979-001/177 Spring pin О О

tool remover
979-001/181 Puller C set О О О
979-001/182 Puller B set О О О
979-001/183 Replacer set О О О
979-001/184 Replacer О
No.2
979-001/185 Handle set О О

19. APPENDIX 19-987
Section
979-005/496 Battery О
hanger
979-005/555 Tube, oil О

level
19
19-988 19. APPENDIX
19.2. SERVICE STANDARDS
19.2.1. BATTERY
Item All models
Specific gravity upon perfect charging 1.280 (at 20°C)
Specific gravity upon end of discharge 1.150 (at 20°C)
Voltage upon end of discharge 36V 32.0
V 48V 42.5
Insulation resistance 1 or more
MΩ
19.2.2. DRIVE MOTOR

Item All models
Stator ASSY insulation resistance Standard: 100 or more
MΩ
Motor cable continuity Standard: 0
Ω
Thermo-sensor resistance Standard: Approx. 11 to 15 (at 20°C)
kΩ
19.2.3. PUMP MOTOR

Item All models
Clearance between the end frame and rpm Standard: 0.43 to 0.50
sensor (10.8 to 12.8)
in. (mm)
Stator ASSY insulation resistance Standard: 100 or more
MΩ
Motor cable continuity Standard: 0
Ω
Thermo-sensor resistance Standard: Approx. 11 to 15 (at 20°C)
kΩ
19.2.4. DRIVE UNIT & FRONT AXLE

Item All models
Hub starting force Standard: 6.12 to 14.1 [27.2 to 62.9]
lbf. [N]
Tightening torque ft·lbf. [N·m]
Gear case set bolt Standard: 73.8 to 108 [100 to 146]
Hub lock nut Standard: Refer to DRIVE UNIT section
19. APPENDIX 19-989
19.2.5. REAR AXLE

Item All models
Rear axle ASSY
Rear axle ASSY starting force Standard: 22.5 to 45.0
lbf. [N] [100 to 200]
Rear Wheel starting force Standard: STD (Cushion): 1.3 to 3.4 [5.8 to 15.2]
lbf. [N] OPT (Pneumatic): 3.3 to 8.8
[15 to 39]
Rear axle cylinder
Rear axle cylinder bore Standard: 2.16 (55.0)
in. (mm) Limit 2.179 (55.35)
Rear axle ASSY lock nut Standard: 7 to 15 [10 to 20]
Rear axle cylinder set bolt Standard: 166 to 273 [265 to 370]
Tire angle sensor set bolt Standard: 1.4 to 1.6 [1.0 to 1.2]
Tire angle sensor cover set bolt Standard: 7.4 to 11.8 [10 to 16]
19.2.6. STEERING
Item All models
Steering wheel play Standard: 0.79 to 1.97 (20 to 50)
in. (mm)
Hydrostatic steering valve ASSY
Relief set pressure Standard: 1624 to 1697 [11.2 to 11.7]
psi [MPa]
Steering wheel set nut Standard: 18.4 to 33.2 [25 to 45]
19.2.7. BRAKE
Item All models
Wet brake 19
Brake disk thickness Standard: 0.138 (3.5)
in. (mm) Limit 0.130 (3.3)
Brake plate wheel thickness Standard: 0.079 (2.0)
in. (mm) Limit 0.071 (1.8)
Brake pedal
Brake pedal height (no pad) Standard: 5.20 to 5.39 (132 to 137)
in. (mm)
Brake pedal play Standard: 0.04 to 0.20 (1 to 5)
in. (mm)
Parking Brake
Parking brake cable set position Standard: 0 to 0.08 (0 to 2)
in. (mm)
Parking brake operating force Standard: Refer to BRAKE section
19-990 19. APPENDIX
19.2.8. FRAME
Item All models
Counterweight
Counterweight set bolt Standard: 236 to 354 [320 to 480]
19.2.9. MATERIAL HANDLING SYSTEM

Item
Natural drop test
Natural drop Limit 1.77 (45)
in. (mm)
Natural forward tilt test
Natural forward tilt 1 ton series Standard: 0.59 (15) or less
in. (mm) 2 ton series Limit 0.79 (20) or less
Oil leak test
Lift cylinder oil leak amount Standard: 8 (0.49) or less
in.3 (cm3)
Tilt cylinder oil leak amount (total for lift and tilt) Standard: 0.98 (16) or less
in.3 (cm3)
19.2.10. MAST
Item
Mast adjustment (QM MAST)
Mast rollers Inner mast roller clearance Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Outer mast roller clearance Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Carriage rollers Middle and lower lift roller clearance Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Side roller clearance Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Mast strip to inner mast clearance Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Mast strip thickness Limit 0.059 (1.5)
in. (mm)
Fork
Fork front end misalignment Limit 0.39 (10)
in. (mm)
Mast support cap set bolt Standard: 63 to 115
[84 to 156]
Back rest set bolt Standard: 89 to 129
[62 to 115]
Chain adjusting nut Standard: Refer to MAST section
19. APPENDIX 19-991
19.2.11. CYLINDER
Item
Rear Lift cylinder (TT)
Piston rod outside diameter Standard: 1.574 (40)
in. (mm) Limit 1.5716 (39.92)
Cylinder bore Standard: 1.77 (45)
in. (mm) Limit 1.7795 (45.2)
Piston rod bend Standard: 0.08 (2.0)
in. (mm)
Rear Lift cylinder (QM)
Piston rod outside diameter Standard: 1.77 (45)
in. (mm) Limit 1.7685 (44.92)
Cylinder bore Standard: 2.17 (55)
in. (mm) Limit 2.1791 (55.35)
Piston rod bend Standard: 0.08 (2.0)
in. (mm)
Front cylinder (TT)
Piston rod outside in. (mm) Standard: 1.654 (42)
diameter Limit 1.650 (41.92)
Cylinder bore in. (mm) Standard: 1.968 (50)
Limit 1.980 (50.3)
Piston rod bend in. (mm) Standard: 0.08 (2.0)
Front cylinder (QM)
Piston rod outside in. (mm) Standard: 2.0 (50.8)
diameter Limit 1.9969 (50.72)
Limit 2.7697 (70.35)
Tilt cylinder
Piston rod outside diameter in. (mm) Standard: 1.1811 (30)
Limit 1.1780 (29.92)
19
Limit 2.7697 (70.35)
Lift cylinder cover Standard: TT: 225 (166) [2290]
QM: 200 to 220 [271 to 298]
Valve Standard: TT: 21.4 to 28.8
[29.0 to 39.0]
QM: 43.5 to 53.9
[59 to 73]
Tilt cylinder piston castle nut Standard: 322 [436]
Tilt cylinder cover Standard: 260 [353]
19-992 19. APPENDIX
19.2.12. OIL PUMP

Item
Oil pump assy
Side plate thickness Limit 0.006 (0.15)
in. (mm)
Gear shaft outside diameter Limit 0.78 (19.85)
in. (mm)
Body inside surface wipe depth Standard: 0.0004 to 0.0024 (0.010 to 0.060)
in. (mm)
19.2.13. OIL CONTROL VALVE

Item
Oil control valve
Relief set pressure Lift Standard: 2494 to 2567
psi [KPa] [17.2 to 17.7]
Tilt Standard: 1987 to 2059
[13.7 to 14.2]
19.2.14. PSS
Item
Tilt angle sensor set bolt Standard: 5.8 to 13.4
[7.8 to 18.2]
Load sensor Standard: 16.2 to 19.2
[22 to 26]
Lifting height switch ASSY set bolt Standard: Refer to PSS section
19. APPENDIX 19-993
19.3. CONNECTOR LOCATION

• FR STAY and MAST
• CABLES
• INSTRUMENT PANEL
• TOE BOARD No.1
• TOE BOARD No.2
• RR BODY No.1
• RR BODY No.2
SYMBOLS WIRE NAME
A BODY MAIN WIRE
B FR STAY WIRE
C TEN KEY WIRE
D BODY SUB NO.1 WIRE
E STOP LAMP SWITCH WIRE
F MAST WIRE
G C/V WIRE
H RR UPR WIRE
I HOOD WIRE (FINGERTIP CONTROL LEVER)
J HOOD SUB WIRE
K DC/DC WIRE
L CLAMP INTERLOCK WIRE
19
19-994 19. APPENDIX
19.3.1. FR STAY and MAST

19. APPENDIX 19-995
㻯㻺㻝㻠㻲㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻝㻢㻴㻱㻭㻰㻌㻸㻭㻹㻼
㻯㻺㻢㻞㻯㻻㻹㻼㻭㻾㼀㻹㻱㻺㼀㻌㻸㻵㻳㻴㼀㻌㻿㼃
㻯㻺㻢㻟㻯㻻㻹㻼㻭㻾㼀㻹㻱㻺㼀㻌㻸㻵㻳㻴㼀
㻯㻺㻥㻜㻹㻭㻿㼀㻌
㻯㻺㻥㻞㻴㻱㻵㻳㻴㼀㻌㻿㼃
㻯㻺㻥㻥㻯㻸㻭㻹㻼㻌㻸㻻㻯㻷㻌㼂㻭㻸㼂㻱
㻯㻺㻝㻣㻞㻲㻾㻌㻿㼀㻭㼅㻌㻌㻾㻴㻝
㻯㻺㻝㻣㻟㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴㻞
㻯㻺㻝㻣㻠㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻝
㻯㻺㻝㻣㻡㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻞
㻯㻺㻝㻣㻥㻵㻺㼀㻱㻾㻸㻻㻯㻷㻌㻿㻻㻸
㻯㻺㻞㻠㻠㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴
19
19-996 19. APPENDIX
19.3.2. CABLES
㻯㻭㻮㻸㻱㻿
REFER TO RR BODY No.2
REFER TO TOE BOARD No.2

19. APPENDIX 19-997
19.3.3. INSTRUMENT PANEL
㻵㻺㻿㼀㻾㼁㻹㻱㻺㼀㻌㻼㻭㻺㻱㻸㻭㻮㻻㻰㼅㻌㻹㻭㻵㻺㻌㼃㻵㻾㻱㻯㼀㻱㻺㻌㻷㻱㼅㻌㼃㻵㻾㻱

FINGERTIP CONTROL LEVER
㻖㻝㻌㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻛㻶㻻㼅㻌㻿㼀㻵㻯㻷㻰㻮㻻㻰㼅㻌㻿㼁㻮㻌㻺㻻㻚㻝㻌㼃㻵㻾㻱㻱㻿㼀㻻㻼㻌㻸㻭㻹㻼㻌㻿㼃㻵㼀㻯㻴㻌㼃㻵㻾㻱
㻖㻞㻌㻯㻻㼃㻸㻌㻸㻱㼂㻱㻾
㻯㻺㻝㻥㻯㻺㻣
㻯㻺㻠
㻯㻺㻟
㻯㻺㻤㻤㻖㻞㻯㻺㻟㻟
㻯㻺㻝㻜㻯㻺㻟㻜
㻯㻺㻝㻝㻣㻖㻞
㻯㻺㻤㻡
㻯㻺㻞㻝㻟㻖㻞
㻯㻺㻝㻣㻜
㻖㻞㻯㻺㻠㻢
㻯㻺㻥㻤
㻯㻯㻺㻝㻣㻤
㻯㻺㻝㻣㻡
㻯㻺㻝㻠㻢
㻯㻺㻝㻣㻠㻯㻺㻞㻠㻠
㻯㻺㻝㻡㻯㻺㻞㻥㻱㻯㻺㻝㻣㻞

