Sit Down Counterbalanced-4460

Maintenance Manual
Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck
Model: Serial Numbers:

4460 00001 and Up
Publication: 1237640A Issued: 26 May 2017

This publication, 1237640A, applies to Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck,
S/N 00001 and up, and to all subsequent releases of this product until otherwise indicated in new editions or
bulletins. Changes occur periodically to the information in this publication.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Sales and Service center.
To locate your local authorized Raymond Sales and Service center, go to www.raymondcorp.com.
©2017 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Raymond. All other brand and product
names are trademarks or registered trademarks of their respective companies.
i
Table of Contents
1 GENERAL................................................................................................. 2
2 BATTERY ............................................................................................... 22
3 CONTROLLER ....................................................................................... 32
4 DISPLAY................................................................................................. 79
5 TROUBLESHOOTING.......................................................................... 171
6 MOTOR ................................................................................................. 707
7 DRIVE UNIT AND FRONT AXLE ......................................................... 721
8 REAR AXLE.......................................................................................... 732
9 STEERING ............................................................................................ 751
10 BRAKE.................................................................................................. 766
11 BODY & FRAME................................................................................... 783
12 MATERIAL HANDLING SYSTEM ........................................................ 791
13 MAST .................................................................................................... 797
14 CYLINDER ............................................................................................ 825
15 OIL PUMP ............................................................................................. 846
16 OIL CONTROL VALVE......................................................................... 853
17 PSS FUNCTIONS ................................................................................. 903
18 APPENDIX ............................................................................................ 921
1-2 1 GENERAL
1 GENERAL
1.1 LIFT TRUCK EXTERIOR VIEW ................................................................ 3
1.2 LIFT TRUCK MODELS.............................................................................. 4
1.3 FRAME NUMBER...................................................................................... 4
1.4 HOW TO USE THIS MANUAL .................................................................. 5
1.5 OPERATING TIPS..................................................................................... 7
1.6 STANDARD BOLT & NUT TIGHTENING TORQUE ............................... 10
1.7 PRECOAT BOLTS................................................................................... 13
1.8 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ................. 13
1.9 RECOMMENDED LUBRICANT QUANTITY AND TYPES...................... 14
1.10 LUBRICATION CHART ........................................................................... 15
1.11 PERIODIC MAINTENANCE TABLE........................................................ 16
1.12 PERIODIC REPLACEMENT TABLE ....................................................... 21
1 GENERAL 1-3
1.1 LIFT TRUCK EXTERIOR VIEW 1

1-4 1 GENERAL
1.2 LIFT TRUCK MODELS

Capacity Capacity (L.C.24
Vehicle model
(L.C.500 mm) inch) Voltage Control method
code
kg lbs.
AC microcomputer con-
C30 1500 3000 36/48V
troller
C35S AC microcomputer con-
1750 3500 36/48V
C35 troller
AC microcomputer con-
C40 1810 4000 36/48V
troller
1.3 FRAME NUMBER
(a)
This illustration shows the punching position (a) of your frame number.
Lift truck model Punching format
C30
C35S
446-16-00001
C35
C40
(a) Frame serial number location
1 GENERAL 1-5
1.4 HOW TO USE THIS MANUAL 1
1.4.1 EXPLANATION METHOD

1. Operation procedure
• The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with illustration.
Pattern B: Explanation or operation procedure by indication step numbers in one illustration, followed
by explanation of cautions and notes summarized as point operations.
Example
13-262 13 CYLINDER
13.2.1 REMOVAL AND INSTALLATION
7
6
Step number
* Step Nos. are partially sometimes

3
omitted in illustrations.
a (except J3.5-on models): T = 29 - 39 N·m (300 - 400 kgf·cm)
a (J3.5-ton models): T = 59 - 69 N·m (602 - 703 kgf·cm)
Tightening torque
REMOVAL PROCEDURE
1. Remove the lift cylinder rod end set bolt.
2. Hoist the inner mast. [Point 1]
3. Remove the front hose cover.
4. Remove the lift cylinder bottom end set bolt.
5. Loosen the lift cylinder support set bolt.
6. Disconnect the hoses. [Point 2] Point operation covered on
7. Remove the safety down valve.
the following page
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
[Point 1]
667 Removal:
Hoist the inner masts (middle masts) by slinging with
wire, attach the SST to the inner mast (middle mast)
tie beam, and lower the inner masts until they come
into contact with the SST.
SST 09610-22000-71
2. Matters omitted from this manual

This manual omits descriptions of the following jobs, but perform them in actual operation:
• Cleaning and washing of removed parts as required
• Visual inspection (partially described)
1-6 1 GENERAL
1.4.2 TERMINOLOGY
CAUTION
Important matters of which negligence may cause hazards on the human body. Make sure to observe
them.
NOTICE
Indicates information to be considered important, to do your job right and easier, and to keep your
lift truck running well.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
1.4.3 ABBREVIATIONS
Abbreviation Abbreviation
Meaning Meaning
(code) (code)
ASC Automatic Speed Control PS Power steering
Performance Stability System (PSS
ASSY Assembly PSS (SAS)
and SAS are interchangeable terms)
ATT Attachment QR Quick Reference
FR Front RH Right hand
LH Left hand RR Rear
Society of Automotive Engineers
L/ Less SAE
(USA)
OCL Over Current Limit SOL Solenoid
OCV Oil Control Valve SST Special service tool
OPS Operator Presence Sensor STD Standard
OPT Option T= Tightening torque
PKB Parking brake W/ With
1 GENERAL 1-7
1.5 OPERATING TIPS 1

1. Safe operation
• After jacking up, always support with wooden blocks or rigid stands.
• When hoisting the lift truck or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
• Always disconnect the battery plug before the inspection or servicing of electrical parts.
2. Careful operation
• Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTs before starting operation.
• Before disconnecting wiring, always check the cable color and wiring state.
• When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
• When disassembling and inspecting such a precision part as the control valve, use clean tools and op-
erate in a clean location.
• Follow the described procedures for disassembly, inspection and reassembly.
• Replace, gaskets, packing and O-rings with new ones each time they are disassembled.
• Use genuine Raymond parts for replacement.
• Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
(Tighten to the center of the specified tightening torque range.) If no tightening torque is specified,
tighten the bolt or nut according to the standard tightening torque table.
3. Protection of functional parts
• Thoroughly check each connector for any failure in or imperfect connection before reconnecting the
battery plug after the end of lift truck inspection or maintenance.
Failure in or imperfect connection of connectors related to controllers, especially, may dam-
age elements inside the controllers.
4. Confirming defect status
• Do not start immediate disassembly or replacement, but first confirm if such disassembly or replace-
ment is actually needed.
5. Handling of waste fluid, etc.
• When draining waste fluid from the lift truck, always receive it with an appropriate container. Since
careless or arbitrary discharge or disposal of oil, fuel, coolant, oil filter, battery or any other harmful
substance may cause adverse affect to people or environmental destruction, sort each waste and al-
ways ask an authorized contractor for appropriate disposal.
6. Handling of electronic parts
• Never apply impacts to electronic parts such as a microcomputer or relay.
• Never let electronic parts be exposed to a high temperature or humidity.
• Do not touch connector pins since they may be deformed or be damaged due to static electricity.
7. Disconnect the battery plug
When unplugging the battery plug, use the grip. Do not pull up on the cable.
1-8 1 GENERAL
1.5.1 JACK-UP POINT
(a)
(b)
(a) Jack-up point

(b) Wooden block or stand setting points
NOTICE
• A jack-up point is provided at the bottom of the frame to the rear of the front tire.
• The jack-up point is provided within a range of 5.9 in. (150 mm) from the fender. Jack up the lift truck at
the specified jack-up point.
1 GENERAL 1-9
1.5.2 HOISTING THE VEHICLE 1
NOTICE
• Position the mast in the full rearward tilt position.
• Remove any Optional Lamps that are installed at the rear of the overhead guard.
• When preparing the lift truck for hoisting (and the lifting straps are tight), confirm that the draw bar has
not moved upward. If the draw bar has moved upward, push the draw bar downward.
• The length of lifting straps are different based on the specification of the lift truck and mast. When hoist-
ing the lift truck, adjust the length of the lifting straps to prevent deformation of the overhead guard at the
contact points with the overhead guard
• Use protective padding if there is contact between the lifting straps and the overhead guard.
1-10 1 GENERAL
1.6 STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.
1 GENERAL 1-11
1.6.1 BOLT STRENGTH TYPE IDENTIFICATION METHOD 1

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

Hexagon head bolt Stud bolt
1-12 1 GENERAL
1.6.2 TIGHTENING TORQUE TABLE

Specified torque Specified torque
Hexagon head bolt Hexagon flange bolt
Diameter Pitch
Class
mm mm
ft-lbf. N•m ft-lbf. N•m

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

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

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

TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with a
clean cloth to remove foreign matters and dirt.
Also check that there are no dents or other damage on the contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the
fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Standard tightening torque
Nominal diameter of Hose nominal size
ft-lbf. [N•m]
screw in. (mm)
Standard Tightening range
17.7 to 19.2
7/16 - 20UNF 18.4 [25] 0.24 (6)
[24 to 26]
23.6 to 26.6
9/16 - 18UNF 25.1 [34] 0.35 (9)
[32 to 36]
3/4 - 16UNF 41.3 to 45.7
43.5 [59] 0.47 (12)
7/8 - 14UNF [56 to 62]
54.6 to 60.5
7/8 - 14UNF 57.5 [78] 0.59 (15)
[74 to 82]
82.6 to 90.7
1・1/16 - 12UNF 87.1 [118] 0.75 (19)
[112 to 123]
95.9 to 106.2
1・5/16 - 12UNF 101.1 [137] 0.98 (25)
[130 to 144]
17.7 to 19.2
PF1/4 18.4 [25] 0.24 (6)
[24 to 26]
1-14 1 GENERAL
23.6 to 26.6
PF3/8 25.1 [34] 0.35 (9)
[32 to 36]
41.3 to 45.7
PF1/2 43.5 [59] 0.47 (12)
[56 to 62]
82.6 to 90.7
PF3/4 87.1 [118] 0.75 (19)
[112 to 123]
95.9 to 106.2
PF1 101.1 [137] 0.98 (25)
[130 to 144]
1.9 RECOMMENDED LUBRICANT QUANTITY AND

TYPES
Application Type Capacity
(ATF) AUTOMATIC TRANSMISSION FLUID
Drive unit Approx.0.145 US gal (0.55 L)
T-IV or MOBIL ATF 3309
STD: Hydraulic oil (ISO VG32)
See “Hydraulic oil level by lifting
Hydraulic oil Cold storage lift truck: Castle Auto Fluid Spe-
height” below
cial
MP grease
Chassis parts Molybdenum disulfide grease Appropriate amount
Esso beacon 325
Battery Distilled water Appropriate amount
Brake fluid SAE J-1703 DOT3 Appropriate amount
Hydraulic oil level by lifting height
All models
Lifting height
US gal (L)
To 118 in. Capacity 4.70 (17.8 )
(3000mm) Hydraulic oil level in the tank 3.59 (13.6)
To 157.5 in. Capacity 5.17 (19.6)
To 275.6 in. Capacity 5.41 (20.5)
1 GENERAL 1-15
1.10 LUBRICATION CHART 1
○: Inspection and addition

●: Replacement
A: MP grease I. Inspection every 8 hours (daily)
B: Motor oil II. Inspection every 40 hours (weekly)
C: AUTOMATIC TRANSMISSION FLUID T-IV III. Inspection every 500 hours (3 months)
D: Hydraulic oil ISO VG 32 IV. Inspection every 1000 hours (6 months)
Castle auto special (cold storage models)
E: Molybdenum disulfide grease V. Inspection 2000 hours (annual)
F: Brake fluid SAE J-1703, DOT-3
1. Mast strip 8. Steering rack and pinion gear

2. Tilt cylinder front pin 9. Accelerator link
3. Mast support bushing 10. Oil tank
4. Lift chain 11. Tilt steering lock device
5. Drive unit 12. Rear wheel bearing
6. Brake link 13. Rear axle bearing
7. Oil control valve lever pin 14. Master cylinder or Reservoir tank
1-16 1 GENERAL
1.11 PERIODIC MAINTENANCE TABLE

INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening
C : Cleaning
L : Lubrication
*Same as the left column
*1: For new lift truck
*2: Fissure and crack detector
Inspection Period Every
Every Every Every
(Accomplish based on operating hours or months, 12
6 weeks 3 months 6 months
whichever is soonest.) months
Every Every Every Every
Item 250 500 1000 2000
hours hours hours hours
ELECTRICAL SYSTEM
Rotation sound I*1 I * *
Motor Terminal looseness T*1 T * *
Insulation resistance M * *
1
Charging level I* I * *
1
Electrolyte level I* I * *
Electrolyte specific gravity M*1 M * *
1
Terminal looseness I* I * *
Battery Abnormality in the upper porting of the
I*1 I * *
battery case
Insulation resistance M * *
Voltage measurement of each battery cell
M
after charging
Contact looseness, damage, abrasion I*1 I * *
Operating condition of the auxiliary con-
I*1 I * *
tact, contamination, abrasion
Mounting condition of the arc shooter I
Magnetic contactor
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead
I
wire looseness
Operating condition and timing I*1 I * *
Micro switch
Damage and looseness of installing parts I*1 I * *
Direction control
Operating condition, damage I*1 I * *
lever
Direction switch Contact inspection I*1 I * *
Operating condition I*1 I * *
1
Controller Interior contamination, damage C* C * *
Overcorrect limited value M
Fuse Looseness I*1 I * *
1 GENERAL 1-17

(Accomplish based on operating hours or months,
Every Every Every
12 1
Item 250 500 1000 2000
Harness deterioration, clamp damage and
I*1 I * *
looseness
Looseness in connecting parts, taping
Wiring (including I*1 I * *
condition
charging cord)
Connection condition and damage of the
I*1 I * *
battery connector
Wiring harness insulation damage I
POWER TRANSMISSION SYSTEM
Oil leak I*1 I * *
Drive unit Oil level I*1 I * *
Bolt or nut looseness T
DRIVE SYSTEM
Tire cuts, damage and uneven wearing I*1 I * *
1
Loose rim and hub nuts T* T * *
1
Tire groove depth M* M * *
Metal chips, pebbles and other foreign
I*1 I * *
matter trapped in tire grooves
Wheels
Rim, side bearing and disc wheel damage I*1 I * *
Abnormal sound and looseness of front
I*1 I * *
wheel bearing
Abnormal sound and looseness of rear
I*1 I * *
wheel bearing
Front axle Damage and deformation I
Rear axle Damage and deformation I
STEERING SYSTEM
Play and looseness I*1 I * *
Steering wheel 1
Function I* I * *
1
Oil leak I* I * *
Steering valve
Looseness of mounting T*1 T * *
Steering system Left and right turn angle I
1
Oil leak and oil level I* I * *
Power steering Mounting and linkage looseness I*1 I * *
Damage of power steering hose I
BRAKING SYSTEM
Brake pedal Braking effect I*1 I * *
Operating force I*1 I * *
Parking brake 1
Braking effect I* I * *
1
Brake pipe Leak, damage and mounting condition I* I * *
Reservoir tanks Leak and fluid level I*1 I * *
Function, wear, damage, leak and mount-
Master cylinder I
ing looseness
Looseness and damage I*1 I * *
Rod and cable
Operating condition I*1 I * *
1-18 1 GENERAL

Every Every Every
Item 250 500 1000 2000
Oil leak I*1 I * *
1
Cooling oil level (Drive unit oil level) I* I * *
Wet Brake Brake valve function, damage, or loose-
I
ness in the installed parts
Brake disc clearance adjustment (disc
I
wear)
LOAD HANDLING SYSTEM
Abnormality of fork and stopper pin I*1 I * *
Misalignment between left and right fork
Forks I*1 I * *
fingers
Cracks at fork heel and hangers I*2
Deformation and damage of each part and
I*1 I * *
cracks on welded part
Roller bearing looseness I*1 I * *
1
Mast and carriage looseness I* I * *
Mast and carriage 1
Mast support metal wear and damage I* I * *
Wear, damage and rotating condition of
I*1 I * *
rollers
Wear and damage of roller pins I
Tension, deformation and damage of
I*1 I * *
chains
Chain lubrication I*1 I * *
Chain and chain 1
Abnormality of chain anchor bolt I* I * *
wheel
Wear, damage and rotating condition of
I*1 I * *
chain wheel
Chain wheel bearing wear I*1 I * *
Various attachments Abnormality and mounting condition of
I*1 I * *
(Option) each part
HYDRAULIC SYSTEM Cylinder
Loosening and damage of cylinder mount-
T*1 T * *
ing
Deformation and damage of rod, rod
I*1 I * *
screw and rod end
Cylinder operation I*1 I * *
Natural drop and natural forward tilt (hy-
Cylinder M*1 M * *
draulic drift)
Oil leak and damage I*1 I * *
Wear and damage of pin and cylinder sup-
I*1 I * *
port
Lifting speed M*1 M * *
1
Uneven movement I* I * *
Oil leak and abnormal sound I*1 I * *
Oil pump
Drive system wear I
1 GENERAL 1-19

(Accomplish based on operating hours or months,
Every Every Every
12 1
Item 250 500 1000 2000
Oil level and contamination I*1 I * *
Hydraulic oil tank Tank and oil strainer C *
1
Oil leak I* I * *
Hydraulic filter Filter clogging I
Loose linkage I*1 I * *
Control lever
Operation I*1 I * *
1
Oil leak I* I * *
Oil control valve Relief pressure measurement M
Relief valve and tilt lock valve functions I*1 I * *
1
Oil leak I* I * *
1
Hydraulic piping Deformation and damage I* I * *
Loose joint T*1 T * *
SAFETY DEVICES, ETC.
Cracks at welded portion I*1 I * *
Overhead guard
Deformation and damage I*1 I * *
1
Loosening of mounting T* T * *
Back-rest 1
Deterioration, cracks and damage I* I * *
Lighting system
Function and mounting condition I*1 I * *
(Option)
Horn Grease horn contact ring and horn contact
L
spring
Turn signals
(Option)
Instruments Functions I*1 I * *
Buck-up buzzer
Function and mounting condition T*1 I * *
(Option)
Dirt, damage I*1 I * *
Rear-view mirror 1
Rear reflection status I* I * *
(Option)
1
Deformation, cracking and damage I* I * *
Functions I*1 I * *
Loosening and damage at sensor mount-
I*1 I * *
ing portion
Damage, deformation, oil leakage and
PSS
loosening of the mounting of functional I*1 I * *
parts
Loosening and damage of wire harnesses I*1 I * *
Rusting and corrosion of load sensor I
Operator Presence
Functions I*1 I * *
Sensor System
Loosening and damage of mounting I*1 I * *
1
Seat Seat damage and function I* I * *
1
Operating condition of seat switch I* I * *
1-20 1 GENERAL

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

Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
NOTICE
• Periodic maintenance is fundamental. Replace even before replacement interval if abnormality is
seen in Periodic Maintenance, because deterioration differs from condition.
• Have customers conduct weekly maintenance (40 hr) as mentioned in Operator's Manual
● : Replacement
Inspection Period
(Accumulated hours of operation or Every Every Every Every
monthly periods of operation, 6 weeks 3 months 6 months 12 months
whichever comes sooner.)
Item
250 hours 500 hours 1000 hours 2000 hours
Hydraulic oil ●
●
Hydraulic oil return filter ●
(New Truck)
Brake fluid ●
Drive unit gear oil
●
(Wet disc brake oil)
Wheel bearing grease ●
1
Power steering hoses Every 2 years *
Power steering rubbers parts Every 2 years *1
Hydraulic hoses Every 2 years *1
Chains Every 3 years *2
*1: Replace without reservation at indicated interval in case of hard operation conditions mentioned below.
In case of normal operating condition, the distributors are entrusted with the responsibility for determining
whether the parts should be replaced or not.
If the replacement is determined to be unnecessary, make sure to inspect at the next periodic maintenance.
Note: Definition of "hard operation" is the following.
• Extended heavy duty operations (e.g. multi-shift or continuous use)
• High temperature areas (e.g. steel mills or foundries)
• Low-temperature operations (e.g. freezer operation)
• Sudden temperature changes (e.g. traveling between freezer, room temperature, and oven or fur-
nace environments)
• Dusty or sandy conditions (e.g. cement plants, lumber or flour mills, coal dust or stone-crushing
areas)
• Corrosive chemical atmosphere (e.g. fish, meat, or poultry processing plants, tanneries, chlorine or
saltsea air environments)
• High humidity, wet, damp, or moist conditions
*2: The distributors are entrusted with the responsibility for determining whether the parts should be replaced
or not. If the replacement is determined to be unnecessary, make sure to inspect at the next periodic main-
tenance.
2-22 2 BATTERY
2 BATTERY
2.1 Battery Compartment Size and Necessary Weights of Battery ............... 22
2.2 SERVICE STANDARDS.......................................................................... 23
2.3 DISPLAY.................................................................................................. 26
2.4 TROUBLESHOOTING............................................................................. 27
2.5 BATTERY ASSY...................................................................................... 28
2.1 Battery Compartment Size and Necessary Weights

of Battery
When installing a battery, refer to the table below and adjust the weight so that the necessary minimum and
maximum weight is satisfied.
Battery compartment dimensions Necessary min- Necessary max-
in. (mm) imum battery imum battery
Model weight (with weight (with
Forward- case) case)
Width Y Height Z
Rear X lbs. (kg) lbs. (kg)
C30
21.7 (551) 39.2 (997) 24.5 (623) 1543 (700) 2270 (1030)
C35S
STD
C35
25.1 (638) ↑ ↑ 2105 (955) 2710 (1230)
C40
20.7 (527) or
39.0 (992) 24.1 (613) 1543 (700) 2270 (1030)
C30 less
C35S 20.8 (528) to
↑ 23.1 (587) ↑ ↑
21.7 (551)
R/O*
24.1 (614) or
↑ 24.1 (613) 2105 (955) 2710 (1230)
C35 less
C40 24.2 (615) to
↑ 23.1 (587) ↑ ↑
25.1 (638)
* R/O: Battery Roll Out specification
2 BATTERY 2-23
2.2 SERVICE STANDARDS

Specific gravity upon full charge
1.280 [68°F (20°C)]
Specific gravity upon end of discharge

1.150 [68°F (20°C)]
36V 32V
Discharge end voltage
48V 42.5V
Electrolyte
Refined dilute sulfuric acid
Fluid to be added
Distilled water
Insulation resistance
1 MΩ or more
2.2.1 Battery list

The recommended batteries are shown in the table below. Refer to Battery Compartment Size and Neces-
sary Weights of Battery for the necessary minimum weight.
2-24 2 BATTERY
Installed Battery Battery Case

Ca- dimensions
Vehicle pa- Weight
Voltage length width height
Model Supplier Model city
(AH/6 (lbs.) (kg) (in.) (mm) (in.) (mm) (in.) (mm)
HR)
18-
770 1818 825 17.94 456 38.53 979 23.36 593
ENER- E110-15
SYS 18-
880 2070 940 20.21 513 38.33 974 23.36 593
E110-17
18-85S-
595 1818 825 18.69 475 37.75 959 22.88 581
15
36
18-85S-
Crown 680 2070 940 20.13 511 38.25 972 22.88 581
17
18-110-1
880 2106 956 20.13 511 38.25 972 22.88 581
7
18-85C-
GNB 680 1933 878 19.94 506 38.25 972 22.63 575
C30 17
STD
C35S 24-
550 1776 806 17.71 450 37.98 965 23.36 593
ENER- E110-11
SYS 24-
660 2112 959 20.72 526 37.97 964 23.36 593
E110-13
24-75S-
375 1728 785 17.63 448 37.75 959 22.88 581
11
48
24-85S-
Crown 510 2000 908 20.63 524 37.75 959 22.88 581
13
24-110-1
660 2095 951 20.63 524 37.75 959 22.88 581
3
24-85C-
GNB 510 1869 849 20.50 521 38.00 965 22.63 575
13
18-
990 2322 1054 22.46 570 38.33 974 23.36 593
ENER- E110-19
SYS 18-
1100 2574 1169 24.54 623 38.33 974 23.36 593
E110-21
18-85S-
765 2322 1054 22.31 567 38.13 969 22.94 583
19
36
18-85S-
Crown 850 2484 1128 24.63 626 38.25 972 22.88 581
21
18-110-2
1100 2520 1144 24.63 626 38.25 972 22.88 581
1
C35 18-85C-
STD GNB 850 2314 1051 24.56 624 38.25 972 22.63 575
C40 21
24-
660 2112 959 20.72 526 37.97 964 23.36 593
ENER- E110-13
SYS 24-
770 2424 1100 23.74 603 38.71 983 23.36 593
E110-15
24-110-1
48 660 2095 951 20.63 524 37.75 959 22.88 581
3
Crown
24-110-1
770 2460 1117 23.63 600 38.25 972 22.88 581
5
24-85C-
GNB 595 2148 975 23.50 597 38.19 970 22.62 575
15
2 BATTERY 2-25
Installed Battery Battery Case

Ca- dimensions
Vehicle pa- Weight 2
Voltage length width height
Model Supplier Model city
(AH/6 (lbs.) (kg) (in.) (mm) (in.) (mm) (in.) (mm)
HR)
18-
770 1818 825 17.94 456 38.53 979 23.36 593
ENER- E110-15
SYS 18-
880 2070 940 20.21 513 38.33 974 23.36 593
E110-17
18-85S-
36 680 2070 940 20.13 511 38.25 972 22.88 581
17
Crown
18-110-1
880 2106 956 20.13 511 38.25 972 22.88 581
7
18-85C-
GNB 680 1933 878 19.94 506 38.25 972 22.63 575
C30 17
R/O*
C35S 24-
550 1776 806 17.71 450 37.98 965 23.36 593
ENER- E110-11
SYS 24-
660 2112 959 20.72 526 37.97 964 23.36 593
E110-13
24-85S-
48 510 2000 908 20.63 524 37.75 959 22.88 581
13
Crown
24-110-1
660 2095 951 20.63 524 37.75 959 22.88 581
3
24-85C-
GNB 510 1869 849 20.50 521 38.00 965 22.63 575
13
ENER- 18-
990 2322 1054 22.46 570 38.33 974 23.36 593
SYS E110-19
18-85S-
36 Crown 765 2322 1054 22.31 567 38.13 969 22.94 583
19
18-85C-
GNB 850 2314 1051 24.56 624 38.25 972 22.63 575
21
24-
660 2112 959 20.72 526 37.97 964 23.36 593
C35 ENER- E110-13
R/O*
C40 SYS 24-
770 2424 1100 23.74 603 38.71 983 23.36 593
E110-15
24-110-1
48 660 2095 951 20.63 524 37.75 959 22.88 581
3
Crown
24-110-1
770 2460 1117 23.63 600 38.25 972 22.88 581
5
24-85C-
GNB 595 2148 975 23.50 597 38.19 970 22.62 575
15
* R/O: Battery Roll Out specification
2-26 2 BATTERY
2.3 DISPLAY
Battery Charge Indicator
The battery charge indicator indicates 10 levels of
battery charge on the LCD.
LCD
Battery
10 1
discharged state % 9 8 7 6 5 4 3 2
F E
0 to 10 (exclusive) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
10 to 20 (exclusive) − ○ ○ ○ ○ ○ ○ ○ ○ ○
20 to 30 (exclusive) − − ○ ○ ○ ○ ○ ○ ○ ○
30 to 40 (exclusive) − − − ○ ○ ○ ○ ○ ○ ○
40 to 50 (exclusive) − − − − ○ ○ ○ ○ ○ ○
50 to 60 (exclusive) − − − − − ○ ○ ○ ○ ○
60 to 70 (exclusive) − − − − − − ○ ○ ○ ○
70 to 80 (exclusive) − − − − − − − ○ ○ ○
80 to 90 (exclusive) − − − − − − − − ○ ○
90 to 100 (exclusive) − − − − − − − − − ○
100 or more − − − − − − − − − −
Battery Overdischarge Warning

When the battery charge drops below the preset level in active “low battery level warning”, all segments in
the battery level indicator blink and a buzzer sounds to warn the operator.
Low Remaining Battery Charge Warning

When the battery charge drops below the preset level, the battery level indicator blinks. When the operator
turns the key switch from OFF to ON with this condition, a buzzer will sound for five seconds to warn the op-
erator.
2 BATTERY 2-27
2.4 TROUBLESHOOTING
2
Plate corrosion Sulfation Plate warpage and active substance freeing
Improper charging
Long storage Repeated overdischarge/
without operation overcharge
End of life Short circuit
between cells
Excessive charging
Defect of electrolyte
Insufficient current
Defective electrolyte
electrolyte
Overdischarge Excessive ambient
Battery defect
temperature
Crack or
Damaged Improper chipping of cell
separator water supply Imperfect
Overcharge terminal
connection
Deposition of freed Fouled terminal or

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

2-28 2 BATTERY
2.5 BATTERY ASSY
Removal Procedure
1. Disconnect the battery plug.
2. Release the steering release lever.
3. Open the battery hood.
4. Remove the battery ASSY. [Point 1]
2 BATTERY 2-29
Point Operations
[POINT1] 2
Removal and Installation:
SST
SST 979-001/276
2.5.2 INSPECTION
1. Electrolyte inspection
The battery electrolyte is normal when it is transpar-
ent. Check turbidity when inspecting the specific
gravity. If it cannot be checked clearly, put the elec-
trolyte in a beaker for inspection.
2. Battery electrolyte specific gravity inspection

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

is used.
Equation for converting specific gravity
S20=St+0.0007 (t-20)
S20: Specific gravity at 68°F (20°C)
St: Specific gravity at t°C
t: Electrolyte temperature upon measurement (°C)
2-30 2 BATTERY
* How to use the hydrometer

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

Measure the resistance between the battery and bat-
tery case with an insulation resistance meter
(megohmmeter).
Insulation resistance .... 1 MΩ or more
NOTICE! When the insulation resistance is less
than 1 MΩ, wash the battery with water after re-
moving it from the lift truck. Fully dry the washed
battery and measure the insulation resistance
again. Install the battery on the lift truck after
confirming that the insulation resistance is 1 MΩ
or more.
* Battery control table
Prepare a control table for each battery to record and maintain the inspection results.
Inspection date Specific Electrolyte Added water
Inspected cell No. Remarks Inspector
and time gravity temperature quantity
2.5.3 REPLACING BATTERY PLUG TERMINAL

1. Disconnect battery plug cable one by one.
CAUTION! Never disconnect more than one cable at the
same time. A short circuit may cause a fatal accident.
2 BATTERY 2-31
2. Insert a screwdriver (c) from the terminal side (a), push

down the spring (b) at the bottom of the terminal and pull the
(a) (c) cable to draw it out of the terminal. 2
(b) (b)
3. Peel off the tip of the cable for Approx. 1.18 in. (30 mm),
solder sufficiently and insert it in the contact portion of the new
terminal.
NOTICE! Make sure to prevent solder from pouring out and
adhering to the contact surface of the terminal.
4. Crimping method: When crimping cables, never bend the

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

Check that the tip of the terminal goes over the tip of the spring
(a) (b) and is securely set in position.
(a) Case
(b) Terminal
(c) Spring
(d) Cable
(c) (d)
3-32 3 CONTROLLER
3 CONTROLLER
3.1 GENERAL................................................................................................ 33
3.2 ELECTRICAL COMPONENTS LAYOUT DRAWING .............................. 35
3.3 LAYOUT OF CONTROLLER CABLES.................................................... 36
3.4 SPECIFICATIONS................................................................................... 36
3.5 BEFORE INSPECTION ........................................................................... 37
3.6 CONNECTOR INSPECTION................................................................... 37
3.7 DISASSEMBLY PROCEDURE ............................................................... 51
3.8 MAIN CONTROLLER .............................................................................. 52
3.9 DRIVE AND PUMP MOTOR DRIVER..................................................... 58
3.10 CONTACTOR PANEL (STANDARD) ...................................................... 59
3.11 FAN.......................................................................................................... 66
3.12 DISPLAY.................................................................................................. 67
3.13 COMBINATION SWITCH ........................................................................ 68
3.14 ACCELERATOR SENSOR (POTENTIOMETER) ................................... 70
3.15 BRAKE SENSOR (POTENTIOMETER) .................................................. 72
3.16 BRAKE SWITCH ADJUSTMENT ............................................................ 73
3.17 OVER CURRENT LIMIT (OCL) MEASUREMENT .................................. 75
3 CONTROLLER 3-33
3.1 GENERAL
1. Controller system configuration 3
The controller system to drive the AC motors has:
▪ Microcomputer-assisted inverter control,
▪ CAN (Controller Area Network) communication function between the main controller, drive/pump motor
drivers, and the multi-function display.
This is a multi-functional control system with advanced electronics technologies.
The pump motor driver is also used for the PS (Power Steering) control.
The multi-function display has been connected to the CAN communication. This lift truck has optional fea-
tures such as “PIN Code Entry System”.
The controller offers the power select feature and power keep feature that take full advantage of the AC
power system.
Multi-function
Main Controller
CAN Display
Communication
Driver Driver Driver

(Drive Motor LH) (Drive Motor RH) (Pump Motor)
Drive Motor LH Drive Motor R Pump Motor
2. Controller configuration
(1) Construction of main controller
The main controller has been designed with small parts on the printed circuit board and efficiently configured
inner construction. In addition, the weight of the controller has been kept light by using case materials from
aluminum and resin.
The degree of protection provided by enclosures (IP code) is equivalent to IP20.
(2) Construction of motor driver
The main circuit device is trench MOS-FET that has lowered dissipation.
The drive motor driver is the same as the pump motor driver.
The degree of protection provided by enclosures (IP code) is equivalent to IP65.
3-34 3 CONTROLLER
(c)
(d)
(b)
(a)
(e)
(a) Drive motor driver (c) Aluminium (e) Main controller

(b) Pump motor driver (d) Resin
3 CONTROLLER 3-35
3.2 ELECTRICAL COMPONENTS LAYOUT DRAWING

3
(1)
(4)
(2) (3)
(1) Main controller (a) Drive motor driver RH (e) Pump motor driver
(2) Brake sensor (b) Drive motor driver LH (f) Combination switch
(3) Accelerator sensor (c) Contactor panel (g) Ten-key
(4) Stop lamp switch (d) Fan (h) Multi-function display
3-36 3 CONTROLLER
3.3 LAYOUT OF CONTROLLER CABLES
(a) (b) (c) (d) (q) (e) (f) (g)
N2 N2
45° 45° 45°
45° 60° 45°

WR WL (h)
30° 45° 45°

(q)
VR VR VL V
(p)
30° 30° 30°
UR UL U
90°
P4 P4 P4 P4
(i)
90°
P1
(m)
(n) (k)
(o) (j)
(l) (f)
(a) Drive motor driver RH (g) DC/DC harness N2 (m) To the drive motor LH
(b) Connector cable N2 (h) DC/DC harness (n) To the drive motor RH
(c) Drive motor driver LH (i) Pump motor driver (o) To the battery plug
(d) Main harness N2 (j) DC/DC harness P4 (p) Connector cable
(e) Contactor panel (k) To the pump motor (q) Main harness
(f) Cupper bar (l) Connector cable P1
CAUTION! Caution for installation
1. The angles at which cables are shown assembled are for reference only.
During actual assembly, run the cables so that they do not touch adjacent terminals.
2.Terminal tightening torque
T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]
3.4 SPECIFICATIONS
36V spec. 48V spec.
Fuse F1 (for drive and pump circuit) 700A 600A
Standard:
Contactor MB (for power supply) ME255 ←
3 CONTROLLER 3-37
3.5 BEFORE INSPECTION

Inspection 3
1. Insulation resistance measurement
NOTICE! : Always measure before inspecting the
controller.
(1) Disconnect the battery plug and measure the res-
istance between battery plug and body.
Measurement terminals Controller side of battery plug-body

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

TO USE SST
Use SSTs for quick and accurate measure on the C30, C35S, C35, and the C40. The check will fail if the
connection method is wrong. Since boards may be damaged by incorrect connection, use care when per-
forming this operation.
CAUTION
Always unplug the battery plug before SST connection and disconnection. If the battery plug is still
connected, various boards may be damaged.
Part No. Purpose Remarks

Measure the voltage or resistance
979-001/159 For use CN101 to CN104
for main controller.
3-38 3 CONTROLLER
INSPECTION
When inspecting each board and the cause of the trouble is found, do not immediately replace the board but
check the following items.
▪ Abnormality in related harnesses
▪ Looseness of the related connectors
▪ Bending or damage of connector pin and defective contact of any related connector pin
If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will
be damaged.
Always replace the board after careful inspection.
Measurement method and standard list

How to read the list
Tester Probe +
Tester Probe -
Connector pin No.
Connector No. ↔ Connector No. Conditions Standard Remarks

CN101-1 CN101-26
Key switch OFF, DSF ON. Approx. 0 V
(45, DSF) (51, LS-)
Conditions for measurement
Terminal name
Electric Level No.
3 CONTROLLER 3-39
Main controller
CN101 CN102 CN103 CN104
7 6 5 4 3 2 1 7 6 5 4 3 2 1 6 5 4 3 2 1 7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 8
27 26 25 24 23 22 21 20 19 18 27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28 31 30 29 28 27 26
Conventional Lever
CN101 connector basic conditions (battery plug connected, key switch ON)
Connector No. ↔ Connector No. Conditions Standard: Remarks
Lift lock solenoid
Approx. 0.0V
CN101-1 CN102-16 (OFF operation with ACTIVE TEST)
(3, SOLLU+) (4, SLLL-) Lift lock solenoid
Approx. 11V
(ON operation with ACTIVE TEST)
Tilt forward solenoid
Approx. 0.0V
(6, SLTFB+) (7, SLTFL-) Tilt forward solenoid
Approx. 11V
CN101-3 - Unused -
CN101-4 CN104-4
- Battery voltage
(41, VBBT) (N2, N2)
CN101-5 - Unused -
CN101-6 - Unused -
CN101-7 - Unused -
CN101-8 - Unused -
CN101-9 - Unused -
CN101-10 - Unused -
CN101-11 - Unused -
CN101-12 - Unused -
CN101-13 - Unused -
CN101-14 - Unused -
CN101-15 - Unused -
CN101-16 - Unused -
CN101-17 - Unused -
CN101-18 - Unused -
CN101-19 CN104-4 Key switch OFF Approx. 0.0V
(43, VBKY) (N2, N2) Key switch ON Battery voltage
3-40 3 CONTROLLER

CN101-20 CN101-32
- Approx. 4.8V
(57, VRTA+) (51, POT-)
CN101-21 - Unused -
CN101-22
- - -
(50, VRA-)
CN101-23 CN101-32
- Approx. 4.8V
(316, VRTRA+) (51, POT-)
CN101-24 - Unused -
CN101-25 CN101-32
- Approx. 4.6V
(28, VRL+) (51, POT-)
CN101-26 CN101-32
- Approx. 4.8V
(55, VRA2+) (51, POT-)
CN101-27 CN101-22
- Approx. 4.8V
(53, VRA1+) (50, VRA-)
CN101-28 - Unused -
CN101-29 CN101-32
- Approx. 4.6V *1
(30, VRAT1+) (51, POT-)
CN101-30 CN101-32
- Approx. 4.6V *2
(31, VRAT2+) (51, POT-)
CN101-31 - Unused -
CN101-32
- - -
(51, POT-)
CN101-33 CN101-32
- Approx. 4.8V
(74, VRB2+) (51, POT-)
CN101-34 CN101-22
- Approx. 4.8V
(72, VRB1+) (50, VRA-)
*1: W/ ATT1
*2: W/ ATT2
Fan 1 stop
Battery voltage
(98, FNDC1) (N2, N2) Fan 1 rotate
Approx. 0.0V
Fan 2 stop
Battery voltage
(99, FNDC2) (N2, N2) Fan 2 rotate
Approx. 0.0V
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
(19, VBMBSL) (N2, N2) Key switch ON Battery voltage
CN102-5 - Unused -
CN102-6 - Unused -
Steering synchronizer solenoid
Approx. 0.0V
(329, SLS+) (330, SLS-) Steering synchronizer solenoid
Approx. 11V
3 CONTROLLER 3-41

CN102-8 CN104-4 Key switch OFF Approx. 14V
(333, OACC3) (N2, N2) Key switch ON Approx. 0.0V
3
CN102-9 CN104-4 Buzzer OFF Approx. 14V
*1
(332, OACC2) (N2, N2) Buzzer ON Approx. 0.0V
CN102-10
- - -
(51, LS-)
CN102-11 - Unused -
CN102-12 - Unused -
CN102-13 - Unused -
CN102-14 CN102-7 Resistance measurement with bat-
Approx. 10 Ω
(330, SLS-) (329, SLS+) tery plug disconnected
CN102-15 - Unused -
Approx. 10 Ω
(4, SLLL-) (3, SOLLU+) tery plug disconnected
Approx. 10 Ω
(5, SLUL-) (3, SOLLU+) tery plug disconnected
Approx. 10 Ω
(8, SLTBL-) (6, SLTFB+) tery plug disconnected
Approx. 10 Ω
(7, SLTFL-) (6, SLTFB+) tery plug disconnected
Attachment 1 lever in the neutral pos-
Approx. 2.3V
CN102-20 CN102-26 ition
*2
(25, VRA12) (51, POT-) Attachment 1 lever in the forward or Approx. 0.5V to
backward position 4V
Approx. 2.3V
CN102-21 CN102-26 ition
*2
Key switch OFF, tilt lever in the neut-
CN102-22 Approx. 5V
CN102-26 ral position
(23, VRT2)
(51, POT-) Key switch OFF, tilt lever in the back-
(62, SWTR) Approx. 0.0V
ward position
Key switch OFF, tilt lever in the neut-
CN102-23 Approx. 5V
CN102-26 ral position
(22, VRT1)
(51, POT-) Key switch OFF, tilt lever in the for-
(61, SWTF) Approx. 0.0V
ward position
CN102-24 CN102-35
- Approx. 2.5V
(304, CSBAT) (305, CSBAT-)
CN102-25 CN102-26 Approx. 0.8 to
Key switch OFF, brake pedal pressed
(73, VRB2) (51, POT-) 4.7V
CN102-26
- - -
(51, POT-)
CN102-27 - Unused -
Approx. 2.3V
CN102-28 CN102-26 ition
*3
3-42 3 CONTROLLER

Approx. 2.3V
CN102-29 CN102-26 ition
*3
CN102-30 CN101-22 Key switch OFF, accelerator pedal Approx. 0.4V to
(52, VRA1) (50, VRA-) pressed 4.7V
CN102-31 CN102-26
Tire position in neutral Approx. 2.5V
(317, VRTRA) (51, POT-)
CN102-32 CN102-26 Key switch OFF, accelerator pedal Approx. 0.7V to
(54, VRA2) (51, POT-) pressed 4.7V
CN102-33 CN101-22 Approx. 0.5V to
Key switch OFF, brake pedal pressed
(71, VRB1) (50, VRA-) 4.7V
CN102-34 - Unused -
CN102-35
- - -
(305, CSBAT-)
*1: W/ motion alarm
*2: W/ ATT1
*3: W/ ATT2
CN103-1 - Unused -
CN103-2 - Unused -
CN103-3
- - -
(14, DGND)
(42, KYSAT) (N2, N2) Key switch ON Battery voltage
CN103-5
- - -
(N2, N2)
CN103-6
- - -
(51, LS-)
CN103-7 - Unused -
CN103-8 CN102-26
- Approx. 5V
(300, IPL+) (51, POT-)
CN103-9 - Unused -
CN103-10 - Unused -
CN103-11
- Immeasurable -
(145, CAN1H)
CN103-12
- Immeasurable -
(146, CAN1L)
CN103-13 CN103-6
- Approx. 14V
(311, SSTR+) (51, LS-)
CN103-14 CN103-3
- Approx. 6.5V
(16, D7V) (14, DGND)
CN103-15 - Unused -
CN103-16 - Unused -
CN103-17 CN102-26 Variation upon changeover from for-
Approx. 1V to 4V
(56, VRTA) (51, POT-) ward to backward tilting
3 CONTROLLER 3-43

Lift lever in the neutral position Approx. 2.3V
CN103-18 CN102-26
(21, VRL2) (51, POT-) Lift lever in the forward or backward Approx. 0.5V to
position 4V 3
CN103-19 CN102-26
- Approx. 2V
(302, IPL2) (51, POT-)
CN103-20
- Unused -
CN103-21
- Unused -
CN103-22
- Unused -
CN103-23 - Unused -
Key switch OFF, mast height switch
Approx. 5V
CN103-24 CN103-6 2-1 OFF
(91, SH2-1) (51, LS-) Key switch OFF, mast height switch
Approx. 0.0V
2-1 ON
CN103-25 - Unused -
Lift lever in the neutral position Approx. 2.3V
CN103-26 CN102-26
(20, VRL1) (51, POT-) Lift lever in the forward or backward Approx. 0.5V to
position 4V
CN103-27 - Unused -
CN103-28 - Unused -
Forks on the ground Approx. 1V or less
CN103-29 CN102-26
(59, SPLF) (51, POT-) Amount of change between raising Approx. 0.5V to
and lowering on the lift with a load 4.5V
CN103-30 CN102-26
- Approx. 2V
(301, IPL1) (51, POT-)
CN103-31 - Unused -
Key switch OFF, automatic fork level-
Approx. 5V
CN103-32 CN103-6 ing switch OFF
(70, STK) (51, LS-) Key switch OFF, automatic fork level-
Approx. 0.0V
ing switch ON
CN103-33 - Unused -
CN103-34 - Unused -
CN103-35 - Unused -
CN104 Connector basic conditions (battery plug connected, key switch ON)
CN104-1 CN104-4
- Battery voltage
(41, B48V) (N2, N2)
(44, VBMB) (N2, N2) Key switch ON Battery voltage
Key switch OFF Approx. 0.0V
CN104-3 CN104-9
(1, CBAT+) (2, CBAT-) Approx. 11V to
Key switch ON
12V
CN104-4
- - -
(N2, N2)
CN104-5
- - -
(N2, N2)
3-44 3 CONTROLLER

