Service Manual Controller EP16N-20CN 99759-68100

Service Manual
Controller
EP16N-48V ETB15-20011-up
EP18N-48V ETB15-70001-up
EP20CN-48V ETB17-20011-up
For use with EP16N-EP20CN Chassis Service Manual. 99759-68100

FOREWORD
This service manual is a guide to servicing of Cat® lift trucks. The instructions are grouped by
systems to serve the convenience of your ready reference.
Long productive life of your lift trucks depends to a great extent on correct servicing — the
servicing consistent with what you will learn from this service manual. We hope you read the
respective sections of this manual carefully and know all the components you will work on
before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the trucks of
serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right
to change specifications or design without notice and without incurring obligation.
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicate a specific potential hazard

! WARNING resulting in serious bodily injury or
death.
Indicate a specific potential hazard

! CAUTION
resulting in bodily injury, or damage
to, or destruction of, the machine.
Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.
Pub. No. 99759-68100

! WARNING
SAFETY
! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this lift truck, recommended and understand the instructions in the
by Cat lift truck, are outlined in the OPERATION OPERATION & MAINTENANCE MANUAL.
& MAINTENANCE MANUAL for these trucks. Improper truck operation is dangerous and
Improper performance of lubrication or could result in injury or death.
maintenance procedures is dangerous and
could result in injury or death. Read and 4. Lower the forks or other implements to the ground
understand the OPERATION & MAINTENANCE before performing any work on the truck. If this
MANUAL before performing any lubrication or cannot be done, make sure the forks or other
maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using steps,
work. A knowledge of the system and/or components ladders and walkways. When it is not possible to
is important before the removal or disassembly of any use the designed access system, provide ladders,
component. scaffolds, or work platforms to perform safe repair
Because of the size of some of the truck components, operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting operation.
1. Read and understand all warning plates and decals
on the truck before operating, lubricating or 7. To avoid burns, be alert for hot parts on trucks
repairing the product. which have just been stopped and hot fluids in
lines, tubes and compartments.
2. Always wear protective glasses and protective
shoes when working around trucks. In particular, 8. Be careful when removing cover plates. Gradually
wear protective glasses when pounding on any part back off the last two bolts or nuts located at
of the truck or its attachments with a hammer or opposite ends of the cover or device and pry cover
sledge. Use welders gloves, hood/goggles, apron loose to relieve any spring or other pressure, before
and other protective clothing appropriate to the removing the last two bolts or nuts completely.
welding job being performed. Do not wear loose- 9. Be careful when removing filler caps, breathers and
fitting or torn clothing. Remove all rings from plugs on the truck. Hold a rag over the cap or plug
fingers when working on machinery. to prevent being sprayed or splashed by liquids
3. Do not work on any truck that is supported only by under pressure. The danger is even greater if the
lift jacks or a hoist. Always use blocks or jack truck has just been stopped because fluids can be
stands to support the truck before performing any hot.
disassembly.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or 22. When handling the parts containing asbestos, be
wire to provide a weld metal strength equivalent at careful not to inhale the asbestos. Doing so is
least to that of parent metal. hazardous to your health.
15. Do not damage wiring during removal operations. If the shop dust may contain asbestos, follow the
Reinstall the wiring so it is not damaged nor will it precautions described below.
be damaged in operation by contacting sharp a. Do not use compressed air for cleaning.
corners, or by rubbing against some object or hot b. Do not brush or apply grinder on asbestos
surface. Place wiring away from oil pipe. containing materials.
16. Be sure all protective devices including guards and c. To clean asbestos containing materials, wipe
shields are properly installed and functioning with moistened cloth or use a vacuum cleaner
correctly before starting a repair. If a guard or with particle filter.
shield must be removed to perform the repair work,
d. If you have to handle the parts containing
use extra caution.
asbestos for a long time, be sure to do it in a
17. Always support the mast and carriage to keep well-ventilated area.
carriage or attachments raised when maintenance
e. If the asbestos in the air cannot be removed,
or repair work is performed, which requires the
wear a mask.
mast in the raised position.
f. Be sure to observe the working rules and
18. Loose or damaged fuel, lubricant and hydraulic
regulations.
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which g. When disposing of materials with asbestos, be
have been bent or damaged. Inspect lines, tubes sure to observe the environmental protection
and hoses carefully. Do not check for leaks with regulations of your area.
your hands. Pin hole (very small) leaks can result h. Avoid working in the atmosphere where
in a high velocity oil stream that will be invisible asbestos particles may be suspended.
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
Procedures are described in the text.

Disassembling sequence
209603
Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)
Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
Item SI unit Customary unit

1N 0.1020 kgf
Force
(1 lbf) (0.4536 kgf)
1 kPa 0.0102 kgf/cm2
Pressure
(1 psi) (0.0703 kgf/cm2)
1 N·m 0.1020 kgf·m
Torque
(1 lbf·ft) (0.1383 kgf·m)
GROUP INDEX
GROUP INDEX Items
Controller system, Controller features, Setup option, Diagnosis, Removal and

CONTROLLER
installation, Basic check
1
TROUBLESHOOTING
Faulty central vehicle monitor system, Faulty diagnosis indication,
FOR CONTROL 2
or Other abnormalities
CIRCUITS
Motor installation positions, Specifications, Structures, Tightening of high-power

MOTORS cable terminals, Procedures and suggestions for removal and installation, 3
Procedures and suggestions for disassembly and reassembly
CONTROLLER
Controller System .................................................................................. 1 – 1

System Layout .......................................................................................... 1 – 1 1
Controller Area Network (CAN) ................................................................. 1 – 3
Outline of Controller .................................................................................. 1 – 4
Controller Features ................................................................................ 1 – 10
Traction Features ...................................................................................... 1 – 10
Lifting Features ......................................................................................... 1 – 12
Outline Features ....................................................................................... 1 – 13
Setup Option ........................................................................................... 1 – 16
Outline ...................................................................................................... 1 – 16
Operation Procedure ................................................................................ 1 – 16
Details of Setup Options ........................................................................... 1 – 18
Diagnosis .................................................................................................. 1 – 35
Outline ...................................................................................................... 1 – 35
Operation Procedure ................................................................................ 1 – 35
Self-Diagnostics ........................................................................................ 1 – 38
Run Time Diagnostics ............................................................................... 1 – 39
Removal and Installation ...................................................................... 1 – 41
Inverter Discharging Procedure ................................................................ 1 – 41
Replacing Inverter ..................................................................................... 1 – 42
Replacing DSP (Digital Signal Processor) Card ........................................ 1 – 44
Replacing Logic Unit ................................................................................. 1 – 46
Replacing Logic Card ............................................................................... 1 – 47
Replacing Power Supply Card .................................................................. 1 – 48
Replacing Input Unit ................................................................................. 1 – 49
Replacing Output Unit ............................................................................... 1 – 50
Basic Check ............................................................................................. 1 – 51
Testing Tools ............................................................................................. 1 – 51
Measurement of Card Voltage ................................................................... 1 – 52
Checking Contactor Coil ........................................................................... 1 – 57
Checking Contactor Tip ............................................................................. 1 – 57
Checking Inverter ...................................................................................... 1 – 58
Regeneration Check ................................................................................. 1 – 59
AC Motor System Basics ..................................................................... 1 – 60
CONTROLLER
Controller System
The configuration of the controller system is classified
System Layout into two types according to the lifting system.
Four or six independent controllers are linked together The input unit is connected to the FC control lever.
by the Controller Area Network (CAN) to communicate The output unit is connected to the FC hydraulic control
with each other to control the truck. valve assembly.
The logic unit is the heart of the control system for the The inverters are connected to the each motor.
lift trucks.
The logic unit is connected to the other devices.
System layout for FC type
Contactors
Switches
Display Logic
unit
Key
switch FC control lever
Power
B2
R
N
F
Direction lever
Input
unit
Accelerator
CAN bus
Lift cylinder,
Right Left Pump Output Tilt cylinder
traction traction inverter unit
inverter inverter
FC hydraulic
control valve
Sensors Sensors Sensors assembly
U U U Lift lock
V M V M V M solenoid valve
W W W
Hydraulic
Right drive motor Left drive motor Pump motor pump
211321
1-1
CONTROLLER
System layout for MC type
Contactors
Switches
Display
Key
switch
Power
B2
R
N
F
Logic
Direction lever unit
Accelerator
CAN bus
Right Left Pump

traction traction inverter Lift cylinder,
inverter inverter Tilt cylinder
Micro switches
MC hydraulic
Sensors Sensors Sensors control valve
U U U assembly
V M V M V M
W W W Lift lock
Hydraulic solenoid valve
Right drive motor Left drive motor Pump motor pump Unload
solenoid valve
211322
1-2
CONTROLLER
Controller Area Network (CAN)

Each controller has internal terminal resistors and is
linked with the truck harness to form a network as
follows.
*1 *2
Right Left Logic Input Output Pump
traction traction unit unit unit inverter
inverter inverter
CAN H
CAN L
*1, * 2: Input unit and output unit are used

for FC model only.
211323
The data are expressed with electric potential difference

in high- and low-level signals as follows.
They are transferred to each controller through serial
communication protocol.
Kind of VCAN-L
potential
bit Logic Vdiff Vdiff
dominant 0 VCAN-H
recessive 1 recessive dominant recessive

time
211176
Main specifications
Communication protocol CANbus 2.0B passive Non-Return to Zero method

Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
1-3
CONTROLLER
Outline of Controller
1. Logic unit
This controller includes the power card and logic card.
It controls all the jobs for the truck based on the
operator’s input.
The controller sends a motor control command to the
right and left traction inverters through the input of the
direction lever or the accelerator pedal. It also monitors
malfunctions of the traction system.
The lever input triggers to send the motor control
commands to the pump inverter. It also monitors
malfunctions in the hydraulic control system. In the FC
specifications, this controller sends a control command
to the solenoid valves from the output unit by the lever
input. A malfunction in the valve control system is also
monitored by this controller.
The truck speed and residual battery power are
monitored and shown on the display unit.
The logic unit sets its model information and optional
default data into internal memory. The information is
secured when the power supply is turned off. This
information is set at the factory.
The following table shows the model information. The
system will not work properly if the actual controller
system is different from the model information.
Model information
Item Description SUO No.

Truck type Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Hydraulic control selection FC type, MC type #43
Mast type Mast type #44
Valve section Number of valves #45
Battery voltage adjust Battery voltage adjustment #46
Foot direction Optional equipment #47
The current information is available to confirm and

modify.
Refer to Setup Option on page 1-16 for details and
setting procedure.
1-4
CONTROLLER
Logic unit
šŽŲųź
ŧųƀŷůź¸ŢŽ¼¼ ŬŬŬŬŬŬ
211177
Logic card
CN1
Harness B side CN3 Harness B side CN2 Harness B side CN1

211178
Power supply card

&+6,%"%%*%%KZg)#(
CN1
ŬŬŬŬŬŬ
B>IHJ7>H=>=:6KN>C9JHIG>:H!AI9 '%%*#BVg#KZg)#(
Power supply card side CN1 Harness B side CN4

211179
The Service Tool connector exists on harness B CN21.

1-5
CONTROLLER
2. Inverter When a malfunction occurs, it stops the motors and

informs to the logic unit.
The inverter is a motor drive controller that consists of
Digital Signal Processor (DSP) card, Insulated Metal The IMS module has plural MOS-FET modules and
Substrate (IMS) module and their drive boards. converts the battery DC current into AC current for
supplying to the drive and pump motors. See also the
It drives the AC induction motors according to the
“AC Motor System Basics” section on page 1-60.
motor control command from the logic unit. It also
monitors malfunctions of motors and its own condition.
Traction inverter (right and left)
DSP card
ŧųƀŷůź¸ŢŽ¼
šŽŲųź
ŬŬŬŬŬŬŽ
Ž¼ 211180
Traction inverter
DSP card
(right and left)
ŬŬŬŬŬŬ
CN2
Harness B side, Traction Right CN7

Inverter card side CN2 Harness B side, Traction Left CN6
211181
1-6
CONTROLLER
Pump inverter
DSP card
ŧųƀŷůź¸ŢŽ¼
šŽŲųź
ŬŬŬŬŬŬ Ž¼
211182
Pump inverter
DSP card
ŬŬŬŬŬŬ
CN2
Inverter card side CN2 Harness B side, Pump CN5

211183
1-7
CONTROLLER
3. Input unit
This input unit is connected on the FC specification
models. It is the dedicated input unit for connecting
equipment such as the FC control lever and switches. It
monitors for the malfunction of connected equipment
and its own condition. When a malfunction occurs, it
informs to the logic unit.
Input unit
šŽŲųź
šŽŲų
ųź ŌōŪ
Ōō
ōŪ
ŧųƀŷůź ŢŽ¼¼ ŬŬŬŬŬŬ
Input unit card

CN1
Input unit card side CN1 FC-IN harness side CN2

211184
1-8
CONTROLLER
4. Output unit
This output unit is connected on the FC specification according to the valve control command from the logic
models. It is the dedicated output unit for controlling unit. It monitors for the malfunction of the solenoid
the solenoid valves. It drives the solenoid valves valves and its own condition. When a malfunction
occurs, it informs to the logic unit.
Current to
solenoid [%]
100
Current increases
drastically as lever
movement angle
increases.
0
100 Lever angle [%]
209550
Current characteristics of proportioning

solenoid valve
Output unit
šŽŲųźŌōŪ
Ō
ŧųƀŷůź ŢŽ¼¼ ŬŬŬŬŬŬ
Output unit card

CN3
Harness B side CN22 FC-OUT harness side CN9

211185
1-9
CONTROLLER
Controller Features
The following describes the features of controller.
Traction Features
1. Modification of traction characteristics
Acceleration power, maximum output power and There are two types of auto regeneration and selectable.
battery consumption can be set. The following two Accelerator regeneration type: The regeneration starts
parameters can be set. when the accelerator
Acceleration rate: Sets acceleration power. pedal is released during
Traveling power: Selection of the maximum output traction.
power changes the amount of Brake regeneration type: Releasing the accelerator
battery consumption. It also pedal during traction
influences the acceleration power causes dry run. The
during loading operation. regeneration starts when
Regeneration power and type of regeneration can be the brake pedal is
set. There are two types of regeneration and each has pressed.
availability of setting for regeneration power. The lever regeneration starts when the travel direction
Auto regeneration: Normal deceleration that occurs and the direction lever are in opposite directions. The
between the traveling and the amount is determined by the pressure on the accelerator
direction lever when they are in the pedal.
same direction.
Lever regeneration: The deceleration that occurs
between the travel and the direction
lever when they are in the opposite
directions.
Setting feature for traction characteristics

Description SUO No.
Acceleration rate Acceleration of traction #8
Powering Traveling power Max. power, amount of battery #9
consumption
Regen function Selection of auto regeneration #21
Regen adjustment for auto regen Rate of regeneration at normal #23
Regeneration slowdown
Regen adjustment for lever regen Rate of regeneration when operating to #22
the opposite direction
Refer to page 1-16 for details and setting procedure of controlled roll-back function prevents hazardous
the “Setup Option.” descending of the truck.
The application preset feature (#1) has the preset The descending speed changes with the steepness of
setting pattern registered. grade, the weight of load and value setting of the SUO
#23.
2. Controlled roll-back NOTICE: When the regeneration is selected by SUO

#21, the controlled roll-back does not work.
When the accelerator pedal is released on a grade, the
1-10
CONTROLLER
3. Boost
When the truck traveling is blocked by a step, the boost Fully depress the accelerator pedal for 2 seconds, the
function prevents stall of the truck. Usually the motor boost function increases the motor torque maximum for
maximum torque is set by SUO #9, this function allows 5 seconds. If the pressure to the accelerator pedal is
to climb over a step regardless of the value setting of reduced or the direction lever is moved, the boost
the motor maximum torque. function is immediately cancelled.
Torque [%]
* Torque required to
climb over a step
* #9
100 HIGH POWER; Full acceleration
85 STANDARD; Full acceleration

70 ECONOMY; Full acceleration
0 Time [sec]
2 7
211324
NOTICE: When the motor overheats, the boost will not work.
If the stall time setting is small, the motor protection function will be applied during prolonged slow
speed traveling.
4. Limitation of maximum travel speed

The speed limitation is classified into two major types Conditional type: The limitation that is triggered from a
and available to set each maximum speed. specific switch input occurrence.
Normal type: The limitation that functions at all Selectable quadruple input signals.
times and is used to keep the speed Available to set a speed limit for each
within the limits. signal.
Feature of maximum speed limit
Description SUO No. Harness Pin No.

Normal Top travel speed limit Always effective #7 –
Auxiliary travel speed limit 1 Effective when aux. input 1 close/open #11, 12 CN2-30
Conditional
Auxiliary maximum travel speed Effective when aux. switch close/open #30, 31 CN2-31
1-11
CONTROLLER
5. Miscellaneous features for traction
Miscellaneous features for traction

Item Description SUO No. Harness Pin No.
Auxiliary power reduction 1 Effective when aux. input 1 close/open #11, 13 CN2-30
Auxiliary output power limit Effective when aux. switch close/open #30, 32 CN2-31
Speed alarm 1 Alarm 1 signal output if speed exceeds set value. #26 CN1-61
Speed alarm 2 Alarm 2 signal output if speed exceeds set value. #34 CN1-62
Tire size adjustment Correction value to compensate for a diameter change #27 –
resulting from tire wear
Stall timer Stops drive motor to protect if truck does not move within #20 –
set time.
Lifting Features
1. Setting and limitation of lift work speed
Each lift work speed can be set. The lift work speed can
be limited or stopped when specific switch input
occurs.
Triple input signals are selectable and available to set
limit value to each signal.
Feature of lifting work speed setting
Description SUO No. Harness Pin No.

Start lift speed Start lift speed setting #2 –
Top lift speed Top lift speed setting #3 –
Lowering lift speed Lowering lift speed setting #35 –
Normal Tilt speed Tilt speed setting #4 –
Auxiliary 1 speed Attachment 1 #5 –
Auxiliary input for lift 1 Stops lift when aux. input 1 close/open #11 30
Conditional Auxiliary input for lift 2 Stops lift when aux. input 2 close/open #14 40
Auxiliary input for lift 3 Stops lift when aux. input 3 close/open #17 41
Refer to page 1-16 for details and setting procedure of

the “Setup Option.”
The application preset feature (#1) has the preset
setting pattern registered.
1-12
CONTROLLER
Outline Features
1. Diagnosis/Run/Setup (DRS) modes
The controller has three major modes and seven
features as shown in the table below.
DRS modes
Mode Description
Self diagnosis Performs failure diagnosis of apparatus.
Diagnosis
Run time diagnosis data Displays malfunction history occurred in use.
Run – Normal mode
Default data set Sets default data of Group 1 & Group 2.
Group 1 data set Sets basic function (#1 to #10).
Setup
Group 2 data set Sets advanced function (#11 to #35).
Group 3 data set Sets model information (#40 to #47).
Refer to page 1-16 for details and setting procedure of

the “Setup Option.” Also, refer to page 1-35 for details
and setting procedure of the “Diagnosis.”
R
DRS switch
DRS switch is installed under floor

plate at right side of truck. 211186
2. PDS (Presence Detection System) features

This controller is part of the “Presence Detection which provides “certain product intelligence” to the
System” (PDS) of the truck. This system features an operator. The table shows processes for traction and
enhanced, integral computer based feed back system lifting. Refer to the Status Transfer Chart for details.
PDS features
Protect condition Result Release method

Seat Sit → Leave Slowdown Sit
Traction control and Direction lever: N
Direction lever F or R Stop Accelerator pedal: Release
Sit
MC
Hydraulic Control valve SW: All open
Seat Sit → Leave Stop
control Sit
FC
FC control lever: All neutral
1-13
CONTROLLER
Status transfer chart
Traction Control PDS Seat SW

Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Normal operation
Seat SW flag: OFF Seat Sw flag :
Seat SW: ON OFF
Direction lever: N (Chosen foot direction: no effect)
Seat SW flag: OFF

Motor: Regen brake Travel speed 0.5km/h
Display: Blinking "E"
Motor: Zero torque

Seat SW flag: OFF Seat SW flag: ON Display: Blinking "E"
Line Contactor OFF
Motor: Regen brake Seat SW flag: OFF Seat SW flag: ON

Display: "E"
Motor: Zero torque

Display: "E"
Direction lever: N
Travel speed 0.5km/h Line Contactor OFF
Accelerator pedal: OFF
Direction lever: N
Accelerator pedal: OFF
Seat SW
Seat Sw flag: ON Seat SW off time Delay time
2 sec or 3 sec
Hydraulic Control PDS
Seat Sw flag :
Seat SW: ON OFF
MC Specification FC Specification
Normal operation Normal operation

Seat SW flag: OFF Seat SW flag: OFF
Lift lock valve: LOCK FC solenoid: All off

Unload valve: UNLOAD Display: Blinking "L"
Display: Blinking "L" 0 Speed: Pump Contactor OFF
0 Speed: Pump Contactor OFF
Seat SW flag: ON Seat SW flag: ON
Seat SW flag: OFF Seat SW flag: OFF
Lift lock valve: LOCK FC solenoid: All off

Unload valve: UNLOAD Display: "H1 to H5"
Display: "H1 to H5" 0 Speed: Pump Contactor OFF
0 Speed: Pump Contactor OFF
Control valve SW: All off FC control lever: All neutral

(LIFT lever doesn't have SW to detect DOWN.) 211187
1-14
CONTROLLER
3. BDI display features

This feature shows with 11 levels (BDI 0 to BDI 10) of
remaining battery capacity of the current battery
voltage.
Set #41 or #42 depends on installed battery type and

voltage.
For further details, see OMM.
4. Miscellaneous features
The table shows miscellaneous features.
Miscellaneous features
Item Description SUO No.