㻯㻺㻝㻣㻢
㻯㻺㻝㻣㻟
㻯㻺㻡
㻯㻺㻝㻞
㻰
㻯㻺㻠㻣
㻯㻺㻞㻝
㻯㻺㻞㻞㻯㻺㻝㻣㻣
㻯㻺㻤㻥
㻭
㻯㻺㻣㻜
19
[FINGERTIP CONTROL LEVER]
㼇㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻛㻶㻻㼅㻌㻿㼀㻵㻯㻷㼉㼇㼃㻛㻻㻌㻱㻹㻱㻾㻳㻱㻺㻯㼅㻌㻿㼃㼉
㻯㻺㻤㻤㻖㻝
㻯㻺㻤㻣㻖㻝
㻯㻺㻟㻜㻝㻯㻺㻝㻣㻢
㻯㻺㻣㻤㻖㻝
19-998 19. APPENDIX
㻯㻺㻟㻴㻻㻾㻺㻌㻿㼃㻯㻺㻝㻣㻠㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻝
㻯㻺㻠㻷㻱㼅㻌㻿㼃㻯㻺㻝㻣㻡㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻞
㻯㻺㻡㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻯㻺㻝㻣㻢㻱㻹㻱㻾㻳㻱㻺㻯㼅㻌㻿㼃
㻯㻺㻣㼀㼁㻾㻺㻒㻸㼀㻌㻿㼃㻔㻸㻴㻌㻰㻵㻾㻕㻯㻺㻝㻣㻣㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴
㻯㻺㻝㻜㻰㻵㻾㻱㻯㼀㻵㻻㻺㻌㻿㼃㻔㻸㻴㻌㻰㻵㻾㻕㻯㻺㻝㻣㻤㼀㻱㻺㻌㻷㻱㼅
㻯㻺㻝㻞㻲㻸㻭㻿㻴㻱㻾㻌㻾㻱㻸㻭㼅㻯㻺㻞㻝㻟㻵㻺㼀㻱㻾㻸㻻㻯㻷㻌㻾㻸㼅㻌㻔㻯㻻㼃㻸㻕
㻯㻺㻝㻡㻼㻷㻮㻌㻿㼃㻯㻺㻞㻠㻠㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴
㻯㻺㻝㻥㻿㼀㻱㻱㻾㻵㻺㻳㻌㻿㻿㻾㻯㻺㻟㻜㻝㻿㻴㻻㻾㼀㻌㻯㻻㻺㻺
㻯㻺㻞㻝㻴㻻㻾㻺㻌㻗
㻯㻺㻞㻞㻴㻻㻾㻺㻌㻙
㻯㻺㻞㻥㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻔㻗㻕
㻯㻺㻟㻜㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻔㻙㻕
㻯㻺㻟㻟㼀㻱㻺㻌㻷㻱㼅
㻯㻺㻠㻢㼀㻭㻵㻸㻌㻸㻼㻌㻾㻱㻸㻭㼅
㻯㻺㻠㻣㻰㻵㻭㻳㻺㻻㻿㻵㻿
㻯㻺㻣㻜㻰㻵㻿㻼㻸㻭㼅
㻯㻺㻣㻤㻯㻛㼂㻌㻼㼁㻸㻸㻌㻿㻻㻸㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻤㻡㻺㼀㻾㻸㻌㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻤㻢㼀㻵㻸㼀㻌㻭㻺㻳㻌㻿㻿㻾
㻯㻺㻤㻣㻯㻛㼂㻌㻼㼁㻿㻴㻌㻿㻻㻸㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻤㻤㻯㻛㼂㻌㻿㻻㻸
㻯㻺㻤㻥㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻥㻤㻿㼀㻱㻱㻾㻵㻺㻳㻌㻿㻻㻸
㻯㻺㻝㻝㻣㻯㻛㼂㻌㻿㻿㻾㻌㻿㼁㻮
㻯㻺㻝㻠㻢㻝㻞㼂㻌㻼㼃㻾㻌㻿㼁㻼㻼㻸㼅
㻯㻺㻝㻣㻜㻭㼀㼀㻌㻭㻯㼀㻌㻿㼃㻌㻔㻯㻻㼃㻸㻕
㻯㻺㻝㻣㻞㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴㻝
㻯㻺㻝㻣㻟㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴㻞
19. APPENDIX 19-999
19.3.4. TOE BOARD No.1
㼀㻻㻱㻌㻮㻻㻭㻾㻰㻌㻺㼛㻚㻝㻭㻮㻻㻰㼅㻌㻹㻭㻵㻺㻌㼃㻵㻾㻱㻳㻯㻛㼂㻌㼃㻵㻾㻱
㻯㻺㻝㻝㻡
㻯㻺㻢㻯㻺㻝㻝㻣
㻯㻺㻡㻢㻳
㻯㻺㻥㻝㻯㻺㻝㻝㻥
㻯㻺㻞㻢
㻯㻺㻝㻟㻟
㻯㻺㻝㻞㻜
㻯㻺㻤㻢
㻯㻺㻝㻞㻟
㻯㻺㻝㻝㻤
㻯㻺㻡㻡㻯㻺㻝㻞㻝㻯㻺㻝㻞㻞
㻯㻺㻡㻠
㻭
㻯㻺㻥㻜
㻯㻺㻡㻟
㻯㻺㻡㻞㻯㻺㻝㻣㻥
㻯㻺㻝㻤㻟
19
19-1000 19. APPENDIX
㻯㻺㻢㻮㻾㻭㻷㻱㻌㻿㻿㻾
㻯㻺㻞㻢㻭㻯㻯㻱㻸㻌㻿㻿㻾
㻯㻺㻡㻞㻰㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾㻌㻾㻴
㻯㻺㻡㻟㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻝㻌㻾㻴
㻯㻺㻡㻠㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻞㻌㻾㻴
㻯㻺㻡㻡㻼㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾
㻯㻺㻡㻢㻼㻹㻌㻿㻼㻰㻌㻿㻿㻾
㻯㻺㻤㻢㼀㻵㻸㼀㻌㻭㻺㻳㻌㻿㻿㻾
㻯㻺㻥㻜㻹㻭㻿㼀㻌㻿㻿㻾
㻯㻺㻥㻝㻼㻾㻱㻿㻿㻌㻿㻿㻾
㻯㻺㻝㻝㻡㻸㻵㻲㼀㻌㻸㼂㻾
㻯㻺㻝㻝㻣㻯㻛㼂㻌㻿㻿㻾㻌㻿㼁㻮
㻯㻺㻝㻝㻤㻹㻻㼀㻻㻾㻌㻲㻭㻺
㻯㻺㻝㻝㻥㻭㼀㼀㻝㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻞㻜㻭㼀㼀㻞㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻞㻝㻰㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾㻌㻸㻴
㻯㻺㻝㻞㻞㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻝㻌㻸㻴
㻯㻺㻝㻞㻟㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻞㻌㻸㻴
㻯㻺㻝㻟㻟 FINGERTIP
㻱㼆㻌㻼㻱㻰㻭㻸 CONTROL LEVER
㻯㻺㻝㻣㻥㻵㻺㼀㻱㻾㻸㻻㻯㻷㻌㻿㻻㻸
㻯㻺㻝㻤㻟㼀㻱㻸㻱㻹㻭㼀㻵㻯㻿
19. APPENDIX 19-1001
19.3.5. TOE BOARD No.2
㼀㻻㻱㻌㻮㻻㻭㻾㻰㻌㻺㼛㻚㻞
㻯
㻮
㼂㻵㻱㼃㻌㻭
㼁㼃
㼂㼂
㼃㼁
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻸㻴㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻾㻴
㼂㻵㻱㼃㻌㻮㼂㻵㻱㼃㻌㻯
㼂
19
㼃
㻼㼁㻹㻼㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻯㻻㻺㻺㻱㻯㼀㻻㻾㻌㻯㻭㻮㻸㻱
19.3.6. RR BODY No.1
[FINGERTIP CONTROL
[MINI LEVER LEVER]
/ JOY STICK LEVER]
㻾㻾㻮㻻㻰㼅㻌㻺㼛㻚㻝 A BODY MAIN WIRE
㻯㻺㻝㻢㻝㻯㻺㻝㻣㻜
H RR UPR WIRE
㻯㻺㻝㻢㻡
HOOD WIRE
I HOOD WIRE(MINI LEVER) 㻯㻺㻝㻢㻢
[FINGERTIP CONTROL LEVER]
㻯㻺㻝㻢㻞
J HOOD SUB WIRE
*1 L/LED
*2 LED 㻯㻺㻝㻢㻟
㻯㻺㻝㻣㻝
㻯㻺㻝㻢㻠
㻯㻺㻟㻝 *2
㻯㻺㻝㻤㻡
㻯㻺㻟㻢
㻯㻺㻟㻝 *1 㼍
㻯㻺㻟㻠 *1 I
㻯㻺㻟㻠 *2
㻯㻺㻡㻤
㻯㻺㻣㻟
㻯㻺㻟㻞
㻯㻺㻝㻞㻡 H
㻯㻺㻟㻤
㼍
㻯㻺㻠㻟
㻯㻺㻠㻠
㻯㻺㻟㻣
㻯㻺㻣㻡
㻯㻺㻣㻢㻯㻺㻞㻟
㼎
㻯㻺㻞㻠㻢
㻯㻺㻣㻣
㻯㻺㻞㻟㻣
㻯㻺㻝㻝㻞
㻯㻺㻞㻠㻯㻺㻞㻟㻤
㻯㻺㻥㻣㻯㻺㻞㻡㻜
㻯㻺㻞㻝㻣
A 㻯㻺㻝㻝㻟
㻯㻺㻞㻝㻞㼎
㻯㻺㻞㻜㻤
㻯㻺㻠㻜
㻯㻺㻞㻜㻣
㻯㻺㻞㻝㻜
㻯㻺㻞㻝㻝
㻯㻺㻞㻟㻮㻭㻯㻷㻌㻮㼁㼆㼆㻱㻾
㻯㻺㻞㻠㻲㼃㻰㻌㻯㻴㻵㻹㻱
㻯㻺㻟㻝㻾㻾㻌㻯㻻㻹㻮㻵㻌㻸㻴㻌㻛㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵㻌㻸㻴
㻯㻺㻟㻞㻾㻾㻌㻴㻻㻾㻺㻌㻿㼃
㻯㻺㻟㻠㻾㻾㻌㻯㻻㻹㻮㻵㻌㻾㻴㻌㻛㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵㻌㻾㻴
㻯㻺㻟㻢㻿㻹㻭㻾㼀㻌㻭㻸㻭㻾㻹
㻯㻺㻟㻣㻾㻾㻌㼁㻼㻾㻌㻹㻭㻵㻺
㻯㻺㻟㻤㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻠㻜㻴㻻㻾㻺㻾㻱㻸㻭㼅
㻯㻺㻠㻟㻴㻻㻻㻰㻌㻿㼁㻮
㻯㻺㻠㻠㻿㻱㻭㼀㻌㻿㼃
㻯㻺㻡㻤㻿㼀㻾㻻㻮㻱㻌㻸㻭㻹㻼
㻯㻺㻣㻟㼃㻻㻾㻷㻵㻺㻳㻌㻸㻭㻹㻼㻌㻿㼃
㻯㻺㻣㻡㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻣㻢㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕㻌
㻯㻺㻣㻣㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕㻌
㻯㻺㻥㻣㼀㻵㻾㻱㻌㻭㻺㻳㻸㻱㻌㻿㻿㻾
㻯㻺㻝㻝㻞㻵㻺㼂㻌㻲㻭㻺㻝
㻯㻺㻝㻝㻟㻵㻺㼂㻌㻲㻭㻺㻞
㻯㻺㻝㻞㻡㼃㻻㻾㻷㻵㻺㻳㻌㻸㻼
㻯㻺㻝㻢㻝㻺㼀㻾㻸㻌㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻝㻢㻞㻸㻵㻲㼀㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻟㼀㻵㻸㼀㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻠㻭㼀㼀㻝㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻡㻭㼀㼀㻞㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻢㻰㻵㻾㻱㻯㼀㻵㻻㻺㻌㻿㼃㻔㻭㻾㻹㻰㻵㻾㻕
㻯㻺㻝㻣㻜㻭㼀㼀㻌㻭㻯㼀㻌㻿㼃㻔㻹㻵㻺㻵㻕
㻯㻺㻝㻣㻝㻭㻾㻹㻾㻱㻿㼀㻌㻴㻻㻾㻺㻌㻿㼃
㻯㻺㻝㻤㻡㻮㻸㼁㻱㻌㻸㻵㻳㻴㼀 19
㻯㻺㻞㻜㻣㻷㻱㼅㻌㻻㻲㻲㻌㻴㻛㻸㻌㻾㻸㼅
㻯㻺㻞㻜㻤㻿㻻㻸㻵㻰㻌㻿㼀㻭㼀㻱㻌㻾㻸㼅㻌㻝
㻯㻺㻞㻝㻜㻴㻱㻭㻰㻌㻸㻼㻌㻾㻸㼅
㻯㻺㻞㻝㻝㻴㻱㻭㻰㻌㻸㻼㻌㻾㻸㼅㻌㻸㻴
㻯㻺㻞㻝㻞㻭㻯㻯㻱㻿㻿㻻㻾㼅㻌㻾㻱㻸㻭㼅
㻯㻺㻞㻝㻣㻿㼁㻾㻳㻱㻌㻷㻵㻸㻸㻱㻾
㻯㻺㻞㻟㻣㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻞㻟㻤㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻞㻠㻢㻝㻞㼂㻌㻼㻻㼃㻱㻾㻌㻿㼁㻼㻼㻸㼅
㻯㻺㻞㻡㻜㻲㼁㻿㻱㻌㻴㻻㻸㻰㻱㻾
19.3.7. RR BODY No.2
㻾㻾㻮㻻㻰㼅㻌㻺㼛㻚㻞 A BODY MAIN WIRE K DC/DC WIRE
㻯㻻㻺㻺㻱㻯㼀㻻㻾㻌㻯㻭㻮㻸㻱㻯㻺㻝㻜㻝
㻯㻺㻝㻜㻞
㻯㻺㻞㻜
㻯㻺㻝㻠㻥㻯㻺㻝㻜㻟
K
㻯㻺㻝㻝㻜㻯㻺㻝㻜㻥
㻯㻺㻝㻝㻝
㻯㻺㻝㻜㻠
N2 N2 N2
WR WL W
VR VL V
UR UL 㻯㻺㻝㻠㻤 U
P4
P1 㻯㻺㻞㻜㻜
㻯㻺㻞㻜㻝
㻯㻺㻝㻞㻣㻯㻺㻝㻠㻠
㻯㻺㻝㻞㻥
㻯㻺㻞㻜㻥㻯㻺㻝㻠㻣
A 㻯㻺㻝㻟㻢㻯㻺㻝㻟㻤㻯㻺㻞㻜㻟
㻯㻺㻝㻟㻜
㻯㻺㻝㻟㻣㻯㻺㻞㻜㻞
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻾㻴
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻸㻴㻼㼁㻹㻼㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱
㻯㻺㻞㻜㻱㻭㻾㼀㻴
㻯㻺㻝㻜㻝㻯㻼㼁㻌㻝
㻯㻺㻝㻜㻞㻯㻼㼁㻌㻞
㻯㻺㻝㻜㻟㻯㻼㼁㻌㻟
㻯㻺㻝㻜㻠㻯㻼㼁㻠
㻯㻺㻝㻜㻥㻰㻾㻵㼂㻱㻌㻵㻺㼂㻌㻸㻴
㻯㻺㻝㻝㻜㻰㻾㻵㼂㻱㻌㻵㻺㼂㻌㻾㻴
㻯㻺㻝㻝㻝㻼㼁㻹㻼㻵㻺㼂
㻯㻺㻝㻞㻣㻹㻵㻺㻵㻸㻱㼂㻱㻾㻌㻿㻻㻸㻌㻾㻸㼅
㻯㻺㻝㻞㻥㻵㻹㻼㻭㻯㼀㻌㻿㻿㻾㻌㻝
㻯㻺㻝㻟㻜㻵㻹㻼㻭㻯㼀㻌㻿㻿㻾㻌㻞
㻯㻺㻝㻟㻢㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻝
㻯㻺㻝㻟㻣㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻞
㻯㻺㻝㻟㻤㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻟
㻯㻺㻝㻠㻠㻰㻯㻛㻰㻯
㻯㻺㻝㻠㻣㻰㻯㻛㻰㻯
㻯㻺㻝㻠㻤㻼㻠
㻯㻺㻝㻠㻥㻺㻞
㻯㻺㻞㻜㻜㻯㻭㻺㻌㻶㻛㻯㻌㻝
㻯㻺㻞㻜㻝㻯㻭㻺㻌㻶㻛㻯㻌㻞
㻯㻺㻞㻜㻞㻯㻭㻺㻌㻶㻛㻯㻌㻟
㻯㻺㻞㻜㻟㻯㻭㻺㻌㻶㻛㻯㻌㻠
㻯㻺㻞㻜㻥㻿㻻㻸㻵㻰㻌㻿㼀㻭㼀㻱㻌㻾㻱㻸㻭㼅㻌㻞
19
19.4. CONNECTOR DRAWING
CN3 HORN SW
CN7 TURN&LT SW (LH DIR)
1 1 6 5 4 3 2 1 1 2 3 4 5 6
2 2 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14
TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 118 - HO+ 1 118 L-Y J2 1 - - - 1 - - -
2 N2 - HO- 2 N2 W-B J10 2 - - - 2 - - -
3 - - - 3 - - -
CN4 KEY SW
4 - - - 4 - - -
5 - - - 5 - - -
2 1 1 2
6 - - - 6 - - -
4 3 3 4
7 116 - BT 7 116 LG CN46-3
TAB REC 8 115 - BH 8 115 P J28
NO P C J NO P C J 9 N2 - T 9 N2 W-B J7
1 41 - AM 1 41 G J5 10 - - - 10 - - -
2 - - - 2 - - - 11 N2 - EL 11 N2 W-B J7
3 - - - 3 - - - 12 109 - TL 12 109 G-Y J26
4 43 - IG 4 43 B-Y J3 13 110 - TB 13 110 L-O CN12-2