CN104-6
- - -
(N2, N2)
CN104-7 - Unused -
CN104-8 - Unused -
Approx. 20 Ω
(2, CBAT-) (1, CBAT+) tery plug disconnected
CN104-10 CN102-35
- Approx. 5V
(303, CSBAT+) (305, CSBAT-)
CN104-11 - Unused -
CN104-12 CN102-26
- Approx. 5V
(58, SPLF+) (51, POT-)
CN104-13 - Unused -
CN104-14 CN104-4
- Approx. 14V
(334, PSACC+) (N2, N2)
CN104-15 - Unused -
CN104-16 - Unused -
CN104-17 - Unused -
CN104-18 CN103-6 Key switch OFF, seat switch OFF Approx. 5V
(67, SDM) (51, LS-) Key switch OFF, seat switch ON Approx. 0.0V
Key switch OFF, direction switch
Approx. 5V
CN104-19 CN103-6 neutral
(46, DSR) (51, LS-) Key switch OFF, direction switch
Approx. 0.0V
backward
Key switch OFF, parking brake
Approx. 5V
CN104-20 CN103-6 switch lock
(66, SPB) (51, LS-) Key switch OFF, parking brake
Approx. 0.0V
switch release
CN104-21 - Unused -
Key switch OFF, mast height switch 1
Approx. 0.0V
CN104-22 CN103-6 ON
(90, SH1) (51, LS-) Key switch OFF, mast height switch 1
Approx. 5V
OFF
CN104-23 - Unused -
CN104-24 CN103-6 Approx. 0.0V to
Steering operation
(314, SSTRC) (51, LS-) 5V
CN104-25 - Unused -
Key switch OFF, direction switch
Approx. 5V
CN104-26 CN103-6 neutral
(45, DSF) (51, LS-) Key switch OFF, direction switch for-
Approx. 0.0V
ward
CN104-27 - Unused -
CN104-28 - Unused -
CN104-29 - Unused -
Steering operation
(312, SSTR1) (51, LS-) 5V
Steering operation
(313, SSTR2) (51, LS-) 5V
3 CONTROLLER 3-45
Drive motor driver LH
CN109
3
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
CN109-1 - Unused -
CN109-2 - Unused -
CN109-3 - Unused -
CN109-4 - Unused -
CN109-5 - Unused -
CN109-6 - Unused -
CN109-7 - Unused -
CN109-8 -
- Battery voltage
(42, KYSAT) (N1, N1)
CN109-9 -
- Approx. 5V
(86, STDML+) (N1, N1)
CN109-10 -
- Approx. 1V to 4V
(87, STDML) (N1, N1)
CN109-11 - Unused -
CN109-12 - Unused -
L: Approx. 0.5V
CN109-13 -
- or
(80, SSDL2) (N1, N1)
H: Approx. 1.5V
L: Approx. 0.5V
CN109-14 -
- or
(79, SSDL1) (N1, N1)
H: Approx. 1.5V
CN109-15 -
- Approx. 15V
(78, SSDL+) (N1, N1)
CN109-16
- Immeasurable -
(146, CAN1L)
CN109-17
- Immeasurable -
(145, CAN1H)
CN109-18 - Unused -
CN109-19 - Unused -
CN109-20 - Unused -
CN109-21 - Unused -
CN109-22 - Unused -
CN109-23 - Unused -
3-46 3 CONTROLLER
Drive motor driver RH
CN110
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
CN110-1 - Unused -
CN110-2 - Unused -
CN110-3 - Unused -
CN110-4 - Unused -
CN110-5 - Unused -
CN110-6 - Unused -
CN110-7 -
- Approx. 0.0V
(150, SETDR0) (N1, N1)
CN110-8 -
- Battery voltage
(42, KYSAT) (N1, N1)
CN110-9 -
- Approx. 5V
(86, STDMR+) (N1, N1)
CN110-10 -
- Approx. 1V to 4V
(85, STDMR) (N1, N1)
CN110-11 - Unused -
CN110-12 - Unused -
L: Approx. 0.5V
CN110-13 -
- or
(77, SSDR2) (N1, N1)
H: Approx. 1.5V
L: Approx. 0.5V
CN110-14 -
- or
(76, SSDR1) (N1, N1)
H: Approx. 1.5V
CN110-15 -
- Approx. 15V
(75, SSDR+) (N1, N1)
CN110-16
- Immeasurable -
(146, CAN1L)
CN110-17
- Immeasurable -
(145, CAN1H)
CN110-18 - Unused -
CN110-19 - Unused -
CN110-20 - Unused -
CN110-21 - Unused -
CN110-22 - Unused -
CN110-23 -
- Approx. 0.0V
(150, SETDR-) (N1, N1)
3 CONTROLLER 3-47
Pump motor driver
CN111
3
8 7 6 5 4 3 2 1
15 14 13 12 11 10 9
23 22 21 20 19 18 17 16
CN111-1 - Unused -
CN111-2 - Unused -
CN111-3 - Unused -
CN111-4 - Unused -
CN111-5 - Unused -
CN111-6 -
- Approx. 0.0V
(152, SETP1) (N1, N1)
CN111-7 - Unused -
CN111-8 -
- Battery voltage
(42, KYSAT) (N1, N1)
CN111-9 -
- Approx. 5V
(88, STPM+) (N1, N1)
CN111-10 -
- Approx. 1V to 4V
(89, STPM) (N1, N1)
CN111-11 - Unused -
CN111-12 - Unused -
CN111-13 - Unused -
L: Approx. 0.5V
CN111-14 -
- or
(82, SSP1) (N1, N1)
H: Approx. 1.5V
CN111-15 -
- Approx. 15V
(81, SSP+) (N1, N1)
CN111-16
- Immeasurable -
(146, CAN1L)
CN111-17
- Immeasurable -
(145, CAN1H)
CN111-18 - Unused -
CN111-19 - Unused -
CN111-20 - Unused -
CN111-21 - Unused -
CN111-22 - Unused -
CN111-23 -
- Approx. 0.0V
(152, SETP-) (N1, N1)
3-48 3 CONTROLLER
Contactor panel ASSY
CN136 CN137 CN138

1 1
3 2 1
3 2 2 3
STD spec: Ap-
CN136-1 CN136-2 Battery plug disconnected, and the
prox. 20 Ω
(2, CBAT-) (1, CBAT+) CN136 connector disconnected
STD spec: Ap-

CN136-2 CN136-1 Apply the negative probe to the
prox. 11V
(1, CBAT+) (2, CBAT-) CN136-1 to measure voltage.
CN136-3 P3 terminal Battery plug disconnected, and the

Approx. 0 Ω
(44, VBMB) (P3, P3) CN136 connector disconnected
Approx. 0 Ω
(P2, FLP) (P2, P2) CN137 connector disconnected
P2 terminal
CN137-2 (P2, P2) Battery plug disconnected, and the
Approx. 0 Ω
(41, VBBT) CN137 connector disconnected
3 CONTROLLER 3-49

Approx. 0 Ω
(19, VBMBSL) (P3, P3) CN137 connector disconnected
3
CN138-1 CN138-2 Apply the negative probe to the
Approx. 5V
(303, CSBAT+) (305, CSBAT-) CN138-2 to measure voltage.
CN138-2
- - -
(305, CSBAT-)
Apply the negative probe to the
CN138-3 CN138-2 CN138-2 to measure voltage.
Approx. 2.5V
(304, CSBAT) (305, CSBAT-) Drive motor, pump motor, all auxiliary
machines OFF
Multi-function display
CN70
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
CN70-1 - Unused -
CN70-2 - Unused -
CN70-3
- - -
(169, TGND)
CN70-4
- - -
(14, DGND)
CN70-5 CN70-4
- Approx. 6.3V
(16, D7V) (14, DGND)
CN70-6 CN70-3
- Approx. 5V *1
(162, ITKY3) (169, TGND)
CN70-7 - Unused -
CN70-8 CN70-3
- Approx. 5V *1
(160, ITKY1) (169, TGND)
CN70-9
- Immeasurable -
(166, OTKY3)
CN70-10
- Immeasurable -
(165, OTKY2)
CN70-11
- Immeasurable -
(164, OTKY1)
CN70-12 CN70-3
- Approx. 0.0V *1
(167, LEDTKY1) (169, TGND)
CN70-13 - Unused -
CN70-14 - Unused -
CN70-15
- Immeasurable -
(146, CAN1L)
CN70-16
- Immeasurable -
(145, CAN1H)
3-50 3 CONTROLLER

CN70-17 - Unused -
CN70-18 - Unused -
CN70-19 CN70-3
- Approx. 3V *1
(168, LEDTKY2) (169, TGND)
CN70-20 CN70-3
- Approx. 5V *1
(161, ITKY2) (169, TGND)
CN70-21 CN70-3
- Approx. 5V *1
(163, IPSTKY1) (169, TGND)
CN70-22 - Unused -
CN70-23 - Unused -
CN70-24 - Unused -
CN70-25 - Unused -
CN70-26 - Unused -
CN70-27 - Unused -
CN70-28 - Unused -
CN70-29 - Unused -
CN70-30 - Unused -
CN70-31 - Unused -
CN70-32 - Unused -
CN70-33 - Unused -
CN70-34 - Unused -
CN70-35 - Unused -
CN70-36 - Unused -
*1: W/ PIN code entry system
Ten-key (w/ pin code entry system)
CN33
5 4 3 2 1
10 9 8 7 6
CN33connector basic conditions (battery plug connected, key switch ON)

CN33-1 CN33-7
- Approx. 5V
(160, ITKY1) (169, TGND)
CN33-2 CN33-7
- Approx. 5V
(161, ITKY2) (169, TGND)
CN33-3 CN33-7
- Approx. 5V
(162, ITKY3) (169, TGND)
CN33-4
- Immeasurable -
(165, OTKY2)
CN33-5 CN33-7
- Approx. 0.0V
(167, LEDTKY1) (169, TGND)
CN33-6 CN33-7
- Approx. 5V
(163, IPSTKY1) (169, TGND)
CN33-7
- - -
(169, TGND)
3 CONTROLLER 3-51

CN33-8
- Immeasurable -
(164, OTKY1)
CN33-9 3
- Immeasurable -
(166, OTKY3)
CN33-10 CN33-7
- Approx. 3V
(168, LEDTKY2) (169, TGND)
3.7 DISASSEMBLY PROCEDURE

Overhauling the control panel is rarely necessary. In most cases, failed parts are replaced after finding out
the cause of the failure from inspection.
Therefore, make sure to repair correctly by referring to the figures of configuration and ASSY.
Caution for Part Replacement

▪ Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tighten-
ing may cause other failure.
▪ When disconnecting the bars and harness, record the connecting location and place tags. When con-
necting them again, make sure to confirm with the record and tags to prevent incorrect connection. Incor-
rect connection may cause other failure.
▪ Always apply new silicon grease when reassembling parts originally coated with silicon grease. Other-
wise, overheating may occur.
▪ After installation, check that there is no interference of the bar and harness connection with other portion.
Additionally, before installation, perform continuity inspection on points by the tester.
(Refer to CONTACTOR PANEL INSULATING RESISTANCE TEST PROCEDUREpage 65)
3-52 3 CONTROLLER
3.8 MAIN CONTROLLER
CAUTION
When replacing the main controller, always check the part No.
3 CONTROLLER 3-53
3.8.1 CONNECTOR-PIN ASSIGNMENT
CN101 CN102 CN103 CN104 3
CN101
No. Terminal name Circuit mode Remarks
102 SOLLU+ SOLLU+ UNLOAD, LIFT+
103 SLTFB+ SLTFB+ TILTF, R+
104 FAN+ FAN+ RYR, FAN+
105 VBBT VBBT
106 SLLA2+ SOL1, 4+
107 SLLA1+ SOL2, 3+
108 --- SOL5+
109 --- SOL5B
110 --- SOL5A
111 SA1PL- SOL3B
112 SA1PS- SOL3A
113 STPL- SOL2B
114 STPS- SOL2A
115 SA2PL- SOL4B
116 SA2PS- SOL4A
117 SLPS- SOL1A
118 SLPL- SOL1B
119 --- VBBA VBBA
120 VBKY VBKY
121 VRTA+ VRTA+ TILT ANGLE SENSOR POWER SUPPLY
122 --- VRS+ SWING ANGLE SENSOR POWER SUPPLY
123 VRA- VRA- ACCELERATOR SENSOR GND
124 VRTRA+ VRTRA+ TIRE ANGLE SENSOR POWER SUPPLY
125 --- VRH+ HEIGHT SENSOR POWER SUPPLY
126 VRL+ VRL+ LIFT POT POWER SUPPLY
127 VRA2+ VRA2+ ACCELERATOR SENSOR 2 POWER SUPPLY
128 VRA1+ VRA1+ ACCELERATOR SENSOR 1 POWER SUPPLY
129 VRT+ VRT+ TILT POT POWER SUPPLY
130 VRAT1+ VRAT1+ ATTACHMENT 1 POWER SUPPLY
131 VRAT2+ VRAT2+ ATTACHMENT 2 POWER SUPPLY
132 --- VRAT3+ ATTACHMENT 3 POWER SUPPLY
133 POT- POT- GND3
134 VRB2+ VRB2+ BRAKE SENSOR 2 POWER SUPPLY
135 VRB1+ VRB1+ BRAKE SENSOR 1 POWER SUPPLY
CN102
3-54 3 CONTROLLER

67 FNDC1 FNDC1 FAN1
68 FNDC2 FNDC2 FAN2
69 VBMBSL VBMBSL VBMBSOL
70 VBMBSL VBMBSL VBMBSOL
71 SOLCOM SOLCOM SOLCOM
72 SOLCOM SOLCOM SOLCOM
73 SLS+ SLS+ KNOB, MPS+
ACCESSORY 3 (for FORWARD → FLEET MAN-
74 OACC3 OACC3
AGEMENT)
75 OACC2 OACC2 ACCESSORY 2 (for BACKWARD)
76 LS- LS- GND2
77 --- OACC1 ACCESSORY 1 (for BRAKE)
78 --- RY2- RYR2
79 RY1 RY1- RYR1
80 SLS- SLS- KNOB-
81 --- MPS-
82 SLLL- SLLL- LIFT-
83 SLUL- SLUL- UNLOAD-
84 SLTBL- SLTBL- TILTR-
85 SLTFL- SLTFL- TILTF-
86 VRA12 VRA12 ATTACHMENT 12
88 VRT2, SWTR VRT2 TILT LEVER SENSOR 2
89 VRT1 , SWTF VRT1 TILT LEVER SENSOR 1
90 CSBAT CSBAT BATTERY CURRENT SENSOR
91 VRB2 VRB2 BRAKE SENSOR 2
92 POT- POT- GND4
93 --- CHK5V 5V POWER SUPPLY for CHECK
96 VRA1 VRA1 ACCELERATOR SENSOR 1
97 VRTRA VRTRA TIRE ANGLE SENSOR
98 VRA2 VRA2 ACCELERATOR SENSOR 2
99 VRB1 VRB1 BRAKE SENSOR 1
100 --- VRS SWING ANGLE SENSOR
101 CSBAT- CSBAT-
CN103
32 --- SLSW+ SWING+
33 --- SLSW- SWING-
34 DGND DGND DISPLAY GND
35 KYSAT KYSAT KEYSTART
36 N2 N2
37 LS- LS- GND4
38 --- SMTSA
3 CONTROLLER 3-55

39
40 --- CAN2H
3
41 --- CAN2L
42 CAN1H CAN1H
43 CAN1L CAN1L
STEERING WHEEL ANGLE SENSOR AND UL-
44 SSTR+ SSTR+ TRA SONIC SENSOR POWER SUPPLY (com-
bined use)
45 D7V D7V DISPLAY POWER SUPPLY
46 --- CHK15V 15V POWER SUPPLY for CHECK
47 --- CHK33V 3.3V POWER SUPPLY for CHECK
48 VRTA VRTA TILT ANGLE SENSOR
49 VRL2 VRL2 LIFT LEVER SENSOR 2
50
51 --- SSTMA
52 --- SMTSK
53 --- SSTMK
54 --- OPTSS2
55 SH2-1 SH2-1 LIFTING HEIGHT SWITCH 2-1
56 --- SHL LIFTING HEIGHT LIMIT SWITCH
57 VRL1 VRL1 LIFT LEVER SENSOR 1
58 --- SYR
59 --- VRH HEIGHT SENSOR
60 SPLF SPLF PRESSURE SENSOR
61
62 --- SH2-2 LIFTING HEIGHT SWITCH 2-2
63 STK STK AUTOMATIC FORK LEVELING SWITCH
64 --- OLM+ LASER POINTER POWER SUPPLY
65 --- VRA32 ATT32
66 --- VRA31 ATT31 (SWITCH for 4/5-WAY SW)
CN104
1 B48V B48V B80V
2 VBMB VBMB
3 CBAT+ CBAT+ MB, P+
4 N2 N2
5 N2 N2
6 N2 N2
7 --- N2
8 --- MP-
9 CBAT- CBAT- MB-
BATTERY CURRENT SENSOR POWER SUP-
10 CSBAT+ CSBAT+
PLY
11 --- SYR-
12 SPLF+ SPLF+ PRESSURE SENSOR POWER SUPPLY
13 --- SYR+ YAW RATE SENSOR POWER SUPPLY
3-56 3 CONTROLLER

14 PSACC+ PSACC+ ACCESSORY POWER SUPPLY
POWER SUPPLY for LOAD METER, AUTO-
15 PSSW+ PSSW+ MATIC FORK LEVELING and SWITCH for 4/5-
WAY SW
16 --- CHKG
17 --- OPT2
18 SDM SDM SEAT SWITCH
19 DSR DSR DIRECTION SWITCH REVERSE
20 SPB SPB PARKING BRAKE
21 --- OPTSSC
22 SH1 SH1 LIFTING HEIGHT SWITCH 1
23 --- SWA ACCELERATOR SWITCH
STEERING WHEEL ANGLE SENSOR 3 (only
24 SSTRC SSTRC
SSC combined with SW)
25 --- OPTSS1
26 DSF DSF DIRECTION SWITCH FORWARD
27 --- LSOPT1
28 SHS SLM LOAD METER
29 --- BMP
30 SSTR1 SSTR1
31 SSTR2 SSTR2
3 CONTROLLER 3-57
3
2
10
a
a
8
7
a : T = 2.84 to 5.28 ft-lbf. N·m [3.9 to 7.2]
Removal Procedure
3. Remove the side cover LH.
4. Remove the DC/DC converter connector cover.
5. Disconnect the wiring of the DC/DC converter connector.
6. Remove the DC/DC converter.
7. Remove the main controller connector cover.
8. Remove the main controller cover.
9. Disconnect the wiring of the main controller.
10. Remove the main controller.
3-58 3 CONTROLLER
3.9 DRIVE AND PUMP MOTOR DRIVER
5 b
7
a
9
a
a 7 b 9
a : T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]

b : 2.84 to 5.28 ft-lbf. [3.9 to 7.2 N•m]
Removal Procedure
1. Remove the battery. (Refer to page BATTERY ASSY)
2. Remove the rear cover.
3. Remove the rear lower cover.
4. Remove the upper cover.
5. Remove the battery guard.
6. Remove the F1 fuse.
7. Remove the copper bars.
8. Disconnect the wiring of the drive motor driver LH, the drive motor driver RH and the pump motor driver
at the connectors and terminals.
9. Remove the drive motor driver LH, the drive motor driver RH and the pump motor driver.
3 CONTROLLER 3-59
3
3.10 CONTACTOR PANEL (STANDARD)
3.10.1 COMPONENTS
h
a
b
g
d
f
a : P1 - P2 Copper bar
b : P3 Copper bar
c : F1 Fuse
d : Current sensor
e : Terminal
f : Harness
g : Insurating sheet
h : Contactor ASSY
3-60 3 CONTROLLER
5
7
a
a
7 9
a: T = 8.26 to 12.39 ft-lbf. [11.2 to 16.8 N•m]
Removal Procedure
1. Remove the battery. (Refer to BATTERY ASSY)
3. Remove the rear lower cover.
4. Remove the upper cover.
5. Remove the battery guard.
6. Remove the F1 fuse.
7. Remove the copper bars.
8. Disconnect the wiring of the contactor panel.
9. Remove the contactor panel. [POINT 1]
3 CONTROLLER 3-61
Point Operations
[POINT 1]
Inspection: 3
Disconnect CN136 connector, and measure the res-
istance of the MB coil.
Portion to be inspected Measurement terminals Standard Tester range

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

F1 fuse Both terminals of fuse 0Ω Ωx1
3-62 3 CONTROLLER
3.10.3 REASSEMBLY
Contactor Panel Reassembly Drawing
1. Tightening torque view
6 7
2
3
10
11
5 4
No. Tightening torque ft-lbf. [N·m]

1-2 5.75 to 8.71 [7.8 to 11.8]
3-5 8.26 to 12.39 [11.2 to 16.8]
6 - 10 1.48 to 2.21 [2.0 to 3.0]
11 0.96 to 1.55 [1.3 to 2.1]
3 CONTROLLER 3-63
2. How to use the F1 fuse separately

Install the F1 fuse while checking the number and color seal attached on the fuse.
Application models 36V spec. 48V spec. 3
Outline drawing 9 1
700A 600A
Red
Numeral 9 1
Color seal - Red
Rated current (A) 700 600
3. F1 fuse installing direction
Install the F1 fuse in the direction shown below.
4. Installing order sequence of F1 fuse.

Installing order sequence of the bolt w/washer (a), F1 fuse (b) and copper bar (c) position on the terminal (d)
as shown below.
(b)
(a)
(c)
(d)
3-64 3 CONTROLLER
5. Installing angle of P2 harness and P3 harness, and installing order sequence of P2 harness and P3 har-
ness
Install with angles of P2 harness and P3 harness, and the installing order sequence of the bolt, nut, washer,
copper bar and terminal on P2 harness and P3 harness portion as shown below.
(a)
(c)
(d)
(e)
(f)
(g)
(b) (h)
45° 45°
(i)
(j)
90°
(a) P2 harness
(c) Bolt w/ washer (e) Copper bar (g) Spring washer (i) Terminal
(white - red)
(b) P3 harness
(d) Terminal (f) Nut (h) Plate washer (j) Copper bar
(blue-black)
3 CONTROLLER 3-65
3.10.4 CONTACTOR PANEL INSULATING RESISTANCE TEST

PROCEDURE
Make sure to perform an insulating resistance test. 3
CN136
1
3 2
CN136 (a)
CN137
1
2 3
CN137 (a)
CN136 CN137
Measurement place
(a) Measurement place instruction view
No. (Measure the insulating resistance between A and B.) Standard Locator
A B
CN136 (Only No.1, 2 Pin:
Reference above chart)
1 Base
CN137 (Only No.1, 3 Pin: DC 500V applied Insulation res-
Reference above chart) 10 MΩ more istance tester
CN137 (Only No.1, 3 Pin: Ref- CN136 (Only No.1, 2 Pin:
2
erence above chart) Reference above chart)
3-66 3 CONTROLLER
3.11 FAN
a: T = 1.0 to 1.3 ft-lbf. [1.3 to 1.7 N·m]
Removal Procedure
1. Remove the counterweight. (Refer to COUNTERWEIGHT)
2. Disconnect the wiring of the fans.
3. Remove the fans. [Point 1]
3 CONTROLLER 3-67
Point Operations
[POINT 1]
Inspection: 3
Disconnect the fan connector, and measure the res-
istance of the fan.
Measurement terminals Standard Tester range

CN112-1 (474) - CN112-2 (98)
∞Ω Ωx1
CN113-1 (475) - CN113-2 (98)
3.12 DISPLAY
If there is trouble with the display, measure the voltage at the display connector.
CN70
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
3-68 3 CONTROLLER
CN70 connector basic condition (Battery plug connected)
Connector No. ⇔ Connector No. Conditions Standard: Remarks

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

b : T = 1.5 to 1.8 ft-lbf. [2.0 to 2.5 N·m]
Removal Procedure
2. Remove the steering wheel. [Point 1]
3. Remove the hand release lever knob.
4. Remove the column cover.
5. Disconnect the wiring of the combination switch.
6. Remove the combination switch ASSY.
3 CONTROLLER 3-69
3
Point Operations
[POINT 1]
SST
Remove:
Use the SST to remove the steering wheel.
SST 979-001/181
3.13.2 DISASSEMBLY, INSPECTION AND REASSEMBLY
3 2
3-70 3 CONTROLLER
Disassembly Procedure
1. Remove the cam.
2. Remove the horn contact.
3. Remove the steering angle sensor.
4. Remove the light control switch ASSY.
5. Remove the direction switch ASSY.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
3.14 ACCELERATOR SENSOR (POTENTIOMETER)

1. Remove the accelerator potentiometer.
2. Check the resistance between terminals.
6 5 4 3 2 1
Terminal 5 - 6 1.8 to 3.5 kΩ

When the potentiometer is rotated, the resistance must increase in propor-
Terminal 4 - 6
tion to its number of rotations.
Terminal 1- 2 1.8 to 3.5 kΩ
Terminal 2- 3
3. Temporarily install the accelerator potentiometer.

NOTICE!
10 degree
Mount the accelerator potentiometer and turn it
about 10 degrees in the clockwise direction and
tighten the screws.
3 CONTROLLER 3-71
4. Display the matching menu and check the output

voltage of the accelerator potentiometer.
Standard: VRA1 0.40V to 1.24V
Standard: VRA2 0.65V to 2.31V 3
If the voltage is within the standard range:
Press and hold down the switch (1) for more than 2
seconds to perform matching.
If the voltage is outside the standard range:
(1) Loosen the screw and adjust the voltage to the
standard value while checking the display and rotat-
ing the accelerator potentiometer.
(2) Tighten the screw.
(3) Press and hold down the switch (1) for more than
2 seconds to perform matching.
(1)
5. Fully press the accelerator pedal and check the
voltage at that time.
Standard:
VRA1 2.00V to 4.79V
VRA2 2.42V to 4.79V
CAUTION!
Before pressing the accelerator pedal, make sure
that the Spanner indicator on the display is blink-
ing.
Replace the accelerator potentiometer or accelerator
pedal.
6. Tighten the screw after adjustment and mark an “I”
(1)
on the screw head with a yellow paint pen.
(1) Switch 1 NOTICE!
▪ After performing the ACCEL OFF matching,
make sure to perform ACCEL ON matching.
▪ While the DRIVE is selected on the matching
menu, the spanner indicator blinks and driv-
ing is disabled.
▪ After entering and exiting the DRIVE on the
matching menu, Drive return to neutral is ac-
tivated. Put the direction lever in neutral and
release the accelerator pedal to cancel it.
3-72 3 CONTROLLER
3.15 BRAKE SENSOR (POTENTIOMETER)

1. Remove the brake potentiometer.
2. Check the resistance between terminals.
6 5 4 3 2 1
Terminal 5 - 6 1.8 to 3.5 kΩ

Terminal 4 - 6
Terminal 1- 2 1.8 to 3.5 kΩ
Terminal 2- 3
3. Temporarily install the brake potentiometer. The

parking brake should be in the release (not applied)
position.
4. Display the matching menu and check the output
voltage of the brake potentiometer.
Standard: VRB1 0.50V to 1.79V
Standard: VRB1 0.79V to 2.88V
(1) Loosen the screw and adjust the voltage to the
standard value while checking the display and rotat-
ing the brake potentiometer.
(2) Tighten the screw.
(3) Press and hold down the switch (1) for more than
2 seconds to perform matching.
(1)
3 CONTROLLER 3-73
5. Step on the brake pedal perpendicularly with 34.1

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

1. Adjust brake pedal play. (Refer to PARKING
BRAKE INSPECTION AND ADJUSTMENT)
2. Adjust brake pedal height. (Refer to BRAKE
PEDAL ADJUSTMENT)
a
3. Check continuity of the limit switch when pedal
stroke from the brake pedal press operation start is
0.20 to 0.35 in. (5 to 9 mm)
Standard:
Not operated: OFF (∞ Ω)
Operated: ON (0 Ω)
a : Stop lamp limit switch
5 to 9 mm
(0.20 to 0.35 in)
3-74 3 CONTROLLER
4. If the standard is not met, make adjustment by

turning the adjust bolt.
a : Adjust bolt
a
3 CONTROLLER 3-75
3.17 OVER CURRENT LIMIT (OCL) MEASUREMENT

For drive circuit 3
1. Preparation before measurement
(a) (1) Make the fork tips contact a wall or steel pole with
a rated load on the forks. Make sure to place a piece
of wood (a) between the fork tip and the wall.
(2) Turn on the SST by pressing the POWER key (a)

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

(3) Press the mode key (a) twice to switch to the AC
+DC A measurement mode.
(a)
3-76 3 CONTROLLER
(a) SHIFT key enabled display

(a)
(4) After pressing the SHIFT key (b), press the
SAMPL key (c) to set the display update rate (d) to
“SLOW”.
(d) (b)
(c)
(a) (a) SHIFT key enabled display
(5) After pressing the SHIFT key (b), press the

CLEAR key (c) to start zero point adjustment. (Press-
ing the CLEAR key makes the “ADJ” indicator flash
and switches the unit to zero point adjustment mode.
When the “ADJ” indicator stays on after flashing, zero
point adjustment is completed (d).)
(b)
(c)
(d)
3 CONTROLLER 3-77
2. Measurement work
(1) Set the clamp sensor of the SST on the motor
cable.
3
NOTICE! Set the clamp sensor so that the cable is
positioned in the center of the clamp with the
clamp sensor aligned perpendicular to the cable.
(2) Turn on the key switch and set the direction

switch to “Forward”. Gradually press the accelerator
pedal to full throttle and hold there. The SST will start
measurement automatically.
NOTICE!
▪ The SST starts measurement automatically as
soon as forward motion starts. Make sure to
wait for approximately 20 seconds before
reading the measurement value. “O.L.” (Over-
flow alert) may be displayed during the first 10
seconds, or the displayed value may not be
stable for a while.
(a) ▪ If the measurement value is not stable after
approximately 20 seconds, retry the measure-
ment by pressing the SHIFT key down then
the PEAK/Hz key to enable filter setting as
shown in the illustration.
▪ Measurement can be done in this mode (AC
+DC A mode, Display update mode: SLOW)
also. However, when using other modes, the
motor current frequency in forward motion is
(b) only 10 Hz or below and current measurement
cannot be obtained.
OCL Standard Value:
(c)
36V: 257 to 340 A
48V: 184 to 250 A
(a) SHIFT key enabled display
(b) SHIFT key
(c) PEAK/Hz key
(d) Filter setting display
(d)
3-78 3 CONTROLLER
For pump circuit

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

OCL Standard Value: 380 to 490 A
4 DISPLAY 4-79
4 DISPLAY
4.1 GENERAL................................................................................................ 79
4
4.2 GENERAL FUNCTIONS.......................................................................... 80
4.3 SERVICE FUNCTIONS ........................................................................... 95
4.4 MULTI-FUNCTION DISPLAY ASSY ..................................................... 169
4.1 GENERAL
The multi-function display has various functions that indicate/notify the lift truck’s information such as lift truck
speed, the battery discharge level, and so on. The operator or administrator can set the lift truck perform-
ance with this display. Furthermore, it has functions to perform maintenance, feeling adjustments and spe-
cification setting as a service function.
On this model, a graphic LCD (Liquid Crystal Display) has been adopted. This provides various easy-to-un-
derstand information with expressive capability.
(5)
(6) (9)
(7) (10)
(8)
(1) (2) (3) (4)
No. Description
(1) Switch (1): Low speed setting switch / Down switch
(2) Switch (2): Power select switch / Left switch
(3) Switch (3): Time or date select switch / Right switch
(4) Switch (4): Meter mode select switch / Enter switch
(5) Multiple screen display area
(6) OPS indicator
(7) Parking brake indicator
(8) Low speed setting indicator
(9) Spanner indicator
(10) Overheat warning indicator
4-80 4 DISPLAY
4.2 GENERAL FUNCTIONS
4.2.1 GENERAL
General Function List
○: Provided
OPT: Option
Functions Remarks
Calendar watch ○
Indication that maximum speed limiter is in active set-
○
ting.
Initial display after Indication that overspeed alarm is in active setting. ○
key-ON Indication that lifting speed limitation is in active setting. ○
Indication that active mast front tilt control is in inactive
○
setting.
Indication that turn speed control is in inactive setting. ○
Operator Presence Sensor indicator ○
Parking brake indicator ○
Low speed setting (turtle) indicator ○
Spanner indicator ○
Overheat warning indicator ○
Battery discharge level indicator ○
Speedometer ○
Status display Power select indicator ○
Power meter ○
Direction indicator ○
Mast tilt indicator ○
Maintenance indicator ○
Lifting speed limitation indicator ○
Menu lock indicator ○
Date/Time ○
Key switch on hour meter ○
Lap time meter ○
Traveling hour meter ○
Material handling hour meter ○
Meter Traveling/Material handling hour meter ○
Seat on hour meter ○
Odometer ○
Trip meter ○
Planed maintenance hour meter ○
4 DISPLAY 4-81
Functions Remarks
Over-discharge warning ○
Low remaining battery level warning ○
Overheat warning ○
4
Low temperature warning ○
Parking brake ON warning ○
Parking brake OFF warning ○
Warning function Return to neutral warning for travel Operator Presence
○
Sensor
Return to neutral warning for material handling Operator
○
Presence Sensor
Return to neutral warning at starting ○
Diagnostic code display ○
Overspeed alarm ○
Clock set ○
Power select function ○
Travel power control level setting ○
Material handling power control level setting ○
Low speed setting ○
Setting function Maximum speed limitation setting ○
Overspeed alarm setting ○
Planned maintenance hour setting ○
Auto power off time setting ○
Second password registration for administrator ○
Menu lock setting ○
Support function PIN code entry and setting OPT
With PIN Code Entry
for PIN code entry Profile setting OPT
Initial screen after key-on

This screen is displayed for 2 seconds after the igni-
tion key switch is turned on.
Display Description
SEP/ 1/2015 (TUE) Calendar watch is displayed.
Indicates if the maximum speed limiter is in active

setting.
Indicates if the overspeed alarm is in active setting.

4-82 4 DISPLAY
Display Description
Indicates if the lifting speed limitation is in active set-

ting.
Indicates if the active mast front tilt control is in inact-

ive setting.
Indicates if the turn speed control is in inactive set-

ting.
4 DISPLAY 4-83
4.2.2 ADMINISTRATOR FUNCTIONS

Administrators can set the lift trucks’s performance and each function.
Administrator functions are protected with a password so that the general operators cannot change these
settings.
4
W/O PIN code entry system
Setting menu Setting Screen
Power Mode Select*
Power Control Functions Setting of Travel Power Control Level*
Setting of Material Handling Power Control Level*
Speed Setting of Low Speed*
Travel Functions Speed Setting of Maximum Speed Limiter
Speed Setting of Overspeed Alarm*
Setting of Maintenance Hour Meter
Setting of Auto Power Off Time
Vehicle Management Functions
Setting of Administrator’s Second Password
Switching of Menu Lock
*: When menu lock setting is released, the operator can set it.
W/ PIN code entry system

Setting menu Setting Screen
Registry of PINs for Operations
Change of Profile Assign
PIN Code Entry Functions Delete of PINs for Operators
Profile Setting
Change of Initial PIN
Setting of Maintenance Hour Meter
Setting of Auto Power Off Time
Vehicle Management Functions Setting of Auto Log Off Time
Setting of Administrator’s Second Password
Switching of Menu Lock
Administrator's Password
NOTICE
• Always operate switches on the display with a finger tip. If a sharp pointed tool is used, the
switch may be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning.
4-84 4 DISPLAY
Password Entry Procedure

Step Display Operation Vehicle response
When pressing the

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

2 A short beep sounds.
seconds.
(2)

seconds.
(2)
When pressing the

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

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

6
ally.
Administrator MENU screen
(a) (b)
(a) W/O PIN code entry (b) W/ PIN code entry

4 DISPLAY 4-85
Icons
Icon Description Icon Description
This icon can set the drive and lift

This icon can set the PIN code 4
entry system function. (Models
power control function.
with PIN code entry system only)
This icon can set the travel control

Returning to status screen.
function.
This icon can set the vehicle man-

agement function.
Administrator Menu Screen (W/O PIN code entry)

Status screen
Operating Procedure
1. Input the password on the status screen to display
the Administrator Menu screen.
(1) (2) (3) (4)

4-86 4 DISPLAY
2. Press switch (2) or switch (3) to select the desired

menu tab. The selected tab is emphatically displayed
and items that can be set are displayed below.
3. Press switch (1) to select the item, and press

switch (4) (enter) to display the menu or setting
screen for each function.
NOTICE! : Select the return tab on the Adminis-

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

▪ Power Mode Select
▪ Setting of Travel Power Control Level
▪ Setting of Material Handling Power Control Level
4 DISPLAY 4-87
Travel setting menu screen

▪ Speed Setting of Low Speed
▪ Speed Setting of Maximum Speed Limiter
▪ Speed Setting of Overspeed Alarm 4
Vehicle management setting menu screen

▪ Setting of Maintenance Hour Meter
▪ Setting of Auto Power Off Time
▪ Setting of Administrator’s Second Password
▪ Switching of Menu Lock
Return to status screen
1. Power Control Setting Menu Screen

This menu screen can set the travel and material
handling power control function.
NOTICE! : When the H mode lock setting is “YES”,
H mode cannot be selected. Please refer to a ser-
vice function about the way to release the H mode
lock.
4-88 4 DISPLAY
▪ Power mode select screen

The power select mode (L, P, H or Original) can
be selected by pressing switch (2) or switch (3)
on the power select screen by shifting to the cor-
responding indicator position.
This is the same as the one in the operator func-
tions.
Switch (2): LPH -> H -> P -> L
Switch (3): L -> P -> H -> LPH
Switch (4): Returning to power control setting
menu screen.
When the original mode is selected, all of L, P,
and H are inverted.
▪ Travel power control level setting screen
The travel power of the original mode can be set
in five steps.
Switch (2): Select the lower level.
Switch (3): Select the higher level.
menu screen.
tions.
▪ Material handling power control level setting
screen
The material handling power of the original mode
can be set in five steps.
Switch (2): Select the lower level.
Switch (3): Select the higher level.
menu screen.
tions.
2. Travel Setting Menu Screen
This menu screen can set the travel control function.
4 DISPLAY 4-89
▪ Low speed setting screen

The speed limit of the Low speed setting function
can be changed.
Switch (2): Setting speed limit down.
Switch (3): Setting speed limit up. 4
Switch (4): Returning to setting menu screen.
It is adjustable from 2 to 12 mph by 1 mph. When
MPH setting is “NO” in option set, it is adjustable
from 2 to 20 km/h by 1 km/h.
If the operator set the speed to more than 12 mph
(20km/h), the low speed function is disabled. In
that case “OFF” is displayed.
▪ Maximum speed limiter setting screen

The speed limit of the Maximum speed limitation
can be changed.
Switch (2): Setting traveling speed limit down.
Switch (3): Setting traveling speed limit up.
Switch (4): Returning to setting menu screen
(20 km/h), the low speed function is disabled. In
▪ Overspeed alarm setting screen

▪ The speed to activate the overspeed alarm func-
tion can be changed.
Switch (2): Setting threshold speed down.
Switch (3): Setting threshold speed up.
Switch (4): Returning to setting menu screen
(20 km/h), the low speed function is disabled. In
4-90 4 DISPLAY
3. Vehicle Management Setting Menu Screen

This menu screen can set the vehicle management
function.
▪ Maintenance hour meter setting screen

Time for maintenance hour meter can be set from
10 up to 2400 hours by 10 hours for 10 to 200
hours, and 50 hours for 200 to 2400 hours.
Switch (2): Decreasing setting time
Switch (3): Increasing setting time
Switch (4): Returning to menu screen
Pressing switch (1) for more than 2 seconds will
reset the current hour meter value to 0.
NOTICE! : This reset operation does not reset the
setting value and keeps it with the same value.
Press switch (2) to decrease the set time of the main-
tenance hour meter function. Below 10 h would be
“OFF”.
The current value is kept, but the maintenance indic-
ator and the buzzer are deactivated using this “OFF”
setting.
▪ Auto power off time setting screen
The time that activates the auto power off func-
tion can be changed.
Switch (2): Decreasing set time
Switch (3): Increasing set time
It is adjustable from 2 to 60 minutes with a step of
1 minute.
Auto power off function is disabled by selecting
“OFF” which is next to “60 min”.
4 DISPLAY 4-91
▪ Administrator’s second password setting screen

(1) The administrator can register the second password.
The second password can be registered by continuing to press switch (1) for 2 seconds after enter-
ing the password by using switch (1) to (4). If you press the switch (4) for 2 seconds or more, the
screen returns to the menu screen. 4
The Administrator should manage the second password so that it does not get lost.
If it has been lost, the service technician can clear it on the service menu.
(2) (4)
(1) (3)
(2) Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s second
password setting screen.
If you press the switch (4) for 2 seconds or more, the screen returns to the menu screen.
(2) (4)
(1) (3)
4-92 4 DISPLAY
▪ Menu lock setting screen

This function can limit the change of the lift truck
setting by the operator.
When the menu lock setting is “YES”, the follow-
ing items are limited.
• Operator setting menu is NOT displayed.
• Power control setting menu is NOT displayed.
• Operator cannot change the power select
mode.
Switch (2): Selecting “Yes”
Switch (3): Selecting “No”
NOTICE!
▪ The condition to release Menu lock is varied
by the option set item, "MENULOCK SPEC".
In the factory setting, "MENULOCK SPEC" is
preset to "A" on standard models.
MENULOCK SPEC : A
The lock release setting (“NO”) is effective un-
til key-OFF. (It means it is set to “YES” auto-
matically when the key is turned off.)
▪ This is not available (NOT Locked) before

“hour meter start”.
4. End Menu Screen
Switch (4): Returning to the status screen
4 DISPLAY 4-93
Administrator Menu Screen (W/ PIN code entry)

Status screen
▪ Entering Administrator Password
4
1. PIN Code Entry System Setting Menu Screen

This menu screen can set the PIN Code Entry Sys-
tem function.
▪ Registry of PINs for Operators
▪ Change of Profile Assign
▪ Delete of PINs for Operators
▪ Profile Setting
▪ Change of Initial PIN
2. Vehicle Management Setting Menu Screen

4-94 4 DISPLAY
This menu screen can set the vehicle management

function.
For details, refer to “Vehicle Management Setting
Menu Screen” (W/O PIN code entry).
▪ Setting of Maintenance Hour Meter
▪ Setting of Auto Power Off TIme
▪ Setting of Auto Log Off Time
▪ Setting of Administrator’s Second Password
▪ Switching of Menu Lock
4 DISPLAY 4-95
3. End Menu Screen

Switch (4): Returning to status screen
4.3 SERVICE FUNCTIONS
4.3.1 GENERAL
In the multi-function display, aside from the general functions that an operator or an administrator normally
use, the following service functions can be used by the service staff for lift truck maintenance and specifica-
tion setting. The service functions are password protected so that the important internal data will not be dam-
aged mistakenly by wrongfully using the service functions.
Service Function List

When used
Function Description Vehicle deliv- Board re-
Others
ery placement
Displays the electrical system
Upon lift
status and reads the error in-
Analyzer - - truck abnor-
formation detected by control-
mality
lers.
Makes fine adjustment of trav- As reques-
○
Tuning eling and material handling - ted by cus-
*2
functions. tomer
Specification Sets each lift truck option and ○
- -
setting other specifications. *1 *2,*3
Option set Each control
Enables or disables each con- ○
function en- - -
trol function. *2,*3
able/disable
Traveling
Updates voltage values of ○
PSS ○
sensor signals under the - *4,*5,*7,*8,*
Material hand- *2,*3
standard lift truck condition. 9
ling lever
Matching
OCV activating Set the current level for activat- ○ ○
-
current level ing the oil control valve. *2 *5
Makes the speedometer read- ○ ○
Tire data -
ing appropriate. *2 *6
4-96 4 DISPLAY
When used
Function Description Vehicle deliv- Board re-
Others
ery placement
Starts counting the hour meter,
Hour meter ○
odometer, trip meter and main- ○ -
start *3
tenance hour meter.
Enables simultaneous opera-
Before
tion of traveling and material
Demo mode - - starting the
handling before starting the
hour meter
hour meter.
Initialize a set value with the ○ When it is
To default set -
default value. *2,*3 necessary
Others menu
Service
Sets the service second pass- ○ When it is
second pass- -
word. *3 necessary
word setting
Administrator’s As reques-
Delete the administrator’s ○
second pass- - ted by cus-
second password. *3
word clear tomer
As reques-
LCD contrast Adjusts the contrast of the dis- ○
- ted by cus-
adjustment play screen. *3
tomer
*1: These functions are used to adjust the controller and display setups to the availability of optional or
control features. They do not enable or disable the actual functioning of the optional or control fea-
tures.
*2: Board: Main controller control board
*3: Board: Control board for the multi-function display
*4: When the accelerator sensor or the brake sensor is replaced, removed/installed, or the pedal height is
adjusted.
*5: When the oil control valve is replaced.
*6: When tire size is changed or tire is replaced.
*7: When the mast, tilt angle sensor, tilt cylinder, load sensor or tire angle sensor is replaced, removed /
installed or adjusted.
*8: When the attachment and fork is installed or changed.
*9: When the material handling lever angle sensor is replaced, removed / installed or adjusted.
4 DISPLAY 4-97
4.3.2 PASSWORD
NOTICE
4
• Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch
may be damaged.
• If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the
beginning. If the SERVICE MENU cannot be displayed after several attempts, the system may be
faulty.