Service indicator Shows or warns maintenance time. #10
Speed, error code, hour-meter, BDI, etc. are shown depending on DRS
mode.
Display unit Diag. mode: Refer to Operation on page 1-35. –
Run mode: Normal operation mode.
Setup mode:Refer to Operation on page 1-16.
1-15
CONTROLLER
Setup Option turned off.

The model information and various features are set
Outline during factory shipment.
The logic unit is equipped with a type of memory The setup options are categorized from Group 1 to
module to hold recorded data even if the main power is Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Advanced function (#11 to #35)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value each setup mode.
in a one-step operation and can be customized in Summary list in each group is shown on page 1-31 to 1-
accordance with applications. Since the Group 3 is for 34.
model information, it is required to be set to the same
value as actual control system. It will not work properly
if the model information is different. Operation Procedure
When setting the setup option data for the first time Turning on the key switch allows you to enter one of
after the assembly is completed or the logic card is the modes in each setup group and show as the figure.
replaced, be sure to set Group 3 data first, then the You can not transfer to another mode unless the source
default data of Group 1 and 2, with the “service tool” in power is turned off.
Entry to setup mode
DRS Direction Accel. Lift Tilt Attachment 1

Function Description Seat
switch lever pedal lever lever lever
Default data Sets default data of Not
S R ON OFF OFF OFF
set Group 1 & Group 2. sit
Checks and sets basic Not
Group 1 data S N OFF OFF OFF OFF
function (#1 to #10). sit
Checks and sets advanced Not Pull Pull
Group 2 data S N OFF OFF
function (#11 to #35). sit back back
Checks and sets model Not Pull
Group 3 data S N OFF OFF OFF
information (#40 to #47). sit back
First SUO # of each group

“01” for group 1
Current set value for SUO #11*

donE is flickering for Default data set 209558 *The current value is displayed. For the meaning of
each number or symbol displayed, refer to the
First SUO # of Group 2 setup options “Range” column of the relevant Setup Options
(example) table and Notes below the table.
1-16
CONTROLLER
Selecting SUO # and changing set value

How to change set value
The set value change procedure consists of selecting the When changing setting of SUO #20 (stall timer) from
desired SUO # using the DRS switch, change the set value default 5 seconds to 3 seconds:
by moving the direction lever, and registering the new
value. Step 1. Since the SUO #20 belongs to Group 2 setup
options, cause the first SUO # “11” of the group
to appear on the screen using the operation
• Cycle the DRS switch S → R → S. The set value procedure on page 1-16.
displayed on the screen is registered. The SUO # on the
screen then advances to the next SUO #. Changing the
set value is now possible for the SUO #.
The first half of the DRS switch operation (S→R) is for Step 2. Move the DRS switch as follows to change the
overwriting the previous value with the value on the current setting for the SUO #20.
screen (registering). When the value is registered, a set R (1) Move the DRS switch S →R.
of three dotted lines appears on the screen as shown in S
Pull The display changes as shown
the illustration on the right. The second half of the below. The set value (0) for
operation (R→S) is for advancing the SUO #. the SUO #11 is overwritten
simultaneously.
• Every time the DRS switch is cycled S→R→S, the SUO
# increments. When advancing the SUO # without
changing the set value, simply repeat by cycling the
switch as many times as necessary. When the last SUO
# is reached, “donE” appears in the set value display
area. R (2) Move the DRS switch R →S.
S
Pull The display shows the current
• Use the direction lever to change the set value. The
setting for the next SUO #12.
value increases when the lever is cycled N→F→N; it
decreases when the lever is cycled N→R→N. In either
case, by increasing or decreasing direction, the value
returns to the first or last value in the available value
range.
(3) Cycle the DRS switch S→R→S 8 times to cause the
SUO #20 to appear on the screen.
Default value 5 for SUO #20
Step 3. Change the set value from 5 to 3 by moving the

direction lever N→R twice.
Value increases.
Direction
lever F
N
R
Value decreases.
Step 4. Register the new value by cycling the DRS
switch S → R → S. The current value is
overwritten with the new value. The screen
shows the next SUO #21. 211188
1-17
CONTROLLER
Details of Setup Options

1. Setup Options (Group-1)
#1 Application Pre-Sets (Truck Operation Mode)

Truck mode can be selected from A to E, each with
preset values for maximum vehicle speed, acceleration
rate, power, automatic regeneration power, start lift
speed, top lift speed and tilt speed.
These 7 settings are automatically set by changing the
value of this setting.
Preset values for each setting are as follows (#40 EE
type : C only) .
• 48V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Fast
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Fast
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium Medium
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 15 7
Default value
Acceleration Rate 3 5 2 3 5 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
You can modify these 7 settings afterwards

individually. When settings are changed the indication
(A to E) will be flickered to indicate that the settings
are modified.
1-18
CONTROLLER
• 36V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Fast
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Fast
Characteristic
Acceleration Medium Medium Medium Medium Medium
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium Medium
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 6 10 3 6 6 3
Tilt Speed 5 7 5 7 7 4
Max Vehicle Speed 15 17 12 17 13 7
Default value
Acceleration Rate 3 3 2 3 3 8
Traveling Power 2 3 1 3 2 9
Automatic
5 9 3 7 9 23
Regeneration
#2 Start Lift Speed

This setting affects pump speed when you start lifting
operation.
FC spec: speed when the lift lever is slightly pulled
MC spec: speed when lift switch 1 is turned on
Lift speed of the rise direction will become faster if the
setting value is increased.
The setting range is 1 to 10 (#40 EE type : 1 to 8).
1-19
CONTROLLER
FC MC
#3 Top Lift Speed
This setting affects pump speed when you pull the lift MC spec: speed when lift switch 2 is turned on
lever. If you set a smaller value than #2, then the #2 Lifting speed will become faster if the value setting is
setting will be ignored. increased.
FC spec: speed when the lift lever is pulled The setting range is 1 to 10 (#40 EE type : 1 to 8).
Pump motor Pump motor

output [%] SUO #3 output [%]
(top lift speed)
SUO #3
100 10 100
9 10
8 9
8
SUO #2 SUO #2
(start lift speed)
0 0
100 Lever angle [%] SW1 SW2 Lever operation
Close Close
209551 209553
Pump motor output characteristics Pump motor output characteristics

(FC type, lift-up operation) (MC type, lift-up operation)
#4 Tilt Speed
This setting affects pump speed when you operate the Tilt speed has priority over lifting speed, when the two
tilt lever or tilt switch. levers are operated simultaneously.
Tilt speed will be faster if the value setting is increased.
The setting range is 2 to 10 (#40 EE type : 1 to 7).
Pump motor
Pump motor output [%]
output [%] SUO #4 (Tilt)
SUO #4, #5, #6, #33
100 10 100 10
1 to 9 2
1
0 SW Close Lever operation

0
100 Lever angle [%]
209554
211189
Pump motor output characteristics
Pump motor output characteristics (MC type, tilt and attachment 1, 2 and
(FC type, tilt operations) 3 operations)
1-20
CONTROLLER
FC
Solenoid Pump motor
current [%] output [%]
100 10
100 10
9
1
6
1 to 5
0 100 Lever 0
100 Lever angle [%]
operation
211287 211325
Solenoid current characteristics Pump motor output characteristics

(FC type, tilt operations) (FC type, attachment 1, 2 and 3 operations)
Solenoid
current [%]
#5 Auxiliary 1 Speed
This setting affects pump speed when you operate the
attachment 1 lever or attachment 1 switch. 100 5 to 10
4
Attachment 1 speed will become faster if the value
setting is increased. The setting range is 1 to 10.
1
0
100 Lever operation
211326
Solenoid current characteristics

(FC type, attachment 1, 2 and 3 operations)
#6 Auxiliary 2 Speed gradability or acceleration.

This setting affects pump speed when you operate the The setting range is 5 to 17 [km/h] (#40 EE type : 5 to
attachment 2 lever or attachment 2 switch. 13).
Characteristic is almost the same as auxiliary 1. #8 Acceleration Rate
Attachment 2 speed will become faster if the value This setting affects response time to calculate torque
setting is increased. The setting range is 1 to 10. order from accelerator pedal position.
#7 Top Travel Speed Limit Acceleration of trucks becomes faster if the value
This setting affects maximum truck speed without load. setting is increased. The setting range is 1 to 5 (#40 EE
Truck speed with load will be less than this setting. type : 1 to 3).
This setting affects top speed, and does not affect
1-21
CONTROLLER
#9 Traveling Power
This setting affects torque order which is calculated The figure is a torque characteristic at the time of
from accelerator pedal position. Powering.
The values are selected from three types : ECONOMY,
STANDARD and HIGH POWER (#40 EE type :
ECONOMY only).
Torque
[%] HIGH POWER(3)
100 STANDARD(2)
85
ECONOMY(1)
70
Brake limit*1 (48V: 40%, 36V: 52%)
Thermal, BDI [0] or Service indicator*2
(48V: 32%, 36V: 42%)
Speed
0 5 13 15 17
(km/h)
211190
*1 *2
Brake limit : Torque value resulting from reduction in Thermal, BDI [0] or Service indicator :
current when the service brakes or Curve of limited torque under a condition of
parking brake are applied. overheating or battery voltage low or
maintenance time over.
#10 Service Indicator

This setting sets the maintenance time. The time set You can reduce the truck power when the LED flickers
here is added to the truck’s hour meter and that value is by setting the service indicator selection. You can also
stored in memory as the “maintenance time.” set the demo-mode, which shows the Service Indicator
When the truck’s hour meter reaches maintenance time, function in a short period of time.
the service reminder LED turns on. The setting value is as follows.
It will flicker 20 hours before the time.
– 6 min (test) 100 150 In increments 950 1000

Maintenance time [hour]
of 50
Invalid 0
Set data on display Only warning 0.1 100 150 ····· 950 1000
Torque limit =0.1 =100 =150 ····· =950 =1000
The present hour meter time will be registered if the

DRS switch is operated after the display of #10.
1-22
CONTROLLER
#11 Auxiliary Input for Lift and Drive Speed 1

(Harness pin No. CN2-30)
This setting defines the function of “Auxiliary 1”
switch. This value has an effect on #12 and #13 when 2,
3, 5 or 6 is selected.
The setting value is as follows.
Value Lift Travel

0 – –
1 Stop lift *1 (switch closed) –
2 – Speed limit (switch closed)
3 – Power reduction (switch closed)
4 Stop lift (switch opened) –
5 – Speed limit (switch opened)
6 – Power reduction (switch closed)
*1
Lever is returned to neutral. Lift moves with
operating lever again.
#12 Auxiliary Travel Speed Limit 1 (Harness pin No. #16 Auxiliary Power Reduction 2 (Harness pin No.
CN2-30) CN2-40)
This setting defines maximum speed when the This setting defines traction power reduction when the
“Auxiliary 1” switch is closed or opened. “Auxiliary 2” switch is closed or opened.
The setting range is 5 to 17 [km/h]. Effective when the The setting range is 0 to 100 [%]. Effective when the
data of #11 is 2 or 5. data of #14 is 3 or 6.
#13 Auxiliary Power Reduction 1 (Harness pin No.

CN2-30)
This setting defines traction power reduction when the
“Auxiliary 1” switch is closed or opened.
The setting range is 0 to 100 [%]. Effective when the
data of #11 is 3 or 6.

The setting value is the same as that of #11.
#15 Auxiliary Travel Speed Limit 2 (Harness pin No.

CN2-40)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
1-23
CONTROLLER

The setting value is the same as that of #11.
#18 Auxiliary Travel Speed Limit 3 (Harness pin No.

CN2-41)
This setting defines maximum speed when the
The setting range is 5 to 17 [km/h]. Effective when the
#19 Auxiliary Power Reduction 3 (Harness pin No.

CN2-41)
This setting defines traction power reduction when the
The setting range is 0 to 100 [%]. Effective when the
#20 Stall Timer

This setting shuts down the truck when the drive motor
current is very high (about 90% of maximum). This
function is used to detect pulse sensor faults and to
prevent the controller from overheating.
The setting range is 2 to 10 [second].
#21 Regen Function

This setting defines which regeneration function is
activated.
One is “Brake regen.” “Brake regen” will be applied
while “the brake pedal is pressed” and “the accelerator
pedal is released.”
The other is “Accelerator regen.” “Accelerator regen”
will be applied while “the accelerator pedal is
released.”
In any case, deceleration torque is constant and defined
by #23.
These two regeneration functions are collectively
termed “Auto regen.”
1-24
CONTROLLER
#22 Regen Adjustment for Lever Regen

This setting defines the “Lever regen” characteristic.
When the direction lever is shifted into the position
opposite to the truck’s traveling direction, the “Lever
regen” function is activated. The “Lever regen”
characteristic is shown in this diagram. The setting
range is 1 to 10.
(%)
100 10
9
Amount of 86 Value of #22

lever
regeneration 5
73
2
60 1
100
Level of throttle pedal [%] 211191
Amount of deceleration relative to setting “1” is about

60% of maximum (Setting “10”).
“Lever regen” function is available regardless of the
#21 setting.
Amount of deceleration when the accelerator pedal is
released is determined by #23.
1-25
CONTROLLER
#23 Regen Adjustment for Auto Regen

This setting defines amount of deceleration when
“Auto regen” is activated. Amount of deceleration
relative to setting “1” is about 40% of maximum
(Setting “10”). The setting range is 1 to 10 (#40 EE
type : 1 to 7).
Brake regen Truck

speed [m/s] Accelerator regen
Truck
speed [km/h] Time [s]
211192 211193
#26 Speed Alarm 1 (Harness Pin No. CN1-61)

This setting defines speed of turning on “Speed alarm
1” light.
The setting range is 5 to 17 [km/h].
#27 Tire Size Adjustment

This setting is used to adjust the truck speed indicator.
1 digit equals 4 mm of wear in the diameter. Default
setting is 20.
When the tire diameter becomes 8 mm smaller than
original, set 18 into this setting.
The range setting is 0-40. This allows fitting a bigger
diameter wheel.
1-26
CONTROLLER
#30 Auxiliary Input for Travel Speed (Harness Pin

No. CN2-31)
This setting defines the function of “Speed Limit”
switch.
According to the combination of #30, #31 and #32, you
can reduce travel speed or traction power (torque).
Value Traction power Travel speed

0 – –
1 – Speed limit (switch closed)
2 Power reduction (switch closed) –
3 – Speed limit (switch opened)
4 Power reduction (switch opened) –
#31 Auxiliary Maximum Travel Speed Setting #35 Lowering Speed Adjust
(Harness Pin No. CN2-31) This setting is for adjustment of the maximum lowering
This setting defines the maximum travel speed when the speed.
speed limit function is activated by #30. The range In case the lowering speed is higher than the
setting is 5 to 17 [km/h]. specification as mentioned in the service manual, it can
#32 Auxiliary Output Power Limit (Harness Pin No. be adjusted. When lowering the setting, the current to
CN2-31) the solenoid will be reduced, but this does not mean it
affects the lowering speed immediately due to tolerance
This setting defines the maximum traction power
in oil flow and oil characteristics. Further lowering of
(torque) when speed limit function is activated by #30.
the setting may be required.
This value means a proportion of output torque to
normal condition.
The setting range is 0 to 100 [%].
#33 Auxiliary 3 Speed

This setting affects pump speed when you operate the
attachment 3 lever or attachment 3 switch.
Characteristic is almost the same as tilt.
Attachment 3 speed will become faster if the setting
value is increased. The range setting is 1 to 10.
#34 Speed Alarm 2 (Harness Pin No. CN1-62)

This setting defines speed of turning on “Speed alarm
2” light. The setting range is 5 to 17 [km/h].
1-27
CONTROLLER
#40 Truck Type

This setting defines the type of truck.
The setting value is as follows.
Display value Model

II II II II II No setting
P16:3 EP16NT
P16:3.E EP16NTEE
P18:3 EP18NT
P18:3.E EP18NTEE
P20:3 EP20NT
P20:3.E EP20NTEE
P16 EP16N
P18 EP18N
P20:C EP20CN
! CAUTION
If the truck type setting is incorrect, the track may
show unexpected movement.
#41 Battery Voltage

This setting defines the voltage of battery carried in the truck.
The setting value is 36 or 48 [v].
No setting shows “II II II II II.”
1-28
CONTROLLER
#42 Battery Type

This setting defines the type of battery carried in the
truck.
The setting value is 0, 1 or 2.
0: Normal 1: Tubular 2: Reserve
This value selects Battery Discharge Indicator (BDI)
table. The table is as follows.
Normal BDI Tubular BDI
BDI# 36V 48V BDI# 36V 48V

0 – 34.4 – 45.9 0 – 35.2 – 46.9
1 34.5 – 34.8 46.0 – 46.4 1 35.3 – 35.5 47.0 – 47.3
2 34.9 – 35.2 46.5 – 46.9 2 35.6 – 35.8 47.4 – 47.7
3 35.3 – 35.6 47.0 – 47.4 3 35.9 – 36.1 47.8 – 48.1
4 35.7 – 36.0 47.5 – 47.9 4 36.2 – 36.4 48.2 – 48.5
5 36.1 – 36.4 48.0 – 48.4 5 36.5 – 36.7 48.6 – 48.9
6 36.5 – 36.7 48.5 – 48.9 6 36.8 – 37.0 49.0 – 49.2
7 36.8 – 37.0 49.0 – 49.8 7 37.1 – 37.2 49.3 – 49.5
8 37.1 – 37.3 49.4 – 49.7 8 37.3 – 37.4 49.6 – 49.8
9 37.4 – 37.6 49.8 – 50.1 9 37.5 – 37.6 49.9 – 50.1
10 37.7 – 50.2 – 10 37.7 – 50.2 –
Reserve BDI
BDI# 36V 48V

0 – –
1 – –
2 – –
3 – –
4 – –
5 – –
6 – –
7 – –
8 – –
9 – –
10 – –
1-29
CONTROLLER
#43 Hydraulic Control Selection #46 Battery Voltage Adjust

This setting defines the type of hydraulic control. This setting corrects the gap of the battery voltage
0: FC system 1: MC system which the controller recognizes, and actual battery
voltage. The display shows battery voltage which the
#44 Mast Type controller recognizes.
This setting defines the type of the mast. Measure actual battery voltage using a tester (or a
2-FF: 2-stage full-free 3-FF: 3-stage full-free multi-meter) and operate the direction lever to adjust
the value.
2-SP: 2-stage panorama
Refer to the “Measurement of battery voltage” below.
#45 Valve Section
This setting defines the number of valve sections.
1: 3ways (lift, tilt, attachment 1)
2: 4ways (lift, tilt, attachment 1, 2)
3: 5ways (lift, tilt, attachment 1 to 3)
Direction lever Acceleration pedal Value change [V]

N→F – +0.1
N→R – –0.1
F Release → depress +10
R Release → depress –10
Contactor
- +
Battery
49.6V
V
- +
Tester or Multi-meter Set 49.6 on display.