14 108 - TR 14 108 R-Y J24
CN5 STOP LP SW
CN10 DIRECTION SW (LH DIR)
2 1 1 2
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
TAB REC
NO P C J NO P C J TAB REC
1 111 Y SWST(COM) 1 111 R-L CN37-6 NO P C J NO P C J
2 490 B-Y SWST(NC) 2 490 GR-R CN250-12 1 - - - 1 - - -
CN6 BRAKE SSR

2 103 - DSBU 2 103 R-W CN23-1
3 120 - DSFO 3 120 Y-R CN24-1
6 5 4 3 2 1 1 2 3 4 5 6 4 46 - DSR 4 46 B-O CN104-19

5 45 - DSF 5 45 GR-R CN104-26
6 51 - LS- 6 51 BR J14
TAB REC
7 495 - VBKY 7 495 B-Y J15
NO P C J NO P C J
8 495 - VBKY 8 495 B-Y J15
1 74 - VRB2+ 1 74 BR-R CN101-33
9 - - - 9 - - -
2 51 - POT- 2 51 G J9
10 - - - 10 - - -
3 73 - VRB2 3 73 Y-R CN102-25
11 - - - 11 - - -
4 71 - VRB1 4 71 Y-B CN102-33
12 - - - 12 - - -
5 72 - VRB1+ 5 72 L-O CN101-34
13 - - - 13 - - -
6 50 - VRA- 6 50 B-O J18
14 - - - 14 - - -
15 - - - 15 - - -
16 - - - 16 - - -
17 - - - 17 - - -
18 - - - 18 - - -
CN12 FLASHER RELAY CN19 STEERING SSR
2 1 1 2 2 1 1 2
4 3 3 4 3 4 5 6
6 5 4 3
TAB REC
1 N2 - FRY- 1 N2 W-B J10 NO P C J NO P C J
2 110 - FRY 2 110 L-O CN7-13 1 311 - SSTR+ 1 311 P-L CN103-13
3 - - - 3 - - - 2 51 - LS- 2 51 B J19
4 494 - FRY+ 4 494 B-Y CN250-10 3 312 - SSTR1 3 312 B-Y CN104-30
4 313 - SSTR2 4 313 L-W CN104-31
CN14 FR COMBI 5 314 - SSTRC 5 314 G-Y CN104-24
6 - - - 6 - - -
2 1 1 2
4 3 3 4 CN23 BACK BUZZER
TAB REC 1 1
NO P C J NO P C J 2 2
1 108 - LF+ 1 108 R-Y CN172-2
2 N2 - LF- 2 N2 W-B CN173-2 TAB REC
3 N2 - LC- 3 N2 W-B CN173-3 NO P C J NO P C J
4 104 - LC+ 4 104 G-R CN173-1 1 103 - BZ+ 1 103 R-W CN10-2,37-4,75-6,208-4
2 N2 - BZ- 2 N2 W-B J8
CN15 PKB SW
CN24 FWD CHIME
3 2 1 1 2 3
1 1
2 2
TAB REC
1 66 R NO 1 66 G-W CN177-1 NO P C J NO P C J
2 - - - 2 - - - 1 120 - CHI+ 1 120 Y-R CN10-3,75-2
3 51 B COM 3 51 B CN177-5 2 N2 - CHI- 2 N2 W-B J8
CN16 HEAD LAMP CN26 ACCEL SSR
2 1 1 2 6 5 4 3 2 1 1 2 3 4 5 6
TAB REC TAB REC

1 102 - LH+ 1 102 R-G CN172-1 1 55 - VRA2+ 1 55 GR-R CN101-26
2 N2 - LH- 2 N2 W-B CN172-3 2 51 - POT- 2 51 G J9 19

3 54 - VRA2 3 54 BR-Y CN102-32
CN16 HEAD LAMP (LED)
4 52 - VRA1 4 52 BR-R CN102-30
5 53 - VRA1+ 5 53 BR-W CN101-27
2 1 1 2 6 50 - VRA- 6 50 B-O J18
TAB REC
NO P C J NO P C J
1 102 - LH+ 1 102 R-G CN172-1
2 N2 - LH- 2 N2 W-B CN172-3
CN31 RR COMBI LH CN33 TEN KEY
3 2 1 1 2 3
5 4 3 2 1 1 2 3 4 5
6 5 4 4 5 6
10 9 8 7 6 6 7 8 9 10
TAB REC
NO P C J NO P C J
1 104 - TL 1 104 G-R J49 TAB REC
2 - - - 2 - - - NO P C J NO P C J
3 111 - STL+ 3 111 R-L J45 1 160 - ITKY1 1 160 B-Y CN178-5
4 - - - 4 - - - 2 161 - ITKY2 2 161 R-B CN178-4
5 109 - TRN 5 109 G-Y CN37-9 3 162 - ITKY3 3 162 G CN178-3
6 N2 - E 6 N2 W-B J46 4 165 - OTKY2 4 165 R-Y CN178-2
5 167 - LEDTKY1 5 167 G-Y CN178-1
CN31 LED RR COMBI LH
6 163 - IPSTKY1 6 163 W-L CN178-10
7 169 - TGND 7 169 GR-R CN178-9
8 164 - OTKY1 8 164 L-O CN178-8
2 1 1 2 9 166 - OTKY3 9 166 GR-L CN178-7
10 168 - LEDTKY2 10 168 L-B CN178-6
4 3 3 4
CN34 RR COMBI RH
6 5 5 6
3 2 1 1 2 3
6 5 4 4 5 6
TAB REC
NO P C J NO P C J
TAB REC
1 203 - DSBU 1 203 W-B J48 NO P C J NO P C J
2 211 - STL+ 2 211 R-L J45 1 104 - TL 1 104 G-R J49
3 204 - TL 3 204 G-R J49 2 - - - 2 - - -
4 - - - 4 - - - 3 111 - STL+ 3 111 R-L J45
5 209 - TRN 5 209 G-Y CN37-9 4 103 - DSBU 4 103 R-W J48
6 N2 - E 6 N2 W-B J46 5 108 - TRN 5 108 R-Y CN37-8
6 N2 - E 6 N2 W-B J46
CN32 RR HORN SW
CN34 LED RR COMBI RH
2 1 1 2
2 1 1 2
TAB REC
NO P C J NO P C J
4 3 3 4
1 N2 W-B J46 1 N2 W-B HRS-
2 118 L-Y CN37-5 2 118 L-Y HRS+
6 5 5 6
TAB REC
NO P C J NO P C J
1 203 - DSBU 1 203 R-W J48
2 211 - STL+ 2 211 R-L J45
3 204 - TL 3 204 G-R J49
4 - - - 4 - - -
5 208 - TRN 5 208 R-Y CN37-8
6 N2 - E 6 N2 W-B J46
CN36 SMART ALARM CN37 DC/DC FOR LED RR COMBI CN38

2 1 1 2
TAB REC 5 4 3 2 1 1 2 3 4 5
NO P C J NO P C J
1 103 - BZ+ 1 103 R-W J48,CN37-3 10 9 8 7 6 6 7 8 9 10
2 N2 - BZ- 2 N2 W-B J46
CN37 RR UPR MAIN
TAB REC
NO P C J NO P C J
1 101 L CN73-1 1 101 L CN37-1
5 4 3 2 1 1 2 3 4 5
2 493 B-Y J47 2 493 B-Y CN37-2
10 9 8 7 6 6 7 8 9 10 3 198 R-W CN36-1 3 198 R-W CN37-3,J56

4 203 R-W J48 4 203 R-W CN238-1
5 118 L-Y CN32-2 5 118 L-Y CN37-5
6 211 R-L J45 6 211 R-L CN238-2
7 204 G-R J49 7 204 G-R CN238-3
TAB REC
NO P C J NO P C J 8 208 R-Y CN34-5 8 208 R-Y CN238-5
1 101 L CN73-1 1 101 L J16 9 209 G-Y CN31-5 9 209 G-Y CN238-4
2 493 B-Y J47 2 493 B-Y J27 10 N2 W-B J46 10 N2 W-B CN238-6
3 198 R-W CN36-1 3 198 R-W CN208-4

CN40 HORN RELAY
4 103 R-W J48 4 103 R-W CN23-1
5 118 L-Y CN32-2 5 118 L-Y J2 2 1 1 2
6 111 R-L J45 6 111 R-L CN5-1 4 3 3 4
7 104 G-R J49 7 104 G-R J25
8 108 R-Y CN34-5 8 108 R-Y J24 TAB REC
9 109 G-Y CN31-5 9 109 G-Y J26 NO P C J NO P C J
10 N2 W-B J46 10 N2 W-B J8 1 491 - COIL+ 1 491 G-B CN250-2

2 41 - SW+ 2 41 G-R J11
CN37 DC/DC FOR LED RR COMBI 3 118 - COIL- 3 118 L-Y J2
4 48 - SW- 4 48 L-O J20
CN43 HOOD
5 4 3 2 1 1 2 3 4 5
2 1 1 2
10 9 8 7 6 6 7 8 9 10
NO P C
TAB
J NO P C
REC
J
19
TAB REC 1 67 L-O CN104-18 1 67 L-O CN44-2
NO P C J NO P C J
2 51 BR J14 2 51 BR CN44-1
1 101 L CN38-1 1 101 L J16
2 493 B-Y CN38-2 2 493 B-Y J27 CN44 SEAT SW
3 198 R-W CN38-3 3 198 R-W CN208-4

2 1 1 2
4 103 R-W CN237-1 4 103 R-W CN23-1
5 118 L-Y CN38-5 5 118 L-Y J2 TAB REC
6 111 R-L CN237-2 6 111 R-L CN5-1 NO P C J NO P C J
7 104 G-R CN237-3 7 104 G-R J25 1 51 - SDM- 1 51 BR CN43-2
8 108 R-Y CN237-5 8 108 R-Y J24 2 67 - SDM+ 2 67 L-O CN43-1
9 109 G-Y CN237-4 9 109 G-Y J26
10 N2 W-B CN237-6 10 N2 W-B J8
CN46 TAIL LP RELAY CN53 DM SPD SSR1 RH
2 1 1 2
2 1 1 2
4 3 3 4
TAB REC
1 117 - COIL+ 1 117 GR CN211-1 NO P C J NO P C J
2 487 - SW+ 2 487 L-Y CN250-20 1 76 - SSDR1 1 76 Y CN110-14
3 116 - COIL- 3 116 LG CN7-7 2 75 - SSDR+ 2 75 L CN202-3
4 104 - SW- 4 104 G-R J25
CN47 DIAGNOSIS
1 2 3 4 5 6
6 5 4 3 2 1 CN54 DM SPD SSR2 RH
7 8 9 10 11
11 10 9 8 7
12 13 14 15 16 17 2 1 1 2
17 16 15 14 13 12
TAB REC TAB REC