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

seconds.
(3)

seconds.
(2)
When pressing the

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

Second password screen is displayed. Input the second
5 password.
Other:
This screen is skipped.
6 Service function initial screen is displayed for 5 seconds.

4-98 4 DISPLAY
7 ANALYZER MENU screen is automatically displayed.
SERVICE MENU Screen

Operating Procedure
1. Enter the password on the status screen (Refer to
PASSWORDpage 97) to display the SERVICE
MENU screen.
2. Select a desired function using the switch (2) or

(3). Then press the switch (4) to display the function
screen or setting screen of the selected function.
(2) (3) (4)
Reads information about the error detected by a control-

ANALYZER MENU screen ler and indicates the operating state of the electric sys-
tem of the lift truck.
Fine adjusts the settings for traveling control, material

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

OPTION SET MENU screen specifications of each lift truck or the control conditions
set for it.
Updates the sensor output voltages and the set values

MATCHING MENU screen stored in the memories of the display and each control-
ler.
4 DISPLAY 4-99
This allows you to:

▪ Start each meter*.
▪ Switch demo mode*.
OTHERS MENU screen ▪ Initialize the settings. 4
▪ Set a service second password.
▪ Clear the administrator's second password.
▪ Adjust the contrast of the LCD display.
END of SERVICE MENU From this screen, you can move to a status screen.
*: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be dis-
played on the OTHERS MENU screen.
4-100 4 DISPLAY
4.3.3 ANALYZER
GENERAL
Analyzer function supports operations for inspection/investigating a faulty section by displaying the condition
of the control system, using communication between each controller and the multi-function display.
By switching the multi-function display to analyzer mode, operative conditions of the sensors and actuators
which are used for traveling, material handling and PSS/OPS functions, or the error information detected by
the controller can be read.
This is very useful for checking the operative condition of each function, and saving time for repairing when
there is a defect. Full utilization of the analyzer functions provides quick and easy service.
The analyzer has the following functions:

1. Diagnostic memory function (DIAG MEMORY)
The controller stores up to 10 diagnostic codes (diagnostic codes) detected in the electrical system in
the past.
The diagnostic function reads these diagnostic codes and shows them on the display.
Each diagnostic code is displayed with its detection time as the key ON hour meter reading.
(1) DIAG MEMORY
Reads stored diagnostic codes and its detection time as the key ON hour meter and indicates them.
(2) DIAG MEMORY Quick Reverence (QR)
Displays the QR codes including the stored diagnostic codes and uses the key ON hour meter as
the detection time.
2. In/Out monitor function (I/O MONITOR)
This function displays the analog input voltage for traveling, material handling, PSS and Operator Pres-
ence Sensor switches, sensors and actuators. The circuit or their quality can be judged by monitoring
the displayed value.
(1) I/O TEMP/VOLT
Displays the temperature of each electrical functional part and the analog input voltage detected by
each controller.
(2) I/O TRAVELING
Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing
control.
(3) I/O M. HANDLING
Displays the material handling and mast control switch ON/OFF states and analog input voltages
from material handling and mast control sensors.
(4) I/O STEERING
Displays the ON/OFF states of synchronized steering and the analog input voltages from respective
sensors.
(5) I/O OTHERS
Displays the analog input voltages from the battery current sensor.
3. Active test (ACTIVE TEST)
In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the se-
lected item in order to permit an operation check of that function.
4. Program version display (VERSION)
Displays the program version of each controller.
NOTICE
The diagnostic code indication:
One diagnostic code is displayed in the upper right-hand portion on the I/O MONITOR or ACTIVE
TEST screen, when an error is detected.
4 DISPLAY 4-101
ANALYZER SCREEN ITEM LIST

Analyzer menu screen Screen No. Display item Description
1/2 1. to 5.
1. DIAG MEMORY Indications of errors occurred
2/2 6. to 10. 4
1/2
2. DIAG MEMORY QR - QR code images of errors occurred
2/2
Drive motor L temperature: °C
TDM
Drive motor R temperature: °C
1/6
Drive motor driver L heat sink temperature: °C
TDMDH
Drive motor driver R heat sink temperature: °C
Drive motor driver L board temperature: °C
TDMDB
Drive motor driver R board temperature: °C
2/6
Drive motor driver L condenser temperature: °C
TDMDC
Drive motor driver R condenser temperature: °C
TPM Pump motor temperature: °C
TPMDH Pump motor driver heat sink temperature: °C
3/6
TPMDB Pump motor driver board temperature: °C
3. I/O TEMP/VOLT
TPMDC Pump motor driver condenser temperature: °C
TMCB Main controller board temperature: °C
4/6 TSLLT (Not used)
TDSP Display board temperature: °C
B48V Battery voltage: V
VBKY Voltage after key switch: V
5/6
VBMBSL Solenoid power source voltage: V
VBMB Voltage after MB contactor: V
VDMDL Drive motor driver L main circuit voltage: V
6/6 VDMDR Drive motor driver R main circuit voltage: V
VPMD Pump motor driver main circuit voltage: V
4-102 4 DISPLAY

SPEED Traveling speed: km/h or mph
Accelerator sensor 1 voltage: V
VRA
Accelerator sensor 2 voltage: V
1/5
Brake sensor 1 voltage: V
VRB
Brake sensor 2 voltage: V
SWBK (Not used)
SDM Seat switch
DSF Forward switch
2/5
DSR Reverse switch
SPB Parking brake switch
SH Lifting height switch
3/5 SPLF Load sensor voltage: V (MPa display)
4. I/O TRAVELING SPEED Traveling speed: km/h or mph
Drive motor L rpm: rpm
SPDDML
[Target rpm]: rpm
4/5
Drive motor R rpm: rpm
SPDDMR
[Target rpm]: rpm
Drive motor L rotation sensor 1 voltage: V
SSDL
Drive motor L rotation sensor 2 voltage: V
Drive motor R rotation sensor 1 voltage: V
SSDR
Drive motor R rotation sensor 2 voltage: V
5/5
Drive motor L current sensor 1 voltage: V
CSDL
Drive motor L current sensor 2 voltage: V
Drive motor R current sensor 1 voltage: V
CSDR
Drive motor R current sensor 2 voltage: V
4 DISPLAY 4-103

SLUL Unload solenoid
SLLL Lift lowering lock solenoid
SLTFL Tilt forward lock solenoid
4
SLTBL Tilt backward lock solenoid
1/8
SHS Lift knob switch
STK Tilt knob switch
SDM Seat switch
SHL (Not used)
VRTA Tilt angle sensor voltage: V
SPLF Load sensor voltage: V (MPa display)
2/8
SH Lifting height switch
VRH (Not used)
Pump motor rpm: rpm
3/8 SPDPM
[Target rpm]: rpm
SSP Pump motor driver rotation sensor voltage: V
4/8 Pump motor driver current sensor 1 voltage: V
5. I/O M.HANDLING CSPM
Pump motor driver current sensor 2 voltage: V
SLLL Lift lowering lock solenoid
5/8
Lift lever angle sensor 1 voltage: V
VRL
Lift lever angle sensor 2 voltage: V
SLTFL Tilt forward lock solenoid
6/8 SLTBL Tilt backward lock solenoid
SWTF Tilt forward switch
SWTR Tilt backward switch
7/8 Attachment (1) lever angle sensor 1 voltage: V
VRA1
Attachment (1) lever angle sensor 2 voltage: V
8/8 Attachment (2) lever angle sensor 1 voltage: V
VRA2
Attachment (2) lever angle sensor 2 voltage: V
VRTRA Tire angle sensor voltage: V
SPEED Traveling speed: km/h or mph
6. I/O STEERING 1/1 Steering angle knob position actual value (target
K-POS
value), Steering synchronizer solenoid
SSTR Steering angle sensor signal
CSBAT Battery current sensor voltage: V
7. I/O OTHERS 1/1 IPL (Not used)
DOPT (Not used)
4-104 4 DISPLAY

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

Operating Procedure
Enter the password on the status screen (Refer to
PASSWORDpage 97) to display the service function
initial screen. After 5 seconds, the ANALYZER MENU
screen is automatically displayed.
“1. DIAG MEMORY”

Switch (1): Switching selection to next item
Switch (2): To END of SERVICE MENU
Switch (3): To TUNING MENU
Switch (4): To “DIAG MEMORY” screen
“2. DIAG MEMORY QR”
Switch (4): To “DIAG MEMORY QR” screen
“3. I/O TEMP/VOLT”
Switch (4): To “I/O TEMP/VOLT” screen
4 DISPLAY 4-105
“4. I/O TRAVELING”

Switch (4): To “I/O TRAVELING” screen 4
“5. I/O M.HANDLING”
Switch (4): To “I/O M.HANDLING” screen
“6. I/O STEERING”
Switch (4): To “I/O STEERING” screen
“7. I/O OTHERS”
Switch (4): To “I/O OTHERS” screen
“8. ACTIVE TEST”
Switch (4): To “ACTIVE TEST” screen
“9. VERSION”
Switch (4): To “VERSION” screen
Diagnostic Memory Function (DIAG MEMORY)

The controller stores up to 10 error codes (diagnostic codes) detected in the electrical system in the past.
The diagnostic function reads these error codes and indicates them on the display.
Diagnostic Memory (1) (DIAG MEMORY)
Reads stored diagnostic codes and their detection time as the key ON hour meter and displays them.
Operating Procedure
4-106 4 DISPLAY
2. Check that “1. DIAG MEMORY” is selected on the

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

screen to return to the ANALYZER MENU screen.
NOTICE!
▪ The most recent diagnostic code is displayed
as 1, followed by 2, 3 and so on to 10.
▪ When no diagnostic code is displayed on the
(4) screen, and the hour meter time is 0.0h, it in-
dicates that no errors occurred in the past
after that row.
▪ You cannot move directly from the DIAG
MEMORY screen to another function screen.
Return to the ANALYZER MENU screen.
▪ For details about the diagnostic code, refer to
section 4, Diagnostic Code List.
“DIAG MEMORY 1/2”
Displays diagnostic codes 1 to 5.
Switch (4) : To “DIAG MEMORY 2/2” screen.
“DIAG MEMORY 2/2”

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

The DIAG MEMORY QR screen displays the QR codes including the stored diagnostic codes and its detec-
tion as the key ON hour meter.
4 DISPLAY 4-107
Operating Procedure
screen is automatically displayed. 4
2. Press the switch (1) to select the “2. DIAG

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

NOTICE!
▪ Read the QR code in order from the first to the
second one. If you move to the next screen
before reading the first QR code, return to the
ANALYZER MENU screen and display the first
(4) QR code again.
▪ If you move to the next screen before reading
the first QR code, the second QR code does
not display.
▪ You cannot move directly from the DIAG
MEMORY QR screen to another function
screen. Return to the ANALYZER MENU
screen.
▪ For details of the diagnostic code, refer to
section 4, Diagnostic Code List.
4-108 4 DISPLAY
“DIAG MEMORY QR 1/2”

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

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

4 DISPLAY 4-109
In/Out Monitor Function (I/O MONITOR)

This function displays the analog input voltage from traveling, material handling, PSS and Operator Pres-
ence Sensor switches, sensors and actuators.
The circuit or their quality can be judged by monitoring the displayed value.
4
In/Out Monitor (1) (I/O TEMP/VOLT)
Displays the temperature of each electrical functional part and the analog input voltage detected by each
controller.
Operating Procedure
1. Display the ANALYZER MENU screen.
2. Press switch (1) to select the “3. I/O TEMP/VOLT”

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

TDM: Drive motor L/R temperature: °C
Temperature of the drive motor L/R is displayed.
TDMDH: Drive motor driver L/R heat sink temperat-
ure: °C
Temperature of the drive motor driver L/R heat sink is
displayed.
Switch (4): To “I/O TEMP/VOLT 2/6” screen
4-110 4 DISPLAY

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

TPM: Pump motor temperature: °C
Temperature of pump motor is displayed.
TPMDH: Pump motor driver heat sink temperature:
°C
Temperature of the pump motor driver heat sink is
displayed.
TPMDB: Pump motor driver board temperature: °C
Temperature of the pump motor driver board is dis-
played.
TPMDC: Pump motor driver condenser temperature:
°C
Temperature of the pump motor driver condenser is
displayed.
TMCB: Main controller board temperature: °C
Temperature of main controller board is displayed.
TSLLT: Not used
TDSP: Display board temperature: °C
Temperature of display board is displayed.

B48V: Battery voltage: V
Battery voltage is displayed.
VBKY: Voltage after key switch: V
Voltage after key switch is displayed.
VBMBSL: Solenoid power source voltage: V
Voltage of solenoid power source is displayed.
VBMB: Voltage after MB contactor: V
Voltage of after MB contactor is displayed.
4 DISPLAY 4-111

VDMDL: Drive motor driver L main circuit voltage: V
Voltage of drive motor driver L main circuit is dis-
played.
VDMDR: Drive motor driver R main circuit voltage: V 4
Voltage of drive motor driver R main circuit is dis-
played.
VPMD: Pump motor driver main circuit voltage: V
Voltage of pump motor driver main circuit is dis-
played.
Switch (4): Returning to the ANALYZER MENU
screen
In/Out Monitor (2) (I/O TRAVELING)

Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
Operating Procedure
2. Press the switch (1) to select the “4. I/O TRAVEL-

ING” and press the switch (4) to display the “I/O
TRAVELING 1/5” screen.
TRAVELING screen to other screens. Return to the
screen.
4-112 4 DISPLAY
“I/O TRAVELING 1/5”

SPEED: Traveling speed: km/h or mph
Displays the traveling speed.
VRA: Accelerator sensor 1 / 2 voltage: V
Displays input voltage from the accelerator sensor to
the controller.
Standard:
Accelerator sensor 1
When accelerator is not operated: 0.40 to 1.24 V
When accelerator pedal is fully depressed: 2.00 to
4.79 V
Accelerator sensor 2
When accelerator is not operated: 0.65 to 2.31 V
When accelerator pedal is fully depressed: 2.42 to
4.79 V
VRB: Brake sensor 1 / 2 voltage: V
Displays input voltage from the brake sensor to the
controller.
Standard:
Brake sensor 1
When brake is not operated: 0.50 to 1.79 V
When brake pedal is fully depressed: 1.60 to 4.79
V
Brake sensor 2
When brake is not operated: 0.79 to 2.88 V
When brake pedal is fully depressed: 2.00 to 4.79
V
SWBK: Not used
Switch (4): To “I/O TRAVELING 2/5” screen
4 DISPLAY 4-113

SDM: Seat switch
Switch ON/OFF quality judgment by sitting on and
leaving the operator’s seat
SDM: 0 = OFF when leaving the seat 4
SDM: 1 = ON when sitting on the seat
DSF: Forward switch
DSR: Reverse switch
Switch ON/OFF quality judgment by operating the dir-
ection lever
Standard:
Direction lever: Forward traveling position
Displayed code:
DSF: 1 (= ON)
DSR: 0 (= OFF)
Direction lever: Neutral position
Displayed code:
DSF: 0 (= OFF)
DSR: 0 (= OFF)
Direction lever: Reverse traveling position
Displayed code:
DSF: 0 (= OFF)
DSR: 1 (= ON)
SPB: Parking brake switch
Switch ON/OFF quality judgment by operating the
parking brake lever.
SPB: 0 = OFF (in a state of parking brake being oper-
ated)
SPB: 1 = ON (in a state of parking brake being re-
leased)
SH: Lifting height switch
Judges the quality of the switch ON/OFF by raising
and lowering the fork.
SH2-1 SH2-2
Height Display SH1 Switch
Switch Switch
Low lifting
100 1 (=ON) 0 (=OFF) 0 (=OFF)
height
High lifting
SH1 SH2-1 SH2-2 010 0 (=OFF) 1 (=ON) 0 (=OFF)
height
4-114 4 DISPLAY
SPLF: Load sensor voltage: V (MPa)

Displays input voltage from the load sensor to the
controller, and detected pressure.
Standard at no load: 0.50 to 4.49 V
Voltage increases as load increases.
SPDDML: Drive motor L rpm [target]: rpm
SPDDMR: Drive motor R rpm [target]: rpm
This screen indicates the measured and target num-
bers of revolutions of the drive motor.
The rotation sensor is checked by actually running
the lift truck.
The number of revolutions of the drive motor in-
creases with an increase in the traveling speed.

SSDL: Drive motor L rotation sensor 1 / 2 voltage: V
SSDR: Drive motor R rotation sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor
rotation sensors.
Standard:
When motor is stopped:
Constant, either 0.30 to 0.70V or 0.90 to 1.40V
When motor is rotating:
Variable between approx. 0.30V and 1.40V
CSDL: Drive motor L current sensor 1 / 2 voltage: V
CSDR: Drive motor R current sensor 1 / 2 voltage: V
This screen indicates the voltages of the drive motor
current sensors.
Standard:
Standard value when the lift truck is stopped: Ap-
prox. 2.50V
Standard value when the lift truck is traveling:
Approx. 0.40 to 4.50V
screen
4 DISPLAY 4-115
In/Out Monitor (3) (I/O M.HANDLING)

Displays the material handling and mast control switch ON/OFF states and analog input voltages from mater-
ial handling and mast control sensors.
Operating Procedure
4
2. Press switch (1) to select “5. I/O M.HANDLING”

and press switch (4) to display the “I/O M.HANDLING
1/8” screen.
M.HANDLING screen to other screens. Return to
the ANALYZER MENU screen, then move to the
next screen.
“I/O M.HANDLING 1/8”

SLUL: Unload solenoid
(Conventional Lever)
Displays output signal to the unload solenoid.
SLLL: Lift lowering lock solenoid
Displays output signal to the lift lowering lock solen-
oid.
SLTFL: Tilt forward lock solenoid
Displays output signal to the tilt forward lock solenoid.
SLTBL: Tilt backward lock solenoid
(Conventional Lever)
Displays output signal to the tilt backward lock solen-
oid.
Seat condition Sitting on seat

Lift lever Tilt lever Leaving
Not oper-
Lever condition
ated Forward Backward seat
Raising Lowering
tilt tilt
SLUL 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON)
SLLL 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) 0 (=OFF)
SLTFL 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF)
SLTBL 0 (=OFF) 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF)
SDM 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 1 (=ON) 0 (=OFF)
4-116 4 DISPLAY
SHS: Lift knob switch

Switch ON/OFF quality judgment by operating the lift
knob switch.
SHS: 0 = OFF
SHS: 1 = ON
STK: Tilt knob switch
Switch ON/OFF quality judgment by operating the tilt
knob switch.
STK: 0 = OFF
STK: 1 = ON
SDM: Seat switch
See “I/O TRAVELING 2/5”
SHL: Not used
Switch (4): To “I/O M.HANDLING 2/8” screen
VRTA: Tilt angle sensor voltage: V
Displays input voltage from the tilt angle sensor to the
controller.
Standard with mast in the vertical position: 1.27
to 3.99V
Mast vertical → forward tilt: Input voltage decreases
Mast vertical → backward tilt: Input voltage increases
SPLF: Load sensor voltage: V (MPa)
SH: Lifting height switch
VRH: not used
SPDPM: Pump motor rpm [target]: rpm
This screen indicates the measured and target num-
bers of revolutions of the pump motor.
The number of revolutions of the pump motor in-
creases with an increase in the material handling
speed.
4 DISPLAY 4-117

SSP: Pump motor driver rotation sensor voltage: V
Displays the voltage from the pump motor driver rota-
tion sensor.
Standard: 4
When motor is stopped: Constant, either 0.30 to
0.70V or 0.90 to 1.40V
When motor is rotating: Variable between approx.
0.30V and 1.40V
CSPM: Pump motor driver current sensor 1 / 2
voltage: V
Displays the voltage from the pump motor driver cur-
rent sensor 1 / 2.
Standard:
Do not operate the material handling lever or the
steering, and keep the direction lever in the neut-
ral position: Approx. 2.50 V
In a case other than above: 0.40 to 4.50 V
See “I/O M.HANDLING 1/8”
SLLL: Lift lowering lock solenoid
VRL: Lift lever angle sensor 1 / 2 voltage: V
Displays input voltage from lift lever angle sensor 1 /
2 to the controller.
Standard:
Lift lever angle sensor 1
Lever pull position: 0.30 to 2.87V
Lever push position: 1.65 to 4.50V
Lever neutral position: 1.65 to 2.87V
The voltage increases during lever backward opera-
tion, and it decreases during lever forward operation.
Standard:
Lift lever angle sensor 2
Lever pull position: 1.52 to 4.50 V
Lever push position: 0.30 to 3.01 V
Lever neutral position: 1.52 to 3.01 V
The voltage decreases during lever backward opera-
tion, and it increases during lever forward operation.
4-118 4 DISPLAY

SLTFL: Tilt forward lock solenoid
SLTBL: Tilt backward lock solenoid
SWTF: Tilt forward switch
forward switch.
SWTR: Tilt backward switch
backward switch.
Standard:
Tilt lever: Forward tilt position
Displayed code:
SWTF: 1 (= ON)
SWTR: 0 (= OFF)
Tilt lever: Neutral position
SWTF: 0 (= OFF)
SWTR: 0 (= OFF)
Tilt lever: Reverse tilt position
SWTF: 0 (= OFF)
SWTR: 1 (= ON)
VRA1: Attachment (1) lever angle sensor 1 / 2
voltage: V
Displays input voltage from the attachment 1 lever
angle sensor 1 / 2 to the controller.
Standard:
Attachment 1 lever angle sensor 1
Standard:
The input voltage decreases during lever backward
operation, and it increases during lever forward oper-
ation.
4 DISPLAY 4-119

VRA2: Attachment (2) lever angle sensor 1 / 2
voltage: V 4
Displays input voltage from the attachment (2) lever
angle sensor 1 / 2 to the controller.
Standard:
Standard:
The input voltage decreases during lever backward
operation, and it increases during lever forward oper-
ation.
screen
In/Out Monitor (4) (I/O STEERING)

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

and press switch (4) to display the “I/O STEERING
1/1” screen.
STEERING screen to other screens. Return to the
screen.
4-120 4 DISPLAY
“I/O STEERING 1/1”

VRTRA: Tire angle sensor voltage: V
Displays input voltage from the tire angle sensor to
the controller.
Standard when tires are in the straight ahead pos-
ition:
2.11 to 2.81V
The input voltage increases when you turn the steer-
ing right, while it decreases when you turn the steer-
ing left.
K-POS: Steering angle knob position actual value
This screen indicates the actual (target) position of
the steering knob and the ON/OFF status of the knob
position compensation solenoid.
Actual value:
The knob position calculated and recognized by the
controller from the steering angle sensor signal
Target value:
The knob position calculated and recognized by the
controller from the tire angle sensor signal
Lift truck without synchronized steering:
K-POS: ---- = Always
Lift truck with synchronized steering:
159 One rotation (360°) of the steering wheel is divided by
0 160, and the value is set to “80” when the knob is in
1 the position as indicated in the illustration.
Clockwise turn of the steering wheel: Increase in
80 value
Counterclockwise turn of the steering wheel: De-
crease in value
Steering synchronizer solenoid:
Lift truck without synchronized steering:
K-POS: ---- = Always
Lift truck with synchronized steering:
Arrow indicates the standard position
0 = OFF non-energized state (Position compensation
disabled)
1 = ON energized state (Position compensation en-
abled)
SSTR: Steering angle sensor signal
0 = OFF
1 = ON
When the steering wheel is rotated once, SS1 and
SS2 repeat ON and OFF. SSC only turns on when
the knob is in the standard (center) position.
screen
SS1 SS2 SSC
In/Out Monitor (5) (I/O OTHERS)

Displays the analog input voltages from battery current sensor.
Operating Procedure
4 DISPLAY 4-121
2. Press switch (1) to select “7. I/O OTHERS” and

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

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

In active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected
item in order to permit an operation check of that function.
Active Test Item List
Selection item
Item Description Content of opera- Content of opera-
Signal Signal
tion tion
STEERING Steering synchronizer solen- Tire do not move
OFF Tires move ON
SOL*1 oid forced operation match
Lift lowering lock solenoid Lowering not pos-
LIFT LWR SOL OFF ON Lowering possible
forced operation sible
Tilt forward solenoid forced Forward tilt not pos-
TILT SOL OFF ON Forward tilt possible
operation sible
Tilt backward solenoid forced Backward tilt pos- Backward tilt not pos-
TILT BWD SOL OFF ON
operation sible sible
4-122 4 DISPLAY
Selection item
Item Description Content of opera- Content of opera-
Signal Signal
tion tion
Material handling op-
Unload solenoid forced oper- Material handling op-
UNLOAD SOL OFF ON eration not possible
ation eration possible
(Except lowering)*2
Cooling fan for controller
FAN1 OFF Fan stops ON Fan rotates
forced operation
Cooling fan for motor forced
FAN2*3 OFF Fan stops ON Fan rotates
operation
ACC OUT1 Not used OFF - ON -
Accessory output 2 forced Back buzzer stop Back buzzer sound
ACC OUT2*4 OFF ON
operation Motion alarm stop Motion alarm sound
*1: With synchronized steering only

*2: Depending on the attachment, 3rd to 5th way operation may be possible.
It may slowly tilt forward according to load condition, but this is not a fault.
*3: With cooling fan for motor only
*4: With motion alarm only
▪ On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item.
▪ If the selected item is forcibly turned off or on by pressing switch (2) or (3), and it is switched over to an-
other item by pressing switch (1), forced operation is canceled (and switches over to normal operation).
▪ The operation guidance in connection with switches (2) and (3) indicates whether an item is forcibly oper-
ated or not. (Refer to below)
Operation guidance Condition
Selected item not forcibly operated
Selected item forcibly turned ON
Selected items forcibly turned OFF
Applicable function not provided or its state signal not received
Operating procedure
4 DISPLAY 4-123
2. Press switch (1) to select the “8. ACTIVE TEST”

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

STEERING SOL: Steering synchronizer solenoid
forced operation
Slowly turn the steering wheel, and check the differ-
ence of the rear tire movement.
ON (By-pass open): Tires do not move much
OFF (By-pass close): Tires move (normal operation)
LIFT LWR SOL: Lift lowering lock solenoid forced op-
eration
Check the quality of lowering action by lift lowering
operation.
ON (Solenoid ON): Lowering possible (normal opera-
tion)
OFF (Solenoid OFF): Lowering not possible
TILT SOL: Tilt forward solenoid forced operation
Check the quality of mast forward tilt operation by for-
ward tilt operation.
ON (Solenoid ON): Forward tilt possible
OFF (Solenoid OFF): Forward tilt not possible
TILT BWD SOL: Tilt backward solenoid forced opera-
tion
Check the quality of mast backward tilt operation by
backward tilt operation.
ON (Solenoid ON): Backward tilt possible
OFF (Solenoid OFF): Backward tilt not possible
Switch (1): Selecting the next item on the “ACTIVE
TEST 1/3” screen
Switch (2): Forcibly turning off the selected item
Switch (3): Forcibly turning on the selected item
Switch (4): To “ACTIVE TEST 2/3” screen
4-124 4 DISPLAY

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

Displays program version of each controller.
Operating Procedure
4 DISPLAY 4-125
2. Press switch (1) to select “9. VERSION” and press

switch (4) to display the “VERSION 1/2” screen.
Press switch (4) to display the VERSION 2/2 screen,
and press switch (4) again to return from the VER-
SION 2/2 screen to the ANALYZER MENU screen. 4
NOTICE! You cannot move directly from the VER-
SION screen to another screen. Return to the
screen.
“VERSION 1/2”
DISPLAY: Program version of the multi-function dis-
play
MAIN C/R: Program version of the main controller
CAN BRIDGE: Program version of the CAN bridge
Switch (4): To “VERSION 2/2” screen
“VERSION 2/2”
DM DRIVER L: Program version of the drive motor
driver L
DM DRIVER R: Program version of the drive motor
driver R
PM DRIVER: Program version of the pump motor
driver
screen
4-126 4 DISPLAY
4.3.4 TUNING
This feature performs fine adjustment of traveling and material handling controls. When receiving requests
from users, such as the request to weaken the acceleration-off regenerative braking force, various settings
levels can be changed on the tuning screens.
Tuning functions have 75 items (included spare items)
Tuning Item List

Level (●: Initial setting value)
Menu No. Item
1 2 3 4 5 6 7 8
Activation timing of low battery
Fast
1 capacity warning and battery Slow Disabled
●
over-discharge warning
Battery charge indicator calibra- Slow de- Fast de-
2 ●
tion No.1 crease crease
Batery charge indicator calibra-
3 Sensitive ● Insensitive
tion No.2
Motor torque when the battery Power Power
4 ●
discharge has proceeded. Down Keep
5 Not used - ● -
6 Acceleration pedal sensitivity Insensitive ● Sensitive
7 Acceleration torque Weak ● Strong
8 Acceleration soft-start Slow ● Quick
Regenerative braking torque at
9 Weak ● Strong
accelerator-off
Regenerative braking soft-start
10 Slow ● Quick
at accelerator-off
Acceleration torque at switch-
11 Weak ● Strong
TUNE back
GEN Acceleration soft-start at switch-
12 Slow ● Quick
back
Regenerative braking torque at
13 Weak ● Strong
switch-back
Regenerative braking soft-start
14 Slow ● Quick
at switch-back
Regenerative braking soft-stop
15 Slow ● Quick
at switch-back
16 Accelerator traction torque Weak ● Strong
Accelerator and brake traction Strong
17 Weak
torque ●
Rollback speed when the travel-
Slow
18 ing direction is opposite to the Fast
●
direction lever.
Rollback speed when the travel-
Slow
19 ing direction is the same as the Fast
●
direction lever.
The time of simultaneously oper-
20 able accelerator and brake Short ● Long No limit
(OPT)
4 DISPLAY 4-127
Level (●: Initial setting value)

Menu No. Item
1 2 3 4 5 6 7 8
Short
21 Stop time before rollback* Long
●
Maximum speed limitation during Fast 4
22 Slow
backward traveling ●
Low speed setting during back- Fast
23 Slow
ward traveling ●
24 Not used - ● -
Regenerative braking soft-stop
25 Slow ● Quick
at brake on
Pump motor output during lift up Fast
26 Slow
operation ●
Pump motor output during tilt for-
27 Slow ● Fast
ward and backward operation
TUNE
Pump motor output during the at-
GEN 28 tachment (1) lever push and pull Slow ● Fast
operation
Pump motor output during the at-
29 tachment (2) lever push and pull Slow ● Fast
operation
30 Not used - ● -
31 Not used - ● -
32 Not used - ● -
-
33 Not used -
●
34 Not used - ● -
Tilt forward angle to limit liftup
35 Small ● Large Disabled
speed in low lift position
*: The stop time of the lift truck becomes longer on a sloping road if you increase the setting level. Set
the parking brake if you leave the seat.
4-128 4 DISPLAY
Low battery capacity warning and battery over-discharge warning
[%] 1 2 3 4 5 6 7 8
50
60 (a)
(b)
70
80
90
100
(c)
(a) Battery warning (b) Battery indicator blinks (c) No warning

Over-discharge warning
Ten segment of the battery indicator blink
○: Available
-: NOT available
Lever Level (●: Initial setting value)

Menu No. Item
STD 1 2 3 4 5 6 7 8
Play at the begin-
START ning of lift lever - Wide ● Narrow
down operation
Inching speed during
INCH - Slow ● Fast
lift down operation
Maximum speed
LIFT MAX during lift down op- - Slow ● Fast
DOWN eration
Acceleration speed
ACC during lift down op- - Weak ● Strong
eration
Deceleration speed
DEC during lift down op- - Weak ● Strong
eration
4 DISPLAY 4-129

Menu No. Item
STD 1 2 3 4 5 6 7 8
Play at the begin-
START ning of lift up opera- - Wide ● Narrow
tion 4
INCH ○ Slow ● Fast
lift up operation
Maximum speed
MAX during lift up opera- - Slow ● Fast
LIFT UP
tion
Acceleration speed
ACC during lift up opera- ○ Weak ● Strong
tion
Deceleration speed
DEC during lift up opera- ○ Weak ● Strong
tion
Play at the begin-
START ning of tilt forward - Wide ● Narrow
operation
INCH - Slow ● Fast
tilt forward operation
Maximum speed
TILT MAX during tilt forward - Slow ● Fast
FWD operation
Acceleration speed
ACC during tilt forward ○ Weak ● Strong
operation
Deceleration speed
DEC during tilt forward ○ Weak ● Strong
operation
Play at the begin-
START ning of tilt backward - Wide ● Narrow
operation
INCH tilt backward opera- - Slow ● Fast
tion
Maximum speed
TILT
MAX during tilt backward - Slow ● Fast
BWD
operation
Acceleration speed
ACC during tilt backward ○ Weak ● Strong
operation
Deceleration speed
DEC during tilt backward ○ Weak ● Strong
operation
4-130 4 DISPLAY

Menu No. Item
STD 1 2 3 4 5 6 7 8
Play at the begin-
ning of the attach-
START - WIde ● Narrow
ment (1) lever push
operation
INCH the attachment (1) ○ Slow ● Fast
lever push operation
Maximum speed
during the attach-
ATT1 MAX - Slow ● Fast
ment (1) lever push
PUSH
operation
Acceleration speed
during the attach-
ACC ○ Weak ● Strong
ment (1) lever push
operation
Deceleration speed
during the attach-
DEC ○ Weak ● Strong
ment (1) lever push
operation
Play at the begin-
ning of the attach-
START - Wide ● Narrow
ment (1) lever pull
operation
lever pull operation
Maximum speed
during the attach-
ment (1) lever pull
PULL
operation
Acceleration speed
during the attach-
ment (1) lever pull
operation
Deceleration speed
during the attach-
ment (1) lever pull
operation
4 DISPLAY 4-131

Menu No. Item
STD 1 2 3 4 5 6 7 8
Play at the begin-
ning of the attach-
START - Wide ● Narrow 4
ment (2) lever push
operation
lever push operation
Maximum speed
during the attach-
ment (2) lever push
PUSH
operation
Acceleration speed
during the attach-
ment (2) lever push
operation
Deceleration speed
during the attach-
ment (2) lever push
operation
Play at the begin-
ning of the attach-
START - Wide ● Narrow
ment (2) lever pull
operation
lever pull operation
Maximum speed
during the attach-
ment (2) lever pull
PULL
operation
Acceleration speed
during the attach-
ment (2) lever pull
operation
Deceleration speed
during the attach-
ment (2) lever pull
operation
4-132 4 DISPLAY
TUNING MENU Screen

Operating Procedure
2. By default, the SERVICE MENU screen is dis-

played with the [ANL] tab selected. On this screen,
press switch (3) and select the [TUN] tab.
(2) (3)
“1. GENERAL”
Switch (1): Switching selection to the next item.
Switch (2): To ANALYZER MENU
Switch (3): To OPTION SET MENU
Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER”
“3. TILT LEVER”
“4. ATT1 LEVER”
“5. ATT2 LEVER”
4 DISPLAY 4-133
GENERAL (TUNING GENERAL)

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

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

Switch (4): Returning to the TUNING MENU screen
4-134 4 DISPLAY
LIFT LEVER (TUNING LIFT LEVER)

Sets tuning levels for the lift lever.
Operating Procedure
1. Display the TUNING MENU screen and press the
switch (1). Select the “2. LIFT LEVER”.
2. Press switch (4) to display the TUNING LEVEL

setting screen.
NOTICE! : You cannot move directly from the LIFT
LEVER setting screen to other screens. Return to
the TUNING MENU screen, then move to the next
screen.
(4)
“LIFT DOWN”
“LIFT UP”
4 DISPLAY 4-135
TILT LEVER (TUNING TILT LEVER)

Sets tuning levels for the tilt lever.
Operating Procedure
1. Display the TUNING MENU screen and press 4
switch (1), select the “3. TILT LEVER”.

setting screen.
NOTICE! : You cannot move directly from the TILT
LEVER setting screen to the screen of the other
items. Return to the TUNING MENU screen once,
then move to the screen for each time.
(4)
“TILT FWD”
“TILT BWD”
4-136 4 DISPLAY
ATT1 LEVER (TUNING ATT1 LEVER)

Sets tuning levels for the ATT1 lever.
Operating Procedure
1. Display the TUNING MENU screen and press
switch (1). Select the “4. ATT1 LEVER”.

setting screen.
ATT1 LEVER setting screen to others screens. Re-
turn to the TUNING MENU screen, then move to
the next screen.
(4)
“ATT1 PUSH”
“ATT1 PULL”
4 DISPLAY 4-137
ATT2 LEVER (TUNING ATT2 LEVER)

Sets tuning levels for the ATT2 lever.
Operating Procedure
1. Display the TUNING MENU screen and press 4
switch (1). Select the “5. ATT2 LEVER”.

setting screen.
ATT2 LEVER setting screen to other screens. Re-
turn to the TUNING MENU screen, then move to
the next screen.
(4)
“ATT2 PUSH”
“ATT2 PULL”
4-138 4 DISPLAY
4.3.5 OPTION SET
NOTICE
• The Option Set function is used to fit the specifications of the controller and the multi-function
display for the options actually equipped on the lift truck. It does not enable or disable itself.
• If the main controller or multi-function display is replaced, it is necessary to reset it according to
the lift truck specification.
Option Set Item List

Switching settings
Indication Description Indica- Indica-
Setting content Setting content
tion tion
Setting the traveling speed
MPH* YES mph NO km/h
display unit
DATE TYPE* Setting the calendar format D/M/Y(E) / Y/M/D(J) / M/D/Y(U)
Setting the battery voltage
36V* YES 36V NO 48V
between 36V and 48V
Adjust the charge indicator A1: US Domestic / A2: Export / B1: Japan / B2: Mainten-
B-TYPE*
calculation ance Free
Setting to enable/disable the
H MODE LOCK YES Enabled NO Disabled
H mode lock
Unlock (“NO”) ef- Unlock (“NO”) ef-
MENULOCK Setting the mode of the menu
A fective till key- B fective till set
SPEC* lock release
OFF “YES”
Setting the traction limitation
mode when operating the ac- accelerator prior-
A B brake priority
celerator and the brake simul- ity
taneously
[YFS specification (E34A)only]
ACCEL & BRK* Both A/B are given priority to
The output of the
an accelerator The motor output
drive motor stops
Drive motor output setting gradually stops
A just after the re- B
after the accelerator and after the restric-
striction activ-
brakes simultaneous operation activates.
ates.
tion time progress set by tun-
ing No. 20.
The drive motor The drive motor
HOLD TRQ Drive motor output setting output gradually output stops just
A B
MODE after the pushing operation. stops after the after the opera-
operation. tion.
Inactive setting of the regener-
COASTING RUN ative braking with the acceler- YES Inactive NO Active (Default)
ator pedal off
Setting the number of ways 2/3/4/5
OCV WAY*
for the oil control valve “5” is no used this model.
A: Disable / B: Enable PUSH / C: Enable PULL / D: En-
D ACT ATT1* Double action ATT1
able Both
A: Disable / B: Enable PUSH / C: Enable PULL / D: En-
D ACT ATT2* Double action ATT2
able Both
D ACT ATT3 Reserved A/B/C/D
4 DISPLAY 4-139
Switching settings
tion tion
Setting for the mode of the
buzzer sound when the Oper- 4
BUZZER SPEC* A: Except US / B: Not in use / C: US
ator Presence Sensor and Re-
turn-to-neutral operate
SEAT BUZZER buzzer sound when the seat YES Enabled NO Disabled
switch is off
PKB BUZZER YES Enabled NO Disabled
parking brake off warning
SPD ALM2 YES Enabled NO Disabled
overspeed alarm 2
WHEEL IND Reserved A/B/C
Setting display mode of the
POWER METER YES Enabled NO Disabled
power meter
ASC W/LOAD YES Enabled NO Disabled
auto speed control
MODE traveling speed limit of auto S Enabled A Disabled
speed control
CURVE CONT turn speed control with load YES Enabled NO Disabled
and height sensing
Setting the traction limitation Traction restric- Traction restric-
D-LIM MODE mode at over-discharge warn- A tions regardless B tions according to
ing of discharge level discharge level
Setting the material handling
Lift interrupt while
P-LIM MODE limitation mode at over-dis- A Lift interrupt B
travelling
charge warning
T FWD LIMIT active mast front tilt angle YES Enabled NO Disabled
control
T BWD LEVEL backward tilt automatic level- YES Enabled NO Disabled
ing control
T F-SPD LIM YES Enabled NO Disabled
forward tilt speed limit control
L UP-SPD LIM lifting speed limitation with YES Enabled NO Disabled
mast forward-tilted
KNOB CONT* YES Enabled NO Disabled
steering knob synchronizer
POWER KEEP YES Enabled NO Disabled
power keep control
H-SELECTOR Reserved YES - NO -
Setting the directions of the F: Forward / R: Reverse (Default) / F&R: Forward and Re-
MOTION ALM
motion alarm verse / OFF
D: Direction / MVT: Speed Detection / D&MVT: Direction
Setting the mode of the mo-
DIR-SW/MVT* and Speed Detection / D/MVT: Direction or Speed Detec-
tion alarm
tion
STOP LAMP Reserved A - B -
4-140 4 DISPLAY
Switching settings
tion tion
D-REC iWAREHOUSE CAN commu- YES Enabled NO Disabled
nications
*: These are set according to the lift truck specification at the time of shipment.
OPTION SET MENU Screen

Operating Procedure

press switch (3) to select the [OPT] tab.
(3)
3. Check that “1. OPTION SET” is selected on the

screen, and press switch (4) to display the OPTION
SET screen.
Switch (3): To MATCHING MENU
Switch (4): To OPTION SET screen
WARNING! : You cannot move directly from the
OPTION SET screen to other screens. Return to the
OPTION SET MENU screen, then move to the next
screen.
4 DISPLAY 4-141
“OPTION SET” Screen 1

Switch (2): Switching the selected Option Set item to
the option on the left
Switch (3): Switching the selected Option Set item to 4
the option on the right



4-142 4 DISPLAY




Switch (4): Returning to the OPTION SET MENU
screen
4 DISPLAY 4-143
4.3.6 MATCHING
GENERAL
Each function is controlled by using the sensors and each signal voltage at standard lift truck conditions 4
stored in the controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a
sensor at standard lift truck condition) is required when performing maintenance on a section or replacing
parts related to the sensor.
For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accelerator
and brake fully released, accelerator and brake fully closed are stored, respectively, in the controller to con-
trol based on these values. When servicing these sensors or replacing related parts, MATCHING (updating
the sensor signal voltage value in the standard lift truck condition) is necessary.
The controller stores the values of these functions at the time of shipment; Tilt angle, Load and tire angle
sensors used for PSS functions, signal voltage values under the mast vertical, no load, tire straight, and lift
truck horizontal. When servicing or replacing these sensors, matching (updating the sensor signal voltage
value in the standard lift truck condition) is necessary. Also, matching is needed for the tilt angle sensor
when the lift truck posture has changed excessively, and for the load sensor when the load under no load
condition (no load on forks) is changed because of addition or removal of any attachment or fork, replace-
ment of mast, or change of fork length.
Each lever angle sensor for material handling lever function is controlled based on the memory of the signal
voltage values in the neutral position stored in the controller at the time of shipment. When servicing these
sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard lift
truck condition) is necessary.
It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the
tire size or type is changed according to the “Tire Data List”.
Matching Items and Prerequisite for Implementation
1. DRIVE
Prerequisite for im-
No. Indication Description
plementation
Accelerator sensor output value with fully released ac-
1 ACCEL OFF *1, *2
celerator position to the controller.
Accelerator sensor output value with fully stepped accel-
2 ACCEL ON *1, *2
erator position to the controller.
Brake sensor output value with fully released brake posi-
3 BRAKE OFF *1, *16
tion to the controller.
Brake sensor output value at the start point of wet-brake
4 BRAKE ACT *1, *16
activation to the controller.
2. PSS
plementation
Tilt angle sensor output value with the forks in the hori- *1, *3, *4, *7, *8, *9,
1 TILT LEVEL
zontal position to the controller. *17
Tilt angle sensor output value at the mast vertical posi-
*1, *3, *4, *5, *7, *8,
2 TILT FWD LIMIT tion and the load sensor output value without load to the
*9
controller.
Tire angle sensor output value while the lift truck is trav-
3 TIRE POSITION *1, *6, *17
eling straight to the controller.
4 MAST TYPE The mast type is stored *8, *14, *17
4-144 4 DISPLAY
3. LEVER
plementation
Lift lever angle sensor output value in the lift lever neut-
1 LEVER 1 *1, *10, *17
ral position is stored in the controller.
Tilt lever angle sensor output value in the tilt lever neut-
2 LEVER 2 *1, *11, *17
Attachment (1) lever angle sensor output value in the at-
3 LEVER 3 tachment (1) lever neutral position is stored in the con- *1, *12, *17
troller.
4 LEVER 4 tachment (2) lever neutral position is stored in the con- *1, *13, *17
troller.
4. TIRE DATA
plementation
1 TIRE DATA The tire data according to the tire size is stored. *1, *15
Prerequisite content for implementation
*1: When replacing main controller
*2: When removing/installing or replacing accelerator sensor
*3: When removing/installing or replacing tilt angle sensor
*4: When length change or replacement of tilt angle sensor rod
*5: When removing/installing or replacing load sensor
*6: When removing/installing or replacing tire angle sensor or sensor cover
*7: When installing or changing attachment or fork
*8: When removing/installing or replacing mast
*9: When removing/installing or replacing tilt cylinder
*10: When replacing lift lever angle sensor
*11: When replacing tilt lever angle sensor
*12: When replacing attachment (1) lever angle sensor
*13: When replacing attachment (2) lever angle sensor
*14: When replacing multi-function display
*15: When the tire size or type is changed
*16: When removing/installing or replacing brake sensor
*17: When replacing oil control valve.
4 DISPLAY 4-145
MATCHING MENU Screen

Operating Procedure
PASSWORD section) to display the service function 4

press the switch (3) and select the [MAT] tab.
(3)
“1. DRIVE”
Switch (1): Switching selection to next item.
Switch (3): To OTHERS MENU
Switch (4): To MATCHING DRIVE screen
“2. PSS”
NOTICE! PSS and SAS are interchangeable terms
Switch (4): To MATCHING PSS screen
“3. LEVER”
Switch (4): To MATCHING LEVER screen
“4. OCV”
Switch (4): To MATCHING OCV screen
“5. TIRE DATA”
Switch (4): To TIRE DATA screen
DRIVE (MATCHING DRIVE)

Matching is performed for traveling function.
Operating Procedure
4-146 4 DISPLAY
1. Display the MATCHING MENU screen.