Right traction
inverter
211333
Measurement of battery voltage

#47 Foot Direction
This setting defines the foot direction option.
1: Standard direction lever
2: Foot Directional Control (FoDiCo)
1-30
CONTROLLER
Setup Options (Group 1)
Option Default
Title of Option Description Range
# Value
The value setting of the following 7 items
are registered beforehand.
Application Pre-Sets Top travel speed, Acceleration rate,
#1 A, b, C, d, E A
(Truck Operation Mode) Traveling power, Regen adjustment, Start
(1)
lift speed, Top lift speed, Tilt speed.
Refer to the explanation for details.
Beginning lift speed
Start lift speed cannot exceed top lift
#2 Start Lift Speed 1 to 10 1
speed.
(1: SLOW → 10: FAST)
Lift speed when operating the lever at
#3 Top Lift Speed 1 to 10 6
maximum
#4 Tilt Speed Speed setting for tilt 1 to 10 5
#5 Auxiliary 1 Speed Speed setting for attachment 1 1 to 10 3
#6 Auxiliary 2 Speed Speed setting for attachment 2 1 to 10 1
#7 Top Travel Speed Limit Maximum travel speed 5 to 17 [km/h] 15
Choice of acceleration rate
#8 Acceleration Rate 1 to 5 3
(1: SLOW → 5: FAST)
Choice of powering characteristic
#9 Traveling Power (1: ECONOMY, 2: STANDARD, 3: HIGH 1, 2, 3 2
POWER)
This function notifies service personnel 0, 0.1,
that maintenance time is approaching or 100, 150, ...950, 1000,
has passed. =0.1 (6 min.),
It means the lapsed time when setting up. =100, =150, ..=950, =1000
#10 Service Indicator Approached: !LED flicker (20 hour) (In increments of 50 [hour]) 0
Passed :!LED turn on
and power reduction (selected) “=”: power reduction
(2) 0: no action
NOTICE: (1) Before changing, when parameter data are different from the values of the selected mode, the truck
mode indicator (A to E) flickers.
When the truck mode is changed, all parameter data is replaced by the set values of the selected
mode.
(2) The data from the truck hour meter at set time is saved apart from the selected value. If the key switch
is turned off without setting the DRS switch to R, the data at set time is maintained.
When the DRS switch is set to R, the data at set time is replaced by the current truck hour meter data.
1-31
CONTROLLER
Option Default Harness

# Value Pin No.
When the auxiliary input 1 signal is on, 0: Disable
travel speed or lift speed is limited to 1: Disable lift (switch closed)
set value. 2: Speed limit (switch closed)
Auxiliary Input for The amount of maximum speed is 3: Power reduction 0
#11 Lift and Drive defined at #12. (switch closed) (Pin CN2-30
Speed 1 The amount of power reduction is 4: Disable lift (switch opened) No.30)
defined at #13. 5: Speed limit (switch opened)
6: Power reduction
(switch opened)
12
Auxiliary Travel
#12 Travel speed limit for #11 5 to 17 [km/h] (Pin CN2-30
Speed Limit 1
No.30)
70
Auxiliary Power
#13 Traction power reduction ratio for #11 0 to 100 [%] (Pin CN2-30
Reduction 1
No.30)
When the auxiliary input 2 signal is on,
travel speed or lift speed is limited to
Auxiliary Input for set value. 0
#14 Lift and Drive The amount of maximum speed is Same as #11 (Pin CN2-40
Speed 2 defined at #15. No.40)
The amount of power reduction is
defined at #16.
12
Auxiliary Travel
Speed Limit 2
No.40)
70
Auxiliary Power
#16 Traction power reduction ratio for #14 0 to 100 [%] (Pin CN2-40
Reduction 2
No.40)
When the auxiliary input 3 signal is on,
travel speed or lift speed is limited to
Auxiliary Input for set value. 0
#17 Lift and Drive The amount of maximum speed is Same as #11 (Pin CN2-41
Speed 3 defined at #18. No.41)
The amount of power reduction is
defined at #19.
12
Auxiliary Travel
Speed Limit 3
No.41)
70
Auxiliary Power
#19 Power reduction ratio for #17 0 to 100 [%] (Pin CN2-41
Reduction 3
No.41)
This option allows the truck time to
#20 Stall Timer shut down truck when the drive motor 2 to 10 [sec] 5 –
current is too high.
1-32
CONTROLLER
Option Default Harness

# Value Pin No.
1: Brake regen
This option enables one of two Regen (accel must be off)
#21 Regen Function 2 –
Modes. 2: Accelerator regen
(also called “auto regen”)
Regen Adjustment
#22 10 steps for regen power on lever regen 1 to 10 7 –
for Lever Regen
Regen Adjustment 10 steps for regen power on
#23 1 to 10 5 –
for Auto Regen brake/accelerator regen
12
#26 Speed Alarm 1 Sets speed for turning on alarm 1 light. 5 to 17 [km/h] (Pin CN1-61
No.61)
Tire Size Adjusts the amount of tire wear. It
#27 0 to 40 20 –
Adjustment changes truck’s speed recognition.
0: Disabled
When the auxiliary input signal is on, 1: Travel speed limit
travel speed or traction power is limited (switch closed)
at value of set. 2: Power reduction 0
Auxiliary Input for
#30 The amount of maximum speed is (switch closed) (Pin CN2-31
Travel Speed
defined at #31. 3: Travel speed limit No.31)
The amount of power reduction is (switch opened)
defined at #32. 4: Power reduction
(switch opened)
Auxiliary 12
This option detemines the maximum
#31 Maximum Travel 5 to 17 [km/h] (Pin CN2-31
travel speed limit of #30.
Speed Setting No.31)
70
Auxiliary Output This option detemines the output
#32 0 to 100 [%] (Pin CN2-31
Power Limit traction power limit in % of #30.
No.31)
#33 Auxiliary 3 Speed Speed setting for attachment 3 1 to 10 3 –
12
#34 Speed Alarm 2 Sets speed for turning on alarm 2 light. 5 to 17 [km/h] (Pin CN2-31
No.62)
Lowering Speed In this option, the display shows value
#35 0 to 15 15 –
Adjust for lowering speed adjustment.
1-33
CONTROLLER
Option Default
# Value
This option is used to set the size and type
P16:3 (EP16NT) to
#40 Truck Type of the truck. –
P20:C (EP20CN) 9 pattern
This option is used to set the voltage of
#41 Battery Voltage 36, 48 [V] –
the battery.
This option is used to set the type of the
0: Normal BDI
battery.
#42 Battery Type 1: Tubular BDI –
The electric discharge characteristic of a
2: Reserve BDI
battery changes with battery type.
Hydraulic Control This option is used to set the type of the 0: FC specification
#43 –
Selection hydraulic control. 1: MC specification
2FF: 2-stage full-free
This option is used to set the type of the
#44 Mast Type 3FF: 3-stage full-free –
mast.
2SP: 2-stage panorama
1: 3ways
(lift, tilt, attachment 1)
This option is used to set the number of 2: 4ways
#45 Valve Section –
valve sections. (lift, tilt, attachment 1,2)
3: 5ways
(lift, tilt, attachment 1-3)
This setting corrects the gap of the battery
voltage which the controller recognizes,
and actual battery voltage.
Measure actual battery voltage and
operate the direction lever in order to
#46 Battery Voltage Adjust 5.0 to 120.0 [V] –
adjust the value which is shown on the
display to actual battery voltage.
N→F: +0.1 F, Accel off→on: +10
N→R:–0.1 R, Accel off→on: –10
Refer to the explanation for operation. (4)
1: Standard direction lever
This option is used to enable the function
#47 Foot Direction 2: Foot Directional Control –
for foot direction option.
(FoDiCo)
NOTICE: (1) The data of a group 3 has no default value, but it needs to set data by the actual truck type. If the
value and the truck model aren’t in agreement, the truck does not operate normally.
(2) When you set up for the first time, set up a group 3 first, and then set default data of group 1 and 2.
(3) If SUO data is not set, “| |” is displayed.
(4) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value, when the value
shown on the display is different from actual battery voltage.
1-34
CONTROLLER
Diagnosis
Outline
The controller monitors status of various input/output
equipment to allow diagnosis of truck’s malfunction.
There are two types of diagnosis: Run Time Diagnosis,
diagnosis during normal operation, and Self Diagnosis,
performing equipment check during maintenance.
Diagnosis
Mode Description
Self diagnosis Checks function of each equipment.
Diagnosis
Run time diagnosis data Displays malfunction history occurred in use.
The logic unit is equipped with a type of memory

module to hold recorded data even if the main power is
turned off. The errors occurring during truck use are
compared with the Run Time Diagnosis and recorded so
as to be able to show.
Operation Procedure
Turning on the key allows to enter each diagnosis mode.
You can not transfer to another mode unless the source
power is turned off.
Entry to diagnosis mode
DRS
Function Seat Lift lever Tilt lever Note
switch
When run time diagnosis can not
Self diagnosis D – – –
be performed
Run time diagnosis data D Not sit ON ON
1-35
CONTROLLER
Perform diagnosis using the following procedure.
1. Preparatory operations
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Discharge all inverters. See page 1-41.
(5) Place the direction lever in the N position.
(6) Set the DRS switch to the D (diagnosis) position.
R
(7) Remove the line fuse and pump fuse (500 A).
S D
(8) Connect the battery plug.
Pull
2. Diagnosis procedure
Perform the procedure using the Self-Diagnostics table
in accordance with the following guide.
(1) Start diagnosis with the Step 0 item in the table. 211195
Turn ON the key switch according to the instruction
in the “Do this” box on the Step 0 line. If the item
passes the check without any problem, the next step
number “01” appears on the display. If the item Diagnosis result indication
involves any problem and fails in the check,“dd” is
shown on the display. The display also shows “dd”
when diagnosis is started without removing the
fuse. In this case, diagnosis is prohibited from
going even to the first step.
(2) When the Step 0 item has passed the check,
diagnosis may advance to the next Step 1 item (seat 209561
switch). Cycle the seat switch OFF→ON→OFF
according to the instruction in the “Do this” box on
the Step 1 line. If the item passes the check, the
next step number “02” appears on the display. Do
likewise for the succeeding items, following the
instructions in the “Do this” column boxes. If the
item of a step fails in the check, diagnosis does not
advance automatically. In this case, diagnosis can
be forcibly advanced to the next step by cycling the
DRS switch D→R→D.
1-36
CONTROLLER
(3) When all the step items have been checked through,
turn OFF the key switch and place the DRS switch in R
the R position. Do not forget to reinstall the 500 A line S D
fuse and pump fuse.
Pull
• Turn OFF the key switch to exit from the diagnosis

mode.
• Repair all faults found immediately after diagnosis. 211196
Diagnosis procedure requires moving the DRS switch to

the D or R position. Follow the instructions in the
diagnosis procedure guide above as well as those in the
applicable boxes in the “Do this” column.
1-37
CONTROLLER
Self-Diagnostics
Step Checking Do this Controller check this Result Display Motion
Line contactor
Power line Pass 01
Close line contactor and closes and opens.
0 voltage Turn on key switch.
check power line voltage. Line contactor closes
(Fuse check) Fail dd
and doesn’t open.
Release & press & release Input Pass 02
1 Seat switch
seat SW. OFF → ON → OFF Fail 01
Direction Cycle direction lever. Input changes as Pass 03
2
switch N→R→N→F→N N→R→N→F→N Fail 02
Release & depress & Input Pass 04
3 Parking brake
release parking brake. OFF → ON → OFF Fail 03
Depress and release Input Pass 05
4 Service brake
service brake. OFF → ON → OFF Fail 04
Number 0 to 15 flickers as
Depress accelerator and Pass
accelerator is pressed.
5 Accelerator release.
Fail -
DIAG → RUN - 07
Check battery voltage: Pass 08
7 Battery voltage Automatic
(34V-51V) Fail 07
Input Pass 09
8 Lift switch Pull and release lift lever.
OFF → ON → OFF Fail 08
Input Pass 10
9 Tilt switch Pull and release tilt lever.
OFF → ON → OFF Fail 09
Auxiliary 1 Pull and release Aux. 1 Input Pass 11
10
switch lever. OFF → ON → OFF Fail 10
11
12
Pull any lever and see Pass Flickering pump speed value
Hydraulic
13 display. Fail Other than above
speed check
RUN → DIAG → RUN - 14
Pass 14 Contactor closes
RUN → DIAG See line contactor close.
Fail 14 No operation
14 Line contactor
Pass 15 Contactor opens
DIAG → RUN See line contactor open.
Fail 15 No operation
See pump contactor Pass 15 Contactor closes
RUN → DIAG
Pump close. Fail 15 No operation
15
contactor See pump contactor Pass 98 Contactor opens
DIAG → RUN
open. Fail 98 No operation
Controller
See software version No.
98 software RUN → DIAG → RUN - donE
in hourmeter.
version
NOTICE: Step No.6 is skipped.
1-38
CONTROLLER
Run Time Diagnostics

Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Traction Motor R.H., Overheating Thermistor (145°C, -25°C) * E0 Power reduction Cool
Traction Motor L.H., Overheating Thermistor (145°C, -25°C) * E1 Power reduction Cool
Pump Motor, Overheating Thermistor (135°C, -25°C) * E2 Power reduction Cool

Thermistor
Traction Inverter R.H., Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E5 Power reduction Cool
Thermistor
Traction Inverter L.H., Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E6 Power reduction Cool
Thermistor
Pump Inverter, Overheating (IMS 100°C, -25°C, Capacitor 110°C, -25°C) * E7 Power reduction Cool
Brake Oil, Low Level Level sensor (Contact) * Turn key off
Traction Motor Current Sensor R.H. Line contactor off(*)
Fault Out of normal range * 14 Pump contactor hold Turn key off
Line contactor off
Traction Motor R.H., Over-current More than 492 Arms (1.6 ms), 557 Arms (1 ms) * 15 Pump contactor hold Turn key off
Line contactor off
Traction Motor R.H., Stall Timer Measure time (set by SUO #20) while stalling * 16 Pump contactor hold Turn key off
Traction Motor Current Sensor L.H. Line contactor off(*)
Fault Out of normal range * 24 Pump contactor hold Turn key off
Line contactor off
Traction Motor L.H., Over-current More than 492 Arms (1.6 ms), 557 Arms (1 ms) * 25 Pump contactor hold Turn key off
Line contactor off
Traction Motor L.H., Stall Timer Measure time (set by SUO #20) while stalling * 26 Pump contactor hold Turn key off
Line contactor off(*)
Pump Motor Current Sensor Fault Out of normal range * 34 Pump contactor off(*) Turn key off
More than 985 Arms (1.6 ms), Line contactor off
Pump Motor Over-current 1115 Arms (1.0 ms) * 35 Pump contactor off Turn key off
Line Contactor Fault Check voltage of power circuit * 40 Pump contactor off(*) Turn key off
Pump Contactor Fault Check voltage of power circuit * 42 Pump contactor off(*) Turn key off
Line contactor off
Traction Motor R.H. Open Traction R.H. Motor Open * 45 Pump contactor hold Turn key off
Line contactor off
Traction Motor L.H. Open Traction L.H. Motor Open * 46 Pump contactor hold Turn key off
Line contactor off
Pump Motor Open Pump Motor Open * 47 Pump contactor off Turn key off
Accel SW ON: Below 0.3V Line contactor off
Accelerator Sensor Fault Accel SW OFF: More than 1.41V * 51 Pump contactor hold
Turn key off
Below 0.2V, More than 4.8V
Traction Motor R.H. Pulse Line contactor off
Input Fault Out of normal range (5800 rpm) * 52 Pump contactor hold Turn key off
Traction Motor L.H. Pulse Line contactor off
Input Fault Out of normal range (5800 rpm) * 53 Pump contactor hold Turn key off
FC Lever Fault Below 0.25A, More than 4.75A * 54 Disable lever op. Turn key off
FC Solenoid Fault Below 0.16A, More than 1.9A * 55 Disable solenoid Turn key off
Line contactor off
FC Solenoid Current Leak More than 0.18A * 56 Pump contactor off Turn key off
Out of normal range (4000 rpm) Line contactor off
Pump Motor Pulse Input Fault With no rotation input during output * 57 Pump contactor off Turn key off
Display Communication Fault When serial communication is not going on * 60 Indicate if it possible Turn key off
Line contactor off
Logic Card Initialize Failure SUO Gr. #3 and default setting are not set * 61 Pump contactor off Turn key off
Parity check of SUO data Line contactor off
Logics Fault Sum check of ROM and RAM * 62 Pump contactor off Turn key off
When CAN communication is not going on Line contactor off

Traction Inverter R.H. Fault Sum check of ROM & RAM * 63 Pump contactor off Turn key off
Initial mode SW setting Fault

Traction Inverter L.H. Fault Sum check of ROM & RAM * 64 Pump contactor off Turn key off
1-39
CONTROLLER
Display
Steering operation
LED
Service Indicator
To return
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Pump Inverter Fault Sum check of ROM & RAM
* 65 Pump contactor off Turn key off

Input Unit Fault Sum check of ROM & RAM * 67 Pump contactor off Turn key off
Output Unit Fault Sum check of ROM & RAM * 68 Pump contactor off Turn key off
Line contactor off
Contactor Coil Fault Contactor coil current sensor * 72 Pump contactor off Turn key off
Check current of unload valve Disable all lever op.
Hydraulic Lock Solenoid Fault Check current of lift lock valve * 74 Turn key off
Line contactor off
Battery Voltage Too Low Voltage class is not correct * 78 Pump contactor off Turn key off
Line contactor off
Battery Voltage Too High Voltage class is not correct * 79 Pump contactor off Turn key off
Lever/accel is not neutral at power-on and seat Line contactor off FNR Neutral
Direction Lever or Accelerator, switch closed Disable traction Accel Open
Faulty Setting Seat switch is turned on after lever/accel is E Slow down and Line Seat SW
operated contactor off Close
Line contactor off FNR Neutral
Switch is off at power-on Disable traction
Seat Switch, Faulty Setting For Accel Open
Traction (E) Slow down and Line Seat SW
Seat switch is off during operation contactor off Close
Line contactor off Lever
Switch is off at power-on Pump contactor off
Seat Switch, Faulty Setting For Off/Neutral
Hydraulic (L) Seat SW
Seat switch is off Disable all lever op. Close
Line contactor off
Lever is not neutral at power-on and seat switch Pump contactor off Lever
on Disable pump and Off/Neutral
Lift Lever, Faulty Setting H1 steering op. Seat SW
Close
Seat switch is turned on after lever is pulled Disable all lever op.
Line contactor off
Tilt Lever, Faulty Setting H2 steering op. Seat SW
Close
Line contactor off
Attachment 1 Lever, Faulty Setting H3 steering op. Seat SW
Close
Line contactor off
Close
Line contactor off
Close
Battery Consumption Too Much Too much consumption with small capacity (Lo)
battery * Pump contactor off(*) Turn key off
Battery Consumption Much Charge

Much consumption with small capacity battery (*) Power reduction battery
NOTICE: (1) E0-E7 don’t appear on the display, but are stored in the history folder.
(2) E, (E), (L), H1-H5, and Lo appear on the display, but not stored in the history folder. (E) means
flickering.
(3) “Line contactor off(*)” means that the contactor will open immediately when a fault is detected.
“Line contactor off” means that the contactor will open when a current gets to 0.
(4) Contactor “hold” means “no change.” When the error occurs while the contactor is turned on, it
keeps on.
1-40
CONTROLLER
Removal and Installation
Inverter Discharging Procedure

Discharge electric charges stored in the inverters by using
the following procedure.
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Remove the upper cover from the counterweight.
211216
4. Place a 150 Ω/25 W resistor between P and N

terminals in the right traction inverter to discharge
electric charges stored in the inverter.
5. After touching the resistor to the P and N terminals for
approx. five seconds, measure the voltage between the
terminals with a multi-meter and confirm a reading of 5
V or less.
6. Perform the same procedure for the left traction
inverter and pump inverter in order to discharge electric
charges from all inverters.
Check whether the resistance between + and - of the battery

plug on the truck side is 1 kΩ or more when connecting the 211217
battery plug for the first time after maintenance.
(Discharge electric charges completely before measuring.
Longer measurement time reduces resistance value.)
1-41
CONTROLLER
Replacing Inverter
Removal
1. Raise the front wheels.
2. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Ensure to discharge electric charges from all
inverters.
3. Remove the contactor plate when replacing the pump

Pump inverter
inverter. Remove M8 bolts (two places) fixing the Contactor plate Traction inverter
contactor plate.
4. Disconnect all five power cables from P, N, U, V and
W terminals. For the pump inverter, leave P terminal
as it is, and disconnect F terminal.
5. Disconnect the connector.
! CAUTION
211218
When disconnecting the connector, hold the
connector housing and plug, and unlock the
connector. Traction inverter
Holding the case may cause damage to the inside Pump inverter
card, while holding the cable may cause wire
breakage.
6. Remove M10 bolts (four places for the traction inverter

and six places for the pump inverter) fixing the inveter,
then remove the inverter.
211219
Installation
1. Wipe off the dirt and thermal paste from the inverter
mounting surface once, and also remove dirt from the
mounting surface and the aluminum base plate of the
inverter.
2. Apply thermal paste approx. 1 mm (0.04 in.) thick to
the area where the aluminum base plate of the inverter
comes into contact with the truck body.
! CAUTION
211220
Apply thin and even thermal paste since it works
to release generated heat from the inverter to the
truck body.
1-42
CONTROLLER
3. Fix the inverter with M10 bolts.