NO P C J NO P C J
NO P C J NO P C J
1 - - - 1 - - -
1 77 - SSDR2 1 77 LG CN110-13
2 - - - 2 - - -
2 75 - SSDR+ 2 75 L CN202-4
3 N2 - GND 3 N2 W-B J10
4 486 - FLP 4 486 B-W J4
5 - - - 5 - - -
6 - - - 6 - - -
7 - - - 7 - - -
8 145 - CAN1H 8 145 R-L CN200-8 CN55 PM TEMP SSR
9 146 - CAN1L 9 146 L-Y CN200-11
10 - - - 10 - - -
11 - - - 11 - - -
2 1 1 2
12 334 - PSACC+ 12 334 L-O CN104-14,201-1
13 - - - 13 - - -
TAB REC
14 - - - 14 - - -
NO P C J NO P C J
15 - - - 15 - - -
1 89 - STPM 1 89 R-W CN111-10
16 - - - 16 - - -
2 88 - STPM+ 2 88 GR CN111-9
17 - - - 17 - - -
CN52 DM TEMP SSR RH
2 1 1 2 CN56 PM SPD SSR
2 1 1 2
TAB REC
NO P C J NO P C J
1 85 - STDMR 1 85 R-W CN110-10
TAB REC
2 84 - STDMR+ 2 84 GR CN110-9
NO P C J NO P C J
1 82 - SSP1 1 82 G CN111-14
2 81 - SSP+ 2 81 R-L CN111-15
CN58 STROBE LAMP CN70 DISPLAY
2 1 1 2
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
TAB REC 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
NO P C J NO P C J
1 493 - LS+ 1 493 B-Y J47,CN37-2
2 N2 - LS- 2 N2 W-B J46
CN62 COMPARTMENT LIGHT SW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8 TAB REC
NO P C J NO P C J
1 - - - 1 - - -
TAB REC 2 - - - 2 - - -
NO P C J NO P C J
3 169 - TGND 3 169 GR-R CN178-9
1 112 - SW+ 1 112 G-Y CN63-1
4 14 - DGND 4 14 W-G CN103-3
2 - - - 2 - - -
5 16 - D7V 5 16 Y-B CN103-14
3 - - - 3 - - -
6 162 - ITKY3 6 162 G CN178-3
4 - - - 4 - - -
7 - - - 7 - - -
5 - - - 5 - - -
8 160 - ITKY1 8 160 B-Y CN178-5
6 - - - 6 - - -
9 166 - OTKY3 9 166 GR-L CN178-7
7 101 - SW- 7 101 L CN244-2
10 165 - OTKY2 10 165 R-Y CM178-2
8 - - - 8 - - -
11 164 - OTKY1 11 164 L-O CN178-8
CN63 COMPARTMENT LIGHT 12 167 - LEDTKY1 12 167 G-Y CN178-1

13 - - - 13 - - -
2 1 1 2 14 - - - 14 - - -
15 146 - CAN1L 15 146 W CN200-12
TAB REC 16 145 - CAN1H 16 145 L CN200-9

NO P C J NO P C J 17 - - - 17 - - -
1 112 - LCM+ 1 112 G-Y CN62-1 18 486 - VBKY 18 486 B-W J4
2 N2 - LCM- 2 N2 W-B CN244-1 19 168 - LEDTKY2 19 168 L-B CN178-6
20 161 - ITKY2 20 161 R-B CN178-4
21 163 - IPSTKY1 21 163 W-L CN178-10
22 - - - 22 - - -
23 - - - 23 - - -
24 - - - 24 - - -
25 - - - 25 - - -
26 - - - 26 - - -
19
27 - - - 27 - - -
28 - - - 28 - - -
29 - - - 29 - - -
30 - - - 30 - - -
31 - - - 31 - - -
32 - - - 32 - - -
33 - - - 33 - - -
34 - - - 34 - - -
35 - - - 35 - - -
36 N2 - N1 36 N2 W-B J7
CN73 WARKING LAMP SW CN77 HOOD

HOOD (FINGERTIP
(FINGERTIP
HOOD (MINI
CONTROL LEVER OPTION)
LEVER) CONTROL LEVER OPTION
2 1 1 2
6 5 4 3 2 1 1 2 3 4 5 6
13 12 11 10 9 8 7 7 8 9 10 11 12 13
TAB REC
NO P C J NO P C J
1 101 - SW+ 1 101 L CN37-1 TAB REC
2 107 - SW- 2 107 Y-G CN125-1 NO P C J NO P C J
1 28 V-W CN101-25 1 28 V-W CN162-4
CN75 HOOD (FINGERTIP
HOOD (MINI LEVER) CONTROL LEVER OPTION)
2 20 V-R CN103-26 2 20 V-R CN162-3
3 21 V-G CN103-18 3 21 V-G CN162-2
4 51 GR J68 4 51 GR J51
5 29 R-Y CN101-28 5 29 R-Y CN163-4
4 3 2 1
1 2 3 4 6 22 R-W CN102-23 6 22 R-W CN163-3
8 7 6 5 7 23 R-L CN102-22 7 23 R-L CN163-2

5 6 7 8 8 30 R-G CN101-29 8 30 R-G CN164-4
9 24 R-B CN102-21 9 24 R-B CN164-3
10 25 P-L CN102-20 10 25 P-L CN164-2
11 31 P-G CN101-30 11 31 P-G CN165-4
TAB REC
12 26 P-B CN102-29 12 26 P-B CN165-3
NO P C J NO P C J
13 27 L-Y CN102-28 13 27 L-Y CN165-2
1 495 B-Y J15 1 495 B-Y CN166-8
2 120 Y-R CN24-1 2 120 Y-R CN166-3
CN78 C/V PULL SOL
3 45 GR-R CN104-26 3 45 GR-R CN166-5
4 - - - 4 - - -
5 495 B-Y J15 5 495 B-Y CN166-7
4 3 2 1 1 2 3 4
6 103 R-W CN23-1 6 103 R-W CN166-2
7 46 B-O CN104-19 7 46 B-O CN166-4
8 7 6 5 5 6 7 8
8 - - - 8 - - -
CN76 HOOD
HOOD (FINGERTIP
(MINI LEVER)CONTROL LEVER OPTION
OPTION)
TAB REC
NO P C J NO P C J
1 10 B-Y CN101-17 1 10 - SLPL-
5 4 3 2 1 1 2 3 4 5 2 33 W-G CN101-12 2 33 - STPL-

3 36 W-R CN101-10 3 36 - SA1PL-
10 9 8 7 6 6 7 8 9 10 4 39 Y-B CN101-14 4 39 - SA2PL-
5 481 G-W J62 5 481 - SLPL+
6 482 L J63 6 482 - STPL+
7 483 L J64 7 483 - SA1PL+
TAB REC 8 484 G-W J65 8 484 - SA2PL+

NO P C J NO P C J
1 60 P-L CN104-15 1 60 P-L J53
CN85 NTRL TILT SW
2 N2 W-B J8 2 N2 W-B CN171-1

3 - - - 3 - - - 2 1 1 2
4 - - - 4 - - -
5 - - - 5 - - -
6 68 B-R CN104-28 6 68 B-R CN170-3 TAB REC
NO P C J NO P C J
7 118 L-Y J2 7 118 L-Y CN170-2
1 51 BR J14 1 51 - LS-
8 70 B-L CN103-32 8 70 B-L CN161-3
2 70 B-L CN103-32 2 70 - STK
9 51 BR J14 9 51 BR J52
10 - - - 10 - - -
CN86 TILT ANG SSR CN88 C/V SOL (FINGERTIP CONTROL)

<MINI LEVER>
3 2 1 1 2 3
3 2 1 1 2 3
TAB REC 6 5 4 4 5 6
NO P C J NO P C J
1 57 - VRTA+ 1 57 L-Y CN101-20
2 56 - VRTA 2 56 Y-R CN103-17 TAB REC
3 51 - POT- 3 51 G J9 NO P C J NO P C J
1 - - - 1 - - -
CN87 C/V PUSH SOL
2 477 V CN250-36 2 477 - SLLL+
3 479 Y-R CN250-38 3 479 - SLTFL+
4 3 2 1 1 2 3 4 4 - - - 4 - - -
5 4 B-Y CN102-16 5 4 - SLLL-
6 7 W CN102-19 6 7 - SLTFL-
8 7 6 5 5 6 7 8
CN89 TILT SW
TAB REC
2 1 1 2
NO P C J NO P C J
1 11 B-W CN101-16 1 11 - SLPS- 4 3 3 4
2 34 W-L CN101-13 2 34 - STPS-
3 37 G-B CN101-11 3 37 - SA1PS-
4 40 B-R CN101-15 4 40 - SA2PS-
TAB REC
5 481 G-W J62 5 481 - SLPS+
NO P C J NO P C J
6 482 L J63 6 482 - STPS+
1 22 R-W CN102-23 1 22 - VRT1
7 483 L J64 7 483 - SA1PS+
2 51 GR J13 2 51 - LS-
8 484 G-W J65 8 484 - SA2PS+
3 23 R-L CN102-22 3 23 - VRT2
4 51 GR J13 4 51 - LS-
CN88 C/V SOL
CN90 MAST SSR
4 3 2 1 1 2 3 4
3 2 1 1 2 3
8 7 6 5 5 6 7 8
TAB REC
NO P C J NO P C J
TAB REC 1 51 B CN92-1 1 51 B J19

NO P C J NO P C J 2 91 W CN92-3 2 91 W CN103-24
1
2
478
477
V
V
CN250-34
CN250-36
1
2
478
477
-
-
SLUL+
SLLL+
3 90 R CN92-2 3 90 R CN104-22
19
3 479 Y-R CN250-38 3 479 - SLTFL+
CN91 PRESS SSR
4 8 G CN102-18 4 8 - SLTBL-
5 5 W-L CN102-17 5 5 - SLUL- 1 1
6 4 B-Y CN102-16 6 4 - SLLL-
7 7 W CN102-19 7 7 - SLTFL- 2 2
8 480 Y-R CN250-40 8 480 - SLTBL+
3 3
TAB REC
NO P C J NO P C J
1 58 - SPLF+ 1 58 Y-R CN104-12
2 59 - SPLF 2 59 Y-G CN103-29
3 51 - POT- 3 51 G J9
CN92 HEIGHT SW CN101 CPU1
3 2 1 1 2 3
7 6 5 4 3 2 1
TAB REC 17 16 15 14 13 12 11 10 9 8
NO P C J NO P C J
27 26 25 24 23 22 21 20 19 18
1 51 B CN90-1 1 51 - LS-
34 33 32 31 30 29 28
2 90 R CN90-3 2 90 - SH1
3 91 W CN90-2 3 91 - SH2-1
CN97 TIRE ANGLE SSR 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
3 2 1 1 2 3
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
TAB REC
NO P C J NO P C J
TAB REC
1 51 - POT- 1 51 GR J13,J68
NO P C J NO P C J
2 317 - VRTRA 2 317 L-R CN102-31
1 3 - SOLLU+ 1 3 G-B J32
3 316 - VRTRA+ 3 316 L-W CN101-23
2 6 - SLTFB+ 2 6 G-W J33
CN98 STEERING SOL 3 97 - FAN+ 3 97 R-W CN127-3

4 41 - VBBT 4 41 G J5
2 1 1 2 5 9 - SLLA2+ 5 9 Y-R J67
6 32 - SLTA1+ 6 32 Y-L J66
TAB REC 7 - - - 7 - - -
NO P C J NO P C J 8 - - - 8 - - -
1 330 - SLS- 1 330 W-L CN102-14 9 - - - 9 - - -
2 485 - SLS+ 2 485 R CN250-32 10 36 - SA1PL- 10 36 W-R CN78-3
11 37 - SA1PS- 11 37 G-B CN87-3
CN99 CLAMP LOCK VALVE
12 33 - STPL- 12 33 W-G CN78-2
13 34 - STPS- 13 34 W-L CN87-2
2 1 1 2
14 39 - SA2PL- 14 39 Y-B CN78-4
15 40 - SA2PS- 15 40 B-R CN87-4
TAB REC
16 11 - SLPS- 16 11 B-W CN87-1
NO P C J NO P C J
17 10 - SLPL- 17 10 B-Y CN78-1
1 113 G-W CN179-1 1 113 - SLIL+
18 - - - 18 - - -
2 N2 W-B CN179-2 2 N2 - SLIL-
19 43 - VBKY 19 43 B-Y J3
20 57 - VRTA+ 20 57 L-Y CN86-1
21 - - - 21 - - -
22 50 - VRA- 22 50 B-O J18
23 316 - VRTRA+ 23 316 L-W CN97-3
24 - - - 24 - - -
25 28 - VRL+ 25 28 V-W CN117-1,77-1
26 55 - VRA2+ 26 55 GR-R CN26-1
27 53 - VRA1+ 27 53 BR-W CN26-5
28 29 - VRT+ 28 29 R-Y CN77-5
29 30 - VRAT1+ 29 30 R-G CN117-4,77-8
30 31 - VRAT2+ 30 31 P-G CN117.3,77-11
31 - - - 31 - - -
32 51 - POT- 32 51 G J9
33 74 - VRB2+ 33 74 BR-R CN6-1
34 72 - VRB1+ 34 72 L-O CN6-5
CN102 CPU2 CN103 CPU3
7 6 5 4 3 2 1 6 5 4 3 2 1
19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
TAB REC TAB REC