NOTICE! PSS and SAS are interchangeable terms.
2. Check that “1.DRIVE” is selected on the screen,

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

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

Memorize accelerator sensor signals with the pedal
fully released.
Values in the bracket ( ) are currently stored values.
Values outside the bracket ( ) are current lift truck
condition values.
Switch (1): Pressing this for more than 2 seconds will
perform matching.
Switch (4): To “ACCEL ON” screen
If matching is performed, “OK” is indicated on the dis-
play.
Lift truck condition
▪ All parts related to the accelerator pedal should
be formally mounted.
▪ The accelerator pedal should be fully released.
4 DISPLAY 4-147
“ACCEL ON” Screen

Memorize accelerator sensor signals with the pedal
fully stepped on.
Values outside the bracket ( ) are current lift truck 4
condition values.
perform matching.
Switch (4): To “BRAKE OFF” screen
play.
▪ All parts related to the accelerator pedal should
be formally mounted.
▪ The accelerator pedal should be fully stepped on.
“BRAKE OFF” Screen
Memorize brake sensor signals with the pedal fully
released.
condition values.
perform matching.
Switch (4): To “BRAKE ACT” screen
play.
▪ All parts related to the brake pedal should be
formally mounted and adjusted.
Moreover, the parking brake should be in the re-
leased (not applied) position.
▪ The brake pedal should be fully released.
“BRAKE ACT” Screen
Memorize brake sensor signals at the start point of
the wet-brake activation.
condition values.
perform matching.
Switch (4): To MATCHING MENU screen
play.
4-148 4 DISPLAY

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

Matching is performed for PSS function.
Operating Procedure
1. Display the MATCHING MENU screen and press
switch (1), select the “2. PSS (SAS)”.
2. Press switch (4) to display “TILT LEVEL” screen.

matching set screen of "PSS" to other matching
NOTICE! In standard lift truck condition, if the
(4) value in the bracket ( ) and the value outside the
bracket ( ) are different, matching is required.
`
4 DISPLAY 4-149
“TILT LEVEL” Screen

condition values.
Switch (1): Pressing this for more than 2 seconds will 4
perform matching.
Switch (4): To “TILT FWD LIMIT” screen
play.
TT/QM Lift truck condition

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

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

Values outside the bracket ( ) are the current lift truck
condition values.
perform matching.
Switch (4): To “TIRE POSITION” screen
play.
4-150 4 DISPLAY
TT/QM Lift truck condition

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

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

condition values.
perform matching.
Switch (4): To “MAST TYPE” screen
play.
ment, including forks or attachments, and moun-
ted as specified.
However, it is acceptable to do this procedure in
a condition of no forks, but only for the fork-less
specification.
▪ Lift truck should be with no load, and on the level
ground.
▪ Forks or attachments should be lowered as low
as possible so that the lift truck direction can be
checked easily.
▪ The mast should be approximately vertical to the
ground. (The visual observation is acceptable.)
▪ The tire angle should be adjusted to the straight
position.
4 DISPLAY 4-151
“MAST TYPE” Screen

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

Matching is performed for material handling lever.
Operating Procedure
the switch (1). Select the “3. LEVER”.
2. Press switch (4) to display the “LEVER1” screen.

matching set screen of "LEVER" to other matching
(4)
4-152 4 DISPLAY
“LEVER1” Screen
condition values.
perform matching.
Switch (4): To “LEVER2” screen
play.
After matching is performed, operate the lever to
push side and pull side at full position.
▪ Inputting data for the oil control valve into the
main controller should be completed.
▪ All the material handling levers should be in the
neutral positions.
“LEVER2” Screen
condition values.
perform matching.
play.
▪ All the material handling levers should be in the
neutral positions.
“LEVER3” Screen
condition values.
perform matching.
play.
▪ All the material handling levers should be at the
nuetral positions.
NOTICE! : “Lever3” screen will be displayed ac-
cording to the number of ways being set.
4 DISPLAY 4-153
“LEVER4” Screen
condition values.
Switch (1): Pressing this for more than 2 seconds will 4
perform matching.
Switch (4): To MATCHING MENU screen
play.
▪ All the material handling levers should be at the
neutral positions.
NOTICE! : “Lever4” screen will be displayed ac-
cording to the number of ways being set.
TIRE DATA
Used to set the tire data.
The tire data is set according to the type of mounted tires before shipment from the factory. However, if the
type or size of drive tire is changed, the tire data should be set again according to the “Tire Data List”.
Operating Procedure
switch (1), select the “5. TIRE DATA”.
2. Press switch (4) to display the “TIRE DATA”

screen.
(4)
4-154 4 DISPLAY
“TIRE DATA” Screen

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

Applicable model Tire size Tire type Tire data
Cushion 245
Smooth
All models 18X7X12.1/8 Cushion non-marking 246
Lug Cushion non-marking 248
4 DISPLAY 4-155
4.3.7 OTHERS MENU
NOTICE
4
After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be dis-
played on the “OTHERS MENU”.
Before hour meter start After hour meter start
Operating Procedure
4-156 4 DISPLAY

press switch (3) and select the [etc.] tab.
(2) (3)
“1. METER START”

Switch (4): To “METER START” screen
“2. DEMO MODE”
Switch (4): To “DEMO MODE” screen
“3. TO DEFAULT SET”
Switch (4): To “TO DEFAULT SET” screen
“4. MASK PASSWORD”
Switch (4): To “MASK PASSWORD” screen
“5. MANAGER PASS CLR”
Switch (4): To “MANAGER PASS CLR” screen
“6. CONTRAST”
Switch (4): To “CONTRAST” screen
HOUR METER START (METER START)

This menu item is used to make the following meters start counting: hour meters, odometer, trip meter and
maintenance hour meter.
With this menu option, you can also enable the following functions or operations regardless of whether the
demo mode is enabled or disabled.
▪ Enables the material handling operation during traveling.
▪ Enables the parking brake reminder function.
▪ Enables all functions of the PIN code entry system (option).
4 DISPLAY 4-157
NOTICE
• This option does not clear the PIN code authentication data that was set when the demo mode
was enabled.
4
• Once the hour meter has started, it cannot be returned to the state where it was before it started.
Operating Procedure
PASSWORD section ) to display the service function

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

screen, and press switch (4) to display the “METER
START” screen.
NOTICE! :
▪ After completing the hour meter start setting,
“METER START” and “DEMO MODE” will not
be displayed on the “OTHERS MENU”.
▪ Pay attention so H mode lock is maintained as
the former state of hour meter start.
The hour meter start screen always displays
the H mode lock condition.
4-158 4 DISPLAY
“METER START” screen

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

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

screen.
4 DISPLAY 4-159
Hour meter NOTICE! : On completion of the hour meter start

Key ON hour meter before the start operation, the hourglass icon on the key ON hour
meter blinks to indicate that the hour meter has
started to count up.
4
Key ON hour meter after the start
DEMO MODE
This menu item is used to enable or disable the demo mode.
Before starting the hour meter, you can enable the following functions temporarily in the demo mode.
Demo mode Yes (enabled) No (disabled)
Material handling during traveling Allowed Not allowed
Parking brake OFF warning Enabled Disabled
Authentication pos-
Authentication pos-
sible only for re-
Authentication function sible by simply press-
gistered authentica-
ing the log-in switch
PIN code entry system (OPT) tion numbers
Registration, change or de-
letion of authentication Enabled Disabled
number
NOTICE
• Even after the demo mode has been disabled, the data recorded and the settings made during the
demo mode are all retained.
• After the start of the hour meter, no settings can be made in the demo mode.
4-160 4 DISPLAY
Operating Procedure

press the switch (3) and select the [etc.] tab.
(3)
3. Press switch (1) to check that “2. DEMO MODE” is

selected.
4. Press switch (4) to display the “DEMO MODE”
screen.
NOTICE!
▪ After the hour meter start operation com-
pletes, “METER START” and “DEMO MODE”
items of other service function menus will not
be displayed.
▪ When “YES” is selected, H mode lock be-
comes NO automatically. The demo mode
screen always displays the H mode lock con-
dition.
▪ When demo mode is changed from “YES” to
“NO”, H mode lock becomes YES automatic-
ally.
“DEMO MODE” screen
Switch (2): Setting from YES
Switch (3): Setting from NO
Switch (4): Return to OTHERS MENU screen
4 DISPLAY 4-161
NOTICE! : During demo mode, “DEMO” is dis-

Display in the key ON hour meter played in the key on hour meter screen.
screen during demo mode
TO DEFAULT SET
This menu item is used to initialize the tuning values or the settings of items with default values.
Setting items applied:
▪ Menu lock setting
▪ Power select function (LPH)
▪ Travel power control level setting, material handling power control level setting
▪ Low speed setting
▪ Maximum speed limitation setting
▪ Overspeed alarm setting
▪ Tuning level
▪ Auto power OFF time
NOTICE
This does not apply to data dependent on each individual lift truck, such as Option Set data, various
matching data, load meter setting data and tire constant data.
Operating Procedure
4-162 4 DISPLAY

(3)
Before hour meter start

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

Default set procedure
1. Press switch (2) and select “YES”.
4 DISPLAY 4-163
2. To initialize the settings, press and hold down

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

This menu item is used to set or clear a service second password.
You can enter any four-digit number as a service second password, using the 4 switches on the multi-func-
tion display.
If you set a service second password, you will be prompted to enter the second password after you enter the
ordinary password necessary to display the SERVICE FUNCTION screen. You can move to the SERVICE
FUNCTION screen only when the passwords you entered coincide with the registered passwords.
No service second password has been set by default.
NOTICE
• Set the service second password only if it is necessary.
• When the service second password is missing, it is necessary to replace the multi-function dis-
play.
• The distributor or dealer must manage the service second password organizationally to avoid
losing the service second password and making the service functions unusable.
• Clear the service second password when the lift truck is out of your service such as lift truck re-
sale.
Operating Procedure
PASSWORDpage 97) to display the service function.
After 5 seconds, the ANALYZER MENU screen is
automatically displayed.
4-164 4 DISPLAY

(3)

3. Press switch (1) to check that “4. MASK PASS-
WORD” is selected.
4. Press switch (4) to display the “MASK PASS-
WORD” screen.
3. Press switch (1), to check that “2. MASK PASS-
WORD” is selected.
4. Press switch (4) to display the “MASK PASS-
After hour meter start WORD” screen.
4 DISPLAY 4-165
“MASK PASSWORD” Screen

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

If you press and hold down switch (1) for more than 2
seconds without entering any digit on the “MASK
PASSWORD” screen, the registered password is de-
leted and “OK” appears on the completion of its dele-
tion.
NOTICE! : The service second password can be
cleared only when no digit has been entered
(when every box is [ ■ ]).
4-166 4 DISPLAY
ADMINISTRATOR'S SECOND PASSWORD CLEAR (MANAGER PASS CLR)

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

(3)

3. Press switch (1) to check that “5. MANAGER
PASS CLR” is selected.
4. Press switch (4) to display “MANAGER PASS
CLR” screen.
3. Press switch (1), to check that “3. MANAGER
PASS CLR” is selected.
4. Press switch (4) to display the “MANAGER PASS
After hour meter start CLR” screen.
4 DISPLAY 4-167
“MANAGER PASS CLR” Screen

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

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

(3)
4-168 4 DISPLAY

3. Press switch (1) to check that “6. CONTRAST” is
selected.
4. Press switch (4) to display the “CONTRAST”
screen.
3. Press switch (1), to check that “4. CONTRAST” is
selected.
4. Press switch (4) to display the “CONTRAST”
After hour meter start screen.
“CONTRAST” Screen
Switch (2): Contrast level down
Switch (3): Contrast level up
Switch (4): Returns to OTHERS MENU screen
4 DISPLAY 4-169
4.4 MULTI-FUNCTION DISPLAY ASSY

4
a
3
a: T = 0.7 to 0.8 ft-lbf. [0.9 to 1.1 N·m]

Removal Procedure
1. Remove the battery plug.
2. Remove the instrument panel RH.
3. Remove the display from the instrument panel RH.
4-170 4 DISPLAY
2
a
a: T = 0.5 to 0.6 ft-lbf. [0.6 to 0.8 N·m]

2. Remove the circuit plate.
3. Remove the display ASSY.
4. Remove the switch plate.
5 TROUBLESHOOTING 5-171
5 TROUBLESHOOTING
5.1 BEFORE TROUBLESHOOTING........................................................... 171
5.2 SST........................................................................................................ 173 5
5.3 DIAGNOSIS CODE LIST....................................................................... 174
5.4 WHEN ERROR CODE IS DISPLAYED................................................. 182
5.5 WHEN NO ERROR CODE IS DISPLAYED .......................................... 672
5.1 BEFORE TROUBLESHOOTING
5.1.1 CONNECTOR HANDLING

1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at
the harness but hold the connector itself and pull it
after unlocking it.
To connect, push the connector fully until it is locked
in position.
3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness
side).
4. If insertion from the rear side is impossible, as in
the case of a waterproof connector, bring the tester
probe carefully into contact with the terminal so as
not to cause deformation of the connector terminal.
5. Do not touch connector terminals directly with your
hand.
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.
5-172 5 TROUBLESHOOTING
5.1.2 WIRE HARNESS AND CONNECTOR INSPECTION

PROCEDURE
When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the
following procedure:
Continuity check
1. Disconnect the connectors at both ends of the cor-
responding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Standard: 10 Ω or less
NOTICE!
▪ Measure while lightly shaking the wire har-
ness up and down and sideways.
▪ Open circuit at the wire harness occurs rarely
partway through a lift truck wiring but mostly
at connectors. Inspect especially the sensor
connectors with sufficient care.
Short circuit check

1. Disconnect the connectors at both ends of the cor-
responding harness.
2. Measure the resistance between the correspond-
ing connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or above
NOTICE! : Measure while lightly shaking the wire
harness up and down and sideways.
3. Measure the resistance between a terminal corres-

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

▪ Disconnect the connectors at both ends of the
corresponding harness.
▪ Visually inspect that there is neither rust nor for-
eign matter trapped at connector terminals.
5
▪ Inspect that there is no loosening or damage at
the locked portion. Also, lightly pull the wire har-
ness from the connector to check that it does not
come off.
▪ Insert a male terminal same as that of the ter-

minal to a female connector and check the ex-
tracting force. Defective contact may exist at a
terminal where the extracting force is less than
that of other terminals.
NOTICE! : Even if there is rust or foreign matter
trapped at the terminal, or the contact pressure
between male and female terminals is low, abnor-
mal contact condition may be changed to normal
by disconnecting and reconnecting the connector.
In that case, repeat connector connection and dis-
connection several times. If defect is perceived
even once, terminal contact may be defective.
5.2 SST
Use SSTs for quick, accurate troubleshooting of the 4460 series electrical system.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect con-
nection, careful operation is necessary.
SST No. SST name
Shorting harness
979-001/160 (SST)
(for CN91 connector)
Shorting harness
(for CN6, CN19,
CN26,CN52,CN53,CN54, CN55,
CN56, CN86, CN97, CN101, CN102,
979-001/161 (SST2)
CN115, CN119, CN120, CN121,
CN122,CN123, CN126, CN129,
CN130, CN138 and CN163 connect-
ors)
CAUTION
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is
kept connected, various boards may be damaged.
5.3 DIAGNOSIS CODE LIST

Indica- Diagnosis code will be indicated on the display when lift truck error occurs.
tion:
Memory: Use this indicated diagnosis code that can be checked on the display when using the service
function DIAG MEMORY.
Indicator:
Spanner
Overheat warning (O/H)
Indica- Detection
Memory Indicator Error mode Page
tion ECU
Drive motor
Drive motor driver power-circuit ab-
DCR A001 O/H lighting driver (LH) page 183
normality
(RH)
Pump motor Pump motor driver power-circuit ab-
PCR A002 O/H lighting page 187
driver normality
A101 A101 Spanner blinking Main controller Main controller high voltage page 191
Drive motor
A102 A102 Spanner blinking Drive motor driver LH high voltage page 193
driver (LH)
Drive motor
A103 A103 Spanner blinking Drive motor driver RH high voltage page 195
driver (RH)
Pump motor
A104 A104 Spanner blinking Pump motor driver high voltage page 197
driver
Main controller overheating abnor-
C/R A201 O/H lighting Main controller page 199
mality
Drive motor
Drive motor driver circuit board / the
DCR A202 O/H lighting driver (LH) page 201
condenser overheating abnormality.
(RH)
Pump motor Pump motor driver circuit board / the
PCR A203 O/H lighting page 206
driver condenser overheating abnormality
A301 A301 Spanner blinking Main controller Battery connection incorrect page 211
A501 A501 Spanner blinking Main controller Seat switch short abnormality page 212
A603 A603 Spanner blinking Main controller Tilt lever switch short abnormality page 214
A801 A801 Spanner blinking Main controller F1 fuse open abnormality page 216
A802 A802 Spanner blinking Main controller F6 fuse open abnormality page 219
F7 fuse / solenoid power supply line
A902 A902 Spanner blinking Main controller page 223
open abnormality
Main controller temperature sensor
AA01 AA01 Spanner blinking Main controller page 225
(open/short) abnormality
Drive motor driver LH board temper-
Drive motor
AA02 AA02 Spanner blinking ature sensor (open/short) abnormal- page 226
driver (LH)
ity
Drive motor driver RH board temper-
Drive motor
AA03 AA03 Spanner blinking ature sensor (open/short) abnormal- page 227
driver (RH)
ity
Pump motor Pump motor driver board temperat-
AA04 AA04 Spanner blinking page 228
driver ure sensor (open/short) abnormality
AB01 AB01 Spanner blinking Main controller Cooling fan overcurrent page 229
Motor driver power delivery abnor-
AC01 AC01 Spanner blinking Main controller page 233
mality
Drive motor driver LH to Main con-
AD01 AD01 Spanner blinking Main controller page 236
troller : communication abnormality
Indica- Detection
tion ECU
Drive motor driver LH to Main con-
Drive motor driver RH to Main con-
troller : communication abnormality 5
Drive motor driver RH to Main con-
Pump motor driver to Main control-
ler : communication abnormality
Pump motor driver to Main control-
ler : communication abnormality
AF01 AF01 Spanner blinking Main controller Main controller CPU error page 255
Drive motor Drive motor driver LH power-circuit
C002 C002 Spanner blinking page 263
driver (LH) abnormality
Drive motor Drive motor driver RH power-circuit
C004 C004 Spanner blinking page 266/p>
driver (RH) abnormality
Drive motor Drive motor driver LH current sensor
driver (LH) neutral voltage error
Drive motor Drive motor driver LH current sensor
driver (LH) over current abnormality
Drive motor Drive motor driver RH current sensor
driver (RH) neutral voltage error
Drive motor Drive motor driver RH current sensor
driver (RH) over current abnormality
Drive motor
DM C201 O/H lighting driver (LH) Drive motor overheating abnormality page 277
(RH)
Drive motor Drive motor LH temperature sensor
driver (LH) (open/short) abnormality
Drive motor Drive motor RH temperature sensor
driver (RH) (open/short) abnormality
Drive motor driver LH power-circuit
Drive motor
C301 C301 Spanner blinking temperature sensor (open/short) ab- page 285
driver (LH)
normality
Drive motor driver RH power-circuit
Drive motor
C302 C302 Spanner blinking temperature sensor (open/short) ab- page 286
driver (RH)
normality
Accelerator potentiometer POT1
C401 C401 Spanner blinking Main controller page 287
open abnormality
Accelerator potentiometer POT2
open abnormality
Accelerator potentiometer POT1VCC
short circuit abnormality
Indica- Detection
tion ECU
Accelerator potentiometer POT2VCC
short circuit abnormality
Accelerator potentiometer offset ab-
normality
Accelerator potentiometer matching
value abnormality
Brake potentiometer POT1 open ab-
normality
Brake potentiometer POT2 open ab-
normality
Brake potentiometer POT1VCC short
circuit abnormality
Brake potentiometer POT2VCC short
circuit abnormality
Brake potentiometer matching value
abnormality
Brake potentiometer matching value
error.
Drive motor Drive motor LH rotation sensor open
Drive motor Drive motor LH rotation sensor short
Drive motor Drive motor RH rotation sensor open
Drive motor Drive motor RH rotation sensor short
CB01 CB01 Spanner blinking Main controller MB contactor open abnormality page 337
CB02 CB02 Spanner blinking Main controller MB contactor short abnormality page 341
MB contactor (coil side) open abnor-
CB03 CB03 Spanner blinking Main controller page 343
mality
MB contactor traveling circuit abnor-
mality
MB contactor (coil side) short abnor-
mality
Drive motor Drive motor driver LH CPU abnor-
CC01 CC01 Spanner blinking page 352
driver (LH) mality
driver (LH) mality
driver (LH) mality
driver (LH) mality
driver (LH) mality
Drive motor Drive motor driver RH CPU abnor-
CD01 CD01 Spanner blinking page 357
driver (RH) mality
driver (RH) mality
driver (RH) mality
Indica- Detection
tion ECU
driver (RH) mality
driver (RH) mality 5
Pump motor Pump motor driver power-circuit ab-
E002 E002 Spanner blinking page 362
driver normality
Pump motor Pump motor driver current sensor
driver neutral voltage error
Pump motor Pump motor driver current sensor
driver over current error
Pump motor
PM E201 O/H lighting Pump motor overheating abnormality page 369
driver
Pump motor Pump motor temperature sensor
driver (open/short) abnormality
Pump motor driver power-circuit tem-
Pump motor
E301 E301 Spanner blinking perature sensor (open/short) abnor- page 376
driver
mality
Pump motor Pump motor rotation sensor open
driver abnormality
Pump motor Pump motor rotation sensor short
driver abnormality
Pump motor
EC01 EC01 Spanner blinking Pump motor driver CPU abnormality page 383
driver
Pump motor
driver
Pump motor
driver
Pump motor
driver
Pump motor
driver
Communication line abnormality :
EE01 EE01 Spanner blinking Main controller page 388
Display to main controller
Communication line abnormality :
EE02 EE02 Spanner blinking Main controller page 389
Display to main controller
Communication line abnormality
F101 F101 Spanner blinking Display page 390
between main controller and display
Communication line abnormality
F102 F102 Spanner blinking Display page 391
between main controller and display
F401 F401 Spanner blinking Display Display CPU defect page 394
Battery current sensor neutral
FB01 FB01 Spanner blinking Main controller page 402
voltage error
FB02 FB02 Spanner blinking Main controller Battery current sensor overcurrent page 405
Indica- Detection
tion ECU
Power supply circuit for display over
FF01 FF01 Spanner blinking Main controller page 408
current
Steering sensor power-supply circuit
FF02 FF02 Spanner blinking Main controller page 409
over current
Drive motor Drive motor driver (LH) : controller ID
3201 3201 Spanner blinking page 411
Drive motor Drive motor driver (RH) : controller
driver (RH) ID abnormality
Pump motor Pump motor driver : controller ID ab-
driver normality
Drive motor Main controller to Drive motor driver
driver (LH) (LH) : communication abnormality
Drive motor Main controller to Drive motor driver
driver (RH) (RH) : communication abnormality
Pump motor Main controller to Pump motor
driver driver : communication abnormality
6101 6101 Spanner blinking Main controller Load sensor open abnormality page 426
6102 6102 Spanner blinking Main controller Load sensor short abnormality page 428
6201 6201 Spanner blinking Main controller Tilt angle sensor open abnormality page 430
6202 6202 Spanner blinking Main controller Tilt angle sensor short abnormality page 432
Tilt switch forward / backward tilt
6301 6301 Spanner blinking Main controller switch simultaneously short abnor- page 434
mality
Tilt switch forward tilt switch continu-
6302 6302 Spanner blinking Main controller page 436
ously short abnormality
Tilt switch backward tilt switch con-
tinuously short abnormality
6401 6401 Spanner blinking Main controller Lift lock solenoid open abnormality page 440
6402 6402 Spanner blinking Main controller Lift lock solenoid short abnormality page 443
Lift lock solenoid drive circuit abnor-
mality
Lift lock solenoid (open / short) ab-
normality
6501 6501 Spanner blinking Main controller Tilt solenoid open abnormality page 452
6502 6502 Spanner blinking Main controller Tilt solenoid short abnormality page 456
Tilt solenoid: traveling circuit abnor-
mality
Tilt solenoid (open / short) abnormal-
ity
Outside matching value range for tilt
angle error
Lifting height switch open / short ab-
normality
Backward lock solenoid open abnor-
mality
Backward lock solenoid short abnor-
mality
Backward lock solenoid drive circuit
abnormality
Indica- Detection
tion ECU
Backward lock solenoid (open /
short) abnormality
7101 7101 Spanner blinking Main controller Tire angle sensor open abnormality page 483
7102 7102 Spanner blinking Main controller Tire angle sensor short abnormality page 485 5
Tire angle sensor anchoring abnor-
mality
Tire angle sensor anchoring abnor-
mality
Steering-wheel angle sensor SS2
open abnormality
Steering-wheel angle sensor SSC
open abnormality
Steering-wheel angle sensor : sensor
power source open abnormality
Steering knob position synchronizer
solenoid open abnormality
solenoid short abnormality
solenoid power-circuit abnormality
solenoid (open / short) abnormality
Tire angle matching : matching value
abnormality
Lift lever potentiometer open abnor-
H101 H101 Spanner blinking Main controller page 522
mality
Lift lever potentiometer short abnor-
mality
Lift lever potentiometer : sensor out-
put declination abnormality
Lift lever potentiometer neutral ab-
normality CAUTION
Lift lever potentiometer matching
value abnormality
Tilt lever potentiometer open abnor-
mality
Tilt lever potentiometer short abnor-
mality
Tilt lever potentiometer : sensor out-
put declination abnormality
Tilt lever potentiometer neutral error
abnormality
Tilt lever potentiometer matching
value abnormality
Attachment 1 lever potentiometer
open abnormality
short abnormality
Attachment 1 lever potentiometer :
H303 H303 Spanner blinking Main controller sensor output declination abnormal- page 549
ity
Indica- Detection
tion ECU
neutral abnormality
matching value abnormality
open abnormality
short abnormality
Attachment 2 lever potentiometer :
H403 H403 Spanner blinking Main controller sensor output declination abnormal- page 560
ity
neutral abnormality
matching value abnormality
Lift proportional valve solenoid open
abnormality (lever pull side)
Lift proportional valve solenoid short
Lift proportional valve solenoid open
abnormality (lever push side)
Lift proportional valve solenoid short
Lift proportional valve solenoid drive
H505 H505 Spanner blinking Main controller /page 579
circuit abnormality
Lift proportional valve solenoid
(open / short) abnormality
Tilt proportional valve solenoid open
Tilt proportional valve solenoid short
Tilt proportional valve solenoid open
Tilt proportional valve solenoid short
Tilt proportional valve solenoid drive
circuit abnormality
Tilt proportional valve solenoid
(open / short) abnormality
Attachment 1 proportional valve
H701 H701 Spanner blinking Main controller solenoid open abnormality (lever pull page 606
side)
H702 H702 Spanner blinking Main controller solenoid short abnormality (lever pull page 609
side)
H703 H703 Spanner blinking Main controller solenoid open abnormality (lever page 612
push side)
H704 H704 Spanner blinking Main controller solenoid short abnormality (lever page 615
push side)
Indica- Detection
tion ECU
H705 H705 Spanner blinking Main controller solenoid : traveling circuit abnormal- page 618
ity
H706 H706 Spanner blinking Main controller

page 622 5
H801 H801 Spanner blinking Main controller solenoid open abnormality (lever pull page 627
side)
H802 H802 Spanner blinking Main controller solenoid short abnormality (lever pull page 630
side)
H803 H803 Spanner blinking Main controller solenoid open abnormality (lever page 633
push side)
H804 H804 Spanner blinking Main controller solenoid short abnormality (lever page 636
push side)
H805 H805 Spanner blinking Main controller solenoid : traveling circuit abnormal- page 639
ity
Proportional valve solenoid power
HB01 HB01 Spanner blinking Main controller supply : RY1 contact open abnormal- page 648
ity
Tilt proportional valve solenoid load-
HB02 HB02 Spanner blinking Main controller page 651
short abnormality
Proportional valve solenoid power
HB03 HB03 Spanner blinking Main controller supply : RY1 over current abnormal- page 654
ity
HC01 HC01 Spanner blinking Main controller Unload solenoid open abnormality page 657
HC02 HC02 Spanner blinking Main controller Unload solenoid short abnormality page 661
Unload solenoid drive circuit abnor-
HC03 HC03 Spanner blinking Main controller page 665
mality
Unload solenoid (open / short) ab-
HC04 HC04 Spanner blinking Main controller page 667
normality
Drive motor
COLD
- O/H lighting * driver (LH) Drive motor driver low temperature
DCR
(RH)
COLD Pump motor
- O/H lighting * Pump motor driver low temperature
PCR driver
*: Multi-function display shows only the each portion and doesn't indicate O/H light.
5.4 WHEN ERROR CODE IS DISPLAYED

Error Code: A001

Failure mode: Drive motor driver power-circuit abnormality
CAUTION 5
• If AB01 occurs at the same time, perform troubleshooting for AB01 first.
• Disconnect the battery plug and check if the power cable or motor cables are loose.
• Do not leave the lift truck standing in a hot place.
Probable cause
▪ The power cable or a motor cable is loose
▪ Connector contact defect
▪ Harness defect
▪ Cooling fan clogging
▪ Cooling fan defect
▪ Overheating (continuous overload operation)
▪ Drive motor driver LH defect
▪ Drive motor driver RH defect
▪ Main controller defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller CN250-27 CN250-28
F52 CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Drive motor driver LH Drive motor driver RH
Temperature sensor Temperature sensor
STEP1
Apply the cooling fan compulsorily by using Active Test and
check the rotary condition.
[ANL] ACTIVE TEST 2/3

FAN1：OFF → ON
Judgment
Result Procedure
Not running Go to step 5
Running Go to step 2
STEP2
Inspection :
Reconfirm the error.
Turn on the key switch and check that error occurs.
Judgment
Result Procedure
"DCR" occurs. Go to step 3
Overheating (continuous overload operation)
When the temperature of the drive motor driver drops, “DCR”
"DCR" does not occur. goes away and the lift truck can be operated as usual. Con-
tinuously running the lift truck in an overloaded condition will
cause this error. Limit running the lift truck in an overloaded
condition.
STEP3
Inspection :
Check the temperature and reconfirm the error.
･Drive motor driver power-circuit temperature LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDMDH
Record the temperature of the drive motor driver power-circuit.
Turn off the key switch and leave the lift truck for approximately
fifteen minutes. Then turn on the key switch and check that the
error occurs.
Judgment
Result Procedure
condition.
STEP4
Inspection :
Reconfirm the temperature
･Drive motor driver power-circuit temperature LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDMDH
5
Check the drive motor driver power-circuit temperature and
compare it to the recorded value.
Judgment
Result Procedure
All temperatures have lowered by 41°F
Go to step 3
(5°C) or more.
Drive motor power-circuit board temperat-
ure LH has not lowered by 41°F (5°C) or Drive motor driver LH defect
more.
Drive motor power-circuit board temperat-
ure RH has not lowered by 41°F (5°C) or Drive motor driver RH defect
more.
STEP5
Turn off the key switch and disconnect the battery plug.
Check the inside of connector CN112, 113 and the crimped por-
tion of the wire to see whether it has a defect or not by visual
confirmation. (Refer to BEFORE TROUBLESHOOTING)
After connecting the connector, connect the battery plug and
turn on the key switch. Then apply the cooling fan compulsorily
by using Active Test and check the rotary condition.

FAN1：OFF → ON
Judgment
Result Procedure
Running Connector contact defect
STEP6
Inspection : Harness
Disconnect the CN102, CN104, CN112 and CN113 connectors
and check the harnesses.
CN102
[Inspection procedure and standard]
Inspect for continuity and short circuiting of the harness.
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2 Perform this check with the battery plug and the CN102,
28 29 30 31 32 33 34 35 CN104, CN112 and CN113 connectors disconnected, and visu-
ally check inside the connector and the crimped portion of its
CN104 wire for defects.
1 2 3 4 5 6 7
CN113 Refer to BEFORE TROUBLESHOOTING
8 9 10 11 12 13 14 15 16 17 1 2 Portion to be inspected Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-1 to CN112-2 Continuity
CN102-1 to CN113-2 Continuity
CN102-1 to CN104-3 No continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7
Inspection : Cooling fan
Disconnect the battery plug, then connect the CN102, CN104,

CN112 and CN113 connectors. Reconnect the battery plug and
turn on the key switch.

FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect
Not running After replacing the cooling fan, if the fan is not running by ap-
plying the cooling fan compulsorily by using Active Test, it is
possible there is another defect. Replace the main controller.
Error Code: A002

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

CN104-3 (1, CBAT+) CN113-1
F52 CN112-2
Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Pump motor driver
Temperature sensor
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
STEP2
Inspection :
Reconfirm the error
Turn on the key switch and check the error occurs.
Judgment
Result Procedure
"PCR" occurs. Go to step 3
When the temperature of the drive motor driver drops, “PCR”
"PCR" does not occur. goes away and the lift truck can be operated as usual. Con-
condition.
STEP3
Inspection :
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Record the temperature of the pump motor driver power-circuit.
fifteen minutes. Then turn on the key switch and check that the
error occurs.
Judgment
Result Procedure
condition.
STEP4
Inspection :
Reconfirm the temperature
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Check the pump motor driver power-circuit temperature and

compare to the recorded value.
5
Judgment
Result Procedure
It has lowered by 41°F (5°C) or more. Go to step 3
It has not lowered by 41°F (5°C) or more. Pump motor driver defect
STEP5
Check the inside of connector CN112,113 and the crimped por-
tion of the wire whether it has a defect or not by visual confirma-
tion. (Refer to BEFORE TROUBLESHOOTING)

FAN1：OFF → ON
Judgment
Result Procedure
STEP6
CN102
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35 CN104, CN112 and CN113 connectors disconnected, and visu-
CN104 wire for defects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 Measurement terminals Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-1 to CN112-2 Continuity
Measurement terminals Standard:

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


FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect
Not running After replacing the cooling fan, if the fan is not running by ap-
plying the cooling fan compulsorily by using Active Test, it is
possible there is another defect. Replace the main controller.
Error Code: A101

Failure mode: Main controller high voltage
CAUTION 5
• If CB01,CB03 or CB05 occurs at same time as A101, perform troubleshooting for CB01,CB03 or
CB05 first.
Probable cause
▪ Battery defect
▪ Out of battery electrolyte
▪ Battery plug defect
▪ Battery overvoltage
▪ The battery plug was disconnected during traveling / load handling
Related portion
MB
P2 P3 CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
Main
controller
N1
STEP1
Turn off the key switch and disconnect the battery plug , then
leave for 2 minutes.
Reconnect the battery plug and turn on the key switch to con-
firm the error.
Judgment
Result Procedure
A101 error occurs. Go to step 3
A301 error occurs. Perform troubleshooting for A301.
A101, A301 error does not occur. Go to step 2
STEP2
Check if the battery plug was disconnected during traveling or
load handling.
Judgment
Result Procedure
Do not disconnect the battery plug during traveling or load
YES
handling.
NO Check the battery.
STEP3
Inspection : Battery voltage check
1. Turn the key switch OFF and disconnect the battery plug.
2. Measure the voltage between both ends of the battery plug
with a circuit tester.
Judgment
Result Procedure
64V or more Check the battery.
Less than 64V Main controller defect.
Error Code: A102

Failure mode: Drive motor driver LH high voltage
CAUTION 5
• If CB01, CB03, or CB05 occurs at same time as A102, perform troubleshooting for CB01, CB03, or
CB05 first.
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver LH
STEP1
Turn off the key switch and disconnect the battery plug, then
firm the error.
Judgment
Result Procedure
STEP2
load handling.
Judgment
Result Procedure
YES
handling.
STEP3
Judgment
Result Procedure
Less than 64V Drive motor driver LH defect.
Error Code: A103

Failure mode: Drive motor driver RH high voltage
CAUTION 5
CB05 first.
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver RH
STEP1
Turn off the key switch and disconnect the battery plug, then
firm the error.
Judgment
Result Procedure
STEP2
load handling.
Judgment
Result Procedure
YES
handling.
STEP3
Judgment
Result Procedure
Less than 64V Drive motor driver RH defect.
Error Code: A104

Failure mode: Pump motor driver high voltage
CAUTION 5
CB05 first.
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Pump motor
driver
STEP1
Turn off the key switch and disconnect the battery plug , then
firm the error.
Judgment
Result Procedure
STEP2
load handling.
Judgment
Result Procedure
YES
handling.
STEP3
1. Turn the key switch OFF and
　disconnect the battery plug.
Judgment
Result Procedure
Less than 64V Pump motor driver defect.
Error Code: A201

Failure mode: Main controller overheating abnormality
CAUTION 5
Probable cause
▪ Temperature sensor defect (Main controller defect)
Related portion
Main controller
Temperature sensor
STEP1
Inspection :
Judgment
Result Procedure
"C/R" occurs. Go to step 2
When the temperature of the drive motor driver drops, “C/R”
"C/R" does not occur. goes away and the truck can be operated as usual. Continu-
ously running the lift truck in an overloaded condition will
condition.
STEP2
Inspection :
Check the main controller board temperature and reconfirm the
error.
[ANL] I/O TEMP/VOLT 4/6 TMCB

Record the main controller board temperature.
Turn off the key switch and leave the truck for approximately
thirty minutes. Then turn on the key switch and check that error
occurs.
Judgment
Result Procedure
"C/R" occurs. Go to step 3
When the temperature of the drive motor driver drops, “C/R”
"C/R" does not occur. goes away and the lift truck can be operated as usual. Con-
condition.
STEP3
Inspection :
Reconfirm the main controller board temperature.
[ANL] I/O TEMP/VOLT 4/6 TMCB
Check the main controller board temperature and compare it to

the recorded value.
Judgment
Result Procedure
It has lowered by 41°F (5°C) or more. Go to step 2
It has not lowered by 41°F (5°C) or more. Temperature sensor defect (Main controller defect).
Error Code: A202

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

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

(Circuit board) (Condenser) (Circuit board) (Condenser)
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
STEP2
Inspection :
Judgment
Result Procedure
condition.
STEP3
Inspection :
･Drive motor driver circuit board temperature LH/RH

･Drive motor driver condenser temperature LH/RH
[ANL] I/O TEMP/VOLT 2/6
TDMDB、TDMDC
Record the temperature of the drive motor driver circuit board

and drive motor driver condenser.
Turn off the key switch and leave the truck for approximately
thirty minutes. Then turn on the key switch and check that error
occurs.
Judgment
Result Procedure
condition.
STEP4
Inspection :
Reconfirm the temperature.
･Drive motor driver circuit board temperature LH/RH 5

･Drive motor driver condenser temperature LH/RH
TDMDB、TDMDC
Check the temperature of the drive motor driver circuit board

and drive motor driver condenser. Then compare to the recor-
ded value.
Judgment
Result Procedure
Go to step 3
(5°C) or more.
Either drive motor driver circuit board tem-
perature, (drive motor driver) condenser LH
Drive motor driver LH defect .
or both have lowered by 41°F (5°C) or
more.
Either drive motor driver circuit board tem-
perature, (drive motor driver) condenser RH
Drive motor driver RH defect .
or both have lowered by 41°F (5°C) or
more.
STEP5
Check the inside of connector CN112,113 and the crimped por-

FAN1：OFF → ON
Judgment
Result Procedure
Running Connector contact defect.
STEP6

CN102
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
28 29 30 31 32 33 34 35
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Perform this check with the battery plug and the CN102,
CN104, CN112 and CN113 connectors disconnected, and visu-
wire for defects.
Refer to BEFORE TROUBLESHOOTING
Portion to be inspected Standard:
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7


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

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

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

(Circuit board) (Condenser)
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
5
STEP2
Inspection :
Turn on the key switch and check the error occurs.
Judgment
Result Procedure
condition.
STEP3
Inspection :

TPMDB、TPMDC
Record the temperature of the pump motor driver circuit board

and pump motor driver condenser.
thirty minutes. Then turn on the key switch and check that the
error occurs.
Judgment
Result Procedure
condition.
STEP4
Inspection :
Reconfirm the temperature.

TPMDB、TPMDC
Check the temperature of the pump motor driver circuit board

and pump motor driver condenser. Then compare it to the re-
corded value.
Judgment
Result Procedure
Go to step 3
(5°C) or more.
Either the pump motor driver circuit board
temperature, (pump motor driver) con-
Pump motor driver defect.
denser or both have lowered by 41°F (5°C)
or more.
STEP5
Check the inside of connector CN112, 113 and the crimped por-

FAN1：OFF → ON
Judgment
Result Procedure
STEP6
CN102
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2 5
28 29 30 31 32 33 34 35
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

CN104, CN112 and CN113 connectors disconnected, and visu-
wire for defects.
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7


FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect.
main controller.
Error Code: A301

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

CN176-1 (41, SWE+) CN176-2 (41, SWE-)
P1 CN250-49 F5
CN250-50 (41) CN104-1 (41, B48V)
Main
controller
BATTERY Emergency switch Less
N1
STEP1
Reconnect the battery plug correctly and turn on the key switch.
Judgment
Result Procedure
Battery plug connector defect or battery plug not connected
A301 error does not occur.
correctly.
STEP2
1. Turn the key switch OFF and
　disconnect the battery plug.
Judgment
Result Procedure
Less than 64V Main controller defect.
Error Code: A501

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

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

[ANL] I/O M.HANDLING 1/8 SDM
Judgment 5
Result Procedure
"0" occurs. Seat switch defect.
"1" occurs. Go to step 3
STEP3
Disconnect the CN102, CN104 and CN44 connectors and
check the harnesses.
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN102, CN104
28 29 30 31 32 33 34 35 CN44 and CN44 connectors disconnected, and visually check inside
the connector and the crimped portion of its wire for defects.
1 2
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 CN102-10(51) to CN44-1(51) Continuity
26 27 28 29 30 31
CN104-18(67) to CN44-2(67) Continuity
CN44-1(51) to CN44-2(67) No continuity
Judgment
Result Procedure
NG Harness defect.
OK Main controller defect.
Error Code: A603

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

CN102-22 (62, VRT2) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2
STEP1
Connector contact inspection :
After disconnecting the CN89 connector, check the inside of the
connector and the crimped portion of the wire to see whether it
has a defect or not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
Connect the CN89 connector, connect the battery plug.
Turn on the key switch to see if an error occurs.
Judgment
Result Procedure
A603 error does not occur. Connector contact defect.
STEP2
Inspection : Tilt switch
Disconnect the CN89 connector. 5
Reconnect the battery plug and turn on the key switch.
Check if an error occurs.
Judgment
Result Procedure
Tilt lever switch defect.
A603 error does not occur.
Tilt lever switch installation defect.
STEP3
Disconnect the CN89 and CN102 connectors and check the

harnesses for continuity.
CN102
CN89
Perform this check with the battery plug and the CN89 and
1 2 3 4 5 6 7 CN102 connectors disconnected, and visually check inside the
1 2
8 9 10 11 12 13 14 15 16 17 18 19 connector and the crimped portion of its wire for defects.
20 21 22 23 24 25 26 27 3 4
28 29 30 31 32 33 34 35 Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect.
Error Code: A801

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

circuit (RH)
Pump motor drive

circuit
STEP1
Inspection of tightening the terminal :
Visually check each terminal for loose bolts (positive terminal,

negative terminal, P4 terminal and N1 terminal of each motor
driver).
Connect the battery plug and turn on the key switch to confirm
the error.
Judgment
Result Procedure
A801 error occurs. Go to step 2 5
A801 error does not occur. Tighten the loose terminal.
STEP2
Check the voltage of the power supply for the motor driver :
Connect the battery plug, and turn on the key switch, then
measure the voltage between the positive and negative termin-
als of the motor driver (LH)
Turn off the key switch, and disconnect the battery plug, then
visually check if there is any abnormality of the copper bar for
connecting positive terminal and negative terminal. (e.g. break,
crack and so on)
Judgment
Result Procedure
0V Go to step 3
[48V battery] : Approx. 48V, [36V battery] :
All motor driver defect.
Approx. 36V
STEP3
F1 fuse installation check :
Check the mounting of the F1 fuse to see if it has a defect or

not by visual confirmation.
the error.
Judgment
Result Procedure
A801 error does not occur. F1 fuse installation defect.
STEP4
Inspection : F1 fuse
After removing the F1 fuse, measure the resistance at both

ends of the fuse.
* : Motor driver defect

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

Failure mode: F6 fuse open abnormality
CAUTION 5
• If CB01, CB03 or CB05 occurs, perform troubleshooting with priority given to CB01, CB03 or CB05.
Probable cause
▪ F6 fuse defect
▪ F6 fuse box defect
▪ Harness defect
Related portion
F6
CN250-51 CN250-52 (44)
MB F1 P4
P3
N1
CN102-3 (19, VBMBSL) Main
CN102-4 (19, VBMBSL) controller
STEP1
After disconnecting the CN104 connector and F6 fuse, check

the inside of the connector and the crimped portion of the wire
to see whether it has a defect or not by visual confirmation.
(Refer to BEFORE TROUBLESHOOTING)
Connect the CN104 connector and F6 fuse, connect the battery

plug.
Judgment
Result Procedure
STEP2
VBMBSL voltage inspection:
[ANL] I/O TEMP/VOLT 5/6 VBMBSL
Judgment
Result Procedure
25V or more Go to step 3
Less than 25V Perform CB-1 troubleshooting.
STEP3
Check fuse installation:
Visual confirm if the F6 fuse is mounted correctly.
Judgment
Result Procedure
A802 error does not occur. F6 fuse installation defect.
STEP4

ends of the fuse.
Judgment
Result Procedure
0Ω Go to step 5
F6 fuse defect.
∞Ω
After replacing F6 fuse, go to STEP 6. 5
STEP5
Inspection : Fuse box
Connect the F6 fuse, and disconnect the connector of the F6

fuse box.
Measure the resistance for both ends of the connector for the
F6 fuse box.
Judgment
Result Procedure
0Ω Go to step 6
∞Ω F6 fuse box defect.
STEP6
If you disconnected the F6 fuse box connector in the former

step, reconnect it.
Disconnect the CN104 connector and the F6 fuse and check

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

Perform this check with the battery plug and the CN104 con-
nector and F6 fuse disconnected, and visually check inside the
connector and the crimped portion of its wire for defects.
CN250-52(44, fuse side) to P3 Continuity
CN104-2(44) to N1 No continuity
Judgment
Result Procedure
NG Harness defect.
Error Code: A902

Failure mode: F7 fuse / solenoid power supply line open abnormality
Probable cause 5
▪ Harness defect
Related portion
MB
CN102-3 (19, VBMBSL)
P3 CN102-4 (19, VBMBSL)
Main
controller
CN250-51 CN250-52 (44)
F6
N1
STEP1
After disconnecting the CN102 connector, check the inside of

the connector and the crimped portion of the wire to see
whether it has a defect or not by visual confirmation. (Refer to
BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
VBMB voltage inspection:
[ANL] I/O TEMP/VOLT 5/6 VBMB

Judgment
Result Procedure
Less than 25V Perform CB-1 troubleshooting.
STEP3
Disconnect the CN102 connector and check the harnesses.