4. Connect the power cables to P, N, U, V and W
terminals. For the pump inverter, include F terminal.
! CAUTION
Use the correct power cables and terminate
marked cable ends to the correct terminals
marked on the motor.
Cables terminated at the wrong terminals on the
motor may cause the motor to rotate in the
opposite direction when activated.
Tightening torque
11.77 ± 1.96 N·m

M8 nut (1.20 ± 0.20 kgf·m)
[8.68 ± 1.45 lbf·ft]
5. Connect the main harness connector to the inverter.
! CAUTION
Since pressing the connector forcibly may cause
damage to the DSP card, hold the connector
housing and press the connector, if not easy to
lock.
6. Install the contactor plate if removed.
1-43
CONTROLLER
Replacing DSP (Digital Signal Processor)

Card
Removal
1. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Make sure to discharge inverters before working
on the electrical system.
2. Disconnect the connector.
! CAUTION
connector.
Holding the case may cause damage to the inside
breakage.
3. Push and lift up at the four corners of the card cover to

remove the cover.
211221
4. Unlock the connector that is connected to the flat cable.

Hold the both ends of the white part of the connector
and pull it straight up.
5. Pull the flat cable to disconnect it.
If it cannot be disconnected smoothly, raise the lock
again to unlock.
6. Pinch the plastic spacers at the four corners of the DSP
card with pliers to unlock and remove the card.
! CAUTION
211201
Be careful not to damage mounted parts with the
pliers since the card has a number of fragile parts.
1-44
CONTROLLER
Installation
1. Align the four mounting holes of the new DSP card
with the plastic spacer positions and press it into place.
! CAUTION
Press at the card edges.
Make sure that the spacer lock works completely
and the card cannot be removed.
2. Confirm that the flat cable connector is unlocked by

raising the connector lock.
3. Insert the flat cable into the connector. Press down the
connector lock.
! CAUTION
Do not forcibly bend the flat cable. Insert its
conductive surface in the direction shown in the
illustration.
Also, confirm that the cable is not tilted.
4. Install the cover while pushing the flat cable toward the
card side slightly.
211202
! CAUTION
Do not forcibly bend the flat cable. Make sure
that the cable will not be pinched underneath the
cover. Confirm that the cover is completely
locked.
5. Connect the main harness connector to the inverter.
! CAUTION
Forcibly pressing the connector may cause
damage to the DSP card. Hold the connector
housing and press the connector. If may not be
easy to lock (for the card with vertical type
connector).
1-45
CONTROLLER
Replacing Logic Unit

Removal
3. Remove the right side step.
211203
Logic unit
211204
4. Disconnect the connector (CN1, 2, 3 complex) from the

logic card and the connector (CN4) from the power
supply card.
! CAUTION
connector.
breakage.
5. Remove M10 bolts (two places) and remove the logic

unit.
Installation
Follow the removal sequence in reverse. 211205
1-46
CONTROLLER
Replacing Logic Card

Cover
Removal
1. Perform step 1 to 5 in Replacing Logic Unit.
2. Remove M3 flat head screws (two places) from the
bottom of the logic unit to remove the cover.
3. Remove M3 screws (four places) fixing the logic card
plate to the logic unit case to remove the logic card and
logic card plate as an assembly.
Logic unit
case
211206
Logic card
Heat sink
Installation
Follow the removal sequence in reverse.
Logic card
plate 211207
! CAUTION
When installing the logic card onto the logic card Logic card
plate, carefully tighten the logic card and heat
sink fixing screws to the specified torque to avoid
excessive stresses. Repair the heat sink first.
Tightening torque
Logic card
plate
0.98 ± 0.20 N·m
M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
Logic card assembly 211328
1-47
CONTROLLER
Replacing Power Supply Card

Removal
1. Perform step 1 to 5 in Replacing Logic Unit. Cover
2. Remove M3 screws (two places) from the bottom of the

logic unit to remove the cover.
3. Remove M3 screws (four places) from the logic unit
case to remove the logic card and logic card plate as an
assembly.
Logic unit
case
211208
Power supply
card
Heat
sink
Installation
! CAUTION
When installing the power supply card onto the
Power supply card assembly 211209
logic unit case, carefully tighten the power supply
card and heat sink fixing screws to the specified
torque to avoid excessive stresses. Fix the heat
sink first.
Tightening torque
0.98 ± 0.20 N·m
M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
1-48
CONTROLLER
FC MODEL ONLY
Replacing Input Unit
Removal
3. Disconnect the input unit connector (CN2 of FC-IN
harness).
! CAUTION
connector.
card, while holding the cable may cause wire 211329
breakage.
4. Remove M6 screws (two places) to remove the input

unit.
Installation
Tightening torque
2.90 ± 0.58 N·m

M6 screw (0.30 ± 0.06 kgf·m)
[2.14 ± 0.43 lbf·ft]
1-49
CONTROLLER
FC MODEL ONLY
Replacing Output Unit
Removal
3. Disconnect the output unit connector (CN9 of FC-OUT
harness).
! CAUTION
connector.
breakage.
211330
4. Remove M6 bolts (four places) to remove the output

unit.
Installation
Tightening torque
6.90 ± 1.38 N·m

M6 bolt (0.70 ± 0.14 kgf·m)
[5.09 ± 1.02 lbf·ft]
1-50
CONTROLLER
Basic Check
Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm his description of the problem with an
operational check.
• Visually inspect cables, connectors, contactor tips, etc.
• Perform basic battery cables to frame resistance test. (at
least 20 k ohm)
• Check battery condition.
Always check each option and write down the reading.
Testing Tools
(a) Circuit tester
(b) Clamp meter (b)
(c) IC clip
(a)
NOTE
(c)
The illustrations show digital circuit testers. In these
testers, the positive (+) terminal is applied with positive
charge, and the negative (–) terminal with negative
charge. It should be noted that the terminals must be
connected inversely when using an analog meter tester.
208282
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
1-51
CONTROLLER
Measurement of Card Voltage
! WARNING
To prevent accidental movement of the truck,
place wood blocks under the truck to lift the front
wheels off the ground. Do not close to the front
wheels.
1. Tilt the mast fully backward. Place blocks under the

mast, and tilt the mast forward.
2. Turn the key switch off.
3. Disconnect the battery plug. Remove the cover.
4. Reconnect the battery plug.
5. Turn the key switch on. Connect the negative terminal
of the circuit tester to the V GND terminal of the card.
6. Set the circuit tester to the 100-VDC range.
7. Connect the positive terminal of the circuit tester to
each pin of connectors.
NOTE
Be careful not to short-circuit pins. For the normal
voltage value, refer to the card voltage chart on the
following pages.
1-52
CONTROLLER
Logic card voltage chart

CN1
No. Name Stand-by voltage Active voltage Note
1 GND-L 0V 0V
2 +15V-L 13.0V to 16.0V 13.0V to 16.0V
3 GND-L 0V 0V
4 +5V-L 5V 5V
5 CANH 0 to 5V 0 to 5V Between CANH and CANL
6 CANL 0 to 5V 0 to 5V Prohibition of [V] measurement with GND terminal
7 BOOT 11.5V 0V
8 FWE 11.5V 0V
9 GND 0V 0V
10 -
11 -
12 -
13 -
14 DISPLAY1-TxD 0 to 12V 0 to 12V
15 KEY OFF2 0V Vbatt
16 DISPLAY1-RxD 0 to 12V 0 to 12V
17 GSE-TxD - -
18 GSE-RxD - -
19 POS VOLTAGE Vbatt Vbatt Battery connector attached : Vbatt
20 ACCEL ANGLE 0V 0 to 4.7V
21 -
22 -
23 GND 0V 0V
24 +5V 5V 5V
25 GND 0V 0V
26 +5V 5V 5V
27 -
28 -
29 -
30 LIFT LIMIT SW1 11.5V 0V
31 SPEED LIMIT SW 11.5V 0V
32 SEAT BELT SW 11.5V 0V
33 SEAT SW 11.5V 0V
34 PARK BRAKE SW 11.5V 0V
35 SERVICE BRAKE SW 11.5V 0V
36 REVERSE SW 11.5V 0V
37 FORWARD SW 11.5V 0V
38 BRAKE FLUID SW 11.5V 0V
39 STEERING PRESSURE SW 11.5V 0V
42 ACCEL IDLE SW 11.5V 0V
43 GND 0V 0V
44 PDS BUZZER 0V 0 to Vbatt
45 DIAG SW 11.5V 0V
46 SET SW 11.5V 0V
47 ATTACH3 SW 11.5V 0V
50 TILT SW 11.5V 0V
51 LIFT2 SW 11.5V 0V
52 LIFT1 SW 11.5V 0V
53 STEERING-1 11.5V 0V
57 LIFT LOCK + 0V 0 to Vbatt
58 LIFT LOCK - 0V 0V
59 LINE CONTACTOR CON 0V 0 to Vbatt
60 HYDRAULIC CONTACTOR CON 0V 0 to Vbatt
61 ALARM1 0V 0 to Vbatt
62 ALARM2 0V 0 to Vbatt
63 CON VE Vbatt Vbatt
64 UNLOAD SOL 0V 0 to Vbatt
Vbatt: Battery voltage
1-53
CONTROLLER
Power supply card voltage chart

CN1
No. Name Voltage Note
1 +12V 12V Fan
2 GND 0V Fan
3 +15V-L 13.0V to 16.0V DSP
4 +5V 8V DSP
5 +15V-G 12V DSP
6 GND 0V DSP
7 +VE-L Vbatt
8 +VE-L Vbatt
9 +15V-L 13.0V to 16.0V Logics
10 +5V 5V Logics
11 GND 0V Logics
12 GND 0V Logics
13 V POW Vbatt Input
14 V POW Vbatt Input
15 V GND 0V Input
16 V GND 0V Input
DSP card voltage chart

CN2
1 MOTOR THERMAL + 0 to 5V 0 to 5V
2 MOTOR THERMAL - 0 to 5V 0 to 5V
3 CANH 0 to 5V 0 to 5V Between CANH and CANL
Prohibition of [V] measurement with
4 CANL 0 to 5V 0 to 5V GND terminal
5 ROTARY SENSOR +15V 12V 12V
6 ROTARY SENSOR A+ 0 to 5V 0 to 5V
7 ROTARY SENSOR B+ 0 to 5V 0 to 5V
8 MODE1 11.5V 0V
9 MODE2 11.5V 0V
10 BOOT 11.5V 0V
11 GND 0V 0V
12 TxD(GSE) - -
13 RxD(GSE) - -
14 CANR+ - -
15 CANR- - -
16 +15V-G 12V 12V
17 +15V-L 13.0V to 16.0V 13.0V to 16.0V
18 +5V 8V 8V
19 GND 0V 0V
20 GND 0V 0V
1-54
CONTROLLER
Input unit card voltage chart
CN1
1 GND 0V 0V
2 12V IN 13.0V to 16.0V 13.0V to 16.0V
3 -
4 RS-232 Tx 0 to 12V 0 to 12V
5 RS-232 Rx 0 to 12V 0 to 12V
6 RS-232 GND 0V 0V
7 CAN H 0 to 5V 0 to 5V
8 CAN L 0 to 5V 0 to 5V
9 CAN R+ - -
10 CAN R- - -
11 BOOT MODE - -
12 -
13 -
14 GND 0V 0V
15 LIFT REDUCTION SW 13.0V to 16.0V 0V
16 -
17 4/5 VALVE CHANGE SW 13.0V to 16.0V 0V
18 -
19 -
20 -
21 -
22 -
23 +5V 5V 5V
24 GND 0V 0V
25 LIFT JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
26 LIFT JOYSTICK2 2.3 to 2.7V 0.1 to 4.9V
27 TILT JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
28 TILT JOYSTICK2 2.3 to 2.7V 0.1 to 4.9V
29 ATTACH1 JOYSTICK1 2.3 to 2.7V 0.1 to 4.9V
1-55
CONTROLLER
Output unit card voltage chart
CN3
1 GND 0V 0V
2 GND 0V 0V
3 SOL V IN Vbatt Vbatt
4 SOL V IN Vbatt Vbatt
5 NODE 0 - -
6 NODE 1 - -
7 GND 0V 0V
8 GND 0V 0V
9 GND 0V 0V
10 RS-232 Tx 0 to 12V 0 to 12V
11 RS-232 Rx 0 to 12V 0 to 12V
12 RS-232 GND 0V 0V
13 CAN H 0 to 5V 0 to 5V
14 CAN L 0 to 5V 0 to 5V
15 CAN R+ - -
16 CAN R- - -
17 BOOT MODE - -
18 -
19 GND 0V 0V
20 +15V 13.0V to 16.0V 13.0V to 16.0V
21 LIFT VALVE A 0V 0 to Vbatt
22 LIFT VALVE B 0V 0 to Vbatt
23 LIFT VALVE - 0V 0 to 0.5V
24 TILT VALVE A 0V 0 to Vbatt
25 TILT VALVE B 0V 0 to Vbatt
26 TILT VALVE - 0V 0 to 0.5V
27 ATTACH1 VALVE A 0V 0 to Vbatt
28 ATTACH1 VALVE B 0V 0 to Vbatt
29 ATTACH1 VALVE - 0V 0 to 0.5V
36 -
1-56
CONTROLLER
Checking Contactor Coil
! CAUTION
Disconnect the battery plug and discharge the
inverter before working on electrical system.
1. Disconnect the lead wire of coil.

2. Set the circuit tester to 200 ohm range.
3. Measure coil resistance.
The resistance must be 44 ohm at -30°C (-22°F) to 65
ohm at 80°C (176°F).
• If the measured value deviates from the above range,
replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the
circuit tester to 200-VDC range.
5. Connect the negative (–) terminal of the circuit tester to
the negative-side coil terminal (small fasten terminal)
and the positive (+) terminal of the circuit tester to the
positive-side coil terminal (large fasten terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
7. The circuit tester should indicate about 24V after the
contactor operates. When the contactor is found
normal in the coil resistance test and if the measured
voltage is not this value, replace the logic card.
Checking Contactor Tip

1. Visually inspect the contactor tips for melting,
adhesion, heat seizure and pitting corrosion.
2. To check for interference, press the tips and release
them.
3. Visually inspect the contactor assemblies. Make sure
there are no foreign materials in the assemblies to
interfere with contactor movement.
4. Measure the gap at each contactor tips using a
208284
thickness gauge.
[It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)]
• If you find any troubles, replace or repair contactor.
1-57
CONTROLLER
Checking Inverter
! CAUTION
Disconnect the battery plug and discharge the
inverter before working on electrical system.
1. Disconnect all five power cables from P, N, U, V and

W terminals. For the pump inverter, leave P terminal as
it is, and disconnect F terminal.
2. Check the resistance between terminals shown in the
following table.
Positive probe Negative probe Resistance (ohm)

U
N V
W - +
8k to 11k
U
V P Tester
W 211212
NOTICE: Short-circuit/disconnection of the inverter

MOSFET can be confirmed by this check.
Other fault cannot be judged.
1-58
CONTROLLER
Regeneration Check
The AC motor uses a common circuit for circulating current
in both loading and regeneration. This allows the following
procedure to confirm regenerating.
1. Place the clamp ammeter onto the cable connected to
the inverter’s P terminal (use DC current range). This
is positive direction as current flows from the battery to Clamp ammeter
setting direction
the inverter.
2. Run the truck forward. With the direction lever shifted
in F position, release the accelerator pedal. Then
perform a full-reverse operation.
3. The clamp ammeter should show a negative value. This
value becomes the regeneration current.
Energy is generated when a motor is rotated with external

force. The regeneration power is produced when this energy
is larger than the one that is consumed with the controller
and motor. This means that the regeneration current is not 211222
measured if the speed or load changes gradually.
1-59
CONTROLLER
AC Motor System Basics
1. Feature of AC motor
The AC motor model trucks covered by this manual use The frequency and voltage can be controlled in a
AC motors (three-phase induction motors) as the drive variety of methods including the “vector control
motor and pump motor. AC motors have the following method” employed in the AC motor model trucks. This
advantages over DC motors: method provides highly responsive control according to
(1) AC motors are simple in construction. As they ever changing truck-operating conditions through high-
have no such friction parts as brushes and speed calculation on huge amount of data. The vector
commutators, daily maintenance load is control calculation is performed by one of the CPUs on
significantly reduced. the logics card. (Fig. 2)
(2) AC motors are compatible with high-speed

operation.
U
(3) An AC motor of a certain size produces higher
power than a DC motor of the same size. V
Inverter IM
2. Speed control of induction motors
W
Speed control of DC motors depends on regulation of
the field and armature current amounts, while that of
AC motors basically depends on adjustment of the
frequency of the alternating current power supply. The V V
U V W
speed of an AC motor is determined by the frequency of
the power supply AC current and the load on the motor. t t
In addition, the voltage and current to the motor must
be controlled properly such that the motor operates in Low-speed operation High-speed operation
its optimum characteristic range. (Fig. 1) (low frequency)
209542
Fig. 1
Logic unit Inverter
Gate
driving MOS-FET modules
pulse
Torque
Calculation for order
Accelerator Vector control
required output
F
calculation IM
N
R
Truck
speed
Current
Brake Speed
211214
Fig. 2
1-60
CONTROLLER
3. Inverter Switch
The truck battery delivers DC current, so the current must
be converted into AC current to drive an AC motor. The VB VL Load
device that converts direct current into alternating current is
generally called “inverter.” The processes involved in
T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = × VB
T1 + T2
ON OFF ON
(1) Changing DC voltage cyclically
Average voltage VL
If the switch in a circuit like a one shown in Fig. 3 is
turned on for time T1 and then turned off for time T2
and this on-off operation is repeated many times, the Small duty ratio Large duty ratio
ON ON ON
average of the voltage applied to the load is determined
by the ratio between T1 and T2. Varying the ratio,
therefore, results in varying voltage. The ratio between
OFF OFF
T1 and T2 is called “duty ratio.” By changing the duty 209544
ratio cyclically, it is possible to obtain cyclically
Fig. 3
changing DC voltage shown in Fig. 3.
(2) Converting DC power into AC power
Driving a three-phase AC motor using battery delivered
power requires creating three phase outputs (U, V, W)
of an identical waveform that differ in phase by 120°
using a circuit with six switches S1 to S6 that are S1 S3 S5
arranged as shown in Fig. 4. The outputs thus created U
V
forms a three-phase alternating current. Fig. 5 shows W
on-off condition of each switch (arm) and output S2 S4 S6
voltage variation.
Functioning as switches in the inverter of the AC motor
trucks are MOS-FET transistors. The MOS-FET
209545
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current. Fig. 4
S1 ON
Switching for U phase

S3 ON
S2 ON
Switching for V phase
S5 ON S4 ON
Switching for W phase
S6 ON
209546
V lt b t t t i
Fig. 5
1-61
TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ............................................................................... 2– 1