1 98 - FNDC1 1 98 V-Y J23 1 - - - 1 - - -
2 99 - FNDC2 2 99 G-R CN118-2 2 - - - 2 - - -
3 19 - VBMBSL 3 19 Y-B J21,J61 3 14 - DGND 3 14 W-G CN70-4
4 19 - VBMBSL 4 19 Y-B J21,J61 4 42 - KYSAT 4 42 R-Y J22
5 17 - SOLCOM 5 17 G-W CN127-7 5 N2 - N2 5 N2 W-B CN200-1
6 17 - SOLCOM 6 17 G-W CN127-6 6 51 - LS- 6 51 B J19
7 329 - SLS+ 7 329 R-G CN250-31 7 - - - 7 - - -
8 333 - OACC3 8 333 G CN209-2 8 300 - IPL+ 8 300 L-B CN203-1
9 332 - OACC2 9 332 R CN208-2 9 - - - 9 - - -
10 51 - LS- 10 51 BR J14 10 - - - 10 - - -
11 - - - 11 - - - 11 145 - CAN1H 11 145 GR-R CN200-7
12 - - - 12 - - - 12 146 - CAN1L 12 146 P-B CN200-10
13 335 - RY1 13 335 LG CN127-5 13 311 - SSTR+ 13 311 P-L CN19-1
14 330 - SLS- 14 330 W-L CN98-1 14 16 - D7V 14 16 Y-B CN70-5
15 - - - 15 - - - 15 - - - 15 - - -
16 4 - SLLL- 16 4 B-Y CN88-6,88-5 16 - - - 16 - - -
17 5 - SLUL- 17 5 W-L CN88-5 17 56 - VRTA 17 56 Y-R CN86-2
18 8 - SLTBL- 18 8 G CN88-4 18 21 - VRL2 18 21 V-G CN117-6,77-3
19 7 - SLTFL- 19 7 W CN88-7,88-6 19 302 - IPL2 19 302 V-Y CN130-2
20 25 - VRA12 20 25 P-L CN117-10,77-10 20 - - - 20 - - -
21 24 - VRA11 21 24 R-B CN117-5,77-9 21 - - - 21 - - -
22 23,62 - VRT2,SWTR 22 23 R-L CN89-3,77-7 22 - - - 22 - - - 19
23 22,61 - VRT1,SWTF 23 22 R-W CN89-1,77-6 23 - - - 23 - - -
24 304 - CSBAT 24 304 L-O CN138-3 24 91 - SH2-1 24 91 W CN90-2
25 73 - VRB2 25 73 Y-R CN6-3 25 - - - 25 - - -
26 51 - POT- 26 51 GR J13,J68 26 20 - VRL1 26 20 V-R CN117-2,77-2
27 - - - 27 - - - 27 - - - 27 - - -
28 27 - VRA22 28 27 L-Y CN117-9,77-13 28 - - - 28 - - -
29 26 - VRA21 29 26 P-B CN117-8,77-12 29 59 - SPLF 29 59 Y-G CN91-2
30 52 - VRA1 30 52 BR-R CN26-4 30 301 - IPL1 30 301 W-L CN129-2
31 317 - VRTRA 31 317 L-R CN97-2 31 - - - 31 - - -
32 54 - VRA2 32 54 BR-Y CN26-3 32 70 - STK 32 70 B-L CN85-2,76-8
33 71 - VRB1 33 71 Y-B CN6-4 33 - - - 33 - - -
34 - - - 34 - - - 34 - - - 34 - - -
35 305 - CSBAT- 35 305 B-O CN138-2 35 - - - 35 - - -
CN104 CPU4 CN109 DRIVE INV LH
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
7 6 5 4 3 2 1
15 14 13 12 11 10 9 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23
17 16 15 14 13 12 11 10 9 8
TAB REC
25 24 23 22 21 20 19 18 NO P C J NO P C J
31 30 29 28 27 26 1 - - - 1 - - -
2 - - - 2 - - -
3 - - - 3 - - -
4 - - - 4 - - -
1 2 3 4 5 6 7
5 - - - 5 - - -
8 9 10 11 12 13 14 15 16 17 6 - - - 6 - - -
18 19 20 21 22 23 24 25 7 - - - 7 - - -
8 42 - KYSAT 8 42 R-Y J22
26 27 28 29 30 31
9 86 - STDML+ 9 86 GR CN121-2
10 87 - STDML 10 87 R-W CN121-1
TAB REC
11 - - - 11 - - -
NO P C J NO P C J
12 - - - 12 - - -
1 41 - B48V 1 41 G J5
13 80 - SSDL2 13 80 R CN123-1
2 44 - VBMB 2 44 R-B J29
14 79 - SSDL1 14 79 R-B CN122-1
3 1 - CBAT+ 3 1 G-R J17
15 78 - SSDL+ 15 78 LG CN203-5
4 N2 - N2 4 N2 W-B CN200-2
16 146 - CAN1L 16 146 G CN203-7
5 N2 - N2 5 N2 W-B CN200-3
17 145 - CAN1H 17 145 GR CN203-10
6 N2 - N2 6 N2 W-B CN200-4
18 - - - 18 - - -
7 - - - 7 - - -
19 - - - 19 - - -
8 - - - 8 - - -
20 - - - 20 - - -
9 2 - CBAT- 9 2 LG-B CN136-1
21 - - - 21 - - -
10 303 - CSBAT+ 10 303 GR-L CN138-1
22 - - - 22 - - -
11 - - - 11 - - -
23 - - - 23 - - -
12 58 - SPLF+ 12 58 Y-R CN91-1
13 - - - 13 - - -
14 334 - PSACC+ 14 334 L-O CN200-5
15 60 - PSSW+ 15 60 P-L CN76-1
16 - - - 16 - - -
17 - - - 17 - - -
18 67 - SDM 18 67 L-O CN43-1
19 46 - DSR 19 46 B-O CN10-4,75-7,133-3
20 66 - SPB 20 66 G-W CN117-1
21 - - - 21 - - -
22 90 - SH1 22 90 R CN90-3
23 - - - 23 - - -
24 314 - SSTRC 24 314 G-Y CN19-5
25 - - - 25 - - -
26 45 - DSF 26 45 GR-R CN10-5,75-3,133-2
27 - - - 27 - - -
28 68 - SHS 28 68 B-R CN76-6
29 - - - 29 - - -
30 312 - SSTR1 30 312 B-Y CN19-3
31 313 - SSTR2 31 313 L-W CN19-4
CN110 DRIVE INV RH CN111 PUMP INV
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
15 14 13 12 11 10 9 9 10 11 12 13 14 15 15 14 13 12 11 10 9 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23 23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23
TAB REC TAB REC

1 - - - 1 - - - 1 - - - 1 - - -
2 - - - 2 - - - 2 - - - 2 - - -
3 - - - 3 - - - 3 - - - 3 - - -
4 - - - 4 - - - 4 - - - 4 - - -
5 - - - 5 - - - 5 - - - 5 - - -
6 - - - 6 - - - 6 152 - SETP1 6 152 G-R CN111-23
7 150 - SETDR0 7 150 G-R 110-23 7 - - - 7 - - -
8 42 - KYSAT 8 42 R-Y J22 8 42 - KYSAT 8 42 R-Y J22
9 86 - STDMR+ 9 84 GR CN52-2 9 88 - STPM+ 9 88 GR CN55-2
10 85 - STDMR 10 85 R-W CN52-1 10 89 - STPM 10 89 R-W CN55-1
11 - - - 11 - - - 11 - - - 11 - - -
12 - - - 12 - - - 12 - - - 12 - - -
13 77 - SSDR2 13 77 LG CN54-1 13 - - - 13 - - -
14 76 - SSDR1 14 76 Y CN53-1 14 82 - SSP1 14 82 G CN56-1
15 75 - SSDR+ 15 75 LG CN203-3 15 81 - SSP+ 15 81 R-L CN56-2
16 146 - CAN1L 16 146 L CN203-8 16 146 - CAN1L 16 146 V CN202-11
17 145 - CAN1H 17 145 W CN203-11 17 145 - CAN1H 17 145 P CN202-8
18 - - - 18 - - - 18 - - - 18 - - -
19 - - - 19 - - - 19 - - - 19 - - -
20 - - - 20 - - - 20 - - - 20 - - -
21 - - - 21 - - - 21 - - - 21 - - -
22 - - - 22 - - - 22 - - - 22 - - -
23 150 - SETDR- 23 150 G-R CN110-7 23 152 - SETP- 23 152 G-R CN111-6
CN112 INV FAN1
2 1 1 2
TAB REC
NO P C J NO P C J
1 474 R CBAT+ 1 474 L-B CN250-26
2 98 B FNDC1 2 98 V-Y J23
CN113 INV FAN2 19

2 1 1 2
TAB REC
NO P C J NO P C J
1 475 R CBAT+ 1 475 P CN250-28
2 98 B FNDC1 2 98 V-Y J23
CN115 LIFT LVR CN120 ATT2 LVR SSR
4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4
TAB REC TAB REC

1 51 - POT- 1 51 GR J41 1 51 - POT- 1 51 GR J41
2 21 - VRL2 2 21 V-G CN117-6 2 27 - VRAT22 2 27 L-Y CN117-9
3 20 - VRL1 3 20 V-R CN117-2 3 26 - VRAT21 3 26 P-B CN117-8
4 28 - VRL+ 4 28 V-W CN117-1 4 31 - VRAT2+ 4 31 P-G CN117-3
CN117 HOOD1 CN121 DM TEMP SSR LH
2 1 1 2
5 4 3 2 1 1 2 3 4 5
10 9 8 7 6 6 7 8 9 10 TAB REC
NO P C J NO P C J
1 87 - STDML 1 87 R-W CN109-10
2 86 - STDML+ 2 86 GR CN109-9
TAB REC CN122 DM SPD SSR1 LH

NO P C J NO P C J
1 28 V-W CN101-25 1 28 V-W CN115-4
2 1 1 2
2 20 V-R CN103-26 2 20 V-R CN115-3
3 31 P-G CN101-30 3 31 P-G CN120-4
4 30 R-G CN101-29 4 30 R-G CN119-4
TAB REC
5 24 R-B CN102-21 5 24 R-B CN119-3 NO P C J NO P C J
6 21 V-G CN103-18 6 21 V-G CN115-2 1 79 - SSDL1 1 79 R-B CN1109-14
7 51 GR J13 7 51 GR J41 2 78 - SSDL+ 2 78 G CN202-1
8 26 P-B CN102-29 8 26 P-B CN120-3
9 27 L-Y CN102-28 9 27 L-Y CN120-2 CN123 DM SPD SSR2 LH
10 25 P-L CN102-20 10 25 P-L CN119-2
2 1 1 2
CN118 MOTOR FAN
2 1 1 2
TAB REC
NO P C J NO P C J
TAB REC
1 80 - SSDL2 1 80 R CN109-13
NO P C J NO P C J
2 78 - SSDL+ 2 78 G CN202-2
1 476 - CBAT+ 1 476 B-W CN250-30
2 99 - FNDC2 2 99 G-R CN102-2
CN125 WORKING LP
CN119 ATT1 LVR SSR

2 1 1 2
4 3 2 1 1 2 3 4
TAB REC TAB REC

1 51 - POT- 1 51 GR J41 1 107 - LW+ 1 107 Y-G CN73-2
2 25 - VRAT12 2 25 P-L CN117-10 2 N2 - LW- 2 N2 W-B J46
3 24 - VRAT11 3 24 R-B CN117-5
4 30 - VRAT1+ 4 30 R-G CN117-4
FINGERTIP
CN127 FINGERTIP CONTROL
MINI LEVER CONTROL
SOL LEVER SOL
RLY LEVER SOL RLY
RLY CN137 CONTACTOR2
1 1
7 6 5 4 3 2 1 1 2 3 4 5 6 7
3 2 2 3
TAB REC TAB REC

1 19 - VBMBSL 1 19 Y-B J61 1 P2 GR J6 1 P2 W FLP
2 19 - VBMBSL 2 19 Y-B J61 2 P2 G-Y CN250-49 2 P2 R VBBT
3 97 - RY1+ 3 97 R-W CN101-3 3 19 Y-B J21 3 19 B VBMBSL
4 - - - 4 - - -
5 335 - RY1- 5 335 LG CN102-13
CN138 CONTACTOR3
6 17 - SOLCOM 6 17 G-W CN102-6

3 2 1 1 2 3
7 17 - SOLCOM 7 17 G-W CN102-5
CN129 IMPACT SSR1 TAB REC

NO P C J NO P C J
3 2 1 1 2 3 1 303 R CSBAT+ 1 303 GR-L CN104-10

2 305 BR CSBAT- 2 305 B-O CN102-35
3 304 W CSBAT 3 304 L-O CN102-24
TAB REC
NO P C J NO P C J CN144 DC/DC
1 51 - POT- 1 51 G J9
2 301 - IPL1 2 301 W-L CN103-30
2 1 1 2
3 300 - IPL+ 3 300 L-B CN202-6
4 3 3 4
CN130 IMPACT SSR2
3 2 1 1 2 3
TAB REC
NO P C J NO P C J
TAB REC 1 233 - IN- 1 233 W-R CN147-2
NO P C J NO P C J 2 232 - IN+ 2 232 L-R CN250-54
1 51 - POT- 1 51 G J9 3 235 - OUT- 3 235 B J31
2 302 - IPL2 2 302 V-Y CN103-19 4 234 - OUT+ 4 234 R-W CN250-55
3 300 - IPL+ 3 300 L-B CN202-5
CN146 12V PWR SUPPLY
CN133 Forward/Reverse
EZ PEDAL Pedal
2 1 1 2
3 2 1 1 2 3
TAB REC
NO P C J NO P C J
TAB REC 1 236 R J30 1 236 - - 19
NO P C J NO P C J 2 235 B J31 2 235 - -
1 51 R NC 1 51 BR J14
2 45 W NO 2 45 GR-R CN104-26 CN147 DC/DC
3 46 W NO 3 46 B-O CN104-19
2 1 1 2
CN136 CONTACTOR1
TAB REC
1 1 NO P C J NO P C J
3 2 2 3 1 231 Y-R CN250-53 1 231 Y-R CN148
2 233 W-R CN144-1 2 233 W-R CN149
TAB REC
NO P C J NO P C J
1 2 B CBAT- 1 2 LG-B CN104-9
2 1 R CBAT+ 2 1 G-R J17
3 P3 L VBMB 3 P3 R-G CN250-51
CN161 NTRL TILT SW CN166 DIRECTION SW (ARM DIR)
2 1 1 2 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
3 3 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
TAB REC
NO P C J NO P C J
TAB REC
NO P C J NO P C J
1 60 - PSSW+ 1 60 P-L J53
1 - - - 1 - - -
2 51 - LS- 2 51 BR J52
2 103 - DSBU 2 103 R-W CN75-6
3 70 - STK 3 70 B-L CN76-8
3 120 - DSFO 3 120 Y-R CN75-2
CN162 LIFT LVR SSR 4 46 - DSR 4 46 B-O CN75-7
5 45 - DSF 5 45 GR-R CN75-3
4 3 2 1 1 2 3 4 6 51 - LS- 6 51 BR J52
7 495 - VBKY 7 495 B-Y CN75-5
TAB REC 8 495 - VBKY 8 495 B-Y CN75-1
NO P C J NO P C J
9 - - - 9 - - -
1 51 - POT- 1 51 GR J51
10 - - - 10 - - -
2 21 - VRL2 2 21 V-G CN77-3
11 - - - 11 - - -
3 20 - VRL1 3 20 V-R CN77-2
12 - - - 12 - - -
4 28 - VRL+ 4 28 V-W CN77-1
13 - - - 13 - - -
CN163 TILT LVR SSR