CN102
1 2 3 4 5 6 7 nector disconnected, and visually check inside the connector
8 9 10 11 12 13 14 15 16 17 18 19 and the crimped portion of its wire for defects.
20 21 22 23 24 25 26 27
CN102-3(19) to P3 Continuity
Judgment
Result Procedure
NG Harness defect.
Error Code: AA01

Failure mode: Main controller temperature sensor (open/short) abnormality
CAUTION 5
• If AA01 occurs, the Main controller is defective. Replace it.
Probable cause
Related portion
Main controller
Temperature sensor
Error Code: AA02

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

Failure mode: Drive motor driver RH board temperature sensor (open/short)
abnormality
5
CAUTION
• If AA03 occurs, the drive motor driver circuit is defective. Replace it.
Probable cause
Related portion
Temperature sensor
Error Code: AA04

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

Failure mode: Cooling fan overcurrent
CAUTION 5
• When checking if AB01 error occurs, wait 100 seconds after turning on the FAN1, FAN2 by using
Active Test.
(It takes 100 second to confirm the error AB01)
Probable cause
▪ Motor driver cooling fan 1 defect
▪ Motor driver cooling fan 2 defect
▪ Motor cooling fan defect
▪ Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Cooling fan 2
Main CN104-3 (1, CBAT+) CN113-1
F52
CN102-2 (99, FANDC2) CN112-2
CN104-1 (41, B48V) Cooling fan 1

CN112-1
CN250-25 CN250-26
+ F51
CN118-2
Motor fan
CN118-1
CN250-29 CN250-30
F53
STEP1
Inspection :
Check the inside of connector CN112, CN113, CN118 and the
crimped portion of the wire to see whether it has a defect or not
by visual confirmation. (Refer to BEFORE TROUBLESHOOT-
ING)
by using Active Test and check if an error occurs.

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Connector contact defect
AB01 error occurs. Go to step 2
STEP2
Inspection : Cooling fan circuit
After disconnect the CN112, CN113, CN118 connector, connect
the battery plug and turn on the key switch. Then apply the
cooling fan compulsorily by using Active Test and check if an
error occurs.

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

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Go to step 4
AB01 error occurs. Motor driver cooling fan 1 defect.
STEP4
Inspection : Motor driver cooling fan 2
After connecting CN112 and disconnecting the CN113, CN118 5
connector, connect the battery plug and turn on the key switch.
Then apply the cooling fan compulsorily by using Active Test

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB01 error does not occur. Motor cooling fan defect
AB01 error occurs. Motor driver cooling fan 2 defect
STEP5
Disconnect the CN102, CN104, CN112, CN113, CN118 con-
nectors and check the harnesses.
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

CN104, CN112, CN113, CN118 connectors disconnected, and
visually check inside the connectors and the crimped portion of
their wires for defects.

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

Failure mode: Motor driver power delivery abnormality
Probable cause 5
▪ Harness defect
Related portion
+
Drive motor
CN109-8 (42) driver LH
MB
P2 P4 +
Drive motor
CN110-8 (42) driver RH
+ F1
+
N1 Pump motor
CN111-8 (42) driver
-
CN103-4 (42, KYSAT)
Main
CN250-49 CN250-50 (41) CN104-1 (41, B48V) controller
F5 CN101-4 (41, VBBT)
STEP1
Disconnect the CN101, CN103, CN104, CN109, CN110,
CN111 connectors and check the harness.
CN103
1 2 3 4 5 6
CN109
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
CN110 CN111
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23

Perform the continuity check of CN103 to CN109, CN110,

CN111 connectors with the battery plug and the CN101,
CN103, CN104, CN109, CN110, CN111 connectors disconnec-
ted, and visually check inside the connectors and the crimped
portion of their wires for defects.
Inspect for continuity between the harness and N1.
Judgment
Result Procedure
NG Harness defect
OK Go to step 2
STEP2
Inspection : Main controller
Disconnect the CN109, CN110, CN111 connectors, then con-
nect the CN101, CN103, CN104 connectors.
the error.
Judgment
Result Procedure
AC01 error occurs. Main controller defect
AC01 error does not occur. Go to step 3
STEP3
Inspection : Drive motor driver LH
Disconnect the CN110, CN111 connectors, then connect the 5
CN101, CN103, CN104, and CN109 connectors.
the error.
Judgment
Result Procedure
AC01 error occurs or not. Go to step 4
STEP4
Inspection : Drive motor driver RH
Disconnect the CN109, CN111 connectors, then connect the
the error.
Judgment
Result Procedure
AC01 error occurs or not. Go to step 5
STEP5
Inspection : Pump motor driver
Disconnect the CN109, CN110 connectors, then connect the
the error.
Judgment
Result Procedure
AC01 error occurs at STEP 3 Drive motor driver LH defect
AC01 error occurs at STEP 4 Drive motor driver RH defect
AC01 error occurs at STEP 5 Pump motor driver defect
Error Code: AD01

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

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
nect the CN103, CN109 connectors, and visually check inside

turn on the key switch to confirm the error.
Judgment
Result Procedure
AD01 or AD02 error occurs. Perform troubleshooting for AD02
AD01 or AD02 error does not occur. Connector contact defect
Error Code: AD02

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

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

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

1. Check if the connector plug CN109 is wired correctly. The
connector plug could be connected to the wrong controller.
CN103
CN109
1 2 3 4 5 6 2. Inspect for continuity and short circuiting of the harness.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
Perform this check with the battery plug and the CN103, CN109
connectors disconnected, and visually check inside the con-
nector and the crimped portion of its wire for defects. (Refer to
*1: Perform if "AD-4 error does not occur and AD-6 error oc-
curs" or "AD-4 error occurs and AD-6 error does not occur".
*2: Perform if "AD-4 and AD-6 error occur".
Portion to be inspected Standard: Remarks
No continu-
CN109-7 to CN109-23 *1
ity
No continu-
CN109-6 to CN109-23 *1
ity
No continu-
CN109-7 to N2 *1
ity
No continu-
CN109-6 to N2 *1
ity
CN103-4 to CN109-8 Continuity *2
Judgment
Result Procedure
Go to step 5
NG
Harness defect
Go to step 5
OK
Drive motor driver LH defect
STEP5
Confirm the error recorded at STEP3.
Judgment
Result Procedure
Only AD02 error occurs. Replace the defective portion in STEP4.
AD02 and AD04 error occur. Go to step 6
STEP6
Inspection :
1. Confirm the identification of drive motor driver RH.
Reconnect the battery plug and turn on the key switch. Record
the occurred error.
2. Inspect harness
1. Check with disconnecting the drive motor driver LH and
pump motor driver to confirm if drive motor driver RH is not op-
CN103
erated as drive motor driver LH or pump motor driver.
1 2 3 4 5 6
CN110
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
2. Inspect for continuity and short circuiting of the harness.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
nector and the crimped portion of its wire for defects. (Refer to
*1: Perform if "AD02 error does not occur and AD06 error oc-
curs" or "AD02 error occurs and AD06 error does not occur".
*2: Perform if "AD02 and AD06 error occur".
No continu-
CN110-6 to CN110-23 *1
ity
No continu-
CN110-6 to N2 *1
ity

Judgment
5
Result Procedure
Harness defect
NG In addition to the harness, replace the defective portion in
STEP4.
Drive motor driver RH defect
OK In addition to drive motor driver RH, replace the defective
portion in STEP4.
STEP7
Inspection :
1. Confirm the identification of pump motor driver
Reconnect the battery plug and turn on the key switch. Record
the occurred error.
2. Inspect harness
1. Check with disconnecting the drive motor driver LH and RH
to confirm if pump motor driver is not operated as drive motor
CN103
driver LH or RH.
1 2 3 4 5 6
CN111
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
2. Inspect for continuity and short circuiting of the harness.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
nectors and the crimped portion of their wires for defects. (Refer
*1: Perform if "AD02 error does not occur and AD04 error oc-
curs" or "AD02 error occurs and AD04 error does not occur".
*2: Perform if "AD02 and AD04 error occur".

No continu-
CN111-7 to CN111-23 *1
ity
No continu-
CN111-7 to N2 *1
ity
Judgment
Result Procedure
Harness defect
NG In addition to the harness, replace the defective portion in
STEP 4.
Pump motor driver defect
OK In addition to pump motor driver, replace the defective por-
tion in STEP 4.
STEP8
Disconnect the CN103, CN104, CN109, CN110, CN111 and
CN70 connectors and check the harnesses.
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
CN103 16 17 18 19 20 21 22 23
CN110 Perform this check with the battery plug and the CN103,
1 2 3 4 5 6
1 2 3 4 5 6 7 8
CN104, CN109, CN110, CN111 and CN70 connectors discon-
7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 nected, and visually check inside the connectors and the
17 18 19 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
crimped portion of their wires for defects. (Refer to BEFORE
CN111 TROUBLESHOOTING)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 Portion to be inspected Standard:
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
OK Go to step 9
STEP9
Inspection: Check the voltage of the main controller power sup-
ply.
Connect the CN103, CN104, CN70 connectors, and disconnect 5
the CN109, CN110, CN111 connectors.
Reconnect the battery plug and turn on the key switch. Check
the voltage of the power supply for the motor driver.
Check the voltage between CN109-8 and N2.
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
Judgment
Result Procedure
Less than 15V Main controller defect
STEP10
Inspection: Drive motor driver LH
Connect the CN103, CN104, CN109 connectors, and discon-
nect the CN110, CN111 connectors.
the voltage of the power supply for the motor driver and check if
an error occurs.

CN110
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Check with the drive motor driver RH and pump motor driver
disconnected, and the main controller and drive motor driver LH
connected.
Check the voltage by using the disconnected drive motor driver

RH harness.
Judgment
Result Procedure
Go to step 11
Voltage: less than 15V
Record the result
Go to step 11
Voltage: 15V or more AD02 error occurs
Record the result
Voltage: 15V or more AD02 error does not Go to step 11
occur Record the result
STEP11
the power supply voltage for the motor driver and check if an er-
ror occurs.

CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Check with the drive motor driver LH and pump motor driver
disconnected, and the main controller and drive motor driver
RH connected.

LH harness.
Judgment
Result Procedure
Go to step 12
Record the result
Go to step 12
Record the result
STEP12
Inspection: Pump motor driver

the voltage of the power supply for the motor driver and check if
an error occurs.
5
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Check with the drive motor driver LH and RH disconnected, and
the main controller and the pump motor driver connected.

LH harness.
Judgment
Result Procedure
Go to step 13
Record the result
Go to step 13
Record the result
STEP13
Confirm the STEP10, 11, 12
Judgment
Result Procedure
Defect for inspection item of less than 15V (Drive motor
Any voltage: less than 15V
driver LH, Drive motor driver RH, Pump motor driver)
Main controller defect
All voltage: 15V or more All error occurs If the symptom persists after replacing the main controller,
there are other problems. Replace the drive motor driver LH,
drive motor driver RH, and pump motor driver.
All voltage: 15V or more At least one error Defect for inspection item of the occurred error (Drive motor
is not displayed driver LH, Drive motor driver RH, Pump motor driver)
Error Code: AD03

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

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
nect the CN103, CN110 connectors, and visually check inside
After connecting the connectors, connect the battery plug and

Judgment
Result Procedure
Error Code: AD04

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

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

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

CN110 Perform this check with the battery plug and the CN110 con-
1 2 3 4 5 6 7 8
nector disconnected. Visually check inside the connector and
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
the crimped portion of its wire for defects.
CN110-7(150) to CN110-23 Continuity
CN110-6 to N2(N2) No continuity
Judgment
Result Procedure
NG Harness defect
OK Drive motor driver RH defect
STEP5
Disconnect the CN103, CN110 connectors and check the har-
nesses.
CN103
CN110
1 2 3 4 5 6 connectors disconnected. Visually check inside the connectors
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
and the crimped portion of their wires for defects.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
Error Code: AD05

Failure mode: Pump motor driver to Main controller : communication abnormality
CAUTION 5
Probable cause
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

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

Judgment
Result Procedure
Error Code: AD06

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

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

CN111-17 (145, CAN1H)
CN111-16 (146, CAN1L)
Pump motor
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
Turn off the key switch, and disconnect the battery plug. Check
if the part number of the motor driver is correct.
Judgment
Result Procedure
Wrong part number Wrong motor driver type 5
STEP2
nect the CN111 connector. Visually check inside the connector
and the crimped portion of its wire for defects. (Refer to BE-
Judgment
Result Procedure
STEP3
Inspection :
Confirm the identification of pump motor driver
Turn off the key switch and disconnect the battery plug. Discon-
nect the CN109 and CN110 connectors.
Reconnect the battery plug and turn on the key switch. Confirm
the occurred error.
Check if the connector plug CN109 is wired correctly. The con-
nector plug could be connected to the wrong controller.
Judgment
Result Procedure
AD02 and AD04 errors occur Go to step 5
STEP4
Disconnect the CN111 connector and check the harness.

1 2 3 4 5 6 7 8
nectors disconnected. Visually check inside the connector and
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
the crimped portion of its wire for defects.
CN111-7 to N2(N2) No continuity
Judgment
Result Procedure
NG Harness defect
OK Pump motor driver defect
STEP5
nesses.
Inspect for continuity and short circuiting of the harnesses.
CN103
CN111
1 2 3 4 5 6 connectors disconnected, and visually check inside the con-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
nectors and the crimped portion of its wire for defects.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
Error Code: AF01

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

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF03

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

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF05

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

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF07

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

CAUTION
Probable cause
Related portion
Main controller
Error Code: C002

Failure mode: Drive motor driver LH power-circuit abnormality
CAUTION 5
• If CB03 occurs at the same time, perform troubleshooting for CB03 first.
• Jack up the lift truck until the drive wheels leave the ground and support the frame with wooden
blocks before you start troubleshooting.
Probable cause
▪ Drive motor cable tightening is defective
▪ Drive motor LH defect
▪ Drive motor cable defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off the key switch and disconnect the battery plug. Visually
check the fastened and crimped portions of the motor cables for
defects. (Refer to BEFORE TROUBLESHOOTING)
Connect the drive motor cables, connect the battery plug, and
then turn on the key switch.
Operate the direction lever forward or backward, and check for
errors.
Judgment
Result Procedure
Go to step 2
C002 error occurs.
Record the occurred error code.
C002 error does not occur. Drive motor cable tightening is defective
STEP2
Return the direction lever to neutral, turn off the key switch, and
disconnect the battery plug.
Disconnect the three motor cables from the drive motor driver
LH and isolate them. Make sure the disconnected terminals are
not touching.
Connect the battery plug and turn on the key switch to check if
C002 error occurs.
Judgment
Result Procedure
C002 error does not occur. Go to step 3
C002 error occurs. Drive motor driver LH defect
STEP3
Inspection : Drive motor cable
Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection
Check each drive motor cable for its continuity and short.
nect the three motor cables, visually check each terminal and
the crimped portion and coating of each cable for defects, and
then check the P7, P8 and P9 cables.

Both ends of P7 cable Continuity
P7 cable and P8 cable No continuity
Judgment
Result Procedure
OK (E002 does not occur at the same time
Go to step 4
on STEP1)
OK (E002 occurs at the same time on
Go to step 5
STEP1)
NG Drive motor cable defect
STEP4
Inspection : Drive motor driver
Replace the drive motor driver LH with the pump motor driver.
errors. (Ignore the error codes 3201 and 3203.)
5
Judgment
Result Procedure
C002 error occurs. Drive motor LH defect
E002 error occurs. If the error code changes to E002, replace the drive motor
driver.
STEP5
Inspection : Drive motor
Check the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
OK Drive motor driver LH defect
Error Code: C004

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

V Drive motor RH
driver RH
P91
W
STEP1
check the fastened and crimped portions of the motor cables for
defects. (Refer to BEFORE TROUBLESHOOTING)
errors.
Judgment
Result Procedure
Go to step 2
C004 error occurs.
C004 error does not occur. Drive motor cable tightening is defective
STEP2
Disconnect the three motor cables from the drive motor driver
RH and isolate them. Make sure the disconnected terminals are
not touching.
Connect the battery plug and turn on the key switch to check if 5
C004 error occurs.
Judgment
Result Procedure
C004 error occurs. Drive motor driver RH defect
STEP3
Inspection : Drive motor cable
Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection
Check each drive motor cable for continuity and shorts.
nect the three motor cables, visually check each terminal and
then check the P71, P81, and P91 cables.

Judgment
Result Procedure
Go to step 4
on STEP1)
Go to step 5
STEP1)
NG Drive motor cable defect
STEP4
Replace the drive motor driver RH with the pump motor driver.
Judgment
Result Procedure
C004 error occurs. Drive motor RH defect
driver.
STEP5
Inspection : Drive motor
Check the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C101

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

Failure mode: Drive motor driver LH current sensor over current abnormality
CAUTION
• If C801 or C802 occurs at the same time as C102, perform troubleshooting for C801 or C802 first.
Probable cause
▪ Drive motor LH cable tightening is defective
▪ Drive motor LH defect
▪ Drive motor LH cable defect
▪ Drive motor LH rotation sensor defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off / on the key switch, and check if C002 error occurs.
Judgment
Result Procedure
C002 error occurs. Perform troubleshooting for C002
STEP2
check the assembled and crimped portions of the motor cables
for defects. (Refer to BEFORE TROUBLESHOOTING)
Sit in the seat and perform a direction lever operation (forward
or backward), checking for errors with pushing the accelerator
pedal.
Judgment
Result Procedure
C102 error does not occur. Drive motor LH cable is loose
Go to step 3 5
C102 error occurs.
STEP3
Inspection : Drive motor cable LH
Inspect with the drive motor cable (drive side and motor side)
disconnected.
nect the three motor cables. Visually check each terminal and
then check the P7, P8, and P9 cables.
Judgment
Result Procedure
Go to step 4
on STEP2)
Go to step 5
STEP2)
NG Drive motor LH cable defect
STEP4
pedal. (Ignore the error codes 3201 and 3203.)
Judgment
Result Procedure
C102 error occurs. Drive motor LH defect
driver.
STEP5
Inspection : Drive motor LH
Turn off the key switch, disconnect the battery plug, and inspect
the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
Error Code: C103

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

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

V Drive motor RH
driver RH
P91
W
STEP1
Turn off / on the key switch, and check if C004 error occurs.
Judgment
Result Procedure
C004 error occurs. Perform troubleshooting for C004
STEP2
Turn off the key switch and disconnect the battery plug, visually
check the assembled and crimped portions of the motor cables
pedal.
Judgment
Result Procedure
C104 error does not occur. Drive motor RH cable tightening is defective
Go to step 3
C104 error occurs.
Record the occurred error code. 5
STEP3
Inspection : Drive motor cable RH
Inspect with the drive motor cable (drive side and motor side)
disconnected.
nect the three motor cables. Visually check each terminal and
Judgment
Result Procedure
Go to step 4
on STEP2)
Go to step 5
STEP2)
NG Drive motor RH cable defect
STEP4
pedal. (Ignore the error codes 3202 and 3203.)
Judgment
Result Procedure
C104 error occurs. Drive motor RH defect
driver.
STEP5
Inspection : Drive motor RH
Turn off the key switch, disconnect the battery plug, and inspect
the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C201

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

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

RH (Drive motor RH)
CN110-10 (85, STDMR) CN52-1
STEP1
Inspection :
Reconfirm the displayed error.
Turn on the key switch and check if the error occurs.
Judgment
Result Procedure
"DM" occurs. Go to step 2
When the temperature of the drive motor driver drops, “DM” goes
"DM" does not occur. away and the lift truck can be operated as usual. Continuously
running the lift truck in an overloaded condition will cause this er-
ror. Limit running the lift truck in an overloaded condition.
STEP2
Inspection :
Confirm the temperature of the drive motor and reconfirm the

error.
･Temperature of drive motor LH/RH

[ANL] I/O TEMP/VOLT 1/6　TDM
Record the temperature of the drive motor.
thirty minutes. Then turn on the key switch and check if the er-
ror occurs.
Judgment
Result Procedure
"DM" occurs. Go to step 3
When the temperature of the drive motor driver drops, “DM” goes
"DM" does not occur. away and the lift truck can be operated as usual. Continuously
STEP3
Inspection :
Reconfirm the temperature of drive motor.
･Temperature of drive motor LH/RH

[ANL] I/O TEMP/VOLT 1/6　TDM
Check the temperature of drive motor and compare to the re-

corded value.
Judgment
Result Procedure
Go to step 2
(5°C) or more.
Temperature of drive motor LH has not
C2-2 Perform troubleshooting from STEP2.
lowered by 41°F (5°C) or more.
Temperature of drive motor RH has not
C2-3 Perform troubleshooting from STEP2.
lowered by 41°F (5°C) or more.
Error Code: C202

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

LH (Drive motor LH)
CN109-10 (87, STDML) CN121-1
STEP1
Disconnect the battery plug and visually check inside the
CN121 connector and the crimped portion of its wire for defects.
Judgment
Result Procedure
C202 error occurs. Go to step 2
C202 error does not occur. Connector contact defect
STEP2
Inspection :
Temperature sensor individual inspection.
Disconnect the CN121 connector, and perform the temperature
sensor individual inspection.
CN121
2 1

Carry out temperature sensor individual inspection.
Measure the temperature sensor resistance between CN121-2

and CN121-1 (sensor side of CN121)
Standard: Approx. 245 Ω to 600 kΩ
* The resistance changes depending on the temperature. So

refer to the below table about rough standard value.
Temperature
sensor resist-
Temperature ance (between
CN121-2 and
CN121-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
100°C Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor LH temperature sensor defect
STEP3
harnesses.
CN109 CN121 Perform this check with the battery plug and the CN109 and
1 2 3 4 5 6 7 8 CN121 connectors disconnected, and visually check inside the
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
connector and the crimped portion of its wire for defects with
disconnecting SST.
*1: It is OK to connect CN121-1 to CN121-2 through SST2

(979-001/161) and check if there is continuity between CN109-9
and CN109-10.
No continu-
CN121-1 to CN121-2
ity
Judgment
Result Procedure
Result Procedure
NG Drive motor LH temperature sensor harness defect
5
Error Code: C203

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

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

CN52 and CN52-1 (sensor side of CN52)
2 1 5
Standard: Approx. 245 to 600 kΩ
* The resistance changes depending on temperature. So refer

to the below table about rough standard value.
Temperature
sensor resist-
CN52-2 and
CN52-1)
68°F (20°C) Approx. 13 kΩ
176°F (80°C) Approx. 1.75 kΩ
212°F (100°C) Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor RH temperature sensor defect
STEP3
harnesses.
CN110 CN52 Perform this check with the battery plug and the CN110 and
1 2 3 4 5 6 7 8 CN52 connectors disconnected, and visually check inside the
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
connector and the crimped portion of its wire for defects with
disconnecting SST.
*1 : It is OK to connect CN52-1 to CN52-2 through SST2

and CN110-10.
No continu-
CN52-1 to CN52-2
ity
Judgment
Result Procedure
NG Drive motor RH temperature sensor harness defect
Error Code: C301

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

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

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

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

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

firm the value changes when the sensor is operating.
CN26-4(52) to CN26-6(50)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to step 3
STEP3
Disconnect the CN101, CN102, CN26 connectors and check

continuity of the harness.
CN101
Inspect for continuity of the harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26 CN102, and CN26 connectors disconnected, and visually check
inside the connector and the crimped portion of its wire for de-
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1: It is OK to connect CN26-5 to CN26-4 through SST2
(979-001/161) and check if there is continuity between
CN101-27 and CN102-30.
CN101-27(53) to CN26-5 Continuity *1
Judgment
Result Procedure
NG Harness defect
5
Error Code: C402

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

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

sensor resistance.
5

CN26-3(54) to CN26-2(51)
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
inside the connector and the crimped portion of its wire for de-
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
*1 : It is OK to connect CN26-1 to CN26-3 through SST2

CN101-26 and CN102-32.

Judgment
Result Procedure
NG Harness defect
Error Code: C403

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

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

sensor resistance.

CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

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

CN101-22 and CN102-30.
Judgment
Result Procedure
NG Harness defect
5
Error Code: C404

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

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

sensor resistance.
5

CN26-3(54) to CN26-2(51)
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
side the connectors and the crimped portion of its wire for de-
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-32 and CN102-32.
Judgment
Result Procedure
NG Harness defect
Error Code: C405

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

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
connector and the crimped portion of wire whether it has a de-
fect or not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2

sensor resistance.

CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

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

5
Judgment
Result Procedure
NG Harness defect
Error Code: C406

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

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
Perform the accelerator potentiometer matching.
(Refer to page MATCHING [page 143]. )
Judgment
Result Procedure
NG matching Go to step 2
OK matching Go to step 3
STEP2
Check the accelerator potentiometer voltage.
Accelerator sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRA

Check if the voltage of the accelerator is within the standard

range of the table below when the accelerator is not operated
and when the accelerator is fully depressed.
Position of accelerator pedal sensor 1 sensor 2
When accelerator is not oper- 0.40V to
0.65V to 2.31V 5
ated 1.24V
During maximum pressing of 2.00V to
2.42V to 4.79V
accelerator 4.79V
Judgment
Result Procedure
Within standard range Main controller defect
Go to step 3
Outside standard range Accelerator potentiometer assembly defect
Perform the matching after reassembly.
STEP3
Turn off the key switch and disconnect the battery plug. Con-
nect the battery plug again after 30 seconds and turn on the key
switch.
Judgment
Result Procedure
C406 error occurs. Main controller defect
Accelerator potentiometer matching defect
C406 error does not occur.
Use as it is.
Error Code: C501

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

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

tiometer resistance.
Inspect brake potentiometer resistance.
5
CN6 Turn off the key switch, disconnect the battery plug, and discon-
nect the CN6 connector. Visually check each terminal and the
Check resistance on both ends of the potentiometer. Confirm

the value changes when the potentiometer is operating.
CN6-4(71) to CN6-6(50)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Brake potentiometer defect
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
side the connector and the crimped portion of its wire for de-
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-34 and CN102-33.
Judgment
Result Procedure
NG Harness defect
Error Code: C502

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

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
Disconnect the CN6 connector. Check the inside of the con-
nector and the crimped portion of the wire to see whether it has
a defect or not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2


CN6-3(73) to CN6-2(51)
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-33 and CN102-25.
Judgment
Result Procedure
NG Harness defect
5
Error Code: C503

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

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
After disconnecting the CN6 connector, check the inside of con-
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2

5

CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-22 and CN102-33.
Judgment
Result Procedure
NG Harness defect
Error Code: C504

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

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


CN6-3(73) to CN6-2(51)
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-32 and CN102-25.
Judgment
Result Procedure
NG Harness defect
5
Error Code: C505

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

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
After disconnecting the CN6 connector, check the inside of con-
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2

CN6
6 5 4 3 2 1
5

Turn off the key switch, disconnect the battery plug and discon-
crimped portion and coating of each cable for defects. (Refer to

CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

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

*2 : CN6-6 to CN6-4 / CN101-22 to CN102-33
*3 : CN6-1 to CN6-3 / CN101-33 to CN102-25
*4 : CN6-2 to CN6-3 / CN101-32 to CN102-25
Judgment
Result Procedure
NG Harness defect
Error Code: C506

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

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
Perform matching of the brake potentiometer.
(Refer to page MATCHING [page 143].)
Judgment
Result Procedure
STEP2
Check the brake potentiometer voltage.
Brake sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRB

Confirm the range is within the value of the following table with
the brake operated and the difference is 0.45V or more com-
pared to the matching voltage with the brake released.
Brake pedal height sensor 1 sensor 2
0.50V to
When the brake is released 0.79V to 2.88V
1.79V
When at the start point of 1.60V to
2.00V to 4.79V
brake activation 4.09V
Judgment
Result Procedure
Within standard range Main controller defect.
Go to step 3
Outside standard range Brake potentiometer assembly defect.
Perform the matching after reassembly.
STEP3
switch.
Judgment
Result Procedure
C506 error occurs. Main controller defect
Brake potentiometer matching value defect
C506 error does not occur.
Use as it is.
Error Code: C801

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

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1
Disconnect the battery plug, and visually check inside the con-
nector between CN109, CN122, CN123 and CN202 and the
crimped portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
CN109 CN122 CN123 Perform this check with the battery plug and the CN109, CN122
1 2 3 4 5 6 7 8 and CN123 connectors disconnected. Visually check inside the
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
*1: It is OK to connect CN122-1 to CN122-2 (CN109 side)

through SST2 (979-001/161) and check if there is continuity
between CN109-15 and CN109-14.
Measurement terminals Standard: Remarks
No continu-
CN109-15 to CN109-13
ity
No continu-
CN109-15 to CN109-14
ity
No continu-
CN109-13 to CN109-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor LH rotation sensor 1/2 harness defect
NG Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3
Connect the CN109 connector, then connect the battery plug
and turn on the key switch. CN122 and CN123 connectors are
still disconnected.
Measure the voltage between CN122-2 and N1, and between
CN123-2 and N1.
CN122 CN123
1 2 1 2
5
Judgment
Result Procedure
12 ~ 16V Go to step 4
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection :
Check the error code
Connect between CN122-1 and CN122-2, and between
CN123-1 and CN123-2 by using SST2. Connector CN109 is
connected.
CN122 CN123
1 2 1 2
that the error occurs.
Judgment
Result Procedure
C802 error occurs Go to step 5
C801 error occurs, or error does not occur Drive motor driver LH defect
STEP5
Disconnect the SST2, and measure the resistance between
CN122-1 (CN109 side) and N1, and between CN123-2 (CN109
side) and N1 with CN109 connected and CN122, CN123 dis-
connected.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx. 100 Ω Go to step 6
Either resistance is not Approx. 100 Ω Drive motor driver LH defect
STEP6
Inspection : Drive motor LH rotation sensor
Reconnect the CN122 and CN123 connector.
Connect the battery plug, turn on the key switch, and wait for
the C801 error to occur.
･Drive motor LH rotation sensor : sensor 1 / sensor 2

[ANL] I/O TRAVELING 5/5　SSDL
Judgment
Result Procedure
Drive motor LH rotation sensor 1 voltage :
0.3 or less
Drive motor LH rotation sensor 1 defect
0.4 to 1.9
0.4 to 1.9
0.3 or less
0.3 or less
Drive motor LH rotation sensor 1/2 defect
0.3 or less
Error Code: C802

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

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1
nector between CN109, CN122, CN123 and CN202 and the
crimped portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
CN109 CN122 CN123 Perform this check with the battery plug and the CN109, CN122
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

No continu-
CN109-15 to CN109-13
ity
No continu-
CN109-15 to CN109-14
ity
No continu-
CN109-13 to CN109-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor LH rotation sensor 1/2 harness defect
NG Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3
and turn on the key switch with CN122 and CN123 connectors
disconnected.
CN123-2 and N1.
CN122 CN123
1 2 1 2
5
Judgment
Result Procedure
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection :
disconnected. Check what error occurred.
Judgment
Result Procedure
C802 error occurs, or error does not occur Drive motor driver LH defect
STEP5
Measure the resistance between CN122-1 (CN109 side) and
N1, and between CN123-2 (CN109 side) and N1 with CN109
connected and CN122, CN123 disconnected.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx.100 Ω Go to step 6
Either resistance is not Approx.100 Ω Drive motor driver LH defect
STEP6
Inspection : Drive motor LH rotation sensor
･Drive motor LH rotation sensor : sensor 1 / sensor 2

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

Failure mode: Drive motor RH rotation sensor open abnormality
CAUTION 5
Probable cause
▪ Drive motor RH rotation sensor 1/2 harness defect
▪ Drive motor RH rotation sensor 1 defect
▪ Drive motor RH rotation sensor 1/2 defect
Related portion
CN110-15 (75, SSDR+) CN202-3 CN53-2
CN203-3 CN202-4 Drive motor RH
P4
+ rotation
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotation
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1
Disconnect the battery plug. Visually check inside the connector
between CN110, CN53, CN54 and CN202 and the crimped por-
tion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Disconnect the CN110, CN53 and CN54 connectors and check
the harnesses.

CN110 CN53 CN54 Perform this check with the battery plug and the CN110, CN53,
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
connectors and the crimped portion of its wire for defects.

CN110-15 and CN110-14.
CN110-15 and CN110-13.
No continu-
CN110-15 to CN110-13
ity
No continu-
CN110-15 to CN110-14
ity
No continu-
CN110-13 to CN110-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor RH rotation sensor 1/2 harness defect
NG Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3
disconnected.
CN54-2 and N1.
CN53 CN54
1 2 1 2
5
Judgment
Result Procedure
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection :
Connect between CN53-1 and CN53-2, and between CN54-1
and CN54-2 by using SST2 with CN110 connected and CN53,
CN54 disconnected.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
C803 error occurs, or error does not occur Drive motor driver RH defect
STEP5
Disconnect the SST2, and measure the resistance between
CN53-1 (CN110 side) and N1, and between CN54-1 (CN110
side) and N1 with CN110 connected and CN53, CN54 discon-
nected.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection : Drive motor RH rotation sensor
･Drive motor RH rotation sensor : sensor 1 / sensor 2

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

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

CN203-3 CN202-4 Drive motor RH
P4
+ rotarion
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotarion
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1
betweenCN110, CN53, CN54 and CN202 and the crimped por-
tion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Disconnect the CN110, CN53 and CN54 connectors and check
the harnesses.
CN110 CN53 CN54 Perform this check with the battery plug and the CN110, CN53,
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

CN110-15 and CN110-14.
CN110-15 and CN110-13.
No continu-
CN110-15 to CN110-13
ity
No continu-
CN110-15 to CN110-14
ity
No continu-
CN110-13 to CN110-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor RH rotation sensor 1/2 harness defect
NG Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3
disconnected.
CN54-2 and N1.
CN53 CN54
1 2 1 2
5
Judgment
Result Procedure
12 to 16V Go to step 4
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection :
disconnected. And check what error occurred.
Judgment
Result Procedure
C804 error occurs, or error does not occur Drive motor driver RH defect
STEP5
Measure the resistance between CN53-1 (CN110 side) and N1,
and between CN54-1 (CN110 side) and N1 with CN110 con-
nected and CN53, CN54 disconnected.
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection : Drive motor RH rotation sensor
･Drive motor RH rotation sensor : sensor 1 / sensor 2

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

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

MB
Contactor CN136-2 (1, CBAT+) CN104-3 (1, CBAT+)
STEP1
Connector contact inspection:
After disconnecting the F5 and F6 fuses, visually confirm

TROUBLESHOOTING)
Connect the F5, F6 fuse, connect the battery plug.
Judgment
Result Procedure
CB01 error occurs. Go to step 2
CB01 error does not occur. Connector contact defect
STEP2
Check the operation of MB contactor:
Check if the MB contactor activates when turn on the key

switch.
Judgment
Result Procedure
OK Go to step 4
NG Go to step 3
STEP3
Check the contact of MB contactor:
check activation of the MB contactor (contamination, freeze and
so on).
Judgment
Result Procedure
OK Perform troubleshooting for CB03.
MB contactor defect
NG
Use as it is after repairing NG items.
STEP4
Remove F6 fuse and measure the resistance across it.
Judgment
Result Procedure
0Ω Go to step 5
F6 fuse defect
∞Ω
After replacing F6 fuse, go to STEP 6
STEP5
Inspection : Fuse box
Connect the F6 fuse, and disconnect the connector of fuse box.

Measure the resistance for both ends of F6 fuse box.
Judgment 5
Result Procedure
0Ω Go to step 6
∞Ω F6 fuse box defect
STEP6
Disconnect the CN102 and CN104 connectors and F6 fuse and

check the harnesses for continuity.
CN102 CN104
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 Perform this check with the battery plug, the CN102 and CN104
28 29 30 31 32 33 34 35 26 27 28 29 30 31 connectors, and F6 fuse disconnected. Visually check inside
the connectors and the crimped portion of its wire for defects.
CN250
1 2 3 4 5 6 7 8 9 10 11 12 Portion to be inspected Standard:
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48 CN102-4(19) to P3 Continuity
49 50 51 52 53 54 55 56 57 58 59 60 CN250-52(44) to CN104-2(44) Continuity
CN250-52 (fuse side) to P3 Continuity
CN250-52 (fuse side) to N1 No continuity
Judgment
Result Procedure
OK Go to step 7
NG Harness defect
STEP7
Voltage inspection
After connecting the connectors, connect the battery plug, and

Measure both ends of the contactor for voltage (contact side).
Refer to the following figure, and measure both ends of the con-
tactor for voltage (contact side).
P2
P3
P4
P1
Judgment
Result Procedure
30V or more MB contactor defect
Error Code: CB02

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

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

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

MB
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
Result Procedure
STEP2
Inspection : MB contactor coil
Disconnect the CN136 connector and measure the resistance

of the MB contactor coil.
Check the resistance of the MB contactor coil.
CN136 STD spec.：15 to
1
CN136-1 to CN136-2 30 Ω (Approx. 20
2 3 Ω：20°C)
Judgment
Result Procedure
OK Go to step 3
NG MB contactor defect
STEP3
Inspection: Harness

nesses.
CN104
CN136
1 2 3 4 5 6 7 connectors disconnected. Visually check inside the connectors
1
8 9 10 11 12 13 14 15 16 17
2 3
and the crimped portion of its wire for defects.
18 19 20 21 22 23 24 25
26 27 28 29 30 31 Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect
5
Error Code: CB04

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

MB
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
Result Procedure
STEP2
Inspection : MB contactor coil 5

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

nesses.
CN136 Perform this check with the battery plug and the CN104, CN136
connectors disconnected. Visually check inside the connectors
1
2 3 and the crimped portion of its wire for defects.
CN136-1(2) to P1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: CB05

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

MB
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
Result Procedure
STEP2
Inspection : MB contactor coil

1
CN136-1 to CN136-2 30 Ω (Approx. 20
2 3 Ω：20°C),
Judgment
Result Procedure
OK Go to step 3
STEP3

nesses.
CN104
CN136
1
8 9 10 11 12 13 14 15 16 17
2 3
and the crimped portion of its wire for defects.
18 19 20 21 22 23 24 25

Judgment
Result Procedure
5
NG Harness defect.
Error Code: CC01

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

Error Code: CC02

CAUTION 5
Probable cause
Related portion

Error Code: CC03

CAUTION
Probable cause
Related portion

Error Code: CC04

CAUTION 5
Probable cause
Related portion

Error Code: CC06

CAUTION
Probable cause
Related portion

Error Code: CD01

Failure mode: Drive motor driver RH CPU abnormality
CAUTION 5
• If CD01 occurs, the drive motor driver RH is defective. Replace it.
Probable cause
Related portion

Error Code: CD02

CAUTION
Probable cause
Related portion

Error Code: CD03

CAUTION 5
Probable cause
Related portion

Error Code: CD04

CAUTION
Probable cause
Related portion

Error Code: CD06

CAUTION 5
Probable cause
Related portion

Error Code: E002

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

V Pump motor
driver
P16
W
STEP1
check the fastened and crimped portions of the pump motor
cables for defects. (Refer to BEFORE TROUBLESHOOTING)
Connect the pump motor cables, connect the battery plug, and
errors.
Judgment
Result Procedure
Go to step 2
E002 error occurs.
E002 error does not occur. Pump motor cable tightening is defective
STEP2
Disconnect the three motor cables from the pump motor driver
and isolate them. Make sure the disconnected terminals are not
touching. 5
Operate the direction lever forward or backward and check if er-
ror E002 occurs.
Judgment
Result Procedure
E002 error does not occur. Go to step 3
E002 error occurs. Pump motor driver defect
STEP3
Inspection : Pump motor cable
Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for continuity and shorts.
Turn off the key switch, disconnect the battery plug and discon-
nect the pump motor cables. Visually check each terminal and

P14 cable to P15 cable No continuity
Judgment
Result Procedure
OK (C002 does not occur at the same time
Go to step 4
on STEP1)
OK (C002 occurs at the same time on
Go to step 5
STEP1)
NG Pump motor cable defect
STEP4
Replace the pump motor driver with the drive motor driver LH.
Judgment
Result Procedure
C002 error occurs. If the error code changes to E002, replace the pump motor
driver.
E002 error occurs. Pump motor defect
STEP5
Inspection : Pump motor
Check the pump motor.
Judgment
Result Procedure
NG Pump motor defect
Error Code: E101

Failure mode: Pump motor driver current sensor neutral voltage error
CAUTION 5
• If E101 occurs, the pump motor driver circuit is defective. Replace it.
Probable cause
Related portion
Pump motor driver
Current sensor
Error Code: E102

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

V Pump motor
driver
P16
W
STEP1
Turn the key switch off and on, operate the direction lever for-
ward or backward, and check if E002 error occurs.
Judgment
Result Procedure
E002 error does not occur. Go to step 2
E002 error occurs. Perform troubleshooting for E002.
STEP2
check the assembled and crimped portions of the pump motor
cables for defects. (Refer to BEFORE TROUBLESHOOTING)
Connect the pump motor cables, connect the battery plug, and
errors.
Judgment
Result Procedure
Go to step 3
E102 error occurs.
E102 error does not occur. Pump motor cable tightening is defective 5
STEP3
Inspection : Pump motor cable
Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for continuity and shorts.
Turn off the key switch, disconnect the battery plug, and discon-
nect the pump motor cables. Visually check each terminal and
Judgment
Result Procedure
OK (C102 does not occur at the same time
Go to step 4
on STEP 2)
OK (C102 occurs at the same time on
Go to step 5
STEP 2)
NG Pump motor cable defect
STEP4
Replace the pump motor driver with the drive motor driver LH.
Judgment
Result Procedure
C102 error occurs. If the error code changes to E102, replace the pump motor
driver.
E102 error occurs. Pump motor defect
STEP5
Inspection: Pump motor
Check the pump motor.
Judgment
Result Procedure
NG Pump motor defect
Error Code: E201

Failure mode: Pump motor overheating abnormality
CAUTION 5
Probable cause
▪ Harness defect
Related portion
CN111-9 (88, STPM+) CN55-2

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

CN104-3 (1, CBAT+) CN118-1
CN250-29 CN250-30
F53
STEP1

FAN2：OFF → ON
* If the cooling fan is not working correctly, start troubleshooting

from STEP2.
Judgment
Result Procedure
Result Procedure
STEP2
Inspection:
Reconfirm the error
Turn the key switch ON and check the error that is displayed.
Judgment
Result Procedure
A "PM" is displayed. Go to step 3
When the temperature of the drive motor driver drops, “PM” goes
No "PM" is displayed. away and the lift truck can be operated as usual. Continuously
STEP3
Inspection:
Confirm the temperature of the pump motor and recheck the er-
ror
･Pump motor temperature

[ANL] I/O TEMP/VOLT 3/6　TPM
Record the temperature of the pump motor.
thirty minutes. Turn the key switch ON and check the error dis-
played.
Judgment
Result Procedure
An "PM" is displayed. Go to step 4
When the temperature of the drive motor driver drops, “PM” goes
No "PM" is displayed. away and the lift truck can be operated as usual. Continuously
STEP4
Inspection:
Recheck the temperature of the pump motor.
･Pump motor temperature

[ANL] I/O TEMP/VOLT 3/6　TPM
Check the pump motor temperature, and compare it to the re-

corded value.
Judgment 5
Result Procedure
It has lowered by 41°F ( 5°C) or more. Go to step 3
It has not lowered by 41°F ( 5°C) or more. E202 Perform troubleshooting from STEP2.
STEP5
Inspection :
Inspect harness
CN102 Portion to be inspected Standard:

1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 CN102-2 to CN104-3 No continuity
28 29 30 31 32 33 34 35 CN118
CN104 2 1
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
Judgment
Result Procedure
NG Harness defect
OK Go to step 6
STEP6
Inspection :
Inspect cooling fan.

turn the key switch ON.