E0 Traction Motor R.H., Overheating ............................................... 2– 3
E1 Traction Motor L.H., Overheating ............................................... 2– 6
E2 Pump Motor, Overheating ............................................................. 2– 9
E5 Traction Inverter R.H., Overheating ........................................... 2 – 12
E6 Traction Inverter L.H., Overheating ............................................ 2 – 15
E7 Pump Inverter, Overheating ......................................................... 2 – 18
Brake Oil, Low Level ....................................................................... 2 – 21
2
14 Traction Motor Current Sensor R.H. Fault ................................ 2 – 23
15 Traction Motor R.H., Over-current .............................................. 2 – 25
16 Traction Motor R.H., Stall Timer .................................................. 2 – 28
24 Traction Motor Current Sensor L.H. Fault ................................ 2 – 30
25 Traction Motor L.H., Over-current ............................................... 2 – 32
26 Traction Motor L.H., Stall Timer .................................................. 2 – 35
34 Pump Motor Current Sensor Fault ............................................. 2 – 37
35 Pump Motor Over-current ............................................................. 2 – 39
40 Line Contactor Fault ....................................................................... 2 – 42
42 Pump Contactor Fault .................................................................... 2 – 44
45 Traction Motor R.H. Open ............................................................. 2 – 46
46 Traction Motor L.H. Open .............................................................. 2 – 49
47 Pump Motor Open ........................................................................... 2 – 52
51 Accelerator Sensor Fault ............................................................... 2 – 55
52 Traction Motor R.H. Pulse Input Fault ....................................... 2 – 58
53 Traction Motor L.H. Pulse Input Fault ........................................ 2 – 61
54 FC Control Lever Fault ................................................................... 2 – 64
55 FC Solenoid Fault ............................................................................ 2 – 66
56 FC Solenoid Current Leak ............................................................. 2 – 68
57 Pump Motor Pulse Input Fault ..................................................... 2 – 70
60 Display Communication Fault ...................................................... 2 – 73
61Logic Card Initialize Failure .......................................................... 2 – 75
62Logics Fault ...................................................................................... 2 – 76
63Traction Inverter R.H. Fault ........................................................... 2 – 77
64Traction Inverter L.H. Fault ........................................................... 2 – 79
65Pump Inverter Fault ........................................................................ 2 – 81
67Input Unit Fault ................................................................................ 2 – 83
68Output Unit Fault ............................................................................. 2 – 86
72Contactor Coil Fault ....................................................................... 2 – 88
74Hydraulic Lock Solenoid Fault ..................................................... 2 – 90
78Battery Voltage Too Low ............................................................... 2 – 92
79Battery Voltage Too High ............................................................... 2 – 94
E Direction Lever or Accelerator, Faulty Setting ........................ 2 – 96
(E)Seat Switch, Faulty Setting For Traction .................................. 2 – 98
(L)
Seat Switch, Faulty Setting For Hydraulic ............................... 2 – 100
H1 Lift Lever, Faulty Setting ............................................................... 2 – 102
H2 Tilt Lever, Faulty Setting ............................................................... 2 – 104
H3 Attachment 1 Lever, Faulty Setting ........................................... 2 – 106
(Lo) Battery Consumption Too Much ................................................. 2 – 112
Battery Consumption Much ......................................................... 2 – 114
Locations of Major Components and Connectors ........................ 2 – 116
Electrical Schematic (AC motor, FC models) ................................. 2 – 119
Electrical Diagram (AC motor, FC models) ...................................... 2 – 121
Electrical Schematic (AC motor, MC models) ................................ 2 – 123
Electrical Diagram (AC motor, MC models) .................................... 2 – 125
General Information
Before replacing devices

Do not replace devices immediately even if replacement is required as a result of troubleshooting. Be sure to check
the following items before replacing devices (logic unit, logic card, power supply card, inverters, inverter DSP cards,
input unit and output unit).
• Loose of battery connectors
• Abnormal of wire harness connections
• Loose of connectors
• Broken, bent or loose of connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See "How to clean harness connectors and system components" on page 2-2.
• Ensure that the main harness is not short-circuited to the truck body by using the following procedures.
Disconnect battery plug and discharge the inverters before

working on electrical system.
Disconnect connector CN4 of logic unit. Check continuity between

CN4-15(21) and truck body (logic unit installation bolts, etc.).
No continuity Continuity
Normal Repair or replace harness.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a
new one. Be sure to check the above items and carefully replace.
Connection of the service tool Error code display

1. Turn off the truck power.
2. Remove floor plates.
3. Find the connector to the service tool near the logics
unit.
4. Remove the cover and connect the PC as shown.
5. Turn on the truck power.
6. Start the service tool software.
211331
2-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components in dirty condition. Dust,
together with greasy matter, forms grime which, in
time, penetrates electrical connections, resulting in
loose metal-to-metal contact or, for worse, electrical
separation of surfaces in contact. For this reason, it is
essential that the connectors and components be
cleaned at each periodic inspection and at when
servicing the truck. Instead of a commonly used
solvent, use electronic parts cleaner (in the manner
illustrated on the right).
Electronic parts cleaner
211223
Electronic parts
Three Bond 29B
cleaner
NOTE
The cleaner liquid is volatile. All you have to do is just
give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Install and
remove the connector several times to wet the surfaces
thoroughly with the activator liquid. After coupling up
Electronic parts
the connector, check to be sure that it is in locked state. cleaner
Contact surface Three Bond 2501S

activator (aerosol)
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
Contact surface
activator
205047
2-2
Problem: Traction Motor R.H., Overheating (E0)

(1) Situation
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations. Service tool "Alarm status" and "E0" displayed.
(2) Possible cause

Overheating of right traction motor, faulty right traction motor or thermal sensor, faulty or open harness wiring,
faulty right traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
abnormality in front axle, faulty display unit.
(3) How the error code is triggered.

Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F).
It becomes normal when motor temperature is less than 70 °C (158 °F).
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
(5) Traction motor becomes normal.
If problem recurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage parking brake.

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

upgrade or to pull large cargo load.
Normal
(10) Perform inverter discharging work. See page 1-41.
(11) Replace right traction (12) Replace right traction

motor. motor or front axle.
See Chassis & Mast. See Chassis & Mast.
With service tool
(13) Confirm temperature of right traction motor with

Without service tool input/output monitor.
70 °C(158 °F) or more Less than 70 °C(158 °F)
(14) Disconnect battery plug. Wait until right traction motor (15) Disconnect battery plug.
temperature becomes close to room temperature.
2-3
(16) Perform inverter discharging work. See page 1-41. (17) Replace display unit. See Chassis & Mast.
(18) Disconnect connector CN14 of right traction motor

speed and thermal sensor. Measure resistance
between CN14(124) and (125) at motor side.
6kΩ at 40°C (104°F) to
19kΩ at 10°C (50°F) Out of range
Thermal
(19) Disconnect connector CN7 of right traction inverter. (20) Replace right traction motor. See Chassis & Mast.
Check continuity between CN7-1 and CN14(125).
Continuity No continuity
Power supply
(21) Check continuity between CN4-3 and CN7-17(252).
Check continuity between CN4-6 and CN7-20(255).
CAN
(22) Disconnect connector CN3 of logic unit.
Check continuity between CN3-5(211) and CN7-3(224).
(23) Connect connector CN4, then turn on power again. (24) Repair or replace harness.
(25) Measure voltage between CN7-17(252) and

CN7-20(255). Confirm value is 14V±2V.
Normal Abnormal
(26) Disconnect battery plug.
(27)Replace power supply card of logic unit. See page 1-48.

With service tool
Without service tool
(28) Ensure all connectors are connected. Check Run
Time Diagnosis data. See page 1-39.
The latest data is "E0". Not "E0"
(29) Disconnect battery (30)Disconnect battery plug.

plug, then perform Replace display unit.
inverter discharging
work. See page 1-41.
(31)Replace DSP card of right traction inverter. See page 1-44.
2-4
Logic
CN3 CN7 Traction inverter (right)
BG 0 to 5V V
CAN 5 WP 211 0 to 5V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
B 255 GND B 20 card card
6 U IUR
5V * 1 Y 1
Power card GND G V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y 6
0 to 5V B
7
GND O 19
CN14 Traction motor (right)

O 127 Speed
B sensor W TWR
Y
146
M U TUR
145 TVR
Y V
126
G Thermal
124 sensor
Y 125 283Ω to 163kΩ
1: With connector disconnected
*
211224
2-5
Problem: Traction Motor L.H., Overheating (E1)

(1) Situation
(2) Possible cause

Overheating of left traction motor, faulty left traction motor or thermal sensor, faulty or open harness wiring, faulty
left traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
abnormality in front axle, faulty display unit.

(4) Checks
(5) Traction motor becomes normal.
If problem recurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage parking brake.

Turn key switch to OFF, rotate front wheels.
Confirm there is no difference in rotation load
between right and left wheels.
No difference Difference
(9) Check if truck is operated on steep
upgrade or to pull large cargo load.
Normal
(11) Replace left traction (12) Replace left traction

motor. motor or front axle.
See Chassis & Mast. See Chassis & Mast.
With service tool
(13) Confirm temperature of left traction motor with

(14) Disconnect battery plug. Wait until left traction motor (15) Disconnect battery plug.
2-6
(18) Disconnect connector CN15 of left traction motor

between CN15(129) and (130) at motor side.
6kΩ at 40°C (104°F) to
Thermal
(19) Disconnect connector CN6 of left traction inverter. (20) Replace left traction motor. See Chassis & Mast.
Power supply
(21) Check continuity between CN4-3(252) and CN6-17(260).
CAN
(22)Disconnect connector CN3 of logic unit.

Normal Abnormal
(27) Replace power supply card of logic unit. See page 1-48.
With service tool

(29) Disconnect battery (30) Disconnect battery plug.

(31) Replace DSP card of left traction inverter. See page 1-44.
2-7
Logic
CN3 CN6 Traction inverter (left)
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
WG 254 12V 259 RY
5 16 P Fuse
R 252 14V 260 RGr 17
Power 3 R 8V 261 R 18 N Battery (-)
4 253 DSP IMS
B 255 GND 262 B card
6 20 card U IUL
5V * 1 Y 1
Power card GND G V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L
6
0 to 5V G
7
GND O 19
CN15 Traction motor (left)

O 132 Speed
G sensor W TWL
L
148
M U TUL
147 TVL
V
V 131 Thermal
G 129 sensor
Y 130 283Ω to 163kΩ
*1: With connector disconnected
211225
2-8
Problem: Pump Motor, Overheating (E2)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E2" displayed.
(2) Possible cause

Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump
motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or
hydraulic lines, faulty display unit.

(4) Checks
(5) Pump motor becomes normal.
If problem recurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(9) Replace pump motor. (10)Repair or replace gear

See Chassis & Mast. pump or piping.
With service tool See Chassis & Mast.
(11) Confirm temperature of pump motor with

(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
(16) Disconnect connector CN20 of pump motor

between CN20(134) and (135).
6kΩ at 40°C (104°F) to
Thermal
(17) Disconnect connector CN5 of pump motor inverter. (18) Replace pump motor. See Chassis & Mast.
2-9
Power supply
CAN

Normal Abnormal
(24)Disconnect battery plug.
With service tool
(26)Ensure all connectors are connected. Check Run
(27) Disconnect battery (28) Disconnect battery

plug, then perform plug. Replace display
inverter discharging unit.
(29) Replace DSP card of pump motor inverter. See page 1-44.
2-10
Logic
CN3 CN5 Pump inverter
BG 0 to 5V V
234
L
3 Inside Inside Pump contactor
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265 RG 16 P
R 14V 266 RY
Power 3 R 252 8V 267 RW
17
N Battery (-)
4 253 18 DSP IMS
B 255 GND 268 B 20 card card
6 U IU
5V* 1 RB 1
Power card GND W V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y
7
GND V 19
CN20 Pump motor

V 138 Speed
Y sensor W PW
R
137
M U PU
136 PV
L V
133 Thermal
W 134 sensor
R 135 160Ω to 163kΩ
1: With connector disconnected
*
211226
2-11
Problem: Traction Inverter R.H., Overheating (E5)

(1) Situation
(2) Possible cause

Overheating of right traction inverter, faulty right traction inverter thermal sensor, open harness wiring, faulty
right traction inverter PC board, abnormal power supply of logic unit, faulty radiation of right traction
inverter, faulty display unit.

Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F).
Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F).
It becomes normal when temperature is less than 70 °C (158 °F).
(4) Checks
(5) Right traction inverter becomes normal.
If problem recurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
Check thermal paste applied on inverter mounting
surface. Thermal paste film should be thin and even.
Normal Abnormal
(8) Replace right traction (9) Clean mounting surface,

inverter. See page 1-42. apply thermal paste,
With service tool then reinstall inverter.
See page 1-42.
(10)Confirm temperature of controller and head capacitor

Without service tool with input/output monitor.
(11) Disconnect battery plug. Wait until inverter (12) Disconnect battery plug.
(14) Replace display unit. See Chassis & Mast.

Thermal
(15) Remove right traction inverter DSP card cover, then
check harness looseness or wire breakage. See page 1-44.
Normal Abnormal
Power supply
(16) Disconnect connector CN7 of right traction inverter. (17) Secure harness if loose.
Check continuity between CN4-3 and CN7-17(252). Replace inverter if wire breaks. See page 1-42.
2-12
CAN
(19)Connect connector CN4, then turn on power again. (20) Repair or replace harness.

Normal Abnormal
With service tool
(25) Disconnect battery (26)

plug, then perform Disconnect battery plug.
inverter discharging Replace display unit.
(27) Replace DSP card of right traction inverter. See page 1-44.
If fault remains
(28) Disconnect battery plug, then perform inverter
discharging work. See page 1-41.
(29)Replace right traction inverter. (DSP card is normal.)

See page 1-42.
2-13
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card Controller V IVR
2 Flat thermistor
CN4
5 cable W IWR
6
7 Capacitor
thermistor
19

DSP flat 127 Speed
cable sensor W TWR
Inverter
146
M U TUR
145 TVR
case V
126
Thermal
DSP card 124 sensor
125
211227
2-14
Problem: Traction Inverter L.H., Overheating (E6)

(1) Situation
(2) Possible cause

Overheating of left traction inverter, faulty left traction inverter thermal sensor, open harness wiring, faulty
left traction inverter PC board, abnormal power supply of logic unit, faulty radiation of left traction
inverter, faulty display unit.

(4) Checks
(5) Left traction inverter becomes normal.
If problem recurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
Normal Abnormal
(8) Replace left traction (9) Clean mounting surface,

inverter. See page 1-42. apply thermal paste,
then reinstall inverter.
With service tool See page 1-42.
(10) Confirm temperature of controller and head

Without service tool capacitor with input/output monitor.
(11)Disconnect battery plug. Wait until inverter (12)Disconnect battery plug.

(13) Perform inverter discharging work. See page 1-41. (14)Replace display unit. See Chassis & Mast.
Thermal
(15)Remove left traction inverter PC board cover, then
check harness looseness or wire breakage. See page 1-44.
Normal Abnormal
Power supply
(16)Disconnect connector CN6 of left traction inverter. (17) Secure harness if loose.
Check continuity between CN4-3(252) and CN6-17(260). Replace inverter if wire breaks. See page 1-42.
2-15
CAN

Normal Abnormal
With service tool
(25) Disconnect battery (26) Disconnect battery plug.

(27)Replace DSP card of left traction inverter. See page 1-44.
If fault remains
(28)Disconnect battery plug, then perform inverter
(29)Replace left traction inverter. (DSP card is normal.)

See page 1-42.
2-16
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
WG 254 12V 259 RY
5 16 P Fuse
R 14V 260 RGr 17
Power 3 R 252 8V 261 R 18 N Battery (-)
4 253 DSP IMS
6 20 card U IUL
1
Power card Controller V IVL
2 thermistor
CN4 Flat
5 cable W IWL
6
Capacitor
7 thermistor
19

DSP flat 132 Speed
cable sensor W TWL
Inverter
148
M U TUL
147 TVL
case V
131
Thermal
DSP card 129 sensor
130
211228
2-17
Problem: Pump Inverter, Overheating (E7)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E7" displayed.
(2) Possible cause

Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter
PC board, abnormal power supply of logic unit, faulty radiation of pump inverter, faulty display unit.

(4) Checks
(5) Pump inverter becomes normal.
If problem recurs
(6) Check if truck is operated to lift large cargo load.
Normal
Normal Abnormal
(8) Replace pump inverter. (9)Clean mounting surface,

See page 1-42. apply thermal paste, then
With service tool reinstall inverter.
See page 1-42.
(10) Confirm temperature of controller and head
capacitor with input/output monitor.
(11) Disconnect battery plug. Wait until inverter (12) Disconnect battery plug.
Thermal
(15) Remove pump inverter DSP card cover, then check
harness looseness or wire breakage. See page 1-44.
Normal Abnormal
Power supply
(16) Disconnect connector CN5 of pump inverter. (17) Secure harness if loose.
2-18
CAN
(19) Connect connector CN4, then turn on power again. (20)Repair or replace harness.

Normal Abnormal
With service tool

(25) Disconnect battery (26)Disconnect battery plug.

(27)Replace DSP card of pump inverter. See page 1-44.
If fault remains

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

See page 1-42.
2-19
Logic
BG 0 to 5V V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
R 14V RY
Power 3 R 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card Controller V IV
2 Flat thermistor
CN4
5 cable W IW
6
Capacitor
7 thermistor
19
CN20 Pump motor

DSP flat 138 Speed
cable sensor W PW
Inverter
137
M U PU
136 PV
case V
133 Thermal
DSP card 134 sensor
135
211229
2-20
Problem: Brake Oil, Low Level

(1) Situation
Lower brake oil indicator ON. Normal truck operation.
(2) Possible cause

Insufficient brake oil, faulty brake oil level sensor, shorted wiring, faulty logic unit, faulty display unit.

Sensor signal is open or short.
(4) Checks
Check oil level in brake oil reservoir tank.
Normal Abnormal
(5) Add brake oil. See Chassis & Mast.
With service tool
Without service tool (6) Confirm brake oil level switch with input/output
monitor.
ON OFF
(7) Disconnect battery plug, then perform inverter (8) Disconnect battery plug. Replace display unit.
discharging work. See page 1-41. See Chassis & Mast.
(9) Disconnect connectors CN2 and CN3 of logic unit and

CN11 of sensor. Check continuity between CN11(139)
and CN11(140) at harness side.
(10) Check continuity of brake oil level sensor connector

coupled to CN11. (11) Repair or replace harness.
(12) Replace brake oil level sensor.

With service tool
Without
service tool
(13) Replace display unit. See Chassis & Mast.
If fault remains
(15) Reinstall display unit and replace logic card of logic

unit. See page 1-47.
2-21
Logic Logic
CN2 CN3
38 23
0V/12V GND
O L
139 140
CN11
O L
Brake fluid
sensor
211230
2-22
Problem: Traction Motor Current Sensor R.H. Fault (14)

(1) Situation
Display: "14". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN
and pump contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction
inverter, faulty right traction inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-41.
(5) Disconnect connector CN7 of right traction inverter

and remove DSP cover. Check DSP flat cable for
looseness or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4 and CN7-18(253). (7) Secure DSP flat cable if loose.
Continuity Abnormal and No continuity
CAN
Continuity Abnormal and No continuity
(9) Connect connector CN4 to logic unit, then turn on (10)Repair or replace harness.
power again.

Normal Abnormal
(12) Disconnect battery plug, then perform inverter discharging work. See page 1-41.
(13)Replace DSP card of right traction inverter. See page 1-44. (14) Replace power supply card of logic unit. See page 1-48.
If fault remains
(15) Perform inverter discharging work, then replace

right traction inverter. (DSP card is normal.)
See page 1-42.
2-23
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14 U current sensor
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
V current sensor
7
19

DSP flat 127 Speed
cable sensor W TWR
Inverter
146
M U TUR
145 TVR
case V
126
Thermal
DSP card 124 sensor
125
211231
2-24
Problem: Traction Motor R.H., Over-current (15)

(1) Situation Display: "15". Traction motor operation inhibited. Pump motor and power steering operations inhibited
if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor
CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction
inverter, faulty right traction inverter, faulty right traction motor, faulty contact or wire breakage of right
traction motor speed sensor harness, faulty main harness, faulty logic unit.

Motor current is more than 1000 A (Moment). Motor current is more than 788 A (Fixed time 1).
Motor current is more than 696 A (Fixed time 2).
(4) Checks
(5) Check right traction motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections

(U, V, W phases) for right traction inverter and motor. (7) Replace right traction motor. See page 3-4.
Normal Abnormal

(9) Secure cable if loose or connect cable correctly.
Normal Abnormal
(10) Confirm connection of right traction motor speed (11) Secure DSP flat cable if loose.
sensor connector CN14. Replace inverter if wire breaks. See page 1-42.
Normal Abnormal
Sensor
(12) Disconnect connectors CN7 and CN14. (13) Connect connector securely.
8V power
supply
CAN
power again.
2-25

Normal Abnormal
(19) Disconnect battery plug, then perform inverter discharging work.
If fault remains
(22)Perform inverter discharging work, then replace right

traction inverter. (DSP card is normal.) See page 1-42.
If fault remains
(23)Perform inverter discharging work, then reinstall right
traction inverter and replace right traction motor.
2-26
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y
6
0 to 5V B
7
GND O 19

DSP flat O 127 Speed
cable B sensor W TWR
Inverter Y
146
M U TUR
145
case Y V TVR
126
Thermal
DSP card 124 sensor
125
211232
2-27
Problem: Traction Motor R.H., Stall Timer (16)

(1) Situation
Display:"16". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause

Stall current flowed more than set time (#20) in right traction motor, faulty right traction inverter current sensor,
shorted harness wiring, faulty right traction inverter DSP card, faulty logic unit.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem recurs Error code 14
(5) Confirm stall timer set time of Setup Option #20.