14 - - - 14 - - -
15 - - - 15 - - -
4 3 2 1 1 2 3 4 16 - - - 16 - - -
17 - - - 17 - - -
TAB REC 18 - - - 18 - - -
NO P C J NO P C J
1 51 - POT- 1 51 GR J51
CN170 ATT ACT SW (COWL)
2 23 - VRT2 2 23 R-L CN77-7

3 22 - VRT1 3 22 R-W CN77-6 2 1 1 2
4 29 - VRT+ 4 29 R-Y CN77-5
CN164 ATT1 LVR SSR TAB REC

NO P C J NO P C J
4 3 2 1 1 2 3 4 1 496 B-R CB213-2 1 496 - SW+
2 114 BR CN213-1 2 114 - SW-
TAB REC
NO P C J NO P C J CN170 ATTACT
ATT ACTSW
SW FINGERTIP
(MINI) CONTROL LEVER
1 51 - POT- 1 51 GR J51
2 25 - VRAT12 2 25 P-L CN77-10 2 1 1 2
3 24 - VRAT11 3 24 R-B CN77-9 3 3
4 30 - VRAT1+ 4 30 R-G CN77-8
TAB REC
CN165 ATT2 LVR SSR
NO P C J NO P C J
1 60 - IG 1 60 P-L J53
4 3 2 1 1 2 3 4
2 51 - E 2 51 BR J52
3 68 - + 3 68 B-R CN76-6
TAB REC
NO P C J NO P C J
1 51 - POT- 1 51 GR J51
2 27 - VRAT22 2 27 L-Y CN77-13
3 26 - VRAT21 3 26 P-B CN77-12
4 31 - VRAT2+ 4 31 P-G CN77-11
CN171 ARMREST HORN SW CN176 EMERGENCY SW
2 1 1 2
2 1 1 2
TAB REC
NO P C J NO P C J
TAB REC 1 41 B SWE+ 1 41 G-R J11
NO P C J NO P C J
2 41 W SWE- 2 41 G J5
1 N2 W-B CN76-2 1 N2 - SW-
2 118 L-Y CN76-7 2 118 - SW+ CN177 BODY SUB
CN172 FR STAY RH1
2 1 1 2 4 3 2 1
3 3 1 2 3 4
8 7 6 5
5 6 7 8
TAB REC
NO P C J NO P C J
1 106 R-G CN16-1 1 106 R-G CN210-4
2 108 R-Y CN14-1 2 108 R-Y J24
TAB REC
3 N2 W-B CN16-2 3 N2 W-B J7 NO P C J NO P C J
1 66 G-W CN15-1 1 66 G-W CN104-20
CN173 FR STAY RH2
2 109 G-Y CN174-2 2 109 G-Y J26
3 - - - 3 - - -
2 1 1 2
4 102 R-G CN174-1 4 102 R-G CN211-4
3 3
5 51 B CN15-3 5 51 B J19
6 104 G-R CN175-1 6 104 G-R J25
TAB REC
7 - - - 7 - - -
NO P C J NO P C J
8 N2 W-B J40 8 N2 W-B J7
1 104 G-R J25 1 104 G-R CN14-4
2 N2 W-B J7 2 N2 W-B CN14-2
CN178 TEN KEY
3 N2 W-B J7 3 N2 W-B CN14-3
CN174 FR STAY LH1
2 1 1 2 5 4 3 2 1 1 2 3 4 5
3 3 10 9 8 7 6 6 7 8 9 10
TAB REC
NO P C J NO P C J
1 102 R-G CN16-1 1 102 R-G CN177-4
TAB REC
2
3
109
N2
R-Y
W-B
CN14-1
CN16-2
2
3
109
N2
G-Y
W-B
CN177-2
J40
NO P C J NO P C J 19
1 167 G-Y CN70-12 1 167 G-Y CN33-5
CN175 FR STAY LH2 2 165 R-Y CN70-10 2 165 R-Y CN33-4

3 162 G CN70-6 3 162 G CN33-3
2 1 1 2 4 161 R-B CN70-20 4 161 R-B CN33-2
3 3 5 160 B-Y CN70-8 5 160 B-Y CN33-1

6 168 L-B CN70-19 6 168 L-B CN33-10
TAB REC 7 166 GR-L CN70-9 7 166 GR-L CN33-9

NO P C J NO P C J 8 164 L-O CN70-11 8 164 L-O CN33-8
1 104 G-R CN177-6 1 104 G-R CN14-4 9 169 GR-R CN70-3 9 169 GR-R CN33-7
2 N2 W-B J40 2 N2 W-B CN14-2 10 163 W-L CN70-21 10 163 W-L CN33-6
3 N2 W-B J40 3 N2 W-B CN14-3
CN179 INTERLOCK SOL TAB
2 1 1 2
TAB REC
NO P C J NO P C J
1 113 G-W CN213-4 1 113 G-W CN99-1
CN200 CN201
CAN J/C1 REC CAN J/C2
2 N2 W-B J10 2 N2 W-B CN99-2
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
CN183 TELEMATICS
NO P C J NO P C J
1 N2 W-B CN103-5 1 334 L-O CN47-12
3 2 1 1 2 3
2 N2 W-B CN104-4 2 334 L-O CN209-1
3 N2 W-B CN104-5 3 N2 W-B CN20-1
6 5 4 4 5 6
4 N2 W-B CN104-6 4 N2 W-B CN183-6
5 334 L-O CN104-14 5 N2 W-B CN20-2
TAB REC 6 334 L-O CN208-1 6 N2 W-B CN183-3
NO P C J NO P C J 7 145 GR-R CN103-11 7 146 LG-B CN202-10
1 440 R-B CN209-4 1 - - - 8 145 R-L CN47-8 8 146 BR CN183-5
2 - - - 2 - - - 9 145 L CN70-16 9 146 - -
3 N2 W-B CN201-6 3 - - - 10 146 P-B CN103-12 10 145 LG-R CN202-7
4 145 BR-W CN201-11 4 - - - 11 146 L-Y CN47-9 11 145 BR-W CN183-4
5 146 BR CN201-8 5 - - - 12 146 W CN70-15 12 145 - -
6 N2 W-B CN201-4 6 - - -
TAB
CN185 BLUE LIGHT
2 1 1 2
TAB REC
NO P C J NO P C J CN202 CN203
CAN J/C3 REC CAN J/C4
1 N2 - LB- 1 N2 W-B J46
2 493 - LB+ 2 493 B-Y J47
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
NO P C J NO P C J
1 78 G CN122-2 1 300 L-B CN103-8
2 78 G CN123-2 2 - - -
3 75 L CN53-2 3 75 LG CN110-15
4 75 L CN54-2 4 - - -
5 300 L-B CN130-3 5 78 LG CN109-15
6 300 L-B CN129-3 6 - - -
7 145 LG-R CN201-10 7 146 G CN109-16
8 145 P CN111-17 8 146 L CN110-16
9 - - - 9 - - -
10 146 LG-B CN201-7 10 145 GR CN109-17
11 146 V CN111-16 11 145 W CN110-17
12 - - - 12 - - -
CN207 KEY OFF H/L RLY CN211 HEAD LP RLY LH
2 1 1 2 2 1 1 2
4 3 3 4 4 3 3 4
TAB REC TAB REC
1 493 - COIL+ 1 493 B-Y J27 1 117 - COIL+ 1 117 GR CN46-1,210-1
2 101 - SW+ 2 101 L J16 2 488 - SW+ 2 488 Y-G CN250-16
3 N2 - COIL- 3 N2 W-B J8 3 115 - COIL- 3 115 P J28
4 117 - SW- 4 117 GR CN210-1 4 102 - SW- 4 102 R-G CN177-4
CN208 SOLID STATE RLY1 CN212 ACCESSARY RELAY
2 1 1 2
3 2 1 1 2 3 4 3 3 4
6 5 4 4 5 6 TAB REC
NO P C J NO P C J
1 44 - COIL+ 1 44 R-B J29
2 41 - SW+ 2 41 G-R J11
TAB REC
3 N2 - COIL- 3 N2 W-B J8
NO P C J NO P C J
4 105 - SW- 4 105 G-W J12
1 334 - PSACC+ 1 334 L-O CN200-6
2 332 - OACC2 2 332 R CN102-9
CN213 INTERLOCK RLY (COWL)
3 - - - 3 - - -
4 103 - LBU+ 4 103 R-W CN37-3,23-1 2 1 1 2
5 - - - 5 - - - 4 3 3 4
6 472 - B48V 6 472 G-W CN250-24
TAB REC
CN209 SOLID STATE RLY2 NO P C J NO P C J
1 114 - COIL+ 1 114 BR CN170-2
2 496 - SW+ 2 496 B-R CN170-1,250-22
3 2 1 1 2 3 3 N2 - COIL- 3 N2 W-B J10
4 113 - SW- 4 113 G-W CN179-1
6 5 4 4 5 6
CN218 SURGE KILLER CN217
TAB REC 2 1 1 2
NO P C J NO P C J
1 334 - - 1 334 L-O CN201-2
TAB REC
2 333 - - 2 333 G CN102-8
NO P C J NO P C J
19
3 - - - 3 - - -
1 48 B CN219-2 1 48 L-O J20
4 440 - - 4 440 R-B CN183-1
2 492 B CN219-1 2 492 G-Y CN250-4
5 - - - 5 - - -
6 473 - - 6 473 G-W CN250-58
CN210 HEAD LP RLY
2 1 1 2
4 3 3 4
TAB REC
NO P C J NO P C J
1 117 - COIL+ 1 117 GR CN207-4,211-1,J16,172-1
2 489 - SW+ 2 489 BR CN250-18
3 115 - COIL- 3 115 P J28
4 106 - SW- 4 106 R-G CN172-1
CN250 FUSE HOLDER
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
CN237 DC/DC FOR LED RR COMBI
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60
3 2 1 1 2 3
6 5 4 4 5 6 NO P C J NO P C J
1 41 G-R J11 31 329 R-G CN102-7
2 491 G-B CN40-1 32 485 R CN98-2
TAB REC 3 41 G-R J11 33 3 G-B J32
NO P C J NO P C J
4 492 G-Y CN217-2 34 478 V CN88-1
1 103 - BUIN 1 103 R-W J56
5 105 G-W J12 35 3 G-B J32
2 111 - STLIN 2 111 R-L CN37-6
6 495 B-Y J15 36 477 V CN88-2
3 104 - TLIN 3 104 G-R CN37-7
7 105 G-W J12 37 6 G-W J33
4 109 - TRNLIN 4 109 G-Y CN37-9
8 493 B-Y J27 38 479 Y-R CN88-3
5 108 - TRNRIN 5 108 R-Y CN37-8
9 105 G-W J12 39 6 G-W J33
6 N2 - GNDIN 6 N2 W-B CN37-10
10 494 B-Y CN12-4 40 480 Y-R CN88-8
CN238 DC/DC FOR LED RR COMBI 11 P2 GR J6 41 9 Y-R J67

12 490 GR-R CN5-1 42 481 G-W CN87-5
13 P2 GR J6 43 32 Y-L J66
3 2 1 1 2 3 14 101 L J16 44 482 L CN87-6
15 P2 GR J6 45 32 Y-L J66
6 5 4 4 5 6 16 488 Y-G CN211-2 46 483 L CN87-7
17 P2 GR J6 47 9 Y-R J67
18 489 BR CN210-2 48 484 G-W CN87-8
TAB REC 19 P2 GR J6 49 P2 G-Y CN137-2
NO P C J NO P C J
20 487 L-Y CN46-2 50 41 G-R J11
1 203 R-W CN38-4 1 203 - BUOUT
21 105 G-W J12 51 P3 R-G CN136-3
2 211 R-L CN38-6 2 211 - STLOUT
22 496 B-R CN213-2 52 44 R-B J29
3 204 G-R CN38-7 3 204 - TLOUT
23 41 G-R J11 53 231 Y-R CN147-1
4 209 G-Y CN38-9 4 209 - TRNLOUT
24 472 G-W CN208-6 54 232 L-R CN144-2
5 208 R-Y CN38-8 5 208 - TRNROUT
25 1 G-R J17 55 234 R-W CN144-4
6 N2 W-B CN38-10 6 N2 - GNDOUT
26 474 L-B CN112-1 56 236 R J30
CN244 FR STAY RH 27 1 G-R J17 57 68 G-R J11