FAN2：OFF → ON
Judgment
Result Procedure
Cooling fan defect
main controller.
Error Code: E202

Failure mode: Pump motor temperature sensor (open/short) abnormality
Probable cause 5
▪ Pump motor temperature sensor defect
▪ Pump motor temperature sensor harness defect
Related portion
CN111-9 (88, STPM+) CN55-2

Pump motor driver Temperature sensor
(Pump motor)
CN111-10 (89, STPM) CN55-1
STEP1
Disconnect the battery plug and visually check inside the con-
nector between CN55 and the crimped portion of its wire for de-
fects. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
E202 error occurs. Go to step 2
E202 error does not occur. Connector contact defect
STEP2
Inspection:
Pump motor temperature sensor individual inspection
Disconnect the CN55 connector and perform the sensor indi-
vidual inspection.
CN55
2 1


and CN55-2 (sensor side of CN55)
Standard: Approx. 245 Ω to 600 kΩ
* The resistance is changed depending on the temperature.

Refer to the table below for the rough standard value.
Temperature
sensor resist-
CN55-2 and
CN55-1)
68°F (20°C) Approx. 13 kΩ
176°F (80°C) Approx. 1.75 kΩ
212°F (100°C) Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Pump motor temperature sensor defect
STEP3
Inspection: Harness
harnesses.
CN111 CN55 Perform this check with the battery plug and the CN111, and
1 2 3 4 5 6 7 8 CN55 connectors disconnected. Visually check inside the con-
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
nector and the crimped portion of its wire for defects with dis-
connecting SST.

and CN111-10.
No continu-
CN55-1 to CN55-2
ity
Judgment
Result Procedure
NG Pump motor temperature sensor harness defect
5
Error Code: E301

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

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

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1
nector between CN56 and CN111 and the crimped portion of its
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Harness
harnesses.

1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
nector and the crimped portion of its wire for defects with the
SST disconnected.

CN111-15 and CN111-14.
No continu-
CN111-15 to CN111-14
ity
Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3
Connect the CN111 connector. Connect the battery plug and
turn on the key switch with the CN56 connector disconnected.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection:
Connect SST2 between CN56-1 and CN56-2 on the CN111

side with CN56 connector disconnected.
CN56
5
1 2
Judgment
Result Procedure
E801 error occurs, or error does not occur. Pump motor driver defect
STEP5
Disconnect SST2, and measure the resistance between
CN56-1 (CN111 side) and N2 with CN56 connector disconnec-
ted.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: E802

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

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1
nector between CN56 and CN111 and the crimped portion of its
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
harnesses.

9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
1 2
nector and the crimped portion of its wire for defects with the 5
SST disconnected.

CN111-15 and CN111-14.
No continu-
CN111-15 to CN111-14
ity
Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3
Connect the CN111 connector. Connect the battery plug and
turn on the key switch with the CN56 connector disconnected.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection:
Connect the battery plug and turn on the key switch with dis-
connecting CN56 connector. And check the occurred error.
Judgment
Result Procedure
E802 error occurs, or error does not occur. Pump motor driver defect
STEP5
Measure the resistance between CN56-1 (CN111 side) and N2
with the CN56 connector disconnected.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: EC01

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

Error Code: EC02

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC03

CAUTION 5
Probable cause
Related portion
Pump motor driver

Error Code: EC04

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC06

CAUTION 5
Probable cause
Related portion
Pump motor driver

Error Code: EE01

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

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:
Check if error F101 or F102 is occurring at display.
Judgment
Result Procedure
F101 or F102 occur Troubleshooting for F101, F102
No occurrence Display or main controller defect
Error Code: EE02

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

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:
Check if error F101 or F102 is occurring at display.
Judgment
Result Procedure
F101 or F102 occur Troubleshooting for F101, F102
No occurrence Display or main controller defect
Error Code: F101

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

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

between CN103 and CN70 and the crimped portion of its wire

turn the key switch ON to confirm the error.
Judgment
Result Procedure
F101 or F102 occurs Perform troubleshooting for F102.
Connector contact defect
F101 and F102 does not occur
Use truck as it is.
Error Code: F102

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

CN103-14 (16, D7V) CN70-5
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15
CN103-5 CN103-4
(N2, N2) (42, KYSAT)
CN109-8
CN109-17 Drive motor
driver LH
CN109-16
CN110-8
CN110-17 Drive motor
driver RH
CN110-16
CN111-8
CN111-17 Pump motor
driver
CN111-16
STEP1
CN103 and CN70 and the crimped portion of its wire for de-
Judgment
Result Procedure
F102 error occurs. Go to step 2
F102 error does not occur. Connector contact defect
STEP2
Inspection: Harness
harnesses.
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35


Continuity (Ap-
CN103-11 to CN70-16
prox. 0 Ω)
Continuity (Ap-
CN103-12 to CN70-15
prox. 0 Ω)
No continuity (Ex-
CN70-15 to CN70-16
cept 0 Ω)
No continuity (Ex-
CN70-15 to CN70-4
cept 0 Ω)
No continuity (Ex-
CN70-15 to CN70-5
cept 0 Ω)
No continuity (Ex-
CN70-16 to CN70-4
cept 0 Ω)
No continuity (Ex-
CN70-16 to CN70-5
cept 0 Ω)
No continuity (Ex-
CN103-11 to CN103-4
cept 0 Ω)
No continuity (Ex-
CN103-12 to CN103-5
cept 0 Ω)
No continuity (Ex-
CN103-11 to CN103-5
cept 0 Ω)

No continuity (Ex-
CN103-12 to CN103-4
cept 0 Ω)
Judgment
Result Procedure 5
NG Harness defect
OK Go to step 3
STEP3
After connecting CN70 and CN103 connectors, connect the bat-
tery plug and turn on the key switch. Check the drive and ma-
terial handling operations of the lift truck.
Judgment
Result Procedure
Display defect
The traveling and load handling operation
can be performed. If the symptom persists after replacement of the display,
there are other problems. Replace the main controller.
The traveling and load handling operation
cannot be performed. If the symptom persists after replacement of the main con-
troller, there are other problems. Replace the display.
Error Code: F401

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

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

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

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

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

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

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

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

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

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
FB01 error occurs. Go to step 2
FB01 error does not occur. Connector contact defect
STEP2
Inspection: Harness
CN102
Check the harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
CN138 and CN138 connectors disconnected. Visually check inside the
connector and the crimped portion of its wire for defects. (Note: 5
1 2 3
CN104 Inspect with the SST disconnected.)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 *1: Connect CN138-1 and CN138-3 on the harness side

18 19 20 21 22 23 24 25
26 27 28 29 30 31
*2: Connect CN138-2 and CN138-3 on the harness side
CN104-10(303) to
Continuity *1
CN138-1(303)
CN102-24(304) to
Continuity *1
CN138-3(304)
CN102-35(305) to
Continuity *2
CN138-2(305)
CN138-1(303) to No continu-
CN138-2(305) ity
CN138-1(303) ity
CN138-2(305) ity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Inspection: Battery current sensor
Check the value of battery current sensor using the Analyzer
menu.
[ANL] I/O OTHERS 1/1 CSBAT
Judgment
Result Procedure
Approx. 0.00 Go to step 4
Except 0.00 Main controller defect
STEP4
Disconnect CN138 and connect CN138-1 to CN138-3 on the
harness side through SST2 (979-001/161).
Check the value of the battery current sensor using the Ana-
lyzer menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FB02

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

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
FB02 error occurs. Go to step 2
FB02 error does not occur. Connector contact defect
STEP2
Inspection: Harness
CN102
Check the harnesses.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
CN138 and CN138 connectors disconnected. Visually check inside the
connector and the crimped portion of its wire for defects. (Note :
1 2 3
CN104 Inspect with the SST disconnected.)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 *1: Connect CN138-1 and CN138-3 on the harness side

18 19 20 21 22 23 24 25
26 27 28 29 30 31
*2: Connect CN138-2 and CN138-3 on the harness side
CN104-10(303) to
Continuity *1
CN138-1(303)
CN102-24(304) to
Continuity *1
CN138-3(304)
CN102-35(305) to
Continuity *2
CN138-2(305)
CN138-2(305) ity
CN138-1(303) ity
CN138-2(305) ity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
lyzer menu.
Judgment
Result Procedure
Approx. 0.00 Go to step 4
STEP4
Disconnect CN138 and connect CN138-1 to CN138-3 on the 5
harness side through SST2 (979-001/161).
lyzer menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FF01

Failure mode: Power supply circuit for display over current
CAUTION
• When FF01 error occurs, error codes cannot be checked on the display. Perform inspection and re-
pair while conducting troubleshooting at where no error is detected.
Probable cause
▪ Display defect
▪ Harness defect
Related portion
CN103-14 (16, D7V) CN70-5
CN103-3 (14, DGND) CN70-4
STEP1
the inside of connectors CN103 and CN70 and the crimped por-
turn on the key switch to confirm the display.
Judgment
Result Procedure
Screen is displayed and FF-1 error does
Connector contact defect
not occur.
Screen isn't displayed. Go to step 2
STEP2
Perform inspection and repair while conducting troubleshooting
at when no error code is displayed.
Troubleshooting at WHEN NO ERROR CODE IS DISPLAYED.

[Classification of Control], errors related to power source and
[Phenomenon occurs on lift truck] are not indicated on the dis-
play while the lift truck runs.
Error Code: FF02

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

turn on the key switch to confirm the display.
Judgment
Result Procedure
FF02 error occurs. Go to step 2
FF02 error does not occur. Connector contact defect
STEP2
Inspection:
Steering sensor power supply inspection.
Measure the voltage between the CN19-1 and CN19-2 connect-
ors on the harness side.

Inspect the steering sensor power supply.
1 2
3 4 5 6 crimped portion and coating of each cable for defects. (Refer to
CN19-1(311) to CN19-2(51) Approx. 15V
Judgment
Result Procedure
NG Go to step 3
OK Steering sensor defect
STEP3
Inspection: Harness
harnesses.
Inspect for continuity and short circuiting of each harness.
CN103
CN19 Perform this check with the battery plug and the CN19 and
1 2 3 4 5 6
1 2
CN103 connectors disconnected. Visually check inside the con-
7 8 9 10 11 12 13 14 15 16
3 4 5 6 nector and the crimped portion of its wire for defects.
17 18 19 20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
Error Code: 3201

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

driver NC
CN111-23 (152, SETP-)
STEP1
After disconnecting the CN109, CN110, CN111 connector,
check the inside of the connector and the crimped portion of
wire to see whether it has a defect or not by visual confirmation.
Connect the CN109, CN110, CN111 connector, connect the
battery plug.

Judgment
Result Procedure
3201 error occurs. Drive motor driver (LH) defect
3201 error does not occur. Connector contact defect
Error Code: 3202

Failure mode: Drive motor driver (RH) : controller ID abnormality
CAUTION 5
• When a new motor driver, a pump motor driver, or a drive motor driver (LH) is installed as a driver
motor driver (RH), the 3202 error always occurs. This is not an abnormality. This will occur at first
power up of the controller replacement.
Probable cause
▪ Drive motor driver (RH) defect
Related portion
CN109-6 CN110-6
NC NC
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1
After disconnecting the CN109, CN110, CN111 connector, visu-
ally confirm whether the inside of the connector and the
crimped portion of the wire has a defect or not. (Refer to BE-
battery plug.

Judgment
Result Procedure
3202 error occurs. Drive motor driver (RH) defect
Error Code: 3203

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

driver NC
CN111-23 (152, SETP-)
STEP1
After disconnecting the CN109, CN110, CN111 connector, visu-
ally confirm whether the inside of the connector and the
battery plug.

Judgment
Result Procedure
3203 error occurs. Pump motor driver defect
Error Code: 3301

Failure mode: Main controller to Drive motor driver (LH): communication abnormality
CAUTION 5
• If AD01 or AD02 occurs, perform troubleshooting for AD01 or AD02 first.
Probable cause
▪ Harness defect
▪ Drive motor driver (LH) defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
After disconnecting the CN103, CN104 and CN109 connector,
visually confirm whether the inside of the connector and the
Connect the CN103, CN104 and CN109 connector, connect the
battery plug.

Especially if the drive motor driver (LH) has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
3301 error occurs. Go to step 2
Result Procedure
STEP2
Inspection: Harness

CN103
CN109
1 2 3 4 5 6 CN104, CN109 connectors disconnected. Visually confirm
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 the wire has a defect or not.
CN103-4(42) to CN103-5(N2) No continuity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Turn off the key switch, and after connecting CN103, CN104,
CN109 connectors, turn on the key switch.
Judgment
Result Procedure
STEP4
Inspection: Motor driver
5
(Ignore the error codes 3201 and 3203.)
Judgment
Result Procedure
Drive motor driver (LH) defect
3303 error occurs. The motor driver that is drive motor driver (LH) before re-
placement is defective.
3301 error occurs. Main controller defect
Error Code: 3302

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

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
After disconnecting the CN103, CN104, CN110 connectors,
Connect the CN103, CN104, CN110 connectors, connect the
battery plug.

Especially if the drive motor driver (RH) has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
Result Procedure
STEP2
Inspection: Harness 5

CN103
CN110
1 2 3 4 5 6 CN104, CN110 connectors disconnected. Visually confirm
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 the wire has a defect or not.
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Judgment
Result Procedure
STEP4
Judgment
Result Procedure
Drive motor driver (RH) defect
3303 error occurs. The motor driver that is drive motor driver (RH) before re-
placement is defective.
Error Code: 3303

Failure mode: Main controller to Pump motor driver: communication abnormality
CAUTION 5
Probable cause
▪ Harness defect
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H) Pump motor
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L) driver
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
After disconnecting the CN103, CN104, CN111 connectors,
Connect the CN103, CN104, CN111 connectors, connect the
battery plug.

Judgment
Result Procedure
Result Procedure
STEP2
Inspect harness:

and check the harnesses for continuity.
CN109
CN103
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
1 2 3 4 5 6
CN104, CN109, CN111 connectors disconnected. Visually
7 8 9 10 11 12 13 14 15 16
CN111 check inside the connectors and the crimped portion of their
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8
wires for defects.
9 10 11 12 13 14 15
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Judgment
Result Procedure
STEP4
5
Judgment
Result Procedure
3301 error occurs. If the error code changes to 3301, replace the pump motor
driver.
Error Code: 6101

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

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Load sensor
Disconnect the CN91 connector and connect CN91-1 to

CN91-2 on the harness side through SST (979-001/160).
the error.
CN91
1 5
2
Judgment
Result Procedure
6102 error occurs. Load sensor defect
6102 error does not occur. Go to step 3
STEP3
Inspection: Harness
Disconnect the CN91, CN101, CN103, CN104 connectors

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

8 9 10 11 12 13 14 15 16 17 2 Portion to be inspected Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 3 CN104-12(58) to CN91-1(58) Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 6102

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

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Load sensor
Disconnect the CN91 connector.

Judgment
Result Procedure
5
6101 error occurs. Load sensor defect
STEP3
Inspection: Harness

CN101 CN91
Perform this check with the battery plug and the CN91, CN101,
1 2 3 4 5 6 7 1
CN103, CN104 connectors disconnected. Visually check inside
8 9 10 11 12 13 14 15 16 17
2 the connectors and the crimped portion of their wires for de-
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 3
fects.
Judgment
Result Procedure
NG Harness defect
Error Code: 6201

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

sensor
CN101-32 (51, POT-) CN86-3
STEP1
After disconnecting the CN86 connector, check inside the con-
nector and the crimped portion of its wires for defects or by
visual confirmation. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Tilt angle sensor

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

nesses for continuity.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN101, CN103
CN86
28 29 30 31 32 33 34
connectors disconnected, Visually check inside the connectors
1 2 3 and the crimped portion of their wires for defects.
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
* : It is OK to connect CN86-1 to CN86-2 through SST2
28 29 30 31 32 33 34 35 (979-001/161) and check if there is continuity between
CN101-20 and CN102-17.
CN101-20(57) to CN86-1(57) * Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 6202

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

sensor
CN101-32 (51, POT-) CN86-3
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Tilt angle sensor
the error.
Judgment
Result Procedure
6201 error occurs. Tilt angle sensor defect
5
STEP3
Inspection: Harness

CN101 [Inspection procedure and standard]
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Perform this check with the battery plug and the CN86, CN101-
CN86 connectors disconnected, Visually check inside the connectors
CN103
and the crimped portion of their wires for defects.
1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 * : It is OK to connect CN86-2 to CN86-3 through SST2
28 29 30 31 32 33 34 35 (979-001/161) and check if there is continuity between
CN103-17 and CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 6301

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

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
A603 error does not occur. Go to step 2
A603 error occurs. Go to troubleshooting for A603
STEP2
Inspection: Tilt lever switch
Operate the tilt lever in either direction to confirm 6301 error.

Judgment
Result Procedure
The forward and backward tilt lever switches turned ON at the
6301 error does not occur. same time in the past. (Check the adjustment of each switch
installation) 5
STEP3
Inspection: Harness

main harnesses for continuity.
CN89
CN102 connectors disconnected. Visually confirm whether the
1 2
inside of the connector and the crimped portion of the wire has
3 4
a defect or not.
Judgment
Result Procedure
Tilt lever switch installation defect.
OK
Tilt lever switch defect
NG Harness defect
Error Code: 6302

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

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
A603 error occurs. To troubleshooting for A603
STEP2
Check the status of the switches when the tilt lever is operated
in the forward direction and returned to the center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTF

Judgment
Result Procedure
“0” occurs after operation repeated many Detect the error for operating in forward direction over 2
times. minutes. Use as it is.
“1” occurs after operation repeated several Tilt lever switch installation defect. 5
times. Tilt lever switch defect
Error Code: 6303

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

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
A603 error occurs. Go to troubleshooting for A603
STEP2
Check the status of the switches when the tilt lever is operated
in the backward direction and returned to the center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTR

Judgment
Result Procedure
“0” occurs after the operation is repeated Detect the error for operating in a backward direction for over
several times. 2 minutes. Use as it is.
“1” occurs after the operation is repeated Tilt lever switch installation defect. 5
several times. Tilt lever switch defect
Error Code: 6401

Failure mode: Lift lock solenoid open abnormality
CAUTION
• If 6403 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 6403.
• If A902 occurs at same time, perform troubleshooting for A902 first.
Probable cause
▪ Lift lock solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
the inside of connector CN88 and the crimped portion of the
wires for defects. (Refer to BEFORE TROUBLESHOOTING)
After connecting CN88, connect the battery plug and turn on the
key switch to confirm the error.
Judgment
Result Procedure
6404 error occurs. Perform troubleshooting for 6404.
STEP2
Apply the lift solenoid compulsorily by using Active Test and
check if an error occurs.
[ANL] ACTIVE TEST 1/3 5

LIFT LWR SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Lift lock solenoid individual inspection
Disconnect the CN88 connector, and check the resistance of

the lift lock solenoid.
Check the resistance of lift lock solenoid.
CN88
4 3 2 1 nect the CN88 connector. Visually check inside the connectors
and the crimped portion of their wires for defects. (Refer to BE-
8 7 6 5
CN88-2 to CN88-6 Approx. 10 Ω
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN102, CN103, CN104 and CN88 con-
nectors, then check the harnesses.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN101,
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN104, CN88 connectors disconnected. Visu-
ally check inside the connectors and the crimped portion of their
CN103 CN88 wires for defects. (Refer to BEFORE TROUBLESHOOTING)
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: Connect the CN88 connector and measure the resistance
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 between CN101-1(3) and CN102-16(4). And it is OK if this res-
28 29 30 31 32 33 34 35
istance is approx.10 Ω.
CN101-1(3) to CN88-2(477) Continuously *1
CN102-16(4) to CN88-6 Continuously *1
Judgment
Result Procedure
NG Harness defect
Error Code: 6402

Failure mode: Lift lock solenoid short abnormality
CAUTION 5
to 6403.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
nect the CN88 connector. Visually check inside the connectors
Judgment
Result Procedure
STEP2
Apply the lift solenoid compulsorily by using Active Test and


LIFT LWR SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Lift lock solenoid individual inspection
Disconnect the CN88 connector, and check the resistance of lift
lock solenoid.
CN88
4 3 2 1 nect the CN88 connector. Visually check inside the connector
and the crimped portion of its wires for defects. (Refer to BE-
8 7 6 5
CN88-2(477) to CN88-6(4) Approx. 10 Ω
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN102 and CN88 connectors, then
CN102
CN88
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 the connectors and the crimped portion of their wires for de-
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8 fects. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
NG Harness defect
5
Error Code: 6403

Failure mode: Lift lock solenoid drive circuit abnormality
Probable cause
▪ Harness defect
▪ F73 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Lift lock solenoid
Check the resistance of the lift lock solenoid.
CN88
8 7 6 5
CN88-2(477) to CN88-6(4) Approx. 10 Ω
Judgment
Result Procedure
Lift lock solenoid defect
NG
Go to step 2
OK Go to step 2 5
STEP2
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN88 Turn off the key switch and disconnect the battery plug. Discon-
28 29 30 31 32 33 34
nect the CN101, CN102 and CN88 connectors. Visually check
1 2 3 4
inside the connectors and the crimped portion of their wires for
CN102 defects. (Refer to BEFORE TROUBLESHOOTING)
5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 CN88-2(477) to CN88-6(4) No continuity
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN101-1(3) to CN102-16(4) No continuity
Judgment
Result Procedure
Harness defect
NG
Main controller defect. Go to step 3
OK Main controller defect. Go to step 3
STEP3
Inspection: F73 fuse
After removing F73 fuse, measure the resistance for both ends
of F73 fuse.
Judgment
Result Procedure
F73 fuse defect
∞Ω Replace the F73 fuse with the defective portion in the former
step.
0Ω Replace the defective portion in the former step.
Error Code: 6404

Failure mode: Lift lock solenoid (open / short) abnormality
CAUTION
to 6403.
Probable cause
▪ F73 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
6404 error does not occur. Connector contact defect.
5
STEP2
Inspection : Check the mounting state of F73 fuse
Visually confirm if the F73 fuse has no defect.
After connecting the fuse, connect the battery plug and turn on
the key switch to confirm the error.
Judgment
Result Procedure
6404 error does not occur. F73 fuse installation defect
STEP3
Inspection : F73 fuse individual inspection
of F73 fuse.
Judgment
Result Procedure
F73 fuse defect.
∞Ω
After replacing F73 fuse, go to STEP5.
0Ω Go to step 4
STEP4
Inspection: F73 fuse box
Connect the F73 fuse, and disconnect the connector of F73

fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5
Inspection : Lift lock solenoid individual inspection

CN88
8 7 6 5
CN88-2(477) to CN88-6(4) Approx. 10 Ω
Judgment
Result Procedure
Lift lock solenoid defect
NG
If replacing the F73 fuse in the former step, perform STEP6.
OK Go to step 6
STEP6
Inspection: Harness
Disconnect the CN101, CN102, CN103 and CN88 connectors,
then check the harnesses.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN88 connectors disconnected. Visually check
CN103 CN88 defects. (Refer to BEFORE TROUBLESHOOTING)
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: If the former step is OK, connect the CN88 connector and
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 measure the resistance between CN101-1(3) and CN102-16(4).
28 29 30 31 32 33 34 35
It is OK if this resistance is approx.10 Ω.
CN88-2(477) to CN88-6(4) No continuity *1
Judgment
Result Procedure
NG Harness defect
5
Error Code: 6501

Failure mode: Tilt solenoid open abnormality
CAUTION
to 6503.
Probable cause
▪ Tilt solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
key switch to the confirm error.
Judgment
Result Procedure
STEP2
Apply the tilt solenoid compulsorily by using Active Test and
[ANL] ACTIVE TEST 1/3 5

TILT SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Tilt solenoid individual inspection
the tilt solenoid.
Check the resistance of tilt solenoid.
CN88
8 7 6 5
CN88-3(479) to CN88-7(7) Approx. 10 Ω
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: Connect the CN88 connector and measure the resistance
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 between CN101-2 and CN102-19. It is OK if this resistance is
28 29 30 31 32 33 34 35
approx.10 Ω.

CN101-2(6) to CN88-3(479) Continuity *
5
Judgment
Result Procedure
NG Harness defect
Error Code: 6502

Failure mode: Tilt solenoid short abnormality
CAUTION
to 6503.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
6504 error occurs . Perform troubleshooting for 6504.
STEP2
Apply the tilt solenoid compulsorily by using Active Test and


TILT SOL：OFF to ON
5
Judgment
Result Procedure
STEP3
Inspection : Tilt solenoid individual inspection
Disconnect the CN88 connector, and check the resistance of tilt
solenoid.
CN88
4 3 2 1 nect the CN88 connector. Visually check each terminal and the
8 7 6 5
CN88-3(479) to CN88-7(7) Approx. 10 Ω
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN102 and CN88 connectors, then check the
harnesses.
CN102
CN88
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 and the crimped portion of their wires for defects. (Refer to BE-
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8 FORE TROUBLESHOOTING)
Judgment
Result Procedure
NG Harness defect
Error Code: 6503

Failure mode: Tilt solenoid drive circuit abnormality
Probable cause 5
▪ Harness defect
▪ F74 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Tilt solenoid
Disconnect the CN88 connector, and check the resistance of tilt
solenoid.
CN88
8 7 6 5
CN88-3(479) to CN88-7(7) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Tilt solenoid defect
OK Go to step 2
STEP2
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN88 Perform this check with the battery plug and the CN101,
28 29 30 31 32 33 34
1 2 3 4
the connectors and the crimped portion of their wires for de-
CN102 fects. (Refer to BEFORE TROUBLESHOOTING)
5 6 7 8
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
NG
Main controller defect Go to step 3
OK Main controller defect Go to step 3
STEP3
of F74 fuse.
Judgment
Result Procedure
F74 fuse defect
step.
０Ω Replace the defective portion in the former step.
Error Code: 6504

Failure mode: Tilt solenoid (open / short) abnormality
CAUTION 5
to 6503.
Probable cause
▪ F74 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Check the mounting F74 fuse to see whether it has a defect or
not by visual confirmation.
Judgment
Result Procedure
6504 error does not occur. F74 fuse installation defect.
STEP3
After removing the F74 fuse, measure the resistance for both
ends of the F74 fuse.
Judgment
Result Procedure
F74 fuse defect
∞Ω
After replacing F74 fuse, go to STEP5
０Ω Go to step 4
STEP4
Inspection : F74 fuse box
fuse box.
F74 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection : Tilt solenoid individual inspection
the tilt solenoid. 5
CN88
4 3 2 1
8 7 6 5

Check the resistance of the tilt solenoid.
CN88-3(479) to CN88-7(7) Approx. 10 Ω
Judgment
Result Procedure
NG
OK Go to step 6
STEP6
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: In case of the OK in the former step, connect the CN88 con-
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 nector and measure the resistance between CN101-2 and
28 29 30 31 32 33 34 35
CN102-19. It is OK if this resistance is approx.10 Ω.

CN88-3(479) to CN88-7(7) No continuity *
Judgment
Result Procedure
NG Harness defect
Error Code: 6601

Failure mode: Outside matching value range for tilt angle sensor
Probable cause 5
▪ Tilt sensor matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching of the tilt horizontal angle and the forward tilt
angle. (Refer to "Matching" of Display section)
Judgment
Result Procedure
STEP2
Tilt sensor voltage inspection:
Check the tilt sensor voltage.
･Tilt sensor voltage inspection:
[ANL] I/O M.HANDRING 2/8 VRTA

Position of tilt angle Voltage
When horizontal position 1.27V to 3.99V
Judgment
Result Procedure
Go to step 3
Outside standard value Tilt sensor assembly defect.
After reassemble, perform matching and STEP3.
Within standard value Main controller defect
STEP3
Check the error:
After 30 seconds, reconnect the battery plug and turn on the
key switch.
Judgment
Result Procedure
Tilt sensor matching defect
6601 error does not occur.
Use as it is.
Error Code: 6701

Failure mode: Lifting height switch open / short abnormality
Probable cause 5
▪ Harness defect
▪ Lifting height switch defect
Related portion
CN90
CN104-22 (90, SH1) 3 3 CN92-2
Main controller CN103-24 (91, SH2-1) 2 2 CN92-3
CN103-6 (51, LS-) 1 1 CN92-1

Lifting height
switch
STEP1
Turn off the key switch and disconnect the battery plug at the lift
trucks lowermost position.
Disconnect the CN90, CN92 connectors. Visually check inside
the connectors of CN90 and CN92, and the crimped portion of
the wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Connect the CN90 and CN92 connectors, connect the battery
plug.

When the lifting height switch arm is released, check if an error
occurs.
In case of being height switch in the truck, lifting height switch
arm is released, check if an error occurs.
Judgment
Result Procedure
STEP2
Inspection: Harness
Turn off the key switch and disconnect the battery plug while
keeping the condition (height) under the occurred error.
Disconnect the CN90 connector and check the height switch for
continuity.

Check the harness for continuity.
3 2 1 the crimped portion of its wires for defects.
Give attention to the inspection contents. These are different

standards for the condition of the height switch lever.
Portion to
Height switch lever condi-
be inspec- Standard
tion
ted
CN90-1(51)
Pushed (low height) to Continuity
CN90-2(90)
CN90-1(51)
Pushed (low height) to No continuity
CN90-3(91)
CN90-2(90)
CN90-3(91)
CN90-1(51)
Released (high height) to No continuity
CN90-2(90)
CN90-1(51)
Released (high height) to Continuity
CN90-3(91)
CN90-2(90)
CN90-3(91)
Judgment
Result Procedure
OK Go to step 3
NG Go to step 4
STEP3
Inspection: Harness

CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 5
17 18 19 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN90, CN102,
28 29 30 31 32 33 34 35
CN90 CN103 and CN104 connectors disconnected. Visually check in-
side the connectors and the crimped portion of their wires for
CN104 1 2 3 defects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 Portion to be inspected Standard
Judgment
Result Procedure
NG Harness defect
STEP4
Inspection: Lifting height switch
Turn off the key switch and disconnect the battery plug while
keeping the condition (height) under the occurred error.
Disconnect the CN92 connector and check the height switch for
continuity.
Check the switch for continuity.
3 2 1 the crimped portion of its wires for defects.
Give attention to the inspection contents. These are different

standards for the condition of the height switch lever.
Portion to
Height switch lever condi-
be inspec- Standard
tion
ted
CN92-1(51)
Pushed (low height) to Continuity
CN92-2(90)
CN92-1(51)
CN92-3(91)
CN92-2(90)
CN92-3(91)
CN92-1(51)
CN92-2(90)
CN92-1(51)
Released (high height) to Continuity
CN92-3(91)
CN92-2(90)
CN92-3(91)
Judgment
Result Procedure
OK Harness defect
NG Lifting height switch defect
Error Code: 6901

Failure mode: Backward lock solenoid open abnormality
CAUTION 5
to 6903.
Probable cause
▪ Backward lock solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid compulsorily by using Active
Test and check if an error occurs.

TILT BWD SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Backward lock solenoid individual inspection
the backward lock solenoid.
Check the resistance of backward lock solenoid.
CN88
8 7 6 5
CN88-8(480) to CN88-4(8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
inside the connectors and the crimped portion of their wires for 5
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
approx.10 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: 6902

Failure mode: Backward lock solenoid short abnormality
CAUTION 5
to 6903.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid compulsorily by using Active

Test and check if an error occurs.

TILT BWD SOL：OFF to ON
Judgment
Result Procedure
STEP3
backward lock solenoid.
CN88
8 7 6 5
CN88-8(480) to CN88-4(8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.
CN102
CN88
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 and the crimped portion of their wires for defects. (Refer to BE-
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
5
Error Code: 6903

Failure mode: Backward lock solenoid drive circuit abnormality
Probable cause
▪ Harness defect
▪ F75 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
backward lock solenoid.
CN88
8 7 6 5
CN88-8(480) to CN88-4(8) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Backward lock solenoid defect
OK Go to step 2 5
STEP2
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
NG
Main controller defect. Go to step 3
STEP3
of F75 fuse.
Judgment
Result Procedure
F75 fuse defect
step.
Error Code: 6904

Failure mode: Backward lock solenoid (open / short) abnormality
CAUTION
to 6903.
Probable cause
▪ F75 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
5
STEP2
Inspection: Check the mounting state of F75 fuse
Visually confirm if the mounting of the F75 fuse has defect.
Judgment
Result Procedure
STEP3
of the F75 fuse.
Judgment
Result Procedure
F75 fuse defect
∞Ω
０Ω Go to step 4
STEP4
fuse box.
F75 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection: Backward lock solenoid individual inspection

the backward lock solenoid.
CN88
8 7 6 5
CN88-8(480) to CN88-4(8) Approx. 10 Ω
Judgment
Result Procedure
Backward lock solenoid defect.
NG
OK Go to step 6
STEP6
Inspection: Harness
then check the harness.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: If the former step is OK, connect the CN88 connector and
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 measure the resistance between CN101-2 and CN102-18. It is
28 29 30 31 32 33 34 35
OK if this resistance is approx.10 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: 7101

Failure mode: Tire angle sensor open abnormality
Probable cause 5
▪ Tire angle sensor defect
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3
Main controller CN102-31 (317, VRTRA) CN97-2 Tire angle

sensor
CN102-26 (51, POT-) CN97-1
STEP1
Connector inspection
Visually check inside the connector of CN97, and the crimped
portion of the wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
After connecting the CN97 connector, connect the battery plug
and turn key switch ON to confirm the error.
Judgment
Result Procedure
7101 errors. Go to step 2
STEP2
Inspection: Tire angle sensor
Disconnect the CN97 connector, and connect between CN97-3
and CN97-2 with SST2 (979-001/161).
the error code.
CN97
1 2 3
Judgment
Result Procedure
7102 error occurs. Tire angle sensor defect.
STEP3
Inspection: Harness
Disconnect the CN101, CN102, and CN97 connectors. Inspect
harnesses with SST disconnected.
CN101
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug and the
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN101, CN102 and CN97 connectors. With SST disconnected,
28 29 30 31 32 33 34 CN97 visually check inside each connector and the crimped portion of
each wire for defects.
1 2 3
1 2 3 4 5 6 7 Portion to be inspected Standard

8 9 10 11 12 13 14 15 16 17 18 19 CN101-23(316) to CN97-3(316) Continuity
20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
Error Code: 7102

Failure mode: Tire angle sensor short abnormality
Probable cause 5
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
and turn the key switch ON to confirm the error.
Judgment
Result Procedure
STEP2
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN101, CN102 and CN97 connectors. Visually check inside the
28 29 30 31 32 33 34 CN97 connectors and the crimped portion of their wires for defects.
1 2 3
CN102
Portion to be inspected Standard
1 2 3 4 5 6 7 CN97-2(317) to CN97-3(316) No continuity
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Disconnect the CN97 connector, then connect the CN101 and
CN102 connectors.
　Check the error code.
Judgment
Result Procedure
7102 error occurs. Main controller defect.
7101 error occurs. Tire angle sensor defect.
Error Code: 7103

Failure mode: Tire angle sensor anchoring abnormality
Probable cause 5
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
and turn on the key switch to confirm the error by turning the
steering wheel.
Judgment
Result Procedure
7103 error does not occur. Connector contact defect.
STEP2
CN102 connectors.
Reconnect the battery plug and turn on the key switch, and
check the error code.
Judgment
Result Procedure
STEP3
Tire angle sensor inspection
CN102 connectors. Connect between CN97-3 and CN97-2 on
the harness side with SST2 connected.
Reconnect the battery plug and turn on the key switch, and
check the error code.
CN97
1 2 3
Judgment
Result Procedure
7102 error occurs. Tire angle sensor defect
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN101, CN102 and CN97 connectors. Visually check inside the
28 29 30 31 32 33 34 CN97 connectors and the crimped portion of their wires for defects.
1 2 3
CN102
Portion to be inspected Standard
1 2 3 4 5 6 7 CN101-23(316) to CN97-3(316) Continuity
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
Error Code: 7201

Failure mode: Steering-wheel angle sensor SS1 open abnormality
Probable cause 5
▪ Harness defect
▪ Steering angle sensor defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
Main controller CN104-31 (313, SSTR2) CN19-4
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
TROUBLESHOOTING)
Turn on the key switch, and check if an error occurs with turning
the steering wheel.
Judgment
Result Procedure
STEP2
Inspection: Steering angle sensor
Check the condition of the sensor when operating the steering

wheel.
[ANL] I/O STEERING 1/1 SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to step 3
STEP3
CN19
1 2
3 4 5 6

Check the condition of the sensor when operating the steering

wheel.
Judgment
Result Procedure
1** (* represents either 0 or 1.) Steering angle sensor defect
STEP4
Inspection: Harness
Disconnect the CN19, CN101, CN103, CN104 connectors and


CN104
CN19 Perform this check with the battery plug and the CN19, CN101,
1 2 3 4 5 6 7 CN103, CN104 connectors disconnected. Visually confirm
8 9 10 11 12 13 14 15 16 17
1
3 4 5 6
2
whether the inside of the connector and the crimped portion of 5
18 19 20 21 22 23 24 25
26 27 28 29 30 31
the wire has a defect or not.

Judgment
Result Procedure
NG Harness defect
STEP5
Check the condition of the sensor while operating the steering

wheel.
Judgment
Result Procedure
0** (* represents either 0 or 1.) Steering angle sensor defect
STEP6
Inspection: Harness

and check the harnesses for their continuity.

CN104
1 2 3 4 5 6 7 CN103 and CN104 connectors disconnected. Visually check in-
8 9 10 11 12 13 14 15 16 17
1
3 4 5 6
2
side the connector and the crimped portion of its wire for de- 5
18 19 20 21 22 23 24 25
26 27 28 29 30 31
fects.
Judgment
Result Procedure
NG Harness defect
Error Code: 7202

Failure mode: Steering-wheel angle sensor SS2 open abnormality
Probable cause
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
TROUBLESHOOTING)
Turn on the key switch, and check if the error occurs with turn-
ing the steering wheel.
Judgment
Result Procedure
STEP2

wheel.

Judgment
Result Procedure
*0* (* represents either 0 or 1.) Go to step 3
5
STEP3
CN19
1 2
3 4 5 6


wheel.
Judgment
Result Procedure
*1* (* represents either 0 or 1.) Steering angle sensor defect
STEP4
Inspection: Harness

check the harnesses for their continuity.

CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
3 4 5 6 the connectors and the crimped portion of their wires for de-
18 19 20 21 22 23 24 25
26 27 28 29 30 31
fects.

5
Judgment
Result Procedure
NG Harness defect
STEP5
Check the condition of the sensor with operating the steering

wheel.
Judgment
Result Procedure
STEP6
Inspection: Harness


CN104
1 2 3 4 5 6 7
1 2
CN103 and CN104 connectors disconnected. Visually check in-
8 9 10 11 12 13 14 15 16 17
3 4 5 6 side the connectors and the crimped portion of their wires for
18 19 20 21 22 23 24 25
26 27 28 29 30 31
defects.
Judgment
Result Procedure
NG Harness defect
Error Code: 7203

Failure mode: Steering-wheel angle sensor SSC open abnormality
Probable cause 5
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
After disconnecting the CN19 connector, visually check inside
the connector and the crimped portion of its wires for defects.
Turn on the key switch, and check if an error occurs while turn-
ing the steering wheel (over one revolution).
Judgment
Result Procedure
STEP2

wheel.

Judgment
Result Procedure
STEP3


wheel.
Judgment
Result Procedure
STEP4
Inspection: Harness

check the harnesses for their continuity.
CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
3 4 5 6 the connector and the crimped portion of its wire for defects.
18 19 20 21 22 23 24 25
Judgment
Result Procedure
NG Harness defect
5
STEP5

wheel.
Judgment
Result Procedure
STEP6
Inspection: Harness

CN104
1 2 3 4 5 6 7
1 2
CN103, CN104 and CN19 connectors disconnected. Visually
8 9 10 11 12 13 14 15 16 17
3 4 5 6 check inside the connector and the crimped portion of its wire
18 19 20 21 22 23 24 25
26 27 28 29 30 31
for defects.
Judgment
Result Procedure
NG Harness defect
Error Code: 7204

Failure mode: Steering-wheel angle sensor : sensor power source open abnormality
CAUTION 5
• Turning the steering angle sensor without turning the steering wheel may cause error code 7204 to
be set.
Probable cause
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
TROUBLESHOOTING)
Turn on the key switch, and turn the steering wheel to see if an
error occurs. (If the steering wheel cannot be turned easily, per-
form this check with the direction switch in the Forward or Re-
verse position.)
Judgment
Result Procedure
STEP2
Check of sensor supply voltage:
Check the supply voltage to the sensor.

CN19-1 to CN19-2
Judgment
Result Procedure
Approx. 0V Go to step 3
Approx. 15V Go to step 4
STEP3
Inspection: Harness

CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN19, CN102,
CN19
28 29 30 31 32 33 34 35 CN103 and CN104 connectors disconnected. Visually check in-
1 2
CN103 3 4 5 6
fects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
STEP4
Reconnect the CN19 connector.

Perform troubleshooting for 7201 (SSTR1).

Perform troubleshooting for 7202 (SSTR2). 5
Error Code: 7301

Failure mode: Steering knob position synchronizer solenoid open abnormality
CAUTION
to 7303.
Probable cause
▪ Steering knob position synchronizer solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
Steering knob CN98-2 (485) CN102-14 (330,SLS-)
N1 position
syncohonizer CN98-1 (330) CN103-5 (N2, N2)
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
TROUBLESHOOTING)
Connect the CN98 connector. Connect the battery plug.

Judgment
Result Procedure
5
STEP2
Using Active Test, forcibly turn on the output of the steering

knob position synchronizer solenoid to see if an error occurs.

STEERING SOL： OFF to ON
Judgment
Result Procedure
STEP3
Inspection: Steering knob position synchronizer solenoid

the steering knob position synchronizer solenoid.
Inspect the solenoid resistance.
CN98
nector disconnected. Visually confirm whether the inside of the
2 1
connector and the crimped portion of the wire has a defect or
not.
between 7 and 17
CN98-2(329) to CN98-1(329) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4
Inspection: Harness

nectors and check the harnesses for their continuity.
CN102
1 2 3 4 5 6 7 CN102, CN103 and CN104 connectors disconnected. Visually
1 2
8 9 10 11 12 13 14 15 16 17 18 19 confirm whether the inside of the connector and the crimped
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
portion of the wire has a defect or not.
*: In case of the OK in the steering knob position synchronizer

solenoid, connect the CN98 connector and measure the resist-
ance between CN102-7 and CN102-14. It is OK if this resist-
ance is between 7 and 17 Ω (approx. 10 Ω at 20°C).
Judgment
Result Procedure
NG Harness defect
Error Code: 7302

Failure mode: Steering knob position synchronizer solenoid short abnormality
CAUTION 5
to 7303.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
TROUBLESHOOTING)

Judgment
Result Procedure
STEP2
Using Active Test, forcibly turn on the output of the steering

knob position synchronizer solenoid to see if an error occurs.

STEERING SOL： OFF to ON
Judgment
Result Procedure
STEP3

CN98
nector disconnected. visually confirm whether the inside of the
2 1
not.
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN98, CN101, CN103 and CN104 connectors 5

and check the harnesses for their continuity.
CN98
CN103 and CN104 connectors disconnected. Visually confirm
1 2 whether the inside of the connector and the crimped portion of
the wire has a defect or not.
Judgment
Result Procedure
NG Harness defect
Error Code: 7303

Failure mode: Steering knob position synchronizer solenoid power-circuit abnormality
Probable cause
▪ Harness defect
▪ F71 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

CN98
2 1
not.
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
Go to step 2
NG
Steering knob position synchronizer solenoid defect
OK Go to step 2 5
STEP2
Inspection: Harness

CN102
1 2
8 9 10 11 12 13 14 15 16 17 18 19 confirm whether the inside of the connectors and the crimped
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
portion of their wires have a defect or not.
Judgment
Result Procedure
NG Harness and main controller defect. Go to step 3
STEP3
of the F71 fuse.
Judgment
Result Procedure
F71 fuse defect
step.
Result Procedure
Error Code: 7304

Failure mode: Steering knob position synchronizer solenoid (open / short) abnormality
CAUTION 5
to 7303.
Probable cause
▪ F71 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Check fuse installation:
Visually confirm if the mounting F71 fuse has no defect.
Judgment
Result Procedure
STEP3
After removing the F71 fuse, measure the resistance for both
ends of the F71 fuse.
Judgment
Result Procedure
F71 fuse defect
∞Ω
0Ω Go to step 4
STEP4
Inspection: Fuse box
fuse box.
F71 fuse box.
Judgment
Result Procedure
0Ω Go to step 5
5
STEP5

CN98
2 1
not.
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
NG If replacing the F71 fuse in the former step, perform the
STEP6.
OK Go to step 6
STEP6
Inspection: Harness


CN102
1 2
8 9 10 11 12 13 14 15 16 17 18 19 confirm whether the inside of the connector and the crimped
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
portion of the wire has a defect or not.
*: Connect the CN98 connector and measure the resistance

between CN102-7 and CN102-14. It is OK if this resistance is
between 7 and 17 Ω (approx. 10 Ω at 20°C).