(6) See troubleshooting for code "14". See page 2-23.
Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo (8) Change set time. See page 1-24.
load or on steps when motor stalls.
Note: The more stall occurs, the more overheating
Normal steeps Heavy load
occurs. Operate truck under normal condition.

(10) Operate under normal condition.

and remove DSP cover, then check DSP flat cable for
looseness or wire breakage. See page 1-44.
Normal Abnormal
Power supply
(12) Check continuity between CN4-5 and CN7-16(254). (13) Secure harness if loose. Replace right traction
Check continuity between CN4-6 and CN7-20(255). inverter if wire breaks. See page 1-42.
CAN
Continuity Abnormal and no continuity
(15)Connect connector CN4 to logic unit, then turn on (16)Repair or replace harness.
power again.

Normal Abnormal
(19) Replace DSP card of right traction inverter. See page 1-44. (20)Replace power supply card of logic unit. See page 1-48.
2-28
Logic
BG V
CAN 5 WP 211 224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14 U current sensor
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
V current sensor
7
19
127 Speed
sensor W TWR
146
M U TUR
145 TVR
V
126
Thermal
124 sensor
125
211233
2-29
Problem: Traction Motor Current Sensor L.H. Fault (24)

(1) Situation
Display: "24". All truck operations inhibited. This fault occurs only when turning on power.
Line contactor OPEN and pump contactor OPEN.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction
inverter, faulty left traction inverter, faulty main harness, faulty logic unit.

(4) Checks
(5)Disconnect connector CN6 of left traction inverter and

remove DSP cover. Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN6-18(261). (7) Secure DSP flat cable if loose.
CAN
(9) Connect connector CN4 to logic unit, then turn on

(10) Repair or replace harness.
power again.
(11)Measure voltage between CN6-18(261) and

Normal Abnormal
(12)Disconnect battery plug, then perform inverter discharging work. See page 1-41.
(13) Replace DSP card of left traction inverter. See page 1-44. (14) Replace power supply card of logic unit. See page 1-48.
If fault remains
(15) Perform inverter discharging work, then replace left

2-30
Logic
BG 0 to 5V V 3
CAN 5 WP 211
0 to 5V
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
WG 254 12V 259 RY
5 16 P Fuse
R 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
V current sensor
7
19

DSP flat 132 Speed
cable sensor W TWL
Inverter
148
M U TUL
147 TVL
case V
131 Thermal
DSP card 129 sensor
130
211234
2-31
Problem: Traction Motor L.H., Over-current (25)

(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter,
faulty left traction inverter, faulty left traction motor, faulty contact or wire breakage of left traction motor speed
sensor harness, faulty main harness, faulty logic unit.

(4) Checks
(5) Check left traction motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections

(U, V, W phases) for left traction inverter and motor. (7) Replace left traction motor. See page 3-4.
Normal Abnormal
(8) Disconnect connector CN6 of left traction inverter and

or wire breakage.
Normal Abnormal
(10) Confirm connection of left traction motor speed (11) Secure DSP flat cable if loose.
sensor connector CN15. Replace inverter if wire breaks. See page 1-42.
Normal Abnormal
Sensor
(12) Disconnect connectors CN6 and CN15. (13) Connect connector securely.
8V power
supply
(14)Check continuity between CN4-4(253) and CN6-18(261).
CAN
power again.
2-32
(18)Measure voltage between CN6-18(261) and

Normal Abnormal
(19) Disconnect battery plug, then perform inverter discharging work.
If fault remains

If fault remains
(23) Perform inverter discharging work, then reinstall left
traction inverter and replace left traction motor.
2-33
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
WG 254 12V 259 RY 16
5 P Fuse
R 14V 260RGr 17
Power 3 R 252 8V 261 R 18 DSP N Battery (-)
4 253 IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L 6
0 to 5V G V current sensor
7
GND O 19

DSP flat O 132 Speed
cable G sensor W TWL
Inverter L
148
M U TUL
147 TVL
case V
V 131 Thermal
DSP card 129 sensor
130
211235
2-34
Problem: Traction Motor L.H., Stall Timer (26)

(1) Situation
Display:"26". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause
Stall current flowed more than set time (#20) in left traction motor, faulty left traction inverter current sensor,
shorted harness wiring, faulty left traction inverter DSP card, faulty logic unit.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
No error, problem recurs Error code 24
(5) Confirm stall timer set time of Setup Option #20.

Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo (8) Change set time. See page 1-24.
load or on steps when motor stalls. Note: The more stall occurs, the more overheating
Normal steeps Heavy load occurs. Operate truck under normal condition.
(9) Disconnect battery plug, then perform inverter (10) Operate under normal condition.

remove DSP cover, then check DSP flat cable for
looseness or wire breakage. See page 1-44.
Normal Abnormal
Power supply
(12) Check continuity between CN4-5(254) and CN6-16(259). (13) Secure harness if loose. Replace left traction
Check continuity between CN4-6(255) and CN6-20(262). inverter if wire breaks. See page 1-42.
CAN
Continuity Abnormal and no continuity
power again.

Normal Abnormal
(19) Replace DSP card of left traction inverter. See page 1-44. (20)Replace power supply card of logic unit. See page 1-48.
2-35
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14 U current sensor
15
WG 254 12V 259 RY
5 16 P Fuse
R 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
V current sensor
7
19
132 Speed
sensor W TWL
148
M U TUL
147 TVL
V
131 Thermal
129 sensor
130
211236
2-36
Problem: Pump Motor Current Sensor Fault (34)

(1) Situation
Display: "34". All truck operations inhibited. This fault occurs only when turning on power.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump
inverter, faulty pump inverter, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connector CN5 of pump inverter and

or wire breakage.
Normal Abnormal
8V power
supply
Check continuity between CN4-6(255) and CN5-20(268). Replace pump inverter if wire breaks. See page 1-42.
CAN
(9) Connect connector CN4 to logic unit, then turn on (10) Repair or replace harness.
power again.

Normal Abnormal
(13) Replace DSP card of pump inverter. See page 1-44. (14) Replace power supply card of logic unit. See page 1-48.
If fault remains
pump inverter. (DSP card is normal.) See page 1-42.
2-37
Logic
BG 0 to 5V V U current sensor
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
R 14V RY
Power 3 R 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4
5 cable W IW
6
V current sensor
7
19
CN20 Pump motor

DSP flat Speed
cable 138
sensor W PW
Inverter
137
M U PU
case 136 PV
V
133 Thermal
DSP card 134 sensor
135
211237
2-38
Problem: Pump Motor Over-current (35)

(1) Situation
Display: "35". All truck operations inhibited.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness,
faulty main harness, faulty logic unit.

(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (U,

V, W phases) for pump inverter and motor. (7) Replace pump motor. See page 3-4.
Normal Abnormal

or wire breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector CN20. Replace pump inverter if wire breaks. See page 1-42.
Normal Abnormal
Sensor
(12) Disconnect connectors CN5 and CN20.
(13) Connect connector securely.
8V power
supply
(14)Check continuity between CN4-4(253) and CN5-18(267).
CAN

power again.
2-39

Normal Abnormal
(20) Replace DSP card of pump inverter. See page 1-44. (21)Replace power supply card of logic unit. See page 1-48.
If fault remains
If fault remains
(23) Perform inverter discharging work, then reinstall
pump inverter and replace pump motor.
2-40
Logic
0 to 5V U current sensor
BG V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
R 14V RY
Power 3 R 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y V current sensor
7
GND V 19
CN20 Pump motor

DSP flat V 138 Speed
cable Y sensor W PW
Inverter R
137
M U PU
136
case L V PV
133 Thermal
DSP card 134 sensor
135
211238
2-41
Problem: Line Contactor Fault (40)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty main harness, faulty logic unit, faulty right traction inverter, faulty left traction
inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Error code 40 Error code 63 or 64
(5) Block wheels, then confirm line contactor (6) See troubleshooting for code "63" or "64". See page
operation in self-diagnosis mode [14]. See page 1-38. 2-77 to 2-79.
Not operated Operated
With service tool
(7) Check DC voltage of right and left traction (8) Disconnect battery plug, then perform
inverters with monitor. These values should be inverter discharging work. See page 1-41.
same as battery voltage.
Right inverter value Left inverter value
abnormal abnormal
(11) Replace right traction inverter.
See page 1-42.
(9) Disconnect battery (10) Disconnect battery
plug, then perform plug, then perform If fault remains
inverter discharging inverter discharging
work. See page 1-41. work. See page 1-41. (14) Disconnect battery plug, then perform
inverter discharging work. See page 1-41.
(12)Replace right traction (13) Replace left traction
inverter. See page 1-42. inverter. See page 1-42.
(15)Replace left traction inverter. See page 1-42.
(17) Check to see if line contactor tip moves smoothly.

Check line contactor tip for melting.
Normal Abnormal
(18) Measure resistance of contactor coil.

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range
(19) Disconnect connectors CN1 and CN4 of logic unit.

Check continuity between CN4-13(4) and contactor (20) Replace line contactor. See Chassis & Mast.
coil plus(+)(249). Check continuity between CN1-59
and contactor coil minus(-)(247).
(21) Perform inverter discharging work, then replace logic

card of logic unit. See page 1-47.
2-42
Logic
CN7
CN3
BG 0 to 5V V Traction inverter
5 211 224 3
CAN 0 to 5V L (right)
6 WP 212 229 4 P
CN6
V
224 3 Traction inverter
L (left) P
229 4
Logic
CN1
voltage
-
Output 59 G 247
Line
Power card
contactor
R +
CN4 13 4 249
27V to battery
voltage
Fuse
211239
2-43
Problem: Pump Contactor Fault (42)

(1) Situation
(2) Possible cause

Faulty pump contactor, faulty main harness, faulty logic unit, faulty pump inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Error code 42 Error code 65
(5) Block wheels, then confirm pump contactor

operation in self-diagnosis mode [15]. See page 1-38.
Not operated Operated
(8) Check to see if pump contactor tip moves smoothly. (9) Replace pump inverter. See page 1-42.
Check pump contactor tip for melting.
Normal Abnormal
(10) Measure resistance of contactor coil.

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range

(12)Replace pump contactor. See Chassis & Mast.
Check continuity between CN4-13(4) and contactor
coil plus(+)(250). Check continuity between CN1-60
and contactor coil minus(-)(248).

logic card of logic unit. See page 1-47.
2-44
Logic
CN3 CN5
BG 0 to 5V V
5 211 234 3
CAN WP 0 to 5V L Pump inverter
6 212 239 4 P
Fuse
F
Logic
CN1 27V to battery
voltage
-
Output 60 B 248
R
Pump
Power card 27V to battery contactor
voltage
R R +
CN4 13 4 250
211332
2-45
Problem: Traction Motor R.H. Open (45)

(1) Situation
Display: "45". Traction motor operation inhibited. Pump motor and power steering operations inhibited
(2) Possible cause

Faulty contact or wire breakage of right traction motor cable, faulty right traction motor, faulty contact or wire
breakage of right traction inverter connector, faulty contact of DSP flat cable in right traction inverter, wire
breakage of main harness, faulty power supply card of logic unit, faulty DSP card of right traction inverter,
faulty right traction inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when torque instruction is requested.
(4) Checks
(5) Check right traction inverter and motor for cable

looseness and improper contact.
Normal Abnormal
(6) Disconnect right traction motor cables from inverter.

(7) Secure cable if loose.
Measure resistance of motor cables
(U. V and W phases).
Less than 1Ω 1Ω or more
(8) Check connector CN7 of right traction inverter for (9) Measure resistance between terminals of both cable
looseness. ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(10) Disconnect connector CN7 of right

traction inverter and remove DSP
cover. Check DSP flat cable for
Normal Abnormal (12) Replace right traction motor. (13) Replace motor cables.
Gate power
supply
(14) Check continuity between CN4-5 and CN7-16(254). (15) Secure DSP flat cable if loose.
CAN
power again.
2-46

Normal Abnormal
If fault remains
(23)Perform inverter discharging work, then replace right

2-47
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4
5 cable W IWR
6
7
19

DSP flat
127 Speed
cable sensor W TWR
Inverter 146
M U TUR
case 145 TVR
V
126
DSP card Thermal
124 sensor
125
211241
2-48
Problem: Traction Motor L.H. Open (46)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of left traction motor cable, faulty left traction motor, faulty contact or wire
breakage of left traction inverter connector, faulty contact of DSP flat cable in left traction inverter, wire breakage
of main harness, faulty power supply card of logic unit, faulty DSP card of left traction inverter, faulty left
traction inverter, when restarting after motor shorted.

Current does not flow when torque instruction is requested.
(4) Checks
(5) Check left traction inverter and motor for cable

looseness and improper contact.
Normal Abnormal
(6) Disconnect left traction motor cables from inverter.

(8) Check connector CN6 of right traction inverter for (9) Measure resistance between terminals of both cable
(10) Disconnect connector CN6 of left

traction inverter and remove DSP
Normal Abnormal
(12) Replace left traction motor. (13) Replace motor cables.
Gate power
supply
CAN
power again.
2-49

Normal Abnormal
If fault remains

2-50
Logic
BG 0 to 5V V 3
CAN 5 WP 211
0 to 5V
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
WG 254 12V 259 RY
5 16 P Fuse
R 14V 260 RGr 17
4 253 DSP IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 Flat
5 cable W IWL
6
7
19

DSP flat
132 Speed
cable sensor W TWL
Inverter 148
M U TUL
case 147
V TVL
131 Thermal
DSP card 129 sensor
130
211242
2-51
Problem: Pump Motor Open (47)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of
pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness,
faulty power supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting
after motor shorted.

Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness

and improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter.

(8) Check connector CN5 of pump inverter for (9) Measure resistance between terminals of both cable
(10) Disconnect connector CN5 of

pump inverter and remove DSP
Normal Abnormal (12) Replace pump motor. (13) Replace motor cables.
Gate power
supply
CAN
power again.
2-52

Normal Abnormal
If fault remains

2-53
Logic
BG 0 to 5V V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
R 14V RY
Power 3 R 252 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4
5 cable W IW
6
7
19
CN20 Pump motor

DSP flat 138 Speed
cable sensor W PW
Inverter
137
M U PU
136 PV
case V
133 Thermal
DSP card 134 sensor
135
211243
2-54
Problem: Accelerator Sensor Fault (51)

(1) Situation
(2) Possible cause

Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.

Accelerator sensor voltage is out of range of 0.2 V to 4.8 V.
Sensor voltage is 1.41 V or more when accelerator switch is opened.
Sensor voltage is 0.3 V or less when accelerator switch is closed.
(4) Checks
Raise front wheels until they clear floor.
Without service tool With service tool
(6) Check accelerator sensor voltage with input/output

(5) Disconnect battery plug. monitor and confirm value is in range of 0.2V to 4.8V.
Check relation between sensor voltage and accelerator
switch operation.
0.3V or less: OFF
(7) Check link length of accelerator pedal. 1.41V or more: ON
Abnormal signal Interrupted
Normal Abnormal
(9) Disconnect battery plug. (10) Adjust accelerator

(8) Adjust accelerator pedal
pedal linkage.
linkage.

Disconnect connector CN16 of accelerator sensor.
(13) Check continuity between CN3-20 and CN16(142).

(Sensor voltage)

(Switch)

Check continuity between CN3-23(140) and CN16(143).

With service tool
Without
service tool
2-55
Without With service tool

service tool
(17) Replace accelerator pedal. (18)Connect connector CN2 and CN3. Turn on power and
check voltage between CN16(141) and CN16(140).
If fault remains 5V Not 5 V

(20) Turn off power. Short-circuit CN16(141)
and CN16(142). Turn on power and check
accelerator voltage with service tool.
(21) Reinstall accelerator pedal, then replace logic card 5V Not 5 V
of logic unit. See page 1-47.
(22) Turn off power. Open CN16(141) and
CN16(142). Short-circuit CN16(142) and
CN16(143). Turn on power and check
accelerator voltage with service tool.
0V Not 0 V
(23) Replace accelerator (24) Disconnect battery

pedal. plug.
(25) Replace logic card of

logic unit.
2-56
CN16
Logic
CN2 143 144 142 141
L 12V/0V
SW 42 144
Accelerator
CN16
L
RW 5V R
24 141
AN 20 G 0.30 to 1.40V
142
G
L 140 GND B
23 143
Logic
CN3
211245
2-57
Problem: Traction Motor R.H. Pulse Input Fault (52)

(1) Situation
(2) Possible cause

Faulty contact of right traction inverter connector, faulty connection of right traction motor connector and cable,
faulty 12V input voltage of right traction inverter, faulty contact or wire breakage of right traction motor speed
sensor harness, faulty DSP card of right traction inverter, faulty right traction motor speed sensor.

Motor rotation speed is more than 5800 rpm.
(4) Checks
(5) Check to see if right traction motor cables (U, V and W-

phases) are connected to right traction inverter properly.
Normal Abnormal
(6) Check to see if connector CN7 of right traction

(7) Connect cables properly.
inverter is fastened securely.
Normal Abnormal
(8) Check to see if connector CN14 of right traction

(9) Fasten connector securely.
motor speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
power again.
2-58

Normal Abnormal
(18) Replace DSP card of right traction inverter. See page 1-44. (19) Replace power supply card of logic unit. See page 1-48.
If fault remains

right traction motor. (DSP card is normal.)
See page 3-4.
2-59
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U IUR
1
Power card V IVR
2 Flat
CN4 12V Y
5 cable W IWR
0 to 5V Y
6
0 to 5V B
7
GND O 19

O 127 Speed
B sensor W TWR
Y
146
M U TUR
145 TVR
Y V
126
Thermal
124 sensor
125
211246
2-60
Problem: Traction Motor L.H. Pulse Input Fault (53)

(2) Possible cause

Faulty contact of left traction inverter connector, faulty connection of left traction motor connector and cable,
faulty 12V input voltage of left traction inverter, faulty contact or wire breakage of left traction motor speed
sensor harness, faulty DSP card of left traction inverter, faulty left traction motor speed sensor.

(4) Checks
(5) Check to see if left traction motor cables (U, V and W-

phases) are connected to left traction inverter properly.
Normal Abnormal
(6) Check to see if connector CN6 of left traction inverter

is fastened securely.
Normal Abnormal
(8) Check to see if connector CN15 of left traction motor

speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN

power again.
2-61

Normal Abnormal
If fault remains

traction motor. (DSP card is normal.) See page 3-4.
2-62
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
WG 254 12V 259 RY 16
5 P Fuse
R 14V 260 RGr 17
Power 3 252
R 253 8V 261 R 18 DSP N Battery (-)
4 IMS
6 20 card U IUL
1
Power card V IVL
2
CN4 12V V 5 Flat
cable W IWL
0 to 5V L 6
0 to 5V G
7
GND O 19

O 132 Speed
G sensor W TWL
L
148
M U TUL
147 TVL
V
V 131 Thermal
129 sensor
130
211247
2-63
Problem: FC Control Lever Fault (54)

(1) Situation
Display: "54". Related lever operation inhibited. Normal traction motor and power steering operations.
(2) Possible cause

Faulty lift FC control lever, faulty tilt FC control lever, faulty attachment 1 and 2 FC control levers, faulty main harness,
faulty input unit.

FC control lever voltage is out of range of 0.1 V to 4.9 V.
(4) Checks
Operate all FC control levers to find faulty FC control lever.
Attachment 2: 4-valve specification only
Attachment 1 and 2: Inspect by checking pump motor running sound if attachment is not installed.
Found Not found, with service tool
(5) Find faulty FC control lever with FC input/output
monitor. FC control lever voltage should be 2.5V±0.2V
if it is not operated.
Notice: -100 % equal 0.25 V

(6) Turn off power. Replace abnormal FC control lever with normal 0 % equal 2.5 V
control lever. Turn on power. Check faulty FC control lever. 100 % equal 4.75 V
Not changed Changed

Replace FC control lever.