28 475 P CN113-1 58 - G-W CN209-6
2 1 1 2 29 1 G-R J17 59 43 B-Y J3
30 476 B-W CN118-1 60 486 B-W J4
TAB REC
NO P C J NO P C J CN300 SHORT CONN CN301 SHORT CONN
1 N2 W-B J10 1 N2 W-B CN63-2
2 101 L J16 2 101 L CN62-7 2 1 2 1
4 3
CN246 12V PWR SUPPLY TAB
TAB NO P C J
2 1 1 2 NO P C J 1 41 G CN301-2
1 - - - 2 41 G CN301-1
TAB REC 2 101 GR CN300-4
NO P C J NO P C J
3 - - -
1 236 R J30 1 235 - -
4 117 GR CN300-2
2 235 B J31 2 236 - -
BODY MAIN
J8 J1 J10 CN3-1 J2 CN37-5 CN4-4 J3 CN250-59 CN47-4 J4 CN250-60

CN76-7
CN40-3 CN101-19 CN70-18
(N2, W-B) (118, L-Y) (43, B-Y) (486, B-W)
CN4-1 CN250-15 CN7-9 CN23-2 CN6-2

CN250-13 CN250-17 CN177-8 CN7-11 CN20-1 CN24-2 CN130-1 CN26-2
CN101-4 J5 CN176-2 CN250-11 J6 CN250-19 CN172-3 J7 CN20-2 J1 J8 CN37-10 CN129-1 J9 CN86-3

CN173-2 CN70-36 CN76-2 CN207-3 CN91-3
CN104-1 CN137-1 CN173-3 CN212-3 CN101-32
(41, G) (P2, GR) (N2, W-B) (N2, W-B) (51, G)
CN3-2 CN40-2 CN250-5 CN89-2 CN10-6

J1 CN12-1 CN250-57 CN176-1 CN250-7 CN89-4 CN76-9 CN133-1
CN244-1 J10 CN22-1 CN250-50 J11 CN212-2 CN212-4 J12 CN250-9 CN117-7 J13 CN97-1 CN102-10 J14 CN43-2
CN213-3 CN47-3 CN250-23 CN250-1
CN179-2 CN250-3 CN250-21 CN102-26 CN85-1
(N2, W-B) (41, G-R) (105, G-W) (51, GR) (51, BR)
CN75-1 CN37-1 CN104-3 CN177-5

CN75-5 CN207-2 CN250-25
CN250-6 CN244-2 CN250-29 CN101-22 CN90-1
(495, B-Y) (101, L) (1, G-R) (50, B-O) (51, B)
CN110-1
CN21-1 CN102-3 CN111-1 CN112-2 CN7-14
(48, L-O) (19, Y-B) (42, R-Y) (98, V-Y) (108, R-Y)
CN46-4 19
CN177-6 CN7-12 CN250-8 CN210-3 CN104-2
(104, G-R) (109, G-Y) (493, B-Y) (115, P) (44, R-B)
CN250-56 J30 CN246-1 CN144-3 J31 CN246-2 CN250-35 J32 CN101-1 C0101-2 J33 CN250-39
CN146-1 CN146-2 CN250-33 CN250-37
(236, R) (235, B) (3, G-B) (6, G-W)

BODY MAIN
CN102-3
CN102-4
CN127-2 CN87-5 CN87-6 CN87-7 CN87-8
(19, Y-B) (481, G-W) (482, L) (483, L) (484, G-W)
CN101-6 J66 CN250-43 CN101-5 J67 CN250-41 CN77-4 J68 CN97-1
CN250-45 CN250-47 CN102-26
(32, Y-L) (9, Y-R) (51, GR)
BODY MAIN SUB C/V SSR
CN174-3 CN115-1
CN177-8 J40 CN175-2 CN120-1 J41 CN117-7
CN175-3 CN119-1
(N2, W-B) (51, GR)
RR UPR MAIN
CN31-6 CN31-1
CN185-1 CN32-1 CN34-1
CN58-2 CN36-2
CN37-6 CN37-10 CN185-2 CN37-4 CN37-7
(111, R-L) (N2, W-B) (493, B-Y) (103, R-W) (104, G-R)
CN37-4 J56 CN237-1
CN38-3
(103, R-W)
HOOD
CN77-4 CN161-2
CN162-1
CN165-1 J51 CN163-1 CN76-9 J52 CN166-6 CN76-1 J53 CN170-1
CN164-1 CN170-2 CN161-1
(51, GR) (51, BR) (60, P-L)

LEVER CONT. UNIT
COMPARTMENT COMPARTMENT
LIGHT SW LIGHT
DISPLAY
SW
TEN KEY
SSR
SW
<COWL LEVER>
DIRECTION
HORN SW
STEERING
TURN&LT
TAB TAB TAB TAB CN62 TAB TAB CN63
REC REC REC REC TAB CN33 TAB REC REC
NTRL TILT ATT ACT REC
CN10 CN3 CN19 CN7 REC
SW SW HEAD LP
CN70
FLASHERRLY
TAIL LAMP RLY
I/LOCK RLY
FLASHER
KEY
TAB
REC
CN4 SW CLEARANCE
STEERING
SOL CN98
TAB TAB TAB
REC REC REC
TAB
REC
CN85 CN170 CN12 CN46 CN213 TAB
CONNECTING DIAGRAM
REC REC CN14 TAB REC

REC CN16
TAB TAB CN178 REC REC CN146
TAB TAB
HEAD LP
FLASHER
CLEARANCE
CN244 CN172 CN173
REC TAB REC
STOP LAMP SW EMERGENCY <COWL LEVER> TAB REC TAB
TAB SW
REC TAB CN89 TAB CN88 TAB CN117 TAB
COM
NC
NO
CN16 REC CN5 REC REC REC
TAB
CN14
REC
TAB
REC
CN176
(48,L-O) CN21
TILT
PKB SW DIAGNOSIS
SW H CN47
CN115
TAB
REC
(N1,W-B) CN22 CN120
CN174 CN175 CN119

TAB REC
TAB TAB TAB

REC REC REC
REC TAB
TAB CN15
REC
C/V
SOL
CN177
TAB
REC
HEIGHT SW <FORWARD/REVERSE NC RVS

COM CN92 BRAKE TRAVEL PEDAL>
VRAD PRESS ACCEL VRAD NO SW
NO SSR SSR SSR COM
REC
TAB
TILT ANG VRAT
NC TAB TAB TAB SSR
REC REC CN91 REC CN26 CN133 NC FWD
CN6 NO SW TAB
REC
TAB
COM
REC
CN86
CN90
TAB
REC
CLAMP LOCK
VALVE CN99 CN179
BATT
REC
TAB
REC
TAB
CN121 CN52
MOTOR
TAB
REC
TAB
REC
FAN
CN122 CN53
DRIVE DRIVE
TAB
TAB
MOTOR MOTOR
LH CN123 RH CN54
TAB
REC REC
TAB
REC REC
SPD2 SPD1 TEMP

SPD2 SPD1 TEMP
W V U W V U
CN118 TAB SEAT
REC
SW
TAB
REC
CN55
CN183
TAB
REC
TEMP
CN56
PUMP
SPD
TAB
REC
MOTOR TAB CN44
REC
CN601 CN603
W V U CN129 J/C J/C
REC
TAB
REC
TAB
IMPACT N2 VBKY
TAB
REC
SSR1
CN202 CN203 CN200 CN201 CN602 CN604
CN144 CAN CAN IMPACT J/C J/C

REC
TAB
TAB
REC
REC
TAB
TAB
REC
REC
TAB
REC
TAB
J/C J/C HORN DISP

TAB
REC
SSR2 12V PWR

DC/DC SUPPLY
TAB
REC
CN130
CN43 TAB
REC
<FR & RR CHIME>
<FINGERTIP CONTROL LEVER> TAB CN246
REC
RY1
TAB
REC
CN208 CHI
CN127 REC
TAB
CN101 REC TAB REC
TAB REC CN111 REC CN109 REC CN110
REC TAB TAB REC TAB TAB TAB
CN147 PUMP INV DRIVE INV LH DRIVE INV RH CN209 TAB
CN104 SOLID REC
(48,Y-R) CN136 REC CN217
CN148 STATE CONTACTOR TAB REC CHI
+ + + BZ
RLY1 TAB
P1 CN138 CN218
CPU U U U
TAB TAB TAB TAB
REC REC REC REC
SOLID
V V V STATE TAB TAB TAB TAB
REC REC REC REC
RLY2
CN24 CN23 CN24 CN23
W W W
(48,W-R) CN113 (48,W-B)
CN149 INV CN20
- - -
TAB
N2 N2
REC
FAN1
N2
CN112
(N1,B) CN219
(N1,B) CN219
INV CN210 CN211 CN212 CN207 CN40

TAB
REC REC REC REC REC SRG

REC
FAN2
CN75 CN76 CN77 CN97 TAB TAB TAB TAB TAB KILLER
TAB TAB TAB TIRE
VRAH ANG
REC CN37
REC REC REC
REC
TAB
TAB
LP
LP
OFF
KEY
SSR
RLY
RLY
<FINGERTIP CONTROL LEVER> CN37

HEAD
RLY
HEAD
RLY LH
ACC
H/L RLY
HORN
REC
CN37 TAB
FUSE HOLDER TAB CN32 CN237
TAB
REC
REC
CN250
DC/DC
REC TAB
TAB REC
REC REC REC CN238

CN36 REC REC CN185 CN73 REC CN125 REC
TAB CN31 TAB CN58 TAB TAB TAB TAB TAB CN34
CN38 REC
CN37 TAB <LED RR COMBI LAMP>
FLASHER STOP BACK BACK STOP FLASHER
RR HORN SW
TAIL UP UP TAIL
WORKING
SMART BLUE
BEACON LAMP
ALRM LIGHT WORKING
LAMP
LAMP SW
<FINGERTIP CONTROL LEVER> NTRL ATT

TAB TAB TAB TILT SW DIRECTION ACT SW
CN75 REC CN76 REC CN77 REC
LIFT TILT SW ATT1 ATT2
LEVER LEVER LEVER LEVER
CN78 TAB CN87 TAB CN88 TAB
REC REC REC
TAB TAB TAB TAB TAB TAB TAB

REC REC REC REC REC REC REC
TILT CN162 CN163 CN161 CN166 CN164 CN165 CN170
SW
<FINGERTIP CONTROL LEVER>
ARMREST
HORN SW
REC
TAB
C/V
SOL CN171
4-698
4-699
ELECTRIC WIRING DIAGRAM
P1 P2
FOR FINGERTIP CONTROL LEVER
MB P3
(P3, R-G)
F6
P4
F1
F53
F52
F51
SWK FOR FINGERTIP CONTROL LEVER FOR COWL LEVER
SWE (OPT) RYMS
(476, B-W)
(475, P)
(474, L-B)
(P2, G-Y) (41, G-R) (41, G) (43, B-Y) ACCEL BRAKE
F5
VRA2 VRB2 LIFT LEVER TILT LEVER
CONTACTOR PANEL (P2, GR) ATT1 LEVER ATT2 LEVER
VRL1 VRL2 VRT1 VRT2
BATT VRTA VRAT11 VRAT12 VRAT21 VRAT22
PIN CODE ENTRY (OPT) FAN3 FAN2 FAN1 SWTF SWTR
36V (48V)
VRTRA
SPLF IPL1 IPL2
VRA1 VRB1 SH SPB
EMERGENCY SW LESS
SSTR
RYAC
FOR COWL LEVER
(22, R-W)
(61, R-W)
(29, R-Y)
(23, R-L)
(62, R-L)
(105, G-W)
CSBAT+ (303, GR-L)
VRA1+ (53, BR-W)

VRA2+ (55, GR-R)
VRA1 (52, BR-R)
VRB2+ (74, BR-R)

VRA2 (54, BR-Y)
IPL1 (301, W-L)
VRTRA+ (316, L-W)
(313, L-W)
CSBAT- (305, B-O)
(314, G-Y)
CSBAT (304, L-O)
IPL2 (302, V-Y)
(312, B-Y)
VRTRA (317, L-R)
IPL+ (300, L-B)
(311, P-L)
SOLCOM (17, G-W)
SOLCOM (17, G-W)
SPB (66, G-W)

(97, R-W)
VRL+ (28, V-W)

RY1 (335, LG)
VRA12 (25, -P-L)

FNDC2 (99, G-R)
VRAT1+ (30, R-G)

CBAT- (2, LG-B)
VRA- (50, B-O)
SPLF (59, Y-G)
VRL2 (21, V-G)
VRAT2+ (31, P-G)

(44, R-B)
VRB2 (73, Y-R)
VRTA (56, Y-R)
SPLF+ (58, Y-R)
VRL1 (20, V-R)
VRA11 (24, R-B)

(43, B-Y)
VBMBSL (19, Y-B)

VBMBSL (19, Y-B)
FNDC1 (98, V-Y)
VRB1+ (72, L-O)

VRB1 (71, Y-B)
VRA21 (26, P-B)

VRTA+ (57, L-Y)
VRA22 (27, L-Y)
POT- (51, GR)