CN102-7(329) to CN102-14(330) * No continuity
5
Judgment
Result Procedure
NG Harness defect
Error Code: 7401

Failure mode: Tire angle matching: matching value abnormality
CAUTION
• If 7101, 7102, 7103 occurs, give priority to troubleshooting for 7101, 7102, 7103. After that, perform
the following.
Probable cause
▪ Tire angle matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform tire angle matching. (Refer to "Matching" of Display

section)
Judgment
Result Procedure
STEP2
Tire angle sensor voltage inspection:
Check the tire angle sensor voltage.
[ANL] I/O STEERING 1/1 VRTRA

Tire angle position Voltage
When straight running condition 2.11V to 2.81V
Judgment
Result Procedure
Go to step 3
Outside standard value Tire angle sensor assembly defect. After reassemble, perform
matching and STEP3. 5
STEP3
Check the error:

key switch.
Judgment
Result Procedure
7401 error does not occur. Tire angle matching defect
Error Code: H101

Failure mode: Lift lever potentiometer open abnormality
CAUTION
• Make sure to perform matching if the lever was removed and inspected.
Probable cause
▪ Harness defect
▪ Lift lever potentiometer defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
Main controller Lift lever
CN103-18 (21, VRL2) CN115-2 potentiometer
CN102-26 (51, POT-) CN115-1
STEP1
After disconnecting the CN115 connector. Visually check inside

the connector and the crimped portion of its wires for defects.
Turn on the key switch to check that the error occurs.
Judgment
Result Procedure
H101 error does not occur. Connector contact defect
H101 error occurs. Go to step 2
STEP2
Inspection: Lift lever potentiometer
Connect between CN115-3 and CN115-4 on the harness side
with SST2 connected.
CN115
1 2 3 4
Connect the battery plug and turn on the key switch to confirm 5
Judgment
Result Procedure
H102 error does not occur. Go to step 4
STEP3
CN115
1 2 3 4
Judgment
Result Procedure
H102 error occurs. Lift lever potentiometer defect
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN115
28 29 30 31 32 33 34
CN103, and CN115 connectors disconnected, Visually check
1 2 3 4 inside the connectors and the crimped portion of their wires for
CN103 defects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Portion to be inspected Standard:
Judgment
Result Procedure
NG Harness defect
Error Code: H102

Failure mode: Lift lever potentiometer short abnormality
CAUTION 5
Probable cause
▪ Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
Inspection: Harness

CN102
1 2 3 4 5 6 7 CN103, and CN115 connectors disconnected. Visually check
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 inside the connectors and the crimped portion of their wires for
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
defects.

Judgment
Result Procedure
NG Harness defect
Error Code: H103

Failure mode: Lift lever potentiometer : sensor output declination abnormality
CAUTION 5
Probable cause
▪ Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN115 CN102, CN103 and CN115 connectors disconnected. Visually
check inside the connectors and the crimped portion of their
CN103 1 2 3 4 wires for defects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Portion to be inspected Standard:
Judgment
Result Procedure
NG Harness defect
STEP4

CN115
1 2 3 4
Judgment
Result Procedure
STEP5
CN115
1 2 3 4
Judgment
Result Procedure
Error Code: H104

Failure mode: Lift lever potentiometer neutral abnormality
CAUTION
• H104 error occurs if the key switch is turned on while operating lift lever.
Probable cause
▪ Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Check if the lift lever potentiometer is installed correctly.
Perform matching the lift lever potentiometer. (Refer to MATCH-

ING [page 143].)
Judgment 5
Result Procedure
NG matching Lift lever potentiometer defect
OK matching Lift lever potentiometer assembly defect
Error Code: H105

Failure mode: Lift lever potentiometer matching value abnormality
CAUTION
• If H101, H102, H103, H104 occurs, give priority to troubleshooting for H101, H102, H103, H104.
Probable cause
▪ Lift lever potentiometer matching value defect
▪ Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
Perform matching the lift lever potentiometer.
(Refer to MATCHING [page 143].)
Judgment
Result Procedure
STEP2
Check the lift lever potentiometer voltage.
Lift lever angle sensor (1/2) voltage

[ANL] I/O M. HANDLING 5/8 VRL

In case of uppermost / lowermost, make sure to confirm the
range is within the following table and the difference of the
sensor neutral matching voltage is over 0.79V.
Position of lift Standard lever spec.

lever sensor 1 sensor 2
Neutral 1.65 ~ 2.87V 1.52 ~ 3.01V
When Uppermost
0.30 ~ 2.87V 1.52 ~ 4.50V
position
When Lowermost
5
1.65 ~ 4.50V 0.30 ~ 3.01V
position
Judgment
Result Procedure
Go to step 3
Outside standard value Lift lever potentiometer assembly defect
Perform the matching after reassemble.
STEP3
switch.
Judgment
Result Procedure
Lift lever potentiometer matching value defect
H105 error does not occur.
Use as it is.
H105 error occurs. Main controller defect
Error Code: H201

Failure mode: Tilt lever potentiometer open abnormality
CAUTION
Probable cause
▪ Harness defect
▪ Tilt lever potentiometer defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
Main controller Tilt lever
CN102-22 (23, VRT2) CN163-2 (23) potentiometer
CN102-26 (51, POT-) CN163-1 (51)
STEP1
After connecting CN163, connect the battery plug and turn on
Judgment
Result Procedure
STEP2
Inspection: Tilt lever potentiometer
Replace CN163 with CN162 (connector of tilt lever poten-
tiometer and lift lever potentiometer).
the error code.
H104, H204 can be ignored.

Judgment
Result Procedure
H101 error occurs. Tilt lever potentiometer defect
5
STEP3
Inspection: Harness
Disconnect the CN101, CN102 and CN163 connector, then
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 CN102, CN163 connectors disconnected. Visually check inside
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 *: It is OK "to connect CN163-3 to CN163-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-28 and CN102-23", and "to connect CN163-2 to
CN163-4 through SST2 (979-001/161) and check if there is
continuity between CN101-28 and CN102-22".
Portions to be checked Standard:
Judgment
Result Procedure
NG Harness defect
Error Code: H202

Failure mode: Tilt lever potentiometer short abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Replace CN163 with CN162 (connector of tilt lever poten-
tiometer and left lever potentiometer).
the error code.

Judgment
Result Procedure
H102 error occurs. Tilt lever potentiometer defect.
5
STEP3
Inspection: Harness
harnesses.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 connectors disconnected. Visually check inside the connectors
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 *: It is OK to connect CN163-1 to CN163-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-28.
Judgment
Result Procedure
NG Harness defect
Error Code: H203

Failure mode: Tilt lever potentiometer : sensor output declination abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Judgment
Result Procedure 5
STEP3
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 and CN163 connectors disconnected. Visually check inside the
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Portions to be checked Standard:
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
STEP4
CN163
1 2 3 4
Judgment
Result Procedure
STEP5
Check the tilt lever potentiometer
CN163
1 2 3 4
Judgment
Result Procedure
H202 error occurs. Tilt lever potentiometer defect.
Error Code: H204

Failure mode: Tilt lever potentiometer neutral error abnormality
CAUTION 5
• H204 error occurs if the key switch is turned on while operating tilt lever.
Probable cause
▪ Tilt lever potentiometer assembly defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Check if the tilt lever potentiometer is installed correctly.
Perform matching the tilt lever potentiometer. (Refer to "Match-
ing" of Display section)
Judgment
Result Procedure
NG matching Tilt lever potentiometer defect.
OK matching Tilt lever potentiometer assembly defect.
Error Code: H205

Failure mode: Tilt lever potentiometer matching value abnormality
Probable cause 5
▪ Tilt lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching of the tilt lever. (Refer to "Matching" of Dis-

play section)
Judgment
Result Procedure
STEP2
Tilt lever potentiometer voltage inspection:
Check the tilt lever voltage.
･Tilt lever potentiometer voltage
[ANL] I/O M.HANDRING 6/8 VRT

Position of tilt lever sensor 1 sensor 2
1.78V to
When neutral position 1.78V to 2.75V
2.75V
Judgment
Result Procedure
Go to step 3
Outside standard value Tilt lever assembly defect. After reassembly, perform match-
ing and STEP 3.
Within standard value Main controller defect.
STEP3
Check the error:
key switch.
Judgment
Result Procedure
Tilt lever potentiometer matching defect
Use as it is.
Error Code: H301

Failure mode: Attachment 1 lever potentiometer open abnormality
CAUTION 5
Probable cause
▪ Harness defect
▪ Attachment 1 lever potentiometer defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-21 (24, VRA11) CN119-3 (24) Attachment 1
Main controller lever
CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection : Attachment 1 lever potentiometer
Replace CN119 with CN115 (connector of attachment lever 1
potentiometer and lift lever potentiometer).
the error code.

Judgment
Result Procedure
H101 error occurs. Attachment 1 lever potentiometer defect
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H302

Failure mode: Attachment 1 lever potentiometer short abnormality
CAUTION 5
Probable cause
▪ Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection: Attachment 1 lever potentiometer
the error code.

Judgment
Result Procedure
STEP3
Inspection: Harness
harnesses.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 * : It is OK to connect CN119-1 to CN119-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-29.
Judgment
Result Procedure
NG Harness defect
Error Code: H303

Failure mode: Attachment 1 lever potentiometer: sensor output declination
abnormality
5
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Attachment 1 potentiometer
Judgment
Result Procedure
STEP3
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
CN119-2 (25) to CN119-4(30) No continuity
Judgment
Result Procedure
NG Harness defect
STEP4
Inspection: Attachment 1 potentiometer
with SST2 (979-001/161) connected.
CN119
1 2 3 4 5
Judgment
Result Procedure
STEP5
CN119
1 2 3 4
Judgment
Result Procedure
Error Code: H304

Failure mode: Attachment 1 lever potentiometer neutral abnormality
CAUTION
• H304 error occurs if the key switch is turned on while operating attachment 1 lever.
Probable cause
▪ Attachment 1 lever potentiometer assembly defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Check if the attachment 1 lever potentiometer is installed cor-
rectly.
Perform matching the attachment 1 lever potentiometer. (Refer
to "Matching" of Display section)
Judgment
Result Procedure
NG matching Attachment 1 lever potentiometer defect
OK matching Attachment 1 lever potentiometer assembly defect
5
Error Code: H305

Failure mode: Attachment 1 lever potentiometer matching value abnormality
Probable cause
▪ Attachment 1 lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching the attachment 1 lever.

(Refer to "Matching" of Display section)
Judgment
Result Procedure
STEP2
Attachment 1 lever potentiometer voltage inspection:
Check the attachment 1 lever voltage.
Attachment 1 lever potentiometer voltage.
[ANL] I/O M.HANDRING 7/8 VRA1

Position of attachment 1
sensor 1 sensor 2
lever
1.65V to
When the neutral position 1.52V to 3.01V
2.87V
Judgment
Result Procedure
Go to step 3
Outside standard value Attachment 1 lever assembly defect. After reassembly, per-
form matching and STEP 3. 5
STEP3
Check the error:
key switch.
Judgment
Result Procedure
Attachment 1 lever potentiometer matching defect
Use as it is.
Error Code: H401

Failure mode: Attachment 2 lever potentiometer open abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2
the error code.

Judgment
Result Procedure
5
STEP3
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H402

Failure mode: Attachment 2 lever potentiometer short abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2
the error code.

Judgment
Result Procedure
5
STEP3
Inspection: Harness
harnesses.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 *: It is OK to connect CN120-1 to CN120-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-30.
Judgment
Result Procedure
NG Harness defect
Error Code: H403

Failure mode: Attachment 2 lever potentiometer: sensor output declination
abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1

TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection : Attachment 2 lever potentiometer
Judgment
Result Procedure 5
STEP3
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
STEP4
CN120
1 2 3 4
Judgment
Result Procedure
STEP5
CN120
1 2 3 4
Judgment
Result Procedure
Error Code: H404

Failure mode: Attachment 2 lever potentiometer neutral abnormality
CAUTION 5
• H404 error occurs if the key switch is turned on or the emergency stop button is released using op-
erating attachment 2 lever.
Probable cause
▪ Attachment 2 lever potentiometer assembly defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Check if the attachment 2 lever potentiometer is installed cor-
rectly.
Perform matching the attachment 2 lever potentiometer. (Refer
to "Matching" of Display section)
Judgment
Result Procedure
NG matching Attachment 2 lever potentiometer defect
OK matching Attachment 2 lever potentiometer assembly defect
Error Code: H405

Failure mode: Attachment 2 lever potentiometer matching value abnormality
Probable cause 5
▪ Attachment 2 lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING:
Perform matching the attachment 2 lever. (Refer to "Matching"

of Display section)
Judgment
Result Procedure
STEP2
Attachment 2 lever potentiometer voltage inspection:
Check the attachment 2 lever voltage.
Attachment 2 lever potentiometer voltage.
[ANL] I/O M.HANDRING 8/8 VRA2

Position of attachment 2
sensor 1 sensor 2
lever
1.65V to
When the neutral position 1.52V to 3.01V
2.87V
Judgment
Result Procedure
Go to step 3
Outside standard value Attachment 2 lever assembly defect. After reassemble, per-
form matching and STEP 3.
STEP3
Check the error:
key switch.
Judgment
Result Procedure
Attachment 2 lever potentiometer matching defect
Use as it is.
Error Code: H501

Failure mode: Lift proportional valve solenoid open abnormality (lever pull side)
CAUTION 5
• If H505 also occurs, disconnect the battery plug at once. Perform troubleshooting with priority given
to H505.
• If HB01 or HB03 occurs at the same time, perform troubleshooting for HB01, HB03 first.
Probable cause
▪ Lift proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
CN127-1 (19,VBMBSL) CN127-7 (17,SOLCOM) CN102-5 (17,SOLCOM)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

Lift PULL controller
solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
solenoid CN104-4 (N2, N2)
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
H506 error occurs. Perform troubleshooting for H506.
STEP2
Operate the pull side of lift lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PULL) individual in-
spection
Disconnect the CN78 connector, and check the resistance of lift

proportional valve solenoid (PULL).
Check the resistance of lift proportional valve solenoid (PULL).
CN78
4 3 2 1 nect the CN78 connector. Visually check inside the connectors
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4 the connectors and the crimped portion of their wires for de- 5
5 6 7 8
1 2 3 4 5 6

17 18 19 20 21 22 23 24 25 26 27 between CN101-5(9) and CN101-17(10). It is OK if this resist-
28 29 30 31 32 33 34 35
ance is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H502

Failure mode: Lift proportional valve solenoid short abnormality (lever pull side)
CAUTION
to H505.
Probable cause
▪ Lift proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Judgment
Result Procedure
5
STEP2
Operate the pull side of lift lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PULL) individual in-
spection
the lift proportional valve solenoid (PULL).
Check the resistance of lift proportional valve solenoid (PULL).
CN78
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H503

Failure mode: Lift proportional valve solenoid open abnormality (lever push side)
CAUTION 5
to H505.
Probable cause
▪ Lift proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of the lift lever more than 1 second to
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PUSH) individual in-
spection
Disconnect the CN87 connector. Check the resistance of lift

proportional valve solenoid (PUSH).
Check the resistance of lift proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connector, and visually check inside each con-
8 7 6 5
nector and the crimped portion of each wire for defects. (Refer
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

17 18 19 20 21 22 23 24 25 26 27 between CN101-5(9) and CN101-16(11). It is OK if this resist-
28 29 30 31 32 33 34 35
ance is approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H504

Failure mode: Lift proportional valve solenoid short abnormality (lever push side)
CAUTION
to H505.
Probable cause
▪ Lift proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
nect the CN87 connector. Visually check inside each connector
and the crimped portion of each wire for defects. (Refer to BE-

Judgment
Result Procedure
5
STEP2
Operate the push side of lift lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Lift proportional valve solenoid (PUSH) individual in-
spection
Disconnect the CN87 connector. Check the resistance of the lift
proportional valve solenoid (PUSH).
Check the resistance of lift proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connector, and visually check inside each con-
8 7 6 5
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H505

Failure mode: Lift proportional valve solenoid drive circuit abnormality
Probable cause 5
▪ Lift proportional valve solenoid defect
▪ Harness defect
▪ F76 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Lift proportional valve solenoid individual inspection
Disconnect the CN78 and CN87 connectors, and check the res-
istance of the lift proportional valve solenoid.

Check the resistance of lift proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78 and CN87 connectors. Visually check each ter-
8 7 6 5
minal and the crimped portion and coating of each cable for de-
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
Lift proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87 FORE TROUBLESHOOTING)
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
NG Main controller defect
Go to step 3
OK
Go to step 3
STEP3
of F76 fuse. 5
Judgment
Result Procedure
F76 fuse defect
step.
Error Code: H506

Failure mode: Lift proportional valve solenoid (open / short) abnormality
CAUTION
• If H505 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to H505.
• If HB01, HB02, or HB03 occurs at the same time, perform troubleshooting for HB01, HB02, HB03
first.
Probable cause
▪ F76 fuse defect
▪ Lift proportional valve solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78 and CN87 connectors. Check the inside of connectors
CN78 and CN87, and the crimped portion of their wires to see
whether it has a defect or not by visual confirmation. (Refer to
5
After connecting CN78 and CN87, connect the battery plug and
Judgment
Result Procedure
STEP2
Check the mounting F76 fuse it has defect or not by visual con-
firmation.
After connecting fuse, connect the battery plug and turn on the
Judgment
Result Procedure
H506 error does not occur. F76 fuse installation defect
STEP3
Inspection: F76 fuse individual inspection
1. Turn off the key switch and disconnect the battery plug.
2. After removing F76 fuse, measure the resistance for both

ends of F76 fuse.
Judgment
Result Procedure
F76 fuse defect
∞Ω
After replacing fuse, go to STEP5
0Ω Go to step 4
STEP4

fuse box.

Judgment
Result Procedure
0Ω Go to step 5
5
STEP5
Inspection: Lift proportional valve solenoid individual inspection
istance of the lift proportional valve solenoid.
Check the resistance of lift proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78 and CN87 connectors. Visually check each ter-
8 7 6 5
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
Lift proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
Inspection: Harness
Disconnect the CN101, CN103, CN78, and CN87 connectors,
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN103, CN78, CN87 connectors disconnected. Visually check
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: In case of the OK in the former step, connect the CN78 con-
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 nector and measure the resistance between CN101-5(9)and
28 29 30 31 32 33 34 35
CN101-17(10). It is OK if this resistance is approx. 8 Ω.
*2: In case of the OK in the former step, connect the CN87 con-
nector and measure the resistance between CN101-5(9)and
CN101-16(11). It is OK if this resistance is approx. 8 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: H601

Failure mode: Tilt proportional valve solenoid open abnormality (lever pull side)
CAUTION 5
• If H605 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to H605.
Probable cause
▪ Tilt proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

Tilt PULL controller
solenoid CN78-2 (33) CN101-13 (34,STPS-)
CN87-6 (482) CN103-5 (N2, N2)

Tilt PUSH CN104-4 (N2, N2)
solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78 connector. Check the inside of connector CN78 and the
ING)
Judgment
Result Procedure
STEP2
Operate the pull side of the tilt lever for more than 1 second to
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PULL) individual in-
spection
the tilt proportional valve solenoid (PULL).
Check the resistance of the tilt proportional valve solenoid
(PULL).
CN78
4 3 2 1 Turn off the key switch and disconnect the battery plug. Discon-
8 7 6 5
CN78-6(482) to CN78-2(33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H602

Failure mode: Tilt proportional valve solenoid short abnormality (lever pull side)
CAUTION
to H605.
Probable cause
▪ Tilt proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
5
STEP2
Operate the pull side of the tilt lever for more than 1 second to
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PULL) individual in-
spection
the tilt proportional valve solenoid (PULL).
(PULL).
CN78
4 3 2 1 Turn off the key switch and disconnect the battery plug, discon-
8 7 6 5
CN78-6(482) to CN78-2(33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H603

Failure mode: Tilt proportional valve solenoid open abnormality (lever push side)
CAUTION 5
to H605.
Probable cause
▪ Tilt proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and
ING)
Judgment
Result Procedure
STEP2
Operate the push side of the tilt lever for more than 1 second to
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PUSH) individual in-
spection
the tilt proportional valve solenoid (PUSH).
(PUSH).
CN87
8 7 6 5
nect the CN87 connectors, and visually check inside each con-
CN87-6(482) to CN87-2(34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H604

Failure mode: Tilt proportional valve solenoid short abnormality (lever push side)
CAUTION
to H605.
Probable cause
▪ Tilt proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
5
STEP2
Operate the push side of the tilt lever more than 1 second to
Judgment
Result Procedure
STEP3
Inspection: Tilt proportional valve solenoid (PUSH) individual in-
spection
the tilt proportional valve solenoid (PUSH).
(PUSH).
CN87
8 7 6 5
nect the CN87 connector, and visually check inside the con-
CN87-6(482) to CN87-2(34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H605

Failure mode: Tilt proportional valve solenoid drive circuit abnormality
Probable cause 5
▪ Tilt proportional valve solenoid defect
▪ Harness defect
▪ F77 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Tilt proportional valve solenoid individual inspection
istance of the tilt proportional valve solenoid.

Check the resistance of the tilt proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78 and CN87 connectors, visually check each ter-
8 7 6 5
8 7 6 5
CN78-6(482) to CN78-2(33) Approx. 8 Ω
CN87-6(482) to CN87-2(34) Approx. 8 Ω
Judgment
Result Procedure
Tilt proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87 to BEFORE TROUBLESHOOTING)
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
Go to step 3
OK
Go to step 3
STEP3
of F77 fuse. 5
Judgment
Result Procedure
F77 fuse defect
step.
Error Code: H606

Failure mode: Tilt proportional valve solenoid (open / short) abnormality
CAUTION
to H605.
first.
Probable cause
▪ F77 fuse defect
▪ Tilt proportional valve solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78, CN87 connectors. Check the inside of connectors CN78,
CN87 and the crimped portion of their wires to see whether they
have a defect or not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
5
Judgment
Result Procedure
STEP2
Check the mounting F77 fuse it has defect or not by visual con-
firm.
Judgment
Result Procedure
STEP3
of F77 fuse.
Judgment
Result Procedure
F77 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
Measure the resistance for both ends of the connector for F77
fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection: Tilt proportional valve solenoid individual inspection
the tilt proportional valve solenoid.
Check the resistance of the tilt proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78, CN87 connectors, and visually check inside
8 7 6 5
each connector and the crimped portion of each wire for de-
8 7 6 5
CN78-6(482) to CN78-2(33) Approx. 8 Ω
CN87-6(482) to CN87-2(34) Approx. 8 Ω
Judgment
Result Procedure
Tilt proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87
1 2 3 4 5 6
1 2 3 4
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 nector and measure the resistance between CN101-6 and
28 29 30 31 32 33 34 35
CN101-12. It is OK if this resistance is approx. 8 Ω.
nector and measure the resistance between CN101-6 and

5
Judgment
Result Procedure
NG Harness defect
Error Code: H701

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever pull
side)
CAUTION
to H705.
Probable cause
▪ Attachment 1 proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

Attachment 1 controller
PULL
solenoid CN78-3 (36) CN101-11 (37,SA1PS-)
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and dis-
connect the CN78 connector. Check the inside of connector
CN78 and the crimped portion of the wire to see whether it has
TROUBLESHOOTING)
Judgment
Result Procedure
H706 error occurs. Perform troubleshooting for H706. 5
STEP2
Operate the pull side of attachment 1 lever more than 1 second
to check if an error occurs.
Judgment
Result Procedure
STEP3
Inspection: Attachment 1 proportional valve solenoid (PULL) in-
dividual inspection
the attachment 1 proportional valve solenoid (PULL).
Check the resistance of attachment 1 proportional valve solen-
oid (PULL).
CN78
8 7 6 5
CN78-7(483) to CN78-3(36) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H702

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever pull
side)
5
CAUTION
to H705.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Turn off the key switch and disconnect the battery plug and dis-
connect the CN78 connector. Check the inside of connector
CN78 and the crimped portion of the wire to see whether it has
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Operate the pull side of attachment 1 lever for more than 1
second to check if an error occurs.
Judgment
Result Procedure
STEP3
dividual inspection
the attachment 1 proportional valve solenoid (PULL).
oid (PULL).
CN78
8 7 6 5
CN78-7(483) to CN78-3(36) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN78
8 9 10 11 12 13 14 15 16 17
1 2 3 4
and the crimped portion of their wires for defects. (Refer to BE- 5
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H703

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever push
side)
CAUTION
to H705.
Probable cause
▪ Attachment 1 proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
C87 connector. Check the inside of connector CN87 and the
ING)
Judgment
Result Procedure
H706 error occurs. Perform troubleshooting for H706. 5
STEP2
Operate the push side of the attachment 1 lever for more than 1
Judgment
Result Procedure
STEP3
Inspection: Attachment 1 proportional valve solenoid (PUSH) in-
dividual inspection
the attachment 1 proportional valve solenoid (PUSH).
Check the resistance of the attachment 1 proportional valve
solenoid (PUSH).
CN87
8 7 6 5
CN87-7(483) to CN87-3(37) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H704

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever push
side)
5
CAUTION
to H705.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
STEP2
Operate the push side of the attachment 1 lever for more than 1
Judgment
Result Procedure
STEP3
dividual inspection
the attachment 1 proportional valve solenoid (PUSH).
oid (PUSH).
CN87
8 7 6 5
CN87-7(483) to CN87-3(37) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN87
8 9 10 11 12 13 14 15 16 17
1 2 3 4
and the crimped portion of their wires for defects. (Refer to BE- 5
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H705

Failure mode: Attachment 1 proportional valve solenoid drive circuit abnormality
Probable cause
▪ Attachment 1 proportional valve solenoid defect
▪ Harness defect
▪ F78 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection: Attachment 1 proportional valve solenoid individual
inspection
istance of the attachment 1 proportional valve solenoid.

solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 Turn off the key switch and disconnect the battery plug. Discon-
nect the CN78 and CN87 connectors. Visually check each ter- 5
8 7 6 5 8 7 6 5

CN78-7(483) to CN78-3(36) Approx. 8 Ω
CN87-7(483) to CN87-3(37) Approx. 8 Ω
Judgment
Result Procedure
Attachment 1 proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
CN87-7(483) to CN87-3 (37) No continuity
Judgment
Result Procedure
Harness defect
Go to step 3
OK
Go to step 3
STEP3
of F78 fuse.
Judgment
Result Procedure
F78 fuse defect
step. 5
Error Code: H706

Failure mode: Attachment 1 proportional valve solenoid (open / short) abnormality
CAUTION
to H705.
first.
Probable cause
▪ F78 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78 and CN87 and the crimped portion of the wires to see
whether they have a defect or not by visual confirmation. (Refer
5
Judgment
Result Procedure
STEP2
Check the mounting of the F78 fuse to see whether it has a de-
fect or not by visual confirmation.
Judgment
Result Procedure
STEP3
of F78 fuse.
Judgment
Result Procedure
F78 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
inspection
Disconnect the CN78, CN87 connectors, and check the resist-
ance of the attachment 1 proportional valve solenoid.

solenoid.
CN78 CN87
8 7 6 5
nect the CN78, CN87 connectors. Visually check inside each
8 7 6 5
connector and the crimped portion of each wire for defects.
CN78-7(483) to CN78-3(36) Approx. 8 Ω
CN87-7(483) to CN87-3(37) Approx. 8 Ω
Judgment
Result Procedure
NG
If replacing the F78 fuse in the former step, perform STEP 6.
OK Go to step 6
STEP6
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87
1 2 3 4 5 6
1 2 3 4
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 nector and measure the resistance between CN101-6 and
28 29 30 31 32 33 34 35
nector and measure the resistance between CN101-6 and
5

Judgment
Result Procedure
NG Harness defect
Error Code: H801

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever pull
side)
5
CAUTION
to H805.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
STEP2
Operate the pull side of the attachment 2 lever for more than 1
Judgment
Result Procedure
STEP3
dividual inspection
Disconnect the CN78 connector, and check the resistance of at-
tachment 2 proportional valve solenoid (PULL).
solenoid (PULL).
CN78
8 7 6 5
CN78-8(484) to CN78-4(39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H802

Failure mode: Attachment 2 proportional valve solenoid short abnormality (lever pull
side)
CAUTION
to H805.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
5
STEP2
Operate the pull side of attachment 2 lever more than 1 second
to check if an error occurs.
Judgment
Result Procedure
STEP3
dividual inspection
tachment 2 proportional valve solenoid (PULL).
oid (PULL).
CN78
8 7 6 5
CN78-8(484) to CN78-4(39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H803

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever push
side)
5
CAUTION
to H805.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
STEP2
Operate the push side of attachment 2 lever more than 1
Judgment
Result Procedure
STEP3
dividual inspection
tachment 2 proportional valve solenoid (PUSH).
oid (PUSH).
CN87
8 7 6 5
CN87-8(484) to CN87-4(40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
Disconnect the CN101, CN103, and CN87 connectors, then
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
approx. 8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H804

Failure mode: Attachment 2 proportional valve solenoid short abnormality (lever push
side)
CAUTION
to H805.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
5
STEP2
Operate the push side of attachment 2 lever more than 1
Judgment
Result Procedure
STEP3
dividual inspection
tachment 2 proportional valve solenoid (PUSH).
oid (PUSH).
CN87
8 7 6 5
nect the CN87 connector. Visually check the terminal and the
CN87-8(484) to CN87-4(40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H805

Failure mode: Attachment 2 proportional valve solenoid drive circuit abnormality
Probable cause 5
▪ Harness defect
▪ F79 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
inspection
istance of attachment 2 proportional valve solenoid.

oid.
CN78 CN87
8 7 6 5
nect the CN78 and CN87 connector. Visually check each ter-
8 7 6 5

CN78-8(484) to CN78-4(39) Approx. 8 Ω
CN87-8(484) to CN87-4(40) Approx. 8 Ω
Judgment
5
Result Procedure
NG
Go to step 2
OK Go to step 2
STEP2
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
Go to step 3
OK
Go to step 3
STEP3
of F79 fuse.
Judgment
Result Procedure
F79 fuse defect
step.
Error Code: H806

Failure mode: Attachment 2 proportional valve solenoid (open / short) abnormality
CAUTION 5
to H805.
first.
Probable cause
▪ F79 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
CN78, CN87 and the crimped portion of their wires to see
whether they have a defect or not by visual confirmation. (Refer
Judgment
Result Procedure
STEP2
Visually confirm if the F79 fuse has a defect.
Judgment
Result Procedure
H806 error turn on the key switch. F79 fuse installation defect
STEP3
ends of the fuse.
Judgment
Result Procedure
F79 fuse defect
∞Ω
０Ω Go to step 4
STEP4
fuse box.
Measure the resistance at both ends of the connector for F79
fuse box.
Judgment
Result Procedure
０Ω Go to step 5
5
STEP5
inspection
istance of attachment 2 proportional valve solenoid.

oid.
CN78 CN87
4 3 2 1 4 3 2 1 Turn off the key switch. Disconnect the battery plug, and dis-
8 7 6 5
connect the CN78 and CN87 connectors. Visually check inside
8 7 6 5
each connector and the crimped portion of each wire for de-
CN78-8(484) to CN78-4(39) Approx. 8 Ω
CN87-8(484) to CN87-4(40) Approx. 8 Ω
Judgment
Result Procedure
NG
OK Go to step 6
STEP6
Inspection: Harness
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN103, CN78, and CN87 connectors disconnected. Visually
check inside the connector and the crimped portion of its wire
CN103 for defects. (Refer to BEFORE TROUBLESHOOTING)
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: If the former step is OK, connect the CN78 connector and
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 measure the resistance between CN101-5 and CN101-14. It is
28 29 30 31 32 33 34 35
OK if this resistance is approx. 8 Ω.
*2: If the former step is OK, connect the CN87 connector and
measure the resistance between CN101-5 and CN101-15. It is

5
Judgment
Result Procedure
NG Harness defect
Error Code: HB01

Failure mode: Proportional valve solenoid power supply : RY1 contact open
abnormality
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4
5
RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
Lift PULL CN78-5 (481)
solenoid CN78-1 (10) CN101-17 (10,SLPL-)
SLPL CN101-16 (11,SLPS-)
Lift PUSH CN87-5 (481)
solenoid CN87-1 (11)
SLPS
F79
CN250-48 (484) CN250-47 (9)
Attachment 2 CN78-8 (484)
PULL CN78-4 (39) CN101-14 (39,SA2PL-) Main
solenoid CN101-15 (40,SA2PS-) controller
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
Attachment 1 CN78-7 (483) CN101-10 (36,SA1PL-)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
Attachment 1 CN87-7 (483) CN104-4 (N2, N2)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
CN127 connector. Check the inside of connector CN127 and
the crimped portion of the wire to see whether it has a defect or
not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
HB01 error does not occur. Connector contact defect
HB01 error occurs. Go to step 2
STEP2
Inspection: Harness
Disconnect the CN101, CN102, CN127, and CN137 connect-
ors, then check the harnesses.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102, CN127, CN137 connectors disconnected. Visually
1 2 3 4 5 6 7 check inside the connectors and the crimped portion of their
CN102 wires for defects. (Refer to BEFORE TROUBLESHOOTING)
1 2 3 4 5 6 7 CN137 Portions to be checked Standard:

8 9 10 11 12 13 14 15 16 17 18 19
1 CN102-13(335) to CN127-5(335) Continuity
20 21 22 23 24 25 26 27
2 3
Judgment
Result Procedure
NG Harness defect
RY1 defect
OK If the symptom persists after replacement of the relay, there
are other problems. Replace the Main controller.
Error Code: HB02

Failure mode: Proportional valve solenoid load-short abnormality
Probable cause 5
▪ Harness defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
CN127, CN78, and CN87 connectors. Check the inside of con-
nector CN127, CN78, and CN87 and the crimped portion of
their wires to see whether they have a defect or not by visual
After connecting CN127, CN78 and CN87, connect the battery
plug and turn on the key switch to confirm the error.
Judgment
Result Procedure
5
STEP2
Inspection: Harness
Disconnect the CN101, CN102, CN103, CN104, CN78, and
CN87 connectors, then check the harnesses.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN104, CN78, and CN87 connectors discon-
nected. Visually check inside the connectors and the crimped
CN104 portion of their wires for defects. (Refer to BEFORE
TROUBLESHOOTING)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 Portions to be checked Standard

18 19 20 21 22 23 24 25
26 27 28 29 30 31
Judgment
Result Procedure
NG Harness defect
Error Code: HB03

Failure mode: Proportional valve solenoid power supply: RY1 over current abnormality
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4
5
RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
CN127 connector. Check the inside of connector CN127 and
the crimped portion of the wire to see whether it has a defect or
not by visual confirmation. (Refer to BEFORE
TROUBLESHOOTING)
Judgment
Result Procedure
STEP2
Inspection: Harness
harnesses.
CN127
connectors disconnected. Visually check inside the connector
1 2 3 4 5 6 7 and the crimped portion of their wires for defects. (Refer to BE-
Portions to be checked Standard
Judgment
Result Procedure
NG Harness defect
RY1 defect
OK If the symptom persists after replacement of the relay, there
are other problems. Replace the Main controller.
Error Code: HC01

Failure mode: Unload solenoid open abnormality
CAUTION 5
• If HC03 also occurs, disconnect the battery plug at once. Perform troubleshooting with priority given
to HC03.
• If A902 occurs at the same time, perform troubleshooting for A902 first.
Probable cause
▪ Unload solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
HC04 error occurs. Perform troubleshooting for HC04.
HC04 error does not occur. Go to step 2
STEP2
Apply the unload solenoid compulsorily by using Active Test

UNLOAD SOL：OFF to ON
Judgment
Result Procedure
HC01 error does not occur. Connector contact defect
HC01 error occurs. Go to step 3
STEP3
Inspection: Unload solenoid individual inspection
the unload solenoid.
Check the resistance of unload solenoid.
CN88
8 7 6 5
CN88-1(478) to CN88-5(5) Approx. 10 Ω
Judgment
Result Procedure
NG Unload solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, and CN88 connectors disconnected. Visually
check inside the connectors and the crimped portion of their 5
CN103 CN88 wires for defects. (Refer to BEFORE TROUBLESHOOTING)
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
approx.10 Ω.

Judgment
Result Procedure
NG Harness defect
Error Code: HC02

Failure mode: Unload solenoid short abnormality
CAUTION 5
to HC03.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
HC04 error occurs. Perform troubleshooting for HC04.
HC04 error does not occur. Go to step 2
STEP2
Apply the unload solenoid compulsorily by using Active Test

UNLOAD SOL: OFF to ON
Judgment
Result Procedure
STEP3
the unload solenoid.
Check the resistance of the unload solenoid.
CN88
8 7 6 5
CN88-1(478) to CN88-5(5) Approx. 10 Ω
Judgment
Result Procedure
NG Unload solenoid defect
OK Go to step 4
STEP4
Inspection: Harness
harnesses.

CN102
CN88
1 2 3 4 5 6 7 CN88 connectors disconnected. Visually check inside the con-
8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4
nectors and the crimped portion of their wires for defects. (Refer 5
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8 to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
NG Harness defect
Error Code: HC03

Failure mode: Unload solenoid drive circuit abnormality
Probable cause 5
▪ Harness defect
▪ F72 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
unload solenoid.
CN88
8 7 6 5
CN88-1(478) to CN88-5(5) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Unload solenoid defect
OK Go to step 2
STEP2
Inspection: Harness
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
Go to step 3
OK
Go to step 3
STEP3
After removing F72 fuse, measure the resistance at both ends
of the fuse.
Judgment
Result Procedure
F72 fuse defect
step.
Error Code: HC04

Failure mode: Unload solenoid (open / short) abnormality
CAUTION 5
to HC03.
• If A902 occurs at the same time, perform troubleshooting for A902 first.
Probable cause
▪ F72 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
STEP2
Check to see if the F72 fuse is mounted correctly. Visually con-
firm if it has a defect or not.
Judgment
Result Procedure
HC04 error does not occur. F72 fuse installation defect
STEP3
After removing F72 fuse, measure the resistance at both ends
of the fuse.
Judgment
Result Procedure
F72 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
unload solenoid. 5
CN88
8 7 6 5
CN88-1(478) to CN88-5(5) Approx. 10 Ω
Judgment
Result Procedure
Unload solenoid defect
NG
OK Go to step 6
STEP6
Inspection: Harness
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: If the former step is OK, connect the CN88 connector and
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 measure the resistance between CN101-1 and CN102-17. It is
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Result Procedure
Error Code: SAFETY MONITOR DRIVE MOTOR

Failure mode: Drive motor driver low temperature
If caution indicator occurs, turn on the key switch, and leave 20
to 30 minutes at normal temperature (23 to 104°F [0 to 40°C]).
5
Error Code: SAFETY MONITOR PUMP MOTOR

Failure mode: Pump motor driver low temperature
If caution indicator occurs, turn on the key switch, and leave 20
to 30 minutes at normal temperature (23 to 104°F [0 to 40°C]).
5.5 WHEN NO ERROR CODE IS DISPLAYED

Probable causes of problems for which no error code is displayed.
If an error code is displayed or the spanner indicator blinks, make sure to perform
checks with priority given to it.
Failed portions and Action and
Control systems Symptom How to check
failure modes remedies
Check the battery
Battery voltage. ▪ Charge the Bat-
: Low voltage : Battery plug is dis- tery
connected.
▪ Check the
Key switch main switch, and re-
body place it if neces-
: Open failure sary
Key switch harness - ▪ Check the har-
: Wire breakage, ness and repair
short circuit or leak- or replace it if
age (harness, con- necessary.
nector or F5 fuse) ▪ Replace the F5
fuse.
Although the key
Numeric keypad har- ▪ Check the har-
switch or ten-key op-
ness (with PIN code ness and repair
eration is turned on, -
entry) or replace it if
power is not sup-
: Open failure necessary.
Power-supply re- plied.
lated control (The multi-function Check the operation
screen does not ap- of each switch.
pear, and the lift : Check if a re-
truck does not move, sponse (lighting of
either.) LED or sounding of
buzzer) is given only
to a particular
switch.
Numeric keypad If there are two
main body (with PIN types of switches: ▪ Replace the nu-
code entry) switch to which a re- meric keypad.
: Switch failure sponse is given and
switch to which no
response is given in
the combination of
(1, 2 and 3), (4, 5
and 6), (7, 8 and 9)
or (OFF, 0 and ON),
it is certain that there
is a defective switch.

Multi-function dis- Using the Adminis-
▪ Register PIN us-
play (with PIN code trator menu, check if
ing the Adminis-
entry) PIN has been re-
trator menu.
: PIN not registered gistered. 5
Display power sup-
Although the key ply and ground har-
switch or ten-key op- ness (with PIN code
eration is turned on, entry)
power is not sup- ▪ Check the har-
: Wire breakage,
Power-supply re- plied. ness and repair
short circuit, leakage
lated control (The multi-function (harness or con- or replace it if
screen does not ap- nector) necessary.
pear, and the lift -
▪ Replace the dis-
truck does not move, Multi-function display.
either.) play (with PIN code
entry) ▪ Replace the
: Internal failure main controller.
Main controller
: Internal failure
(D7V, DGND)
Display power sup-
ply and ground har-
ness ▪ Check the har-
: Wire breakage, ness and repair
The multi-function short circuit, leakage or replace it if
screen does not ap- (harness or con- necessary.
Power-supply re-
pear. nector) -
lated control ▪ Replace the dis-
(The lift truck runs
Multi-function display.
normally.)
play ▪ Replace the
Main controller
: Internal failure

Confirm the caution *It is not abnormal-
indicator and warn- ity. Warm-up func-
ing tone on the dis- tion may be oper-
play ated for several
seconds when turn
*The caution indic- on the key switch.
Warm-up operation
ator is displayed with
with running cold
a warning tone to Operate after the
protect function.
alert the customers warning tone has
the lift truck is run- gone because trav-
ning the warm-up eling and handling
operation (E.g. If left function can not be
for a long time under operated under
low temperature). warm-up function.
After the key switch
was turned on, re-
lease the accelerator
and operate neutral
After the key switch
for the direction
The lift truck does was turned on, the
switch once, then
not run (the drive accelerator was not
operate traveling
Traveling motor does not ro- released or the dir- -
function.
tate) or cannot run at ection switch was
Traveling function
slope suddenly. not returned to neut-
can not be operated
ral.
after detecting the
accelerator released
and neutral for the
direction switch.
Check the direction
switch using Ana-
lyzer.
Direction switch : Accelerator is fully ▪ Check the
main body closed. switch, and re-
: Open failure Operate the direc- place it if neces-
Direction switch har- tion switch to see if it sary
ness turns on and off nor- ▪ Check the har-
: Wire breakage, mally. ness and repair
short circuit (harness (The lift truck does or replace it if
or connector) not run if the forward necessary.
and reverse
switches are turned
on simultaneously.)

Accelerator sensor
main body
: Internal failure Check the acceler-
Accelerator sensor ator sensor voltage ▪ Check the 5
installation portion using Analyzer. sensor and re-
: The link or the in- : Direction switch is place it if neces-
stallation portion is in neutral. sary.
broken or damaged. Fully open and close ▪ Check the har-
Accelerator sensor the accelerator ness and repair
harness pedal to check the or replace it if
: Wire breakage, change in voltage at necessary.
short circuit, leakage that time.
(harness or con-
nector)
Accelerator fully
closed/fully open Check the matching
▪ Perform match-
matching value value on the Match-
ing again.
: No agreement with ing screen.
the lift truck state
Brake sensor main
body
: Internal failure
Check the brake ▪ Check the
Brake sensor install-
sensor voltage using sensor and re-
ation portion: The
The lift truck does Analyzer. place it if neces-
link or the installa-
not run (the drive : Direction switch is sary.
tion portion is broken
Traveling motor does not ro- in neutral.
or damaged. ▪ Check the har-
tate) or cannot run at Fully open and close
slope suddenly. Brake sensor har- the brake pedal to ness and repair
ness check the change in or replace it if
: Wire breakage, voltage at that time. necessary.
(harness or con-
nector)
Brake fully closed /
operational point Check the matching
▪ Perform match-
ing again.
Tire angle sensor
main body
: Internal failure Check the sensor
voltage using Ana- ▪ Check the
Tire angle sensor in-
lyzer. sensor and re-
stallation
: Direction switch is place it if neces-
: The installation
in neutral. sary.
portion is broken or
Fully close the ac-
damaged. ▪ Check the har-
celerator pedal and
Tire angle sensor operate steering ness and repair
harness wheel to check the or replace it if
(harness or con-
nector)

Tire angle sensor
straight running Check the matching
▪ Perform match-
ing again.
Check the seat
switch using Ana-
Seat switch main lyzer. ▪ Check the seat
body : Direction switch in and replace it if
: Open failure neutral, accelerator necessary.
Seat switch harness pedal fully closed ▪ Check the har-
The lift truck does : Wire breakage, Check if the switch ness and repair
not run (the drive (harness or con- turns on and off nor- or replace it if
Traveling motor does not ro- nector) mally, sitting in the necessary.
tate) or cannot run at seat or standing be-
slope suddenly. side it.
Check the brake and
the drive motor. ▪ Check the brake,
Brake : With the battery and repair or re-
: Dragging (internal plug disconnected,
place it if neces-
failure) the parking brake re- sary.
Drive motor leased and the front
▪ Check the drive
: Seizure or dragging wheels off the
ground, motor, and re-
of drive motor (in-
rotate each tire to pair or replace it
ternal failure)
see if it rotates if necessary.
smoothly.