(9) Disconnect connector CN2 of input unit. Disconnect connectors CN3 to CN6 of FC control levers. (FC-IN harness)
Lift Tilt Attachment 1 Attachment 2
(10) (11) (12) (13)

Check continuity between Check continuity between Check continuity between Check continuity between
CN2-25 and CN3(7), CN2-27 and CN4(9), CN2-29 and CN5(11), CN2-31 and CN6(13),
CN2-23 and CN3(5) and CN2-23(5) and CN4(15) and CN2-23(5) and CN5(17) and CN2-23(5) and CN6(19) and
CN2-24 and CN3(6). CN2-24(6) and CN4(16). CN2-24(6) and CN5(18). CN2-24(6) and CN6(20).
Continuity No continuity Continuity No continuity Continuity No continuity Continuity No continuity
(14) Replace input unit. See page 1-49. (15) Repair or replace harness. (FC-IN harness)
If fault remains
discharging work.
(17) Reinstall input unit and replace harness.

(FC-IN harness)
2-64
FC-IN harness FC control lever

CN2 R CN3
5 CN3
R 5V Y
23 5
G Lift 5 8 7 6
Input Y 0 to 5V
25 7 6 B
unit
G 0 to 5V R CN4 CN4
26 8 15
CN2 Y Y
0 to 5V Tilt 15 10 9 16
27 9 L
31 1 L
28 10
0 to 5V
16
B
32 2
Y 0 to 5V R CN5 CN5
29 11 17
Y Attachment 1 17 12 11 18
Br 0 to 5V Br
30 12
B
31 Y 13
0 to 5V 18
R CN6 CN6
W 0 to 5V 19
32 14 Y Attachment 2 19 14 13 20
W
24 B
GND
6
20
B
211248
2-65
Problem: FC Solenoid Fault (55)

(1) Situation
Display: "55". Related lever operation inhibited. Normal traction motor and power steering operations.
(2) Possible cause

Faulty lift solenoid, faulty tilt solenoid, faulty attachment 1 and 2 solenoids, faulty main harness, faulty output unit.

When signal is outputted, current is out of range of 0.16 A to 1.9 A.
(4) Checks
Operate all FC control levers to find faulty solenoid.
Attachment 2: 4-valve specification only
Attachment 1 and 2: Inspect by checking pump motor running sound if attachment is not installed.
Found Not found, with service tool
(5)Find faulty solenoid with FC input/output monitor.

Solenoid current should flow when FC control lever is
operated.

(7) Disconnect connector CN9 of output unit. Disconnect connectors CN1 to CN8 of solenoids. (FC-OUT harness)
Lift Tilt Attachment 1 Attachment 2
(8) Check continuity between (9) Check continuity between (10) Check continuity between (11) Check continuity between
CN9-2 and CN2(2) and CN9-5 and CN4(5) and CN9-8 and CN6(8) and CN9-11 and CN8(11) and
CN9-3(3) and CN2(13). CN9-6(6) and CN4(14). CN9-9(9) and CN6(15). CN9-12(12) and CN8(16).
Continuity No continuity Continuity No continuity Continuity No continuity Continuity No continuity
(12) Measure resistance of solenoid coil. [6.6 Ω at -30 °C(-22 °F) (13) Repair or replace harness. (FC-OUT harness)
to 9.8 Ω at 80 °C (176 °F)]
Normal Abnormal
(14) Replace related solenoid.

(15) Check short circuit between CN9-1(1), CN9-2(2) and CN9-3(3).
Check short circuit between CN9-4(4), CN9-5(5) and CN9-6(6).
Check short circuit between CN9-7(7), CN9-8(8) and CN9-9(9).
Check short circuit between CN9-10(10), CN9-11(11) and
CN9-12(12).
Not shorted Shorted
(16) Replace output unit. See page 1-50. (17) Repair or replace harness. (FC-OUT harness)
2-66
31 32 30 28 29 27 25 26 24 22 23 21 (Output unit side)
11 12 10 8 9 7 5 6 4 2 3 1 Output unit
W O Y O B G G Y V W G L CN9
FC-OUT harness
16 11 12 10 15 8 9 7 14 5 6 4 13 2 3 1
ATT2B ATT2A ATT1B ATT1A TILTB TILTA LIFTB LIFTA

CN8 CN7 CN6 CN5 CN4 CN3 CN2 CN1
Solenoid coils
211249
2-67
Problem: FC Solenoid Current Leak (56)

(1) Situation
Display: "56". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.
(2) Possible cause

Faulty lift solenoid, faulty tilt solenoid, faulty attachment 1 and 2 solenoids, faulty main harness, faulty output
unit.

When signal is not outputted, current is more than 0.18 A.
(4) Checks
Disconnect battery plug, then perform inverter
(5) Disconnect connector CN9 of output unit. Disconnect

connectors CN1 to CN8 of solenoids.
(6) Check short circuit between all pin patterns.

[CN9-1(1) to CN9-12(12)]
Not shorted Shorted
(7) Measure solenoid coil resistance.

[6.6Ω at -30 °C(-22 °F) to 9.8Ω at 80 °C(176 °F)]
Normal Abnormal
(9) Replace output unit. See page 1-50. (10) Replace related solenoid.
2-68
31 32 30 28 29 27 25 26 24 22 23 21 (Output unit side)
11 12 10 8 9 7 5 6 4 2 3 1 Output unit
W O Y O B G G Y V W G L CN9
FC-OUT harness
16 11 12 10 15 8 9 7 14 5 6 4 13 2 3 1
ATT2B ATT2A ATT1B ATT1A TILTB TILTA LIFTB LIFTA

CN8 CN7 CN6 CN5 CN4 CN3 CN2 CN1
Solenoid coils
211249
2-69
Problem: Pump Motor Pulse Input Fault (57)

(1) Situation
(2) Possible cause

Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable,
faulty 12V input voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness,
faulty DSP card of pump inverter, faulty pump motor speed sensor.

Motor rotation speed is zero while current flows to motor.
Motor rotates in reverse.
(4) Checks
(5) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector CN5 of pump inverter is

fastened securely.
Normal Abnormal
(8) Check to see if connector CN20 of pump motor

speed sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
power again.
2-70

Normal Abnormal
If fault remains

pump motor. (DSP card is normal.) See page 3-4.
2-71
Logic
BG 0 to 5V V
CAN 5 WP 211
0 to 5V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG 16 P
R 252 14V RY
Power 3 R 8V
266
RW
17
N Battery (-)
4 253 267 18 DSP IMS
6 U IU
1
Power card V IV
2 Flat
CN4 12V L
5 cable W IW
0 to 5V R 6
0 to 5V Y
7
GND V 19
CN20 Pump motor

V 138 Speed
Y sensor W PW
R
137
M U PU
136 PV
L V
133 Thermal
134 sensor
135
211250
2-72
Problem: Display Communication Fault (60)

(1) Situation
Display: "60". Normal truck operation.
(2) Possible cause

Faulty main harness, faulty display unit, faulty logic unit.

Communication is impossible.
Hour meter data of display unit is abnormal.
(4) Checks
(5) Disconnect connector CN3 of controller. Disconnect

connector CN8 of display unit.
(6) Check to see if these are shorted to other signal cables. (7) Repair or replace harness.
Not shorted Shorted
(8) Replace display unit. (9) Repair or replace harness.
If fault remains

(11) Replace logic card of logic unit. See page 1-47.
2-73
CN9 Key switch

R
Power card 4
G
CN4 13
Battery +
R CN18
13 4 G
2 10 A
G
Fuse holder
CN8
Logic CN8
CN3 152 149
Battery voltage
151 R
151150
WB 149 0 to 12V G
TXD 14
Display
L 0 to 12V L
RXD 16 150
GND 23 L 140
GND
152 B
211251
2-74
Problem: Logic Card Initialize Failure (61)

(1) Situation
(2) Possible cause

Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
faulty logic unit.

Setup Option data is in abnormal setting range.
MC specification is set at #43 while CAN data is received from input unit or output unit.
Other model is set at #40 while steering sensor is installed.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-16.
(5) Set Setup Option Group 3 data. See page 1-28 to 1-30.
(6) Set Setup Option default data. See page 1-16.
(7) Turn on power in "RUN" mode. See page 1-16.
If fault remains
(8) With service tool, set Setup Option Group 3 data.
(9) With service tool, set Setup Option default data.
If fault remains
(13) With service tool, set Setup Option default data.
2-75
Problem: Logics Fault (62)

(1) Situation
(2) Possible cause

Faulty EEPROM data, faulty logic unit.

ROM/RAM SUM value of logic card is different from check data.
EEPROM SUM value of logic card is different from check data.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-16.
(5) Set Setup Option Group 3 data.
(6) Set Setup Option default data.
(7) Turn on power in "RUN" mode. See page 1-16.

Error code "61"
If fault remains "62"
(8) Disconnect battery plug, then perform inverter (9) See troubleshooting for code "61". See page 2-75.

Set Setup Option default data.
2-76
Problem: Traction Inverter R.H. Fault (63)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction inverter,
faulty right traction inverter, faulty main harness, faulty logic unit.

Right traction inverter is connected as pump inverter (CN7-9 is connected to GND).
ROM/RAM SUM value of right taction inverter is different from check data.
Communication with right traction inverter is impossible.
(4) Checks

Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4 and CN7-18(253). (7) Refasten flat cable or replace inverter. See page 1-42.
CAN
Mode
(9) Check CN7-8 and CN7-9 that pin is not inserted in.
Normal Abnormal
power again.

Normal Abnormal
(14) Replace DSP card of right traction inverter. (15) Replace power supply card of logic unit.
See page 1-44. See page 1-48.
2-77
Logic
BG 0 to 5V V
224
L
3 Inside Inside
6 212 229 4 of of
O cover case
14
O
15
5 WG 254 12V R 16 P Fuse
R 252 14V RP
Power 3 R 253 8V RL
17
N Battery (-)
4 18 DSP IMS
6 U
mode 1 8
Power card V
mode 2 9 Flat
CN4
cable W
DSP flat
cable
Inverter
case
DSP card
211252
2-78
Problem: Traction Inverter L.H. Fault (64)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter,
faulty left traction inverter, faulty main harness, faulty logic unit.

Left traction inverter is connected as pump inverter (CN6-9 is connected to GND).
ROM/RAM SUM value of left traction inverter is different from check data.
Communication with left traction inverter is impossible.
(4) Checks

or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN6-18(261). (7) Refasten flat cable or replace inverter. See page 1-42.
CAN
Mode
(10) Check CN6-9 that pin is not inserted in.

Normal Abnormal
power again.

Normal Abnormal
(15) Replace DSP card of left traction inverter. (16) Replace power supply card of logic unit.
2-79
Logic
BG 0 to 5V V 3
224
L 4 Inside Inside
6 212 229 of of
cover case
14
15
WG 254 12V 259 RY
5 16 P Fuse
R 14V 260 RGr 17
Power 3 252
R 253 8V 261 R 18 N Battery (-)
4 DSP IMS
6 20 card U
B
mode 1 8
Power card 262 V
mode 2 9 Flat
CN4
cable W
GND
DSP flat
cable
Inverter
case
DSP card
211253
2-80
Problem: Pump Inverter Fault (65)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty main harness, faulty logic unit.

Pump inverter is connected as traction inverter (CN6-9 is opened).
ROM/RAM SUM value of pump inverter is different from check data.
Communication with pump inverter is impossible.
(4) Checks

or wire breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between CN4-4(253) and CN5-18(267). (7) Refasten flat cable or replace inverter. See page 1-42.
CAN
Mode
(10) Check CN5-8 that pin is not inserted in.

Normal Abnormal
power again.

Normal Abnormal
(15) Replace DSP card of pump inverter. (16) Replace power supply card of logic unit.
2-81
Logic
BG 0 to 5V V
CAN 5 WP 211
0 to 5V
234
L
6 212 239 4 of of
O cover case F
14
O Fuse
15
5 WG 254 12V 265
RG
16 P
R 14V RY
Power 3 R 252 8V
266 17
RW N Battery (-)
4 253 267 18 DSP IMS
B 255 GND 268 B20 card card
6 U
mode 1 8
Power card mode 2 B V
9 Flat
CN4 263
cable W
GND
DSP flat
cable
Inverter
case
DSP card
211254
2-82
Problem: Input Unit Fault (67)

(1) Situation
(2) Possible cause

Faulty remote input unit, faulty main harness, faulty logic unit.

ROM/RAM SUM value of input unit is different from check data.
Communication with input unit is impossible.
(4) Checks
(5) Check input unit status with FC input/output

monitor.
Normal Error
(7) Disconnect battery plug, then replace input unit.

(6) Turn off power.
See page 1-49.
(8) Disconnect connector CN2 of input unit, then measure

voltage between CN2-1(1) and CN2-2(2).
Confirm value is 14V±2V.
Normal Abnormal
(9) Turn off power, then disconnect connector CN23 of

harness B and connector CN1 of FC-IN harness.
(10) Measure voltage between CN23(278) and CN23(279).

Confirm value is 14V±5% .
Normal Abnormal
(11) Repair or replace (12) Disconnect battery plug,

FC-IN harness. then perform inverter
discharging work.
See page 1-41.
(14) Check continuity between CN4-3(252) and CN23(278).

(13) Disconnect battery plug, then perform inverter Check continuity between CN4-6(255) and CN23(279).
discharging work. See page 1-41. Continuity No continuity
(15) Replace power supply (16) Repair or replace main

card of logic unit. harness.
See page 1-48.
2-83

(18) Replace input unit. See page 1-49. (19) Disconnect connector CN1 of FC-IN harness.
Check continuity between CN23(283) and CN3-5(211).
(20) Repair or replace (21) Repair or replace main

FC-IN harness. harness.
2-84
FC-IN Power card

CN2 harness CN1, CN23 CN4
G GND B
1 1 279 255 6
Input Y 14V R
unit 2 2 278 252 3
Br 0 to 5V
7 3 283
L 0 to 5V Logic
8 4 284
CN3
BG
211 5
CAN
21 3 1 279 283 280 WP
212 6
22 4 2 278 284 281
CN1 CN23 Harness B
211255
2-85
Problem: Output Unit Fault (68)

(1) Situation
(2) Possible cause

Emergency switch opened, faulty remote output unit, faulty main harness, faulty logic unit.

Emergency switch is detected. ROM/RAM SUM value of output unit is different from check data.
Communication with output unit is impossible.
(4) Checks
Check emergency switch.
Not pushed Pushed
(5) Release emergency switch.
(6)
(7) Check output unit status with FC input/output

monitor.
Normal Error
(9) Disconnect battery plug, then replace output unit.

(8) Turn off power. See page 1-50.
(10) Disconnect connector CN22 of output unit, then

measure voltage between CN22-20(293) and
Normal Abnormal
(11) Disconnect battery plug, then perform inverter (12) Disconnect battery plug, then perform inverter
discharging work. See page 1-41. discharging work. See page 1-41.
(13) Disconnect connector CN3 of logic unit. (14) Check continuity between CN4-3(252) and
Check continuity between CN3-5(211) and CN22-13(295). CN22-20(293).
Check continuity between CN3-6(212) and CN22-14(296). Check continuity between CN4-6(255) and
Continuity No continuity CN22-19(294).
(15) Replace power supply (16)Repair or replace main

card of logic unit. harness.
See page 1-48.
(17) Replace output unit. See page 1-50. (18) Repair or replace main harness.
2-86
Power card
CN22 CN4
B GND
19 293 252 3
Output R 14V
unit 20 294 255 6
V 0 to 5V BG
13 295 211 5
CAN
L 0 to 5V 212 WP
14 296 6
Logic
CN3
Emergency switch
G 300 O/Battery voltage
3
YB 299 YB G L
4 299 10A FUSE 281 281
280 280 W
4
R
G Key switch
13
10A FUSE
G 2 3
R Battery +
211256
2-87
Problem: Contactor Coil Fault (72)

(1) Situation
Display: "72". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.
(2) Possible cause

Faulty line contactor, faulty pump contactor, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
(5) Find faulty contactor (line contactor or pump

contactor) with input/output monitor.
(6) Disconnect battery plug, then perform (faulty unit only)

(7)Check line contactor or pump contactor.
Line contactor Pump contactor
(8) Remove coil side terminals of (14) Remove coil side

line contactor. terminals of pump contactor.
(9) Check short circuit between coil (15) Check short circuit between
terminal plus(+)(249) and minus(-) coil terminal plus(+)(250) and
(247) of harness. minus(-)(248) of harness.
Not shorted Shorted Shorted Not shorted
(10) Measure coil resistance. (16) Measure coil resistance.

[44Ω at -30 °C (-22 °F) to (11) Repair or replace main harness. [44Ω at -30 °C (-22 °F) to
66Ω at 80 °C (176 °F)] 66Ω at 80 °C (176 °F)]
Abnormal Normal Normal Abnormal
(12) Replace line contactor. (13) Replace logic card of logic unit. (17) Replace pump contactor.
See page 1-47.
2-88
Power card
27V to
R battery voltage
+
CN4 13 4 249
27V to
battery voltage
247 -
Logic
Line contactor
CN1
+
G 250
59
B
60 27V to
battery voltage
248 -
Pump contactor
211257
2-89
Problem: Hydraulic Lock Solenoid Fault (74)

(1) Situation
Display: "74". Pump motor operation inhibited. Normal traction motor operation and power steering operation.
(MC specifications only)
(2) Possible cause

Faulty unload valve, faulty lift lock valve, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
(5) Find faulty valve (unload valve or lift lock valve) with
input/output monitor.
(6) Disconnect battery plug, then perform (faulty unit only)

Unload valve Lift lock valve
(8) Disconnect connector CN1 of logic (14) Disconnect connector CN1 of logic
unit. Disconnect connector CN27 unit. Disconnect connector CN24
of unload valve. of lift lock valve.
(9) Check short circuit between CN27 (15) Check short circuit between
(317) and CN27(318). CN24(308) and CN24(309).
Not shorted Shorted Shorted Not shorted
(10) Check short circuit between (16) Check short circuit between lift
(11) Repair or replace main harness. lock valve side connectors.
unload valve side connectors.
Measure coil resistance. Measure coil resistance.
[7.5Ω at -30 °C (-22 °F) to [7.5Ω at -30 °C (-22 °F) to
12.8Ω at 80 °C (176 °F)] 12.8Ω at 80 °C (176 °F)]
Shorted Not shorted Normal Abnormal
(12) Replace unload valve. (13)Replace logic card of logic unit. (17) Replace lift lock valve.
See page 1-47.
2-90
Power card
CN4 CN27
R
13 4 318
Unload
Logic valve
317
CN1 CN27
B
64
317 318
Logic
Harness B CN24
CN1
309 Lift
57 Y
lock
58 B
308 valve
CN24
308 309
Harness B
211258
2-91
Problem: Battery Voltage Too Low (78)

(1) Situation
(2) Possible cause

Faulty or discharged battery, low voltage battery, improper battery voltage setting (Setup Option #41), improper
battery voltage adjustment setting (Setup Option #46), faulty main harness, faulty logic unit.

Corrected battery voltage is too low.
Battery voltage is corrected with #46 value.
36 V battery: less than 30 V 48 V battery: less than 42 V
(4) Checks
Disconnect battery plug.
Measure battery voltage with tester.
34 V to 55 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

See page 1-16. (6) Charge battery or replace with proper battery.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-28 to 1-30.
(8) Turn off power and turn on power again.
If fault remains

(10) Check continuity between CN3-19(269) and contactor

POS(3).
(11) Perform inverter discharging work, then replace logic (12) Repair or replace main harness.
card of logic unit. See page 1-47.
2-92
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
2-93
Problem: Battery Voltage Too High (79)

(1) Situation
(2) Possible cause

Faulty or highly charged battery, high voltage battery, improper battery voltage setting (Setup Option #41),
improper battery voltage adjustment setting (Setup Option #46), faulty logic unit.

Corrected battery voltage is too high.
36 V battery: more than 42 V 48 V battery: more than 60 V
(4) Checks
Measure battery voltage with tester.
34V to 55 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

See page 1-16. (6) Replace with proper battery.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-28 to 1-30.
(8) Turn off power and turn on power again.
If fault remains

If fault remains
(11) Repair or replace main harness.
2-94
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
2-95
Problem: Direction Lever or Accelerator, Faulty Setting (E)

(1) Situation
Display: "E". Traction motor operation inhibited. Normal pump motor and power steering operations.
Line contactor OPEN.
(2) Possible cause

Key switch turned on while direction lever was left either in forward or reverse position, key switch turned on
while accelerator pedal was depressed, seat switch turned off during running, faulty direction lever switch,
faulty accelerator sensor, faulty main harness, faulty logic unit.