CBAT+ (1, G-R)
SH2-1 (91, W)
(41, G)
(41, G)
POT- (51, G)
SH1 (90, R)
LS- (51, B)
F5A
F45
F44
F43
F42
F41
F56
KEY OFF H/L OFF (OPT)
(496, B-R)
(101, L) (493, B-Y)
(490, GR-R)
VBBT
B48V
VBKY
VBMB
FAN+
VRT+
VRT1
VRT2
SSTRC
SSTR2
SSTR1
SSTR+
RYKH
(489, BR)
(488, Y-G)
(487, L-Y)
LS
MAIN CONTROLLER
(117, GR)
ACT
LB
PASCC+
(3, G-B) SOLLU+

(32, Y-L) SLTA1+
(6, G-W) SLTBL+

(9, Y-R) SLLA2+
(37, G-B) SA1PS-
(40, B-R) SA2PS-
(60, P-L) PSSW+

OACC2
(36, W-R) SA1PL-
(39, Y-B) SA2PL-

(145, GR-R) CAN1H
(8, G) SLTBL-
(7, W) SLTFL-
(42, R-Y) KYSAT
(146, P-B) CAN1L
(4, B-Y) SLLL-

(34, W-L) STPS-
(14, W-G) DGND

(11, B-W) SLPS-
(33, W-G) STPL-
(5, W-L) SLUL-

(10, B-Y) SLPL-
(329, R-G) SLS+
(330, W-L) SLS-
(67, L-O) SDM

(46, B-O) DSR
(68, B-R) SHS
(45, GR-R) DSF

(70, B-L) STK
(16, Y-B) D7V

(51, BR) LS-
F55
F54
N2
N2
N2
N2
(N2, W-B)
(N2, W-B)
(N2, W-B)
(N2, W-B)
(492, G-Y)
(491, G-B)
(334, L-O)
(114, BR)
RYH
F71
F72
F73
F74
F75
(332, R)
SA
F76
F79
F77
F78
(479, Y-R)
(480, Y-R)
STK DSF DSR SDM
(478, V)
(477, V)
(485, R)
RYIL
(481, G-W) (482, L) (483, L) (484, G-W) STK ACT
SWST SWCM SWW RYHR RYHL RYTL
F5C
F57
F58
F59
(48, L-O)
(118, L-Y)
(494, B-Y)
(495, B-Y)
(472, G-W)
(486, B-W)
(113, G-W)
RYF DSBU
RYBU SLPL SLPS STPL STPS SA1PL SA1PS SA2PL SA2PS SLS SLUL SLLL SLTFL SLTBL
(111, R-L)
(112, G-Y)
(107, Y-G)
(106, R-G)
(102, R-G)
(115, P)
(104, G-R)
(116, LG)
SLIL
FOR FINGERTIP CONTROL LEVER FOR COWL LEVER FOR COWL LEVER FOR FINGERTIP CONTROL LEVER
(110, L-O)
H
(103, R-W)
LCM LW SWF
DGND
D7V
(146, W) CAN1L
12V POWER (145, L) CAN1H DISPLAY
SWL SUPPLY
LEDTKY1
LEDKTY2
FORWARD/REVERSE
IPSTKY1
OKTY1
OTKY2
OTKY3
TRAVEL PEDAL (OPT)
TGND
ITKY1
ITKY2
ITKY3
(236, R)
(109, G-Y)
(108, R-Y)
48V
F81
N1
(231, Y-R)
LHR LHL
H T SWHR SWHA SWH
STEP- (152, G-R)

(150, G-R)
(145, GR)
(89, R-W)
(87, R-W)
(85, R-W)
KYSAT (42, R-Y)

(42, R-Y)
(79, R-B)
(42, R-Y)
(81, R-L)
(88, GR)
(86, GR)
(145, W)
(84, GR)
F82
(146, G)
(78, LG)
(75, LG)
(77, LG)
(146, V)
(145, P)
(146, L)
LSTR LSTL
(82, G)
(80, R)
(76, Y)
LBUR LBUL BZ CHI SSDL SSDR SSP
OUT+ (234, R-W)
IN- (233, W-R)

IN+ (232, L-R)
LFL LFR P41 P4
(169, GR-R)
LTL LCL
(166, GR-L)
OUT- (235, B)
(163, W-L)
(167, G-Y)
(161, R-B)
(165, R-Y)
(160, B-Y)
(164, L-O)
(168, L-B)
P7 U P71 U U P14 U
STEP2
CAN1L
CAN1H
STPM+
STPM
SSP1
SSP+
KYSAT
CAN1L
CAN1H
STDML+
STDML
SSDL1
SSDL+
SSDL2
SETDR-
SETDR1
KYSAT
CAN1L
CAN1H
STDMR+
STRMR
SSDR1
SSDR+
SSDR2
STDMR
U U
STDML
(162, G)
STPM
V P8 V ACMDL V P81 V ACMDR V P15 V ACMP
LTR LCR LFLR LFRR W P9 W W P91 W W P16 W
ACMDDL ACMDDR ACMDP
TEN KEY
DC/DC
N1
PIN CODE ENTRY (OPT)
VBKY (486, B-W)

PSACC+ (334, L-O)
CAN1H (145, R-L)

GND (N2, W-B)
CAN1L (146, L-Y)
BATT BATTERY SLTFL SOLENOID, TILT, FORWARD LOCK VRAT21 VARIABLE RESISTOR, ATT2, NO.1 BZ BUZZER RYHR RELAY, HEAD LAMP, RH
MB CONTACTOR, BATTERY SLTBL SOLENOID, TILT, BACKWARD LOCK VRAT22 VARIABLE RESISTOR, ATT2, NO.2 CHI CHIME RYTL RALAY, TAIL LAMP
F FUSE SLIL SOLENOID, CLAMP INTERLOCK H HORN RYF RELAY, FLASHER
STK SWITCH, TILT KNOB SA SURGE ABSORBER RYH RELAY, HORN
ACMDL AC MOTOR, DRIVE, LH SLPL SOLENOID, LIFT PULL ACT SWITCH, ATT CLAMP INTERLOCK RYAC RELAY, ACCESSORY DIAGNOSIS
ACMDR AC MOTOR, DRIVE, RH SLPS SOLENOID, LIFT PUSH DSF DIRECTION SWITCH, FORWARD LHL LAMP, HEAD LH RYIL RELAY, CLAMP INTERLOCK
ACMP AC MOTOR, PUMP STPL SOLENOID, TILT PULL DSR DIRECTION SWITCH, REVERSE LHR LAMP, HEAD RH RYMS RELAY, FINGERTIP CONTROL LEVER SOL
ACMDDL AC MOTOR DRIVER, DRIVE, LH STPS SOLENOID, TILT PUSH SWS SWITCH, SEAT LCL LAMP, CLEARANCE LH RYKH RELAY, KEY OFF H/L OFF
ACMDDR AC MOTOR DRIVER, DRIVE, RH SA1PL SOLENOID, ATT1 PULL SH SWITCH, HEIGHT LCR LAMP, CLEARANCE RH RYBU RELAY, BACK-UP
ACMDP AC MOTOR DRIVER, PUMP SA1PS SOLENOID, ATT1 PUSH SPB SWITCH, PARKING BRAKE LTL LAMP, TAIL LH
SA2PL SOLENOID, ATT2 PULL SWE SWITCH, EMERGENCY LTR LAMP, TAIL RH FR&RR CHIME MOTION ALARM DC/DC FOR LED RR COMBI
FORWARD/REVERSE PEDAL (OPT)
(472, G-W)
SSDL SENSOR, SPEED, DRIVE, LH SA2PS SOLENOID, ATT2 PUSH SWK SWITCH, KEY LFL LAMP, FLASHER LH
(332, R)
SSDR SENSOR, SPEED, DRIVE, RH SWTF SWITCH, TILT FR LFR LAMP, FLASHER RH
(495, B-Y)
(495, B-Y)
SSP SENSOR, SPEED, PUMP VRA1 VARIABLE RESISTOR, ACCEL, NO.1 SWTR SWITCH, TILT RR LFLR LAMP, FLASHER LH RR RYBU
STDML SENSOR, TEMPERATURE DRIVE, LH VRA2 VARIABLE RESISTOR, ACCEL, NO.2 SWST SWITCH, STOP LAMP LFRR LAMP, FLASHER RH RR
(334, L-O)
DSBU DSFO DSBU IN DC/DC OUT
STDMR SENSOR, TEMPERATURE DRIVE, RH VRB1 VARIABLE RESISTOR, BRAKE, NO.1 SWCM SWITCH, COMPARTMENT LIGHT LSTL LAMP,STOP LH 36V (48V) 12V
STPM SENSOR, TEMPERATURE PUMP VRB2 VARIABLE RESISTOR, BRAKE, NO.2 SWW SWITCH, WORKING LAMP LSTR LAMP,STOP RH (103, R-W) BACK-UP BACK-UP (203, R-W)
SPLF SENSOR, PRESSURE LIFT VRTA VARIABLE RESISTOR, TILT ANGLE SWL SWITCH, LIGHT LBUL LAMP, BACK-UP LH (111, R-L) STOP STOP (211, R-L)
(104, G-R) TAIL TAIL (204, G-R)
SSTR SENSOR, STEERING VRTRA VARIABLE RESISTOR, TIRE ANGLE SWF SWITCH, FLASHER LBUR LAMP, BACK-UP RH (109, G-Y) TURN L TURN L (209, G-Y)
(45, GR-R)
(103, R-W)
(120, Y-R)
(103, R-W)
(198, R-W)
(108, R-Y) TURN R TURN R (208, R-Y)
(46, B-O)
IPL1 SENSOR, IMPACT, NO.1 VRL1 VARIABLE RESISTOR, LIFT, NO.1 SWH SWITCH, HORN LW LAMP, WORKING
(51, BR)
(N2, W-B) GND GND (N2, W-B)
IPL2 SENSOR, IMPACT, NO.2 VRL2 VARIABLE RESISTOR, LIFT, NO.2 SWHA SWITCH, HORN ARMREST LCM LAMP, COMPARTMENT
VRT1 VARIABLE RESISTOR, TILT, NO.1 SWHR SWITCH, HORN RR LS LAMP, STROBE LBUR LBUL BZ
SLS SOLENOID, STEERING VRT2 VARIABLE RESISTOR, TILT, NO.2 DSFO DIRECTION SWITCH, FORWARD OPT LB LAMP, BLUE
SLUL SOLENOID, UNLOAD VRAT11 VARIABLE RESISTOR, ATT1, NO.1 DSBU DIRECTION SWITCH, BACK-UP CHI
DSR
DSF
LS
SLLL SOLENOID, LIFT LOCK VRAT12 VARIABLE RESISTOR, ATT1, NO.2 RYHL RELAY, HEAD LAMP, LH
1237640B
Printed in the USA

4460 00001-Up MM

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Maintenance Manual

Model 4460 3-Wheel Sit-Down Counterbalanced

Model: Serial Numbers:

Publication: 1237640B Revised: 25 May 2020

©2020 The Raymond Corporation.

1.1. LIFT TRUCK EXTERIOR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1. LIFT TRUCK EXTERIOR VIEW

1.2. LIFT TRUCK MODELS 1

1.3. FRAME NUMBER

Lift truck model Punching format

(a) Frame serial number location

1.4. HOW TO USE THIS MANUAL

1.4.1. EXPLANATION METHOD

2) Matters omitted from this manual

Standard: Values showing allowable range in inspection and adjustment.

ASC Automatic Speed Control PS Power steering

Performance Stability System (PSS

ATT Attachment QR Quick Reference

FR Front RH Right hand

LH Left hand RR Rear

Society of Automotive Engineers

OCL Over Current Limit SOL Solenoid

OCV Oil Control Valve SST Special service tool

OPS Operator Presence Sensor STD Standard

OPT Option T= Tightening torque

PKB Parking brake W/ With

1.5. OPERATING TIPS

1.5.1. JACK-UP POINT 1

(a) Jack-up point

1.5.2. HOISTING THE VEHICLE

• Position the mast in the full rearward tilt position.

1.6. STANDARD BOLT & NUT TIGHTENING TORQUE 1

1.6.1. BOLT STRENGTH TYPE IDENTIFICATION METHOD

Hexagon flange bolt No mark 4T

Hexagon head bolt Two protruding lines 5T

Hexagon flange bolt Two protruding lines 6T

Hexagon head bolt Three protruding lines 7T

Hexagon head bolt Four protruding lines 8T

IDENTIFICATION BY PART NO.

Hexagon head bolt Stud bolt

1.6.2. TIGHTENING TORQUE TABLE 1

Specified torque Specified torque

Hexagon flange bolt

1.7. PRECOAT BOLTS

2. Method for reuse of precoat bolts

1.8. HIGH PRESSURE HOSE FITTING TIGHTENING

Nominal diameter Standard tightening torque Hose nominal size

1 5/16 - 12UNF 101.1 [137] 95.9 to 106.2 0.98 (25) 1

1.9. RECOMMENDED LUBRICANT QUANTITY AND TYPES

Application Type Capacity

Drive unit (ATF) AUTOMATIC TRANSMISSION FLUID Approx.0.145 US gal (0.55 L)

Chassis parts MP grease Appropriate amount

Battery Distilled water Appropriate amount

Brake fluid SAE J-1703 DOT3 Appropriate amount

Hydraulic oil level by lifting height

Lifting height All models

To 118 in. Capacity 4.70 (17.8)

To 157.5 in. Capacity 5.17 (19.6)

To 275.6 in. Capacity 5.41 (20.5)

1.10. LUBRICATION CHART

○: Inspection and addition

1. Mast strip 8. Steering rack and pinion gear

1.11. PERIODIC MAINTENANCE TABLE 1