Main body of drive
motor rotation
sensor Check the voltage of
: Internal failure the drive motor rota- ▪ Check the drive 5
Drive motor rotation tion sensor using motor rotation
sensor installation Analyzer. sensor, and ad-
portion : Seated in seat, dir- just or replace it
: Gap improperly ad- ection switch in for- if necessary.
justed ward position, brake
released ▪ Check the har-
Drive motor harness Operate the acceler- ness and repair
: Wire breakage, ator and check the or replace it if
short circuit, leakage change in the rota- necessary.
The lift truck does (harness or con- tion sensor voltage.
not run (the drive nector)
Traveling motor does not ro-
tate) or cannot run at
Check the voltage of
slope suddenly.
the drive motor cur-
Drive motor drive cir- rent sensor using
▪ Check the cable
cuit Analyzer. and repair or re-
: Internal failure : Seated in seat, dir- place it if neces-
Motor cables ection switch in for- sary.
: Wire breakage, ward position, brake
▪ Replace the
short circuit or leak- released
Operate the acceler- drive motor drive
age (cable or ter-
ator and check the circuit.
minal board)
change in the cur-
rent sensor voltage.
Main controller ▪ Replace the
-

*It is not an abnor-
Confirm the caution
mality. Warm-up
indicator and warn-
function may be op-
ing tone on the dis-
erated for several
play
seconds when you
turn on the key
*The caution indic-
Warm-up operation switch.
ator is displayed with
with running cold
a warning tone to
protect function. Operate after the
alert customers that
warning tone has
the lift truck is run-
gone because trav-
ning the warm-up
eling and handling
operation (e.g. If left
function can not be
for a long time under
operated under
low temperature).
warm-up function.
Main body of pump
motor rotation
sensor Check the voltage of
: Internal failure ▪ Check the pump
the pump motor ro- motor rotation
Pump motor rotation tation sensor using sensor, and ad-
Load handling can-
sensor installation Analyzer. just or replace it
not be performed
portion : Seated in the seat if necessary.
and the steering is
: Gap improperly ad- Operate the direc-
heavy. ▪ Check the har-
justed tion switch and
(The pump motor ness and repair
Load handling and Pump motor harness check the change in
does not work for or replace it if
power steering : Wire breakage, the rotation sensor
material handling necessary.
short circuit, leakage voltage.
operation, steering
operation and direc- (harness or con-
tion switch opera- nector)
tion.) Check the voltage of
Pump motor drive the pump motor cur- ▪ Check the motor
circuit rent sensor using cables, and re-
: Internal failure Analyzer. pair or replace
Motor cables : Seated in the seat them if neces-
: Wire breakage, Operate the direc- sary.
short circuit or leak- tion switch and ▪ Replace the
age (cable or ter- check the change in pump motor
minal board) the current sensor drive circuit.
voltage.
▪ Check the pump,
and repair or re-
Pump place it if neces-
: Seizure sary.
-
Pump motor ▪ Check the pump
: Seizure motor, and re-
pair or replace it
if necessary.
-

Main body of load
handling lever po-
tentiometer
: Internal failure 5
Measure the voltage
Installation of load ▪ Check the
of the load handling
handling lever po- sensor and re-
lever potentiometer
tentiometer place it if neces-
using Analyzer.
: Installation portion sary.
: Leave the seat
is broken or dam-
Tilt the load handling ▪ Check the har-
aged.
lever forward and ness and repair
Load handling lever backward to check or replace it if
potentiometer har- the change in necessary.
ness voltage.
: Wire breakage,
(harness or con-
nector)
Main body of tilt for-
Only load handling
ward/backward
cannot be per-
switch
formed.
: Internal failure Check the tilt for-
Load handling and (The pump motor
power steering operates normally Installation of tilt forward/backward ▪ Check the
during steering oper- ward/backward switch using Ana- switch, and re-
ation and direction switch lyzer. place it if neces-
switch operation.) : Installation portion : Leave the seat sary
is broken or dam- Operate the tilt lever ▪ Check the har-
aged. forward to backward ness and repair
Tilt forward/back- position to check the or replace it if
ward switch harness switch turns on and necessary.
: Wire breakage, off normally.
(harness or con-
nector)
Check the seat ▪ Check the seat
Seat switch main switch using Ana- adjustment and
body lyzer. seat switch re-
: Open failure : Load handling lever place it if neces-
in neutral sary.
Seat switch harness Check if the switch
: Wire breakage, turns on and off nor- ▪ Check the har-
(harness or con- mally, sitting in the ness and repair
nector) seat or standing be- or replace it if
side it. necessary.

▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve sary. Refer to
Only load handling : Seizure of or leak- the maintenance
cannot be per- age from the unload manual
formed. valve "TROUBLESHO
Load handling and (The pump motor OTING" of oil
Harness of the un- -
power steering operates normally control valve.
load valve solenoid
during steering oper- : Wire breakage, ▪ Check the un-
ation and direction short circuit, leakage load valve solen-
switch operation.) (harness or con- oid and replace
nector) it if necessary.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the pump,
and repair or re-
place it if neces-
sary.
Only load handling ▪ Check the prior-
cannot be per- Pump ity valve, and re-
formed. : Leak pair or replace it
-
Load handling and (The pump motor Priority valve if necessary.
power steering operates normally : Leak, seizure Refer to the
during steering oper- maintenance
ation and direction manual
switch operation.) "TROUBLESHO
OTING" of oil
control valve.
-
Only lowering is im-
If a current flows, ▪ Check the lower-
possible.
Lowering lock valve turn on the lowering ing lock valve,
Load handling and (Other load handling
: Seizure (internal lock solenoid using and repair or re-
power steering operations, including
damage) Active Test to lower place it if neces-
raising, are pos-
the fork. sary.
sible.)
Only forward tilting is
If a current flows, ▪ Check the tilt for-
impossible. Tilt forward lock
turn on the tilt forward lock valve,
Load handling and (Other load handling valve:
ward lock solenoid and repair or re-
power steering operations, including Seizure (internal
using Active Test to place it if neces-
backward tilting, are damage)
forward the fork. sary.
possible.)
Only backward tilting
If a current flows, ▪ Check the back-
is impossible. Tilt backward lock
turn on the tilt backward lock valve,
Load handling and (Other load handling valve
ward lock solenoid and repair or re-
power steering operations, including : Seizure (internal
using Active Test to place it if neces-
forward tilting, are damage)
backward the fork. sary.
possible.)

Lifting height switch Check the lifting
height switch using ▪ Check the
main body
switch, and re-
: High lifting height is Analyzer.
: In ANL, place it if neces-
always detected.
Raise and lower the sary 5
Lifting switch har- lift to its uppermost ▪ Check the har-
ness and lowermost posi- ness and repair
: Wire breakage, tions to see if the or replace it if
short circuit (harness switch turns on and
necessary.
or connector) off normally.
Main body of tilt
angle sensor
: Internal damage
Check the tilt angle ▪ Check the
Tilt angle sensor in-
sensor voltage sing sensor, and ad-
stallation
Analyzer. just or replace it
Load handling and Not activated lift limit : The link or the in-
: In ANL, if necessary.
power steering function stallation portion is
Tilt the mast to its
broken or damaged. ▪ Check the har-
forward and back-
Tilt angle sensor ward tilt limits to ness and repair
harness check the change in or replace it if
: Wire breakage, voltage. necessary.
(harness or con-
nector)
Display setting:
Lifting speed limita- Check the set value
tion disabled. on the Option Set ▪ Setting screen
(OPTION SET L UP- screen.
SPD LIM)
Display setting: Check the set value
: Tuning No.35 on the Tuning ▪ Setting screen
(TUNE GEN. 35) screen.

Check the direction ▪ Check the
Direction switch switch using Ana- switch, and re-
: Open failure lyzer. place it if neces-
Direction switch har- : Accelerator is fully sary
ness closed.
Operate the direc- ▪ Check the har-
: Wire breakage
tion switch to see if it ness and repair
(harness or con-
turns on and off nor- or replace it if
nector)
mally. necessary.
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Installation of steer- sensor and re-
Check the steering
ing angle sensor place it if neces-
angle sensor using
: Cam or steering sary.
Analyzer.
wheel is defective.
: Turn the steering ▪ Check the har-
Steering angle wheel to check the ness and repair
sensor harness input signal. or replace it if
: Wire breakage, necessary.
(harness or con-
The steering is nector)
heavy.
Load handling and (The pump motor ▪ Check the pump,
power steering operates normally and repair or re-
during material place it if neces-
handling.) sary.
▪ Check the prior-
ity valve, and re-
pair or replace it
if necessary.
Pump Refer to the
: Leak maintenance
manual
Priority valve
- "TROUBLESHO
: Leak, seizure
OTING" of oil
PS valve control valve.
: Leak, seizure
▪ Check the PS
valve, and repair
or replace it if
necessary. Refer
to the mainten-
ance manual
"TROUBLESHO
OTING" of steer-
ing.
-
Although ATT1
Display setting:
(ATT2) is operated,
The serial number
no operation is per- Check the set value
Load handling and setting is not in ▪ Change the set-
formed. on the Option Set
power steering agreement with that ting
(Pump motor is not screen.
of the lift truck.
rotated at ATT oper-
(OCV WAY)
ation)

Check the seat
switch using Ana- ▪ Check the
Seat switch main lyzer. switch, and re-
body : Direction switch in place it if neces- 5
Neither traveling Op- neutral, accelerator
erator Presence : Short failure sary
pedal fully closed
Operator Presence Sensor nor load Seat switch harness Check if the switch ▪ Check the har-
Sensor handling Operator : Short circuit (har- turns on and off nor- ness and repair
Presence Sensor ness or connector) mally, sitting in the or replace it if
operates. seat or standing be- necessary.
side it.
-
Drive motor drive cir- ▪ Replace the
Only traveling Oper- cuit - drive motor drive
Operator Presence ator Presence : Internal failure circuit.
Sensor Sensor does not op-
erate. Main controller ▪ Replace the
-

▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the tilt for- sary. Refer to
: Seizure of or leak- ward lock valve us- the maintenance
age from tilt forward ing Active Test. manual
lock valve : Tilt forward solen- "TROUBLESHO
oid forcibly turned off OTING" of oil
Tilt forward solenoid (forward tilting control valve.
harness stopped)
: Short circuit, leak- ▪ Check the solen-
Tilt the fork forward
age (harness or con- oid and replace
to check the opera-
tion.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the tilt back- sary. Refer to
age from tilt back- ing Active Test. manual
Only load handling ward lock valve : Tilt backward "TROUBLESHO
Operator Presence Operator Presence solenoid forcibly OTING" of oil
Sensor Sensor does not op- Tilt backward solen- turned off control valve.
erate. oid harness (backward tilting
: Short circuit, leak- ▪ Check the solen-
stopped) Tilt the fork
age (harness or con- oid and replace
backward to check
the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the lift lower sary. Refer to
: Seizure of or leak- lock valve using Act- the maintenance
age from lift lower ive Test. manual
lock valve : Lift lower lock "TROUBLESHO
solenoid forcibly OTING" of oil
Lift lock solenoid
turned off control valve.
harness
: Short circuit, leak- (lifting stopped) ▪ Check the solen-
age (harness or con- Lower the lift to oid and replace
nector) check the operation. it if necessary.
▪ Check the har-
ness and repair
or replace it if
necessary.

▪ Check the oil
control valve,
and repair or re-
place it if neces- 5
Oil control valve sary. Refer to
: Seizure or leakage Check the unload the maintenance
from unload valve valve using Active manual
Test. "TROUBLESHO
Harness of unload : Unload solenoid
Only load handling OTING" of oil
valve solenoid forcibly turned on
Operator Presence Operator Presence control valve.
: Wire breakage, (lifting stopped)
Sensor Sensor does not op- ▪ Check the solen-
short circuit, leakage Lower the lift to
erate. oid and replace
(harness or con- check the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
-
Backup buzzer main
▪ Check the
body
backup buzzer
: Internal damage
and replace it if
Backup buzzer har- necessary.
ness -
▪ Check the har-
: Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
Auxiliary equipment ▪ Check the auxili-
relay main body ary equipment
: Open failure relay and re-
Auxiliary equipment place it if neces-
The backup buzzer - sary.
relay harness
and smart alarm do
Auxiliary equipment : Wire breakage, ▪ Check the har-
not sound.
short circuit, leakage ness and repair
(motion alarm spec.)
(harness or con- or replace it if
nector) necessary.
Backup relay main
▪ Check the
body
backup relay
: Open failure
and replace it if
Backup relay har- necessary.
ness -
▪ Check the har-
: Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
-

Backup buzzer main ▪ Check the
body backup buzzer
: Internal damage and replace it if
Backup buzzer har- - necessary.
: Short circuit, leak- ness and repair
age (harness or con- or replace it if
nector) necessary.
▪ Check the auxili-
Auxiliary equipment
ary equipment
relay main body
relay and re-
: Short circuit
place it if neces-
The backup buzzer Auxiliary equipment - sary.
and smart alarm do relay harness
Auxiliary equipment ▪ Check the har-
not stop sounding. : Short circuit, leak-
ness and repair
(motion alarm spec.) age (harness or con-
or replace it if
nector)
necessary.
Backup relay main ▪ Check the
body backup relay
: Short circuit and replace it if
Backup relay har- necessary.
-
: Short circuit, leak- ness and repair
age (harness or con- or replace it if
nector) necessary.
-
Display setting
: Operator Presence
Sensor operation Check the set value
notification buzzer on the Option Set ▪ Setting screen
Operator Presence disabled screen.
Sensor operation (BUZZER SPEC,
Buzzer-related con- SEAT BUZZER)
warning does not
trol
sound. Check that the built-
in buzzer sounds a ▪ If the buzzer
Display
short beep when the does not sound,
: Built-in buzzer is
display switch (mi- replace the dis-
broken.
croswitch) is play.
pressed.
Display setting
: Return-to-neutral Check the set value
warning buzzer dis- on the Option Set ▪ Setting screen
The traveling Oper- abled (BUZZER screen.
ator Presence SPEC)
Buzzer-related con-
Sensor return-to- Check that the built-
trol
neutral warning does in buzzer sounds a ▪ If the buzzer
not sound. Display
broken.
croswitch) is play.
pressed.

Display setting
: Return-to-neutral Check the set value
warning buzzer dis- on the Option Set ▪ Setting screen
The load handling
abled (BUZZER screen. 5
Operator Presence
SPEC)
Buzzer-related con- Sensor return-to
trol neutral warning does Check that the built-
not sound. in buzzer sounds a ▪ If the buzzer
Display
broken.
croswitch) is play.
pressed.
Check the parking
brake switch using
Parking brake switch Analyzer.
main body (The switch can also
: Short circuit ▪ Check the
be checked by switch, and ad-
Installation of park- checking if the park- just or replace it
ing brake switch ing indicator on the if necessary.
: Switch is held display goes on and
down. out.) ▪ Check the har-
ness and repair
Parking brake switch : Direction switch is or replace it if
The parking brake harness in neutral.
Buzzer-related con- necessary.
trol
release reminder : Short circuit (har- Operate the parking
does not sound. ness or connector) brake to see if the
switch turns on and
off normally.
Check that the built-
Display
broken.
croswitch) is play.
pressed.
-
Check the parking
brake switch using
: Open failure ▪ Check the
When the lift truck ing brake switch ing indicator on the
runs with the parking : Switch is off. if necessary.
display goes on and
Buzzer-related con- brake released, the ▪ Check the har-
trol parking brake re- Parking brake switch out.) ness and repair
harness : Direction switch is
lease reminder in neutral. or replace it if
sounds. : Wire breakage necessary.
(harness or con- Operate the parking
nector) brake to see if the
switch turns on and
off normally.
-

Display setting
: Parking brake re- Check the set value
minder buzzer dis- on the Option Set ▪ Setting screen
abled screen.
(PKB BUZZER)
Check the parking
brake switch using
: Open failure ▪ Check the
ing brake switch ing indicator on the if necessary.
: Switch is off. display goes on and
▪ Check the har-
Parking brake switch out.) ness and repair
harness : Direction switch is
in neutral. or replace it if
: Wire breakage necessary.
(harness or con- Operate the parking
The parking brake brake to see if the
Buzzer-related connector)
reminder does not switch turns on and
trol
sound. off normally.
Check the seat ▪ Check the seat
Seat switch main switch using Ana- and replace it if
body lyzer. necessary.
: Short failure : Check if the switch
▪ Check the har-
Seat switch harness turns on and off nor-
ness and repair
: Short circuit (har- mally, sitting in the
or replace it if
ness or connector) seat or standing be-
side it. necessary.
Check that the built-
Display
broken.
croswitch) is play.
pressed.
-
Parking brake switch
main body Check the parking ▪ Check the
: Short circuit brake switch using switch, and ad-
Installation of park-
Although the parking ing brake switch : Direction switch is if necessary.
brake is pushing, the : Switch is on. in neutral.
Buzzer-related con- Operate the parking ▪ Check the har-
parking brake re-
trol Parking brake switch brake to see if the ness and repair
minder does not
harness switch turns on and or replace it if
stop sounding.
: Short circuit (har- off normally. necessary.
ness or connector)
-

One of the following
matching operations
is not performed.
▪ Tire straight run- 5
ning angle
matching
▪ Setting screen
▪ Forward tilt limit
* If accelerator pedal
angle matching
fully closed and fully
▪ Tilt horizontal open matching is fin-
angle matching ished by simply per-
▪ Tilt no-load forming fully closed
matching matching and fully
open matching in
[Diagnostic mode in- ▪ Mast type data this order, the set-
dicator] matching
Check the matching ting will not be
Although no error ▪ Accelerator
Multifunction display value on the Match- saved.
code is displayed, pedal fully open ing screen.
the spanner indic- matching * If brake pedal fully
ator is left on. closed and operating
▪ Accelerator
pedal fully point matching is fin-
closed matching ished by simply per-
forming fully closed
▪ Brake pedal fully matching and oper-
open matching ating point matching
▪ Brake pedal fully in this order, the set-
closed matching ting will not be
saved.
▪ Each load hand-
ling lever: neut-
ral voltage
matching
▪ Tire diameter
data

Main body of tilt
angle sensor
: Internal damage
sensor voltage using sensor, and ad-
stallation
: The link or the in-
stallation portion is
forward and back-
[Tilt indicator] : Wire breakage, voltage. necessary.
The correct tilt angle short circuit, leakage
is not displayed. (harness or con-
nector)
The tilt indicator cal- Tilt angle sensor ho-
culates as 0° when rizontal matching Check the matching
matching as hori- ▪ Perform match-
value value on the Match-
Multifunction display zontal angle for no : No agreement with ing screen. ing again.
load. At tilt most for- the lift truck state
ward / most back-
ward position, it may ▪ The tilt indicator
be jolted out of align- calculates as 0°
ment for the actual when matching
tilt angle. But it is as horizontal
normal. angle for no
load. So if load
is carried, have
the potential to
A load is carried. -
display the angle
of backward side
in spite of mak-
ing fork hori-
zontal level, be-
cause tire and
mast bend to for-
ward side.

▪ The automatic
tilt leveling func-
tion stops at the
position of the 5
backward side
corrected for the
load in consider-
ation for the
bend of tire and
[Tilt indicator] mast when a
The tilt angle is not load is carried.
Multifunction display indicated as 0° when A load is carried. - On the other
the automatic fork hand, tilt indic-
leveling is finished. ator calculates
as 0° when
matching as ho-
rizontal angle for
no load.
tilt angle may not
be indicated as
0° depending on
the load, but it is
normal.

▪ Check the tires
Tire specification and replace
-
: Type, diameter them if neces-
sary
Load sensor main Check the load
sensor voltage using ▪ Check the
body
Analyzer. sensor and re-
: Internal damage
Load sensor har- Raise and lower the sary.
ness lift to its uppermost ▪ Check the har-
: Wire breakage, (relief) and lower- ness and repair
short circuit, leakage most positions to
or replace it if
(harness or con- check the change in necessary.
nector) the voltage.
Load sensor no-load
Check the matching
matching value ▪ Perform match-
value on the Match-
: No agreement with ing again.
ing screen.
main body
switch, and re-
The lift truck lacks : Low lifting height is Analyzer.
stability during trav- always detected. : In ANL, place it if neces-
eling. Raise and lower the sary
Lifting switch har- lift to its uppermost
Turn speed control (The speed limit ▪ Check the har-
ness and lowermost posi-
does not activate ness and repair
: Wire breakage, tions to see if the
easily or at all during or replace it if
turning.) necessary.
Tire angle sensor
main body
stallation
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.

Main body of drive
motor rotation ▪ Check the
sensor sensor and re-
: Internal failure place it if neces- 5
Drive motor rotation sary.
sensor harness ▪ Check the har-
: Wire breakage, - ness and repair
The lift truck lacks short circuit, leakage or replace it if
stability during trav- (harness or con- necessary.
eling. nector) ▪ Replace the
Turn speed control (The speed limit Drive motor drive cir- drive motor drive
does not activate cuit circuit.
easily or at all during : Internal failure
turning.) Display setting
: The setting of tire
Check the matching
diameter data is not ▪ Correct the set-
value on the tire dia-
in agreement with ting
meter data screen.
that of the lift truck
state.
-

Main body of tilt
angle sensor
: Internal damage
stallation
forward and back-
(harness or con-
nector)
Tilt angle sensor ho-
rizontal matching Check the matching
▪ Perform match-
ing again.
Main body of auto-
matic fork leveling
switch
Check the automatic
When tilted forward : Open failure ▪ Check the
fork leveling switch
for leveling, the fork Mechanical detec- switch, and re-
using Analyzer.
does not stop auto- tion unit of automatic place it if neces-
: Load handling lever
matically in a hori- fork leveling switch sary
in neutral
Tilt control zontal position. : Gap in detection
Operate the auto- ▪ Check the har-
(The fork tilts to its unit is improperly ad-
matic fork leveling ness and repair
forward tilt limit justed.
switch to see if it or replace it if
without stopping in a Automatic fork level-
turns on and off nor- necessary.
horizontal position.) ing switch harness
mally.
: Wire breakage,
short circuit (harness
or connector)
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Check the tilt control sary. Refer to
Oil control valve valve using Active the maintenance
: Seizure of or leak- Test. manual
age from tilt forward : Tilt forward solen- "TROUBLESHO
lock valve oid forcibly turned off OTING" of oil
Tilt solenoid harness (forward tilting control valve.
: Short circuit, leak- stopped)
▪ Check the solen-
age (harness or con- Tilt the fork forward oid and replace
nector) to check the opera-
it if necessary.
tion.
▪ Check the har-
ness and repair
or replace it if
necessary.
-

Main body of tilt
angle sensor
: Internal damage
Check the tilt angle
sensor voltage using
▪ Check the 5
stallation sensor, and ad-
forward and back-
(harness or con-
nector)
When the fork tilted
forward for leveling, Tilt angle sensor ho-
it does not stop rizontal matching Check the matching
▪ Perform match-
automatically in a value value on the Match-
Tilt control ing again.
horizontal position. : No agreement with ing screen.
(The fork does not the lift truck state
stop in a horizontal Load sensor main Check the load
position.) sensor voltage, us- ▪ Check the
body
ing Analyzer. sensor and re-
: Internal damage
Load sensor har- Raise and lower the sary.
or replace it if
Load sensor no-load
Check the matching
value on the Match-
ing screen.
-

Main body of tilt
angle sensor
: Internal damage
stallation
forward and back-
(harness or con-
nector)
Tilt angle sensor ho-
rizontal matching Check the matching
▪ Perform match-
ing again.
When the fork tilted
forward for leveling, Load sensor main Check the load
it does not stop body sensor voltage using ▪ Check the
automatically in a : Internal damage
Tilt control : In ANL, place it if neces-
horizontal position. Load sensor har-
Raise and lower the sary.
(The fork does not ness
stop in a horizontal : Wire breakage, lift to its uppermost ▪ Check the har-
position.) (relief) and lower- ness and repair
or replace it if
Load sensor no-load
Check the matching
value on the Match-
ing screen.
main body
Analyzer. switch, and re-
: High lifting height is
always detected.
Raise and lower the sary
necessary.
-

Main body of auto-
matic fork leveling
switch
: Open failure Check the automatic
fork leveling switch ▪ Check the 5
Mechanical detec- sensor and re-
using Analyzer.
tion unit of automatic place it if neces-
: Load handling lever
fork leveling switch sary.
in neutral
: Gap in detection
Operate the auto- ▪ Check the har-
unit is improperly ad-
matic fork leveling ness and repair
justed.
switch to see if it or replace it if
Automatic fork level- turns on and off nor- necessary.
ing switch harness mally.
The mast backward : Wire breakage,
Tilt control tilting speed is not short circuit (harness
limited. or connector)
main body
: High lifting height is
always detected.
necessary.
-

Main body of auto-
matic fork leveling
switch Check the automatic
: Short circuit fork leveling switch ▪ Check the
Mechanical detec- using Analyzer. switch, and re-
tion unit of automatic : Load handling lever place it if neces-
fork leveling switch in neutral sary
: Gap in detection Operate the auto- ▪ Check the har-
unit is improperly ad- matic fork leveling ness and repair
justed. switch to see if it or replace it if
Automatic fork level- turns on and off nor- necessary.
ing switch harness mally.
: Short circuit (har-
ness or connector)
▪ Check the oil
control valve,
and repair or re-
place it if neces-
oid forcibly turned off OTING" of oil
The mast backward Tilt forward solenoid control valve.
harness (No backward tilting
Tilt control tilting speed is al-
ways slow. : Short circuit, leak- speed limit) Tilt the ▪ Check the solen-
age (harness or con- fork backward to oid and replace
nector) check the operation. it if necessary.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
: Seizure or leakage ward lock valve us- the maintenance
from tilt backward ing Active Test. manual
lock valve : Tilt backward "TROUBLESHO
Tilt backward solen- solenoid forcibly OTING" of oil
oid harness turned on control valve.
: Wire breakage, (No backward tilting
short circuit, leakage speed limit) Tilt the oid and replace
(harness or con- fork backward to
it if necessary.
nector) check the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.

main body
switch, and re-
always detected.
Raise and lower the sary 5
necessary.
-
Although the load is Display setting : For-
Check the set value
lifted high, the mast ward tilting speed
Tilt control on the Option Set ▪ Setting screen
forward tilting speed setting
screen.
is not limited. (T F-SPD LIM)
main body
: Low lifting height is
always detected.
necessary.
-

height switch, using ▪ Check the
main body
switch, and re-
always detected.
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
OTING" of oil
Tilt forward solenoid oid forcibly turned off
(No backward tilting control valve.
harness
: Short circuit, leak- speed limit) Tilt the ▪ Check the solen-
age (harness or con- fork backward to oid and replace
The mast forward nector) check the operation. it if necessary.
Tilt control tilting speed is al- ▪ Check the har-
ways slow. ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
: Seizure or leakage ward lock valve us- the maintenance
from tilt backward ing Active Test. manual
lock valve : Tilt backward "TROUBLESHO
Tilt backward solen- solenoid forcibly OTING" of oil
oid harness turned on control valve.
: Wire breakage, (No backward tilting
short circuit, leakage speed limit) Tilt the oid and replace
(harness or con- fork backward to
it if necessary.
nector) check the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
-

Tire angle sensor
main body
voltage using Ana-
lyzer.
▪ Check the 5
stallation sensor and re-
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Check the steering
angle sensor using
: Cam or steering sary.
The knob is dis- Analyzer.
wheel is defective.
placed from its nor- : Turn the steering ▪ Check the har-
Knob position com- mal position to a cer- Steering angle wheel to check the ness and repair
pensation control tain position. sensor harness input signal. or replace it if
(OPT) (10° or more from : Wire breakage, necessary.
the straight running short circuit, leakage
position) (harness or con-
nector)
Check the knob pos-
ition compensation
▪ Check the knob
Knob position com- valve using Active position com-
pensation valve Test.
: Tire end pensation valve,
main body and repair or re-
: Leakage, seizure Forcibly turn on (by- place it if neces-
(internal damage) pass) and off (no by-
pass) the knob posi- sary.
Harness of knob po- tion compensation ▪ Check the solen-
sition compensation solenoid to check oid and replace
solenoid how the steering it if necessary.
: Wire breakage, system operates.
short circuit, leakage Forcibly ON ... ▪ Check the har-
(harness or con- ness and repair
Steering idles (light). or replace it if
nector) Forcibly OFF ... necessary.
Steering does not
idles (heavy).
If the road surface is
inclined to the right
The road surface is and left, the knob
-
inclined. position will be dif-
ferent than on a hori-
zontal surface.
-

Tire angle sensor
main body
stallation
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Check the steering
angle sensor using
The knob is dis- : Cam or steering sary.
Analyzer.
placed from its nor- wheel is defective. : Turn the steering ▪ Check the har-
Knob position com-
mal position. Steering angle wheel to check the ness and repair
pensation control
(The knob position is sensor harness input signal. or replace it if
(OPT)
not constant during : Wire breakage, necessary.
straight running.) short circuit, leakage
(harness or con-
nector)
Check the knob pos-
ition compensation
▪ Check the knob
Knob position com- valve using Active position com-
pensation valve Test.
: Tire end pensation valve,
main body and repair or re-
: Leakage, seizure Forcibly turn on (by- place it if neces-
(internal damage) pass) and off (no by-
pass) the knob posi- sary.
Harness of knob po- tion compensation ▪ Check the solen-
sition compensation solenoid to check oid and replace
solenoid how the steering it if necessary.
: Wire breakage, system operates.
short circuit, leakage Forcibly ON ... ▪ Check the har-
(harness or con- ness and repair
Steering idles (light). or replace it if
nector) Forcibly OFF ... necessary.
Steering does not
idles (heavy).
PS cylinder system ▪ Check the cylin-
link is defective. der, and repair
-
: Eccentric pin or or replace it if
kingpin is defective necessary.
-

body sensor voltage using ▪ Check the
: Internal damage
Load sensor har- Raise and lower the sary. 5
or replace it if
Display setting
Check the matching
meter data screen.
state.
▪ In traveling con-
Speed limit applies trol, the attach-
Traveling control at high lifting height ment weight and
(OPT) despite not being the mast weight
loaded are treated as
part of the load
weight, because
they affect the
longitudinal sta-
bility of the lift
Heavy attachment, truck. For a very
mast with a high lift- - heavy mast or
ing height an TT or QM
mast with a high
lifting height, if
its inner middle
mast is rather
heavy, a limit
may sometimes
be placed on the
speed even un-
der no-load con-
ditions.

When the lift is
raised to its upper-
most position, the
load sensor cannot
distinguish this situ-
ation from a situation
in which a heavy
load is carried, be-
cause, in that situ-
ation, a relief pres-
Speed limit applies Lift relief pressure sure remains in the
-
Traveling control at high lifting height detected. lift cylinder pressure
(OPT) despite not being that the load sensor
loaded senses.
After a lift relief,
however, it becomes
possible to perform
operation because
the relief pressure is
discharged when the
lift is lowered even a
little.
-

body sensor voltage using ▪ Check the
: Internal damage
Load sensor har- Raise and lower the sary. 5
or replace it if
main body
: Low lifting height is
always detected.
Although a load is ness and lowermost posi- ness and repair
Traveling control carried, the speed is : Wire breakage, tions to see if the or replace it if
(OPT) not limited when the short circuit (harness switch turns on and
necessary.
lift is raised high. or connector) off normally.
Display setting
: Traveling control
setting disabled Check the set value
Load sensing speed on the Option Set ▪ Setting screen
restriction disabled screen.
(ASC W/LOAD,
MODE)
Display setting
Check the matching
meter data screen.
state.
-
main body
switch, and re-
: Low lifting height is Analyzer.
always detected.
Speed limit applies Raise and lower the sary
Lifting switch har- lift to its uppermost
Traveling control when loaded despite ▪ Check the har-
ness and lowermost posi-
(OPT) being at a low lifting ness and repair
: Wire breakage, tions to see if the
height or replace it if
necessary.
-

Display setting
: Maximum speed Check the set value. ▪ Setting screen
limit is set very low.
A limit is always Display setting
placed on the speed : The setting of tire
Traveling control Check the matching
regardless of diameter data is not ▪ Correct the set-
(OPT) value on the tire dia-
whether a load is in agreement with ting
meter data screen.
carried or not. that of the lift truck
state.
-
6 MOTOR 6-707
6 MOTOR
6.1 DRIVE MOTOR ..................................................................................... 707
6.2 PUMP MOTOR ...................................................................................... 715
6
6.1 DRIVE MOTOR
6.1.1 GENERAL
6-708 6 MOTOR
6.1.2 SPECIFICATIONS
Body size
Battery Nominal Rated
Diameter × Weight Insulation
Voltage Voltage Output Type IP
Length class
(V) (V) (kW) (mm) (kg)
Three phase
36 21 4.8 φ180×261 30 20 F
AC
STD
Three phase
48 29 5.0 φ180×261 30 20 F
AC
6 MOTOR 6-709
3
c
6
d 8
b
6
a: T = 86.8 to 145 ft·lbf. [117.6 to 196.0 N·m]

b: T = 46 to 108 ft·lbf. [63 to 147 N·m]
c: T = 6.5 to 12.0 ft·lbf. [8.8 to 16.3 N·m]
d: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
6-710 6 MOTOR
Removal Procedure
2. Remove the mast ASSY. (Refer to mast section)
3. Jack up the lift truck and remove front wheels. [Point 1]
4. Drain gear oil. [Point 2]
5. Remove the tie rod.
6. Disconnect the PKB brake link and remove PKB bracket set bolt, then free PKB cable.
7. Remove the brake lever.
8. Disconnect the wiring. [Point 3]
9. Remove the drive motor.[Point 4]
Point Operations
[POINT 1]
Removal:
Always jack up the lift truck at the jack-up point. Jack-
ing up the lift truck at the other location is very dan-
gerous. Always support the load of jacked-up lift truck
with wooden blocks at specified points.
[POINT 2]
Installation:
(a)
After installation, fill "AUTOMATIC TRANSMISSION
FLUID T-IV" to the specified level.
A=10 mm (0.39 in.) or less (Target A = 5mm)
(The amount of oil : 0.55 L [Reference])
(a) Upper limit
A
(b) Lower limit
(b)
[POINT 3]
Installation:
Tightening torque of wiring :T = 8.1 to 11 ft･lbf [11 to
15 N･m]
6 MOTOR 6-711
[POINT 4]
Removal:
For removal of the drive motor, place a hand pallet
truck at the drive motor bracket.
NOTICE! Do not crush the downside speed sensor
Apply gasket sealant to the mating face with the drive

unit.
6-712 6 MOTOR
a 1
c 2
a: T = 6.9 to 10.2 ft·lbf. [9.3 to 13.9 N·m ]

b: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
c: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
1. Remove the terminal.
2. Remove the end frame. [Point 1]
3. Remove the rotor ASSY. [Point 2]
6 MOTOR 6-713
4. Remove the stator ASSY. [Point 3]

5. Remove the bracket.
6
CAUTION
Make sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT 1]
Disassembly:
SST 979-001/181
SST
SST
[POINT 2]
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
abnormal noise or damage is observed.
Disassembly:
SST(1)
SST(1) SST(1) 979-001/182
SST(2) 979-001/183
SST(2)
SST(2)
Reassembly:
SST 979-005/492
SST
SST
6-714 6 MOTOR
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: 100 MΩ or more
Inspection:
Check continuity between motor cables.
Measurement terminals: U-V, V-W, and W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of tem-
perature sensor connector
Standard: Approx. 13 kΩ (at 68°C [20°C])
6 MOTOR 6-715
6.2 PUMP MOTOR
6.2.1 GENERAL
Sectional plan
(a) Length (c) Speed Sensor (e) Field Core
(b) Diameter (d) Field Winding (f) Rotor
Body size
Nominal Rated
Diameter × Weight Insulation
Voltage Output Type IP
Length class
(V) (kW) (mm) (kg)
Three
STD 22 12 phase φ180×303 36 20 F
AC
6-716 6 MOTOR

7
a
3 9
11
6 5 10
a: T = 18 to 24 ft·lbf. [24 to 33 N·m]
Removal Procedure
1. Remove the battery ASSY.
2. Remove the toe board and tilt cover.
3. Remove the front battery cover.
4. Disconnect the pump motor wiring. [POINT 1]
5. Remove the return filter set bolt and keep the filter free.
6. Disconnect the oil pump piping (outlet hose).
7. Remove the oil pump set bolt and keep free.
8. Disconnect the inlet hose for oil pump side.
9. Remove the oil pump ASSY W/ fitting.
6 MOTOR 6-717
10. Hoist the pump motor and remove. [POINT 2]

11. Remove the insulator.
6
NOTICE
Apply grease to the spline section of the pump before installation.
Point Operations
[POINT 1]
Installation:
Tightening torque of wiring :T = 8.1 to 11·ft lbf. [11
to 15 N･m]
[POINT 2]
Removal:
Loosen the set bolt of the terminal bracket and hoist
the pump motor.
Removal:
When hoisting the pump motor, make sure not to ap-
ply excess force on the hose.
NOTICE!
▪ Make sure to release the hose clamp suffi-
ciently.
▪ If the hose and tank pipe stick hard, do not
forcefully hoist the pump motor as it may
damage the hydraulic oil tank.
▪ Remove the adhesion of the hose and tank
pipe.
6-718 6 MOTOR

c
1
a
d
3
5
2
a: T = 6.9 to 10.2 ft·lbf. [9.3 to 13.9 N·m]

b: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
c: T = 2.6 to 4.7 ft·lbf. [3.5 to 6.5 N·m]
d: T = 7.7 to 11.5 ft·lbf. [10.4 to 15.6 N·m]
1. Remove the terminal.
2. Remove the end frame. [Point 1]
3. Remove the rotor ASSY. [Point 2]
4. Remove the stator ASSY. [Point 3]
6 MOTOR 6-719
CAUTION
Make sure not to apply impact to the rpm sensor bearing.
Point Operations
[POINT 1] 6
Disassembly:
SST(1) 979-001/181
SST(2) SST(1) SST(2) 979-001/157
Reassembly:
Install the end frame and rpm sensor to the position
A
with the dimension A.

Dimension A 0.43 to 0.50 in. (10.8 to 12.8 mm)
[POINT 2]
Inspection:
Inspect the bearing of the rotor ASSY and replace it if
an abnormal noise or damage is observed.
Disassembly:
SST(1)
SST(1) SST(1) 979-001/182
SST(2) 979-001/183
SST(2)
SST(2)
Reassembly:
SST 979-005/492
SST
SST
6-720 6 MOTOR
[POINT 3]
Inspection:
Measure the insulation resistance of the stator ASSY.
Measurement terminals: between motor cable and
body
Standard: 100 MΩ or more
Inspection:
Check the continuity between motor cables.
Measurement terminals: U-V, V-W, W-U
Standard: 0 Ω
Inspection:
Measure the resistance of the thermo-sensor.
Measurement terminals: Both terminals of tem-
perature sensor connector
Standard: Approx. 13 kΩ (at 68°F [20°C])
7 DRIVE UNIT AND FRONT AXLE 7-721
7 DRIVE UNIT AND FRONT AXLE

7.1 GENERAL.............................................................................................. 722
7.2 SPECIFICATIONS................................................................................. 723
7.3 FRONT AXLE HUB AND DRIVE UNIT.................................................. 724
7
7-722 7 DRIVE UNIT AND FRONT AXLE
7.1 GENERAL
(a) Planetary gear (d) Sun gear (g) First axis (Motor input shaft)
(b) Planetary gear shaft (e) First reduction drive gear
(c) Second axis (Front axle shaft) (f) First reduction driven gear
7.2 SPECIFICATIONS
Vehicle model
All model
Item
Total reduction ratio 27.452
Tire type Tread pattern Tire size Wheel size Air pressure -
Cushion Smooth - - STD 7
Cushion Smooth 18 x 7 x 121/8
- - OPT
Non-Marking Lug
7.3 FRONT AXLE HUB AND DRIVE UNIT
3
1
d
c
b
a: T = 86.8 to 144.6 ft·lbf. [117.6 to 196.0 N·m]

b: T = 127 to 190 ft·lbf. [172 to 258 N·m] (Refer to [POINT 4])
c: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
d: T = 73.8 to 108 ft·lbf. [100 to 146 N·m]
Removal Procedure
1. Jack up the lift truck and remove front wheels. [Point 1]
2. Drain gear oil. [Point 2]
3. Remove the drive unit ASSY. [Point 3]
4. Remove the front axle hub. [Point 4]
NOTICE
The following table : Type and quantity of gear oil
STD
Type (ATF) AUTOMATIC TRANSMISSION FLUID T-IV
Cold storage type
Quantity 0.55L (0.145 US gal) / 1 Wheel
7
NOTICE
The following table : Type of grease
STD
MP grease
Cold storage type
Point Operations
[POINT 1]
Removal:
Always jack up the lift truck at the jack-up point. Jack-
ing up the lift truck at the other location is very dan-
gerous.
Always support the load of the jacked-up lift truck with
wooden blocks at specified points.
[POINT 2]
Installation:
(a)
After installation, fill "AUTOMATIC TRANSMISSION
FLUID T-IV" to the specified level.
A = 0.39 in. (10 mm) or less (Target A = 5 mm)
(The amount of oil: 0.55 L [Reference])
Use the SST to measure the oil
A
SST 979-005/555
(a) Upper limit
(b) (b) Lower limit
[POINT 3]
Installation:
For installation, apply gasket sealant to the mating
face with the drive unit. Make sure to remove the
grease on the face.
Liquid gasket: 979-001/154
[POINT 4]
Inspection:
Install the front axle hub on the drive unit ASSY, and
measure the front axle hub breakaway torque.
(1) Install the front axle hub on the drive unit case W/
front axle bearing the SST.
SST 979-005/501
(a) Wooden Blocks
(a) (a)
(2) Install the front axle shaft, and measure the front
axle hub starting torque without installing the idle
gear.
1. Select proper shim
2. Install claw washer
3. Tighten lock nut (1) : T = 16.2 to 37.7 ft·lbf [21.9
to 51.1 N·m]
4. Running in (1) : 10 to 60 [rpm] and 3 times or
more
5. Tighten lock nut (2) : T = 127 to 190 ft·lbf. [172
to 258 N·m]
6. Running in (2) : 10 to 60 [rpm] and 3 times or
more
7. Measure the value of starting force
Standard : 6.12 to 14.1 lbf. [27.2 to 62.9 N]
8. If OK for standard value, clinch lock nut.
Method when using SST (979-005/555)
1) Remove the plug from the pouring hole at the top

of the axle housing (Fig. 1).
(a) (a) Upper limit
(c) (b) Lower limit
(c) Pouring hole
(b)
Fig. 1
2) Insert the SST (the end with markings) into the

(a) pouring hole (Fig. 2).
(b)
Point: Try to keep the direction of the SST going
forward like shown in Fig. 3.
(a) Upper limit
(c) (b) Mark for insert end
(c) Lower limit
(d) Tip (end)
(d) 7
Fig. 2
(a) Front
(a) (b) Utilize tube's curve
(c) Insert the tip at the front
(b)
(c)
Fig. 3 SST inserting direction

3) When your hand feel that the SST tip reached the
wall of the space, check whether "Mark for insert end"
(a) is at the same level of the hole entrance (Fig. 4).
(a) "Mark for insert end" at the entrance level of the
hole.
This is the measurable condition.
Fig. 4
4) Keep the condition of Fig. 4 for approximately 5
seconds, then block the other side of the SST tip
opening with your finger (Fig. 5).
5) Keep your finger on the SST tip opening. Draw out
the SST from the hole.
Fig. 5
6) Check if the oil level is between the limit lines (Fig.

(a) 6).
If the oil level is out of the correct range, adjust oil by
adding or draining oil.
After you remove the held oil in the SST tip, check
the oil level again repeating the above procedure
steps 2) through 6).
(b) (c)
(a) Oil level
(b) Upper limit
(c) Lower limit
7) When the oil level is satisfied, close the hole by the

Fig. 6 plug.
▪ Clean the inside of the SST every time after us-
ing.
▪ When the tip of the SST makes contact with a
waste cloth, the oil will be removed (Fig. 7).
▪ If the inside of the SST becomes contaminated,
clean it with a cleaning spray.
Fig. 7
NOTICE
• Before using, check if the tube is damaged or dirty.
• Check that the markings on the SST are not erased.
• Do not insert the SST forcefully into the hole.
When the SST cannot be inserted, draw it out fully and insert it again.
• For an accurate oil level inspection, check the oil level 5 minutes or more after parking the lift
truck.
You will not have a accurate oil level inspection if some amount of oil is still attached to the in-
ternal components.
• Do not use strong force. The SST is made of a thin tube.
Inspection SST
Material: Nylon
(a) (b) Outside diameter: Φ3.2mm
inside diameter: Φ2mm
Length: 500mm
Color: Clear of milky white

7
1
3･6 5
1. Remove the idle gear bearing. [Point 1]
2. Remove the planetary gear. [Point 2]
3. Remove the axle shaft bearing and inner bearing.
4. Remove the oil seal and outer bearing