Detects follow signal when turning on power.
Direction lever: F or R Accelerator sensor voltage: More than 0.3 V
(4) Checks
Move direction lever to neutral, and release accelerator pedal.
If fault remains
(5) Turn off power. Move direction lever to neutral, release

accelerator pedal, then turn on power again.

With service tool
(6) Check direction lever and accelerator sensor operations (7) Turn on power in diagnosis mode. Inspect direction
with input/output monitor. lever and accelerator sensor. See page 1-35.
(8) Turn off power. (faulty unit only)
Direction lever Accelerator sensor
(9) Disconnect connector CN10 of direction lever.

Turn on power. (10) Refer to error code "51". See page 2-55.
Normal (E)
(11) Replace direction lever. (12) Disconnect connectors CN2 and CN3 of logic unit.
(13) Check short circuit between CN3-25(108) and

CN2-36(104), CN3-25(108) and CN2-37(103).
Not shorted Shorted
(15) Repair or replace

main harness.
2-96
Logic
CN2
CN10
0/12V O
Forward 37 OL 103 F
Br Direction
Reverse 36 Br 104
0/12V
R lever
GND
102
G
B2
Accel L
42 144
CN10
switch
104 103
102
Main harness
0/12V
Logic Accelerator
CN3 CN16
L
GND 25 W 108
+ 5V 24 RW 141 5V R
AN 20 G 142 0 to 5V G
L 140 GND B
GND 23 143
CN16
143 144 142 141
Main harness
211260
2-97
Problem: Seat Switch, Faulty Setting For Traction ((E))

(1) Situation
Display: "E" flickering. Traction motor operation inhibited. Normal pump and power steering operations.
Line contactor OPEN.
(2) Possible cause

Operator not on seat, seat switch turned off during running, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during running.
(4) Checks
If this fault occurred If this fault occurred when
during running turning on power
(5) Stop truck, then move direction lever to neutral.

Sit properly in operator's seat and release accelerator pedal.
If fault remains Normal
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector CN25, then short-circuit

between terminals (110) and (111). Turn on
power again.

(12) Replace seat switch.

Check continuity between CN25(111) and CN2-33.
(14) Replace logic card of logic unit. See page 1-47. (15) Repair or replace main harness.
2-98
Logic
CN2
0/12V G
32
0/12V YW
33
Seat belt switch CN25
G Logic
310
Y CN3
111
G GND W
110 108 25 GND
Seat switch CN25
111 110 310
Main harness
211261
2-99
Problem: Seat Switch, Faulty Setting For Hydraulic ((L))

(1) Situation
Display: "L" flickering. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN
if truck stops.
(2) Possible cause

Operator not on seat, seat switch turned off during pump motor operation, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during pump operation.
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(5) Sit on seat, then stop pump motor operation.

Fail-safe function
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector CN25, then short-circuit

between terminals (110) and (111). Turn on
power again.
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.

Check continuity between CN25(111) and CN2-33.
2-100
Logic
CN2
0/12V G
32
0/12V YW
33
Seat belt switch CN25
G Logic
310
Y CN3
111
G GND W
110 108 25 GND
Seat switch CN25
111 110 310
Main harness
211261
2-101
Problem: Lift Lever, Faulty Setting (H1)

(1) Situation
Display: "H1" flickering. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
if truck stops.
(2) Possible cause

Key switch turned on while operating lift lever, faulty lift control lever or lift switches 1 and 2,
faulty main harness, faulty logic unit, faulty input unit.

Detects lift control lever signal of CAN when turning on power (FC specification).
Detects lift microswitch 1 or 2 when turning on power (MC specification).
(4) Checks

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without lift operation.
Error code 54 or 67
If fault remains "L" flickering
(8) Refer to error code "54",

(7) Turn off power.
"67" or "(L)".
FC specification
(9) Change lift control lever to other normal control lever.

MC
specification Not changed Error changed
(12) Disconnect connector CN22 of microswitch. Sit on seat, (10) Repair or replace (11) Replace lift control
then turn on power again. FC-IN harness. lever.
(13) Disconnect battery plug, then perform inverter (14) Replace lift switch 1 or 2.

Check short circuit between CN22(303) and CN22(302).
Continuity, Not shorted No continuity, Shorted
(16) Disconnect battery plug. (17) Repair or replace main harness.

2-102
FC specification
CN3 FC-IN harness CN2
5V R
5 23
Lift 7
0 to 5V Y 25 Input
0 to 5V G
control lever 8 26 unit
GND B
6 24
CN3
5 8 7 6
FC-IN harness
MC specification Logic
CN1
CN22 0/12V Y
303 52
Lift 1
0/12V
304 W 51
GND
Lift 2 302
Logic
302 304 CN22 CN3
305 303
W
306 307 108 25
Main harness
211262
2-103
Problem: Tilt Lever, Faulty Setting (H2)

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating tilt lever, faulty tilt control lever or tilt switch, faulty main harness,
faulty logic unit, faulty input unit.

Detects tilt control lever signal of CAN when turning on power (FC specification).
Detects tilt microswitch when turning on power (MC specification).
(4) Checks

Fail-safe function
without tilt operation.
Error code 54 or 67
(8) Refer to error code "54",

(7) Turn off power.
"67" or "(L)".
FC specification
MC (9) Change tilt control lever to other normal control lever.

specification Not changed Error changed
(12) Disconnect connector CN22 of microswitch. Sit on seat, (10) Repair or replace (11) Replace tilt control
then turn on power again. FC-IN harness. lever.
(13) Disconnect battery plug, then perform inverter (14) Replace tilt switch.

2-104
FC specification

5V R
15 5 23
0 to 5V Y
Tilt 9 27 Input
0 to 5V L
16
GND
6
B 24
CN4
15 10 9 16
FC-IN harness
CN22 CN1
0/12V L
305 50
Tilt
GND
302
Logic
302 304 CN22 CN3
305 303 W
306 307
108 25
Main harness
211263
2-105
Problem: Attachment 1 Lever, Faulty Setting (H3)

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating attachment 1 lever, faulty attachment 1 control lever or attachment 1 switch,

Detects attachment 1 control lever signal of CAN when turning on power (FC specification).
Detects attachment 1 microswitch when turning on power (MC specification).
(4) Checks If this fault occurred during If this fault occurred when

Fail-safe function
without attachment 1 operation.
Error code 54 or 67
(7) Turn off power. (8) Refer to error code "54",

"67" or "(L)".
FC specification
MC (9) Change attachment 1 control lever to other normal

specification control lever.
Not changed Error changed
(12) Disconnect connector CN22 of microswitch.
Sit on seat, then turn on power again.
(10) Repair or replace (11) Replace attachment 1
If fault remains Normal FC-IN harness. control lever.
(13) Disconnect battery plug, then perform inverter (14) Replace attachment 1 switch.

Check short circuit between CN22(306) and
CN22(302).
2-106
FC specification

5V R
17 5 23
0 to 5V Y
Attachment 1 11 29 Input
0 to 5V Br
18
GND
6
B 24
CN5
17 12 11 18
FC-IN harness
CN22 CN1
0/12V G
306 49
Aux 1
GND
302
Logic
302 304 CN22 CN3
305 303 W
306 307
108 25
Main harness
211264
2-107

(1) Situation
if truck stops.
(2) Possible cause

Key switch turned on while operating attachment 2 lever, faulty attachment 2 control lever or attachment 2 switch,

Detects attachment 2 control lever signal of CAN when turning on power (FC specification).
Detects attachment 2 microswitch when turning on power (MC specification).
(4) Checks

Fail-safe function
without attachment 2 operation.
Error code 54 or 67
(7) Turn off power. (8) Refer to error code "54",

"67" or "(L)".
FC specification
MC
specification (9) Change attachment 2 control lever to other normal
control lever.
Not changed Error changed
(12) Disconnect connector CN22 of microswitch.
Sit on seat, then turn on power again. (10) Repair or replace (11) Replace attachment 2
If fault remains Normal FC-IN harness. control lever.
(13) Disconnect battery plug, then perform inverter (14) Replace attachment 2 switch.

Check short circuit between CN22(307) and
CN22(302).
2-108
FC specification

R 5V R
19 5 23
0 to 5V Y
Attachment 2 13 31 Input
0 to 5V W
B 20
GND
6
B 24
CN6
19 14 13 20
FC-IN harness
CN22 CN1
0/12V R
307 48
Aux 2
GND
302
Logic
302 304 CN22 CN3
305 303 W
306 307
108 25
Main harness
211265
2-109

(1) Situation
if truck stops.
(2) Possible cause

Faulty logic unit.

Detects attachment 3 signal when turning on power (MC specification).
(4) Checks

Fail-safe function
If fault remains
(7) Check to see if dust is accumulated on terminal CN1-47.
Normal Abnormal
(8) Clean terminal.

If fault remains
2-110
Logic
CN1
47 Attachment 3
switch
Logic
CN3
25 GND
211266
2-111
Problem: Battery Consumption Too Much ((Lo))

(1) Situation
Display: "Lo" flickering. Battery low indicator ON. All truck operations inhibited.
(2) Possible cause

Extremely consumed battery, faulty main harness, faulty logic unit.

Corrected battery voltage is less than 22 V.
(4) Checks
(5) Check battery voltage.

22V or more Less than 22V
(6) Set #46 of Setup Option Group 3. See page 1-30. (7) Charge battery or replace with new battery.
If fault remains

POS(3).
2-112
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
2-113
Problem: Battery Consumption Much

(1) Situation
Battery low indicator flickers. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
and power steering operations.
(2) Possible cause

Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness,
faulty logic unit.

Corrected battery voltage is less than 25 V.
(4) Checks
(5) Check battery voltage.

25V or more Less than 25V
(6) Set #46 of Setup Option Group 3. See page 1-30. (7) Charge battery or replace with new battery.
If fault remains

POS(3).
2-114
Line contactor
Logic
NEG
CN3
Battery voltage
R
19 269 3 Fuse
+
Battery
211259
2-115
Locations of Major Components and Connectors
NOTE
1. The figures described below contain the major components and connectors based on the actual FC model.
2. The component names are basically quoted from the Electrical Schematic and some of the names may be
different from the text the Electrical Diagram.
Joystick box, input unit, output unit, logics and connectors
Seat assy
Joystick box
Input unit
Output unit CN22
Output harness Logics GSE CN21 CN23

Logics power CN4
Seat harness
FC control valve
Logics
DRS switch CN17
211289
2-116
Display, FNR lever assembly, PDS relay, PDS buzzer and connectors
Head lamp (R)
Head lamp (L)
Display
FNR lever assy
CN10
CN8
Horn
PDS relay
PDS buzzer
CN15
CN14
211290
Accelerator, foot brake switch, park brake switch, brake fluid sensor and connectors
Horn SW
Park brake SW
CN11
Accelerator CN16
Brake fluid sensor
Foot brake SW
211291
2-117
Motors, inverters, contactor panel assembly and battery cable
Traction motor R
Battery cable
Traction motor L
Traction inverter (R)
Inverter pump
Pump motor
Contactor panel assy

Traction inverter (L)
211293
Backup buzzer, working lamp and connectors
Working lamp
Backup buzzer (OP)
Inverter trac (R) CN7
Inverter trac (L) CN6
Inverter pump CN5
CN20
211294
2-118
MITSUBISHI CATERPILLAR FORKLIFT
AMERICA INC.
SCHEMATIC(S) INSERTION
Schematic(s) name/number
Insert copy of oversized schematic

99759-68100
Electrical Schematic (AC motor, FC models)
2-119
Electrical Diagram (AC motor, FC models)
2-121
Electrical Schematic (AC motor, MC models)
2-123
Electrical Diagram (AC motor, MC models)
2-125
MOTORS
Motor Installation Positions ................................................................ 3– 1

Specifications .......................................................................................... 3– 1
Structures ................................................................................................. 3– 2
Tightening of High-power Cable Terminals ..................................... 3– 3
Procedures and Suggestions for Removal and Installation ....... 3– 4
Procedures and Suggestions for Disassembly and
Reassembly .......................................................................................... 3– 6
Troubleshooting ...................................................................................... 3– 8
Service Data ............................................................................................ 3– 9
3
MOTORS
Motor Installation Positions
Brake discs
Pump motor
Drive motor
Output shaft
211170
Specifications
Item Drive Motor Pump Motor
Type Induction, three-phase AC Induction, three-phase AC
Voltage (V) 48 36 48 36
Output (kW) 6.3 kW [6.3 kW 14 kW [14 kW

(S2 60 min.) (S2 60 min.)] (S3 15%) (S3 15%)]
Weight kg (lb) 50 (110) 46 (101)
3-1
MOTORS
Structures
Drive Motor
Thermal and speed

sensor connector
U, V, W terminals
211165
Pump Motor
U, V, W terminals
Thermal and speed

sensor connector
211166
The AC motor model lift trucks covered by this manual For the feature and speed control of AC motors, see
use three-phase induction AC motors as the drive “AC Motor System Basics” in CONTROLLER section.
motors and pump motor.
3-2
MOTORS
Tightening of High-power Cable Terminals
! CAUTION
If the high-power cable terminals of the battery-
operated vehicle are not tightened properly, the
increased contact resistance causes excessive Right drive motor
heat generation, and could cause a fire in the (3 terminals)
worst case. To prevent accidents and equipment
problems, be sure to regularly check the Left drive motor
tightening torque of the high-power cable (3 terminals)
terminals. Do not pull the cables to check
connections or during adjustment. If the cable
terminal sections are moved, re-tighten the
connections.
Number of Pump motor

Name of Motor Tightening Torque (3 terminals)
Terminals
15 N·m
Drive motor 3 (1.5 kgf·m)
[11 lbf·ft]
15 N·m
Pump motor 3 (1.5 kgf·m)
[11 lbf·ft]
211171
3-3
MOTORS
Procedures and Suggestions for Removal and Installation
Drive Motors
Removal
(2) Using a crane, remove the head guard and batteries.
(3) Remove the floor plate and battery cover.
(4) Disconnect the harness and cables connected to the
motor.
(5) Remove the brake caliper.
(6) Remove the bolts that secure the front axle on the
vehicle frame. With the drive motor still mounted on the
vehicle, remove the front axle from the vehicle frame.
(7) Using a crane, lift the drive motor to suspend it.
NOTE
Position the hook above the gravitational center of the
Installation
206902
3-4
MOTORS
Pump Motor
Removal
(2) Remove the controller cover and the battery partition
plate.
(3) Disconnect the harness, cables and pipes connected to
the motor.
(4) Remove the pump motor.
Installation
3-5
MOTORS
Procedures and Suggestions for Disassembly and Reassembly
Disassembly
Drive motor
10
12 11
1 2
5
8
6 7
3 4
211168
Sequence
1 Drive end plate 6 Seal 11 Terminal
2 Commutator end plate 7 Sensor bearing 12 Terminal base
3 Rotor 8 Wavy washer
4 Stator 9 O-ring
5 Ball bearing 10 Sensor connector
3-6
MOTORS
Pump motor
2 4 3 11 10
8
5 7
6
211169
Sequence
1 Commutator end plate 5 Ball bearing 9 O-ring
2 Drive end cover 6 Seal 10 Sensor connector
3 Rotor 7 Sensor bearing 11 Terminal
4 Stator 8 Wavy washer
Suggestion for Disassembly and Reassembly

Ball bearings at both ends are of maintenance free. If it is
necessary to remove the bearings when repairing the motor,
the bearings and seals must be replaced.
If a bearing which is to be replaced has only one sealing
lip, it should be greased with quality bearing grease when
installing it.
Replace the bearings and seals after approximately 10,000
operating hours.
3-7
MOTORS
Troubleshooting
Low supply voltage Charge battery and improve power
supply condition.
Blown fuse Replace.
Motor does not Excess load Reduce load.
start. Faulty wire connection Repair, or re-tighten wire connections.
Broken wire in control device Repair or replace.
Broken wire in field coil Repair or replace.
Broken wire in armature coil Repair or replace.
Motor starts but Low supply voltage Charge battery and improve power
does not run at supply condition.
rated speed. Faulty connection of armature circuit Repair connections.
Motor produces Defective bearings Replace bearings.

abnormal
vibrations Loose mounting bolts Retighten bolts and nuts.
and noise. Contact between armature and field coil Repair or replace.
Incorrect installation Correct installation condition.

Severe external vibration Remove the cause of vibration, or take
Bearing appropriate vibration-insulating
overheats. measures.
Defective bearings Replace.
Oil degradation or shortage in bearings Replace.
3-8
MOTORS
Service Data
A: Standard value
Unit: mm (in.)
Truck Models
1 ton class 2 ton class
Item
Stator coil insulation resistance A 1 MV min.

Drive motor and pump motor
U–V A 0
Drive motor
Terminal conductivity
V–W A 0
(V)
Pump motor
W–U A 0
N·m 15 N·m
Cable terminal tightening torque (kgf·m) (1.5 kgf·m)
[lbf·ft] [11 lbf·ft]
3-9
TECHNICAL PUBLICATIONS FEEDBACK
(Please Print)
Dealer name: Submitted by:
Address: P. O. Box:
City: State:
Zip code: Country:
The following discrepancy or omission has been discovered in:

❑ Operation & Maintenance Manual ❑ Option Bulletin
❑ Part List/Manual ❑ Special Instruction
❑ Service Manual ❑ Service Data Manual
❑ Electronic Manual ❑ Other:
Publication # Engine model #
Truck model #
T Issue date #
Truck serial #
T Page #
(Please print)
Explanation of discrepancy or omission:
Please fax or mail completed form to:
Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O. Box 30171
Houston, TX 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No.: 199203169H
Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-6861-9277
Cat Lift Trucks Service Manual Controller (EP16N-EP20CN) 99759-68100
Mitsubishi Caterpillar Forklift Europe B.V.
Hefbrugweg 77 1332 AM
Almere, The Netherlands
99759-68100 Copyright © 2005 by MCFA. All Rights Reserved. Printed in The Netherlands
CATERPILLAR and CAT are registered trademarks of Caterpillar Inc.

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Service Manual

For use with EP16N-EP20CN Chassis Service Manual. 99759-68100

Safety Related Signs

The following safety related signs are used in this service

Indicate a specific potential hazard

Indicate a specific potential hazard

Indicates a condition that can cause

Pub. No. 99759-68100

Disassembly diagram (example)

Procedures are described in the text.

Suggestion for disassembling

Item SI unit Customary unit

GROUP INDEX Items

Controller system, Controller features, Setup option, Diagnosis, Removal and

Motor installation positions, Specifications, Structures, Tightening of high-power

Controller System .................................................................................. 1 – 1

System layout for FC type

System layout for MC type

Right Left Pump

Controller Area Network (CAN)

*1, * 2: Input unit and output unit are used

The data are expressed with electric potential difference

bit Logic Vdiff Vdiff

recessive 1 recessive dominant recessive

Communication protocol CANbus 2.0B passive Non-Return to Zero method

Item Description SUO No.

The current information is available to confirm and

Harness B side CN3 Harness B side CN2 Harness B side CN1

Power supply card

Power supply card side CN1 Harness B side CN4

The Service Tool connector exists on harness B CN21.

2. Inverter When a malfunction occurs, it stops the motors and

Traction inverter (right and left)

Harness B side, Traction Right CN7

Inverter card side CN2 Harness B side, Pump CN5

Input unit card

Input unit card side CN1 FC-IN harness side CN2

Current characteristics of proportioning

Output unit card

Harness B side CN22 FC-OUT harness side CN9

The following describes the features of controller.

Setting feature for traction characteristics

2. Controlled roll-back NOTICE: When the regeneration is selected by SUO

85 STANDARD; Full acceleration

4. Limitation of maximum travel speed

Feature of maximum speed limit

Description SUO No. Harness Pin No.

5. Miscellaneous features for traction

Miscellaneous features for traction

Feature of lifting work speed setting

Description SUO No. Harness Pin No.

Refer to page 1-16 for details and setting procedure of

Refer to page 1-16 for details and setting procedure of

DRS switch is installed under floor

2. PDS (Presence Detection System) features

Protect condition Result Release method

Status transfer chart

Traction Control PDS Seat SW

Direction lever: N (Chosen foot direction: no effect)

Seat SW flag: OFF

1, 2: Input unit and output unit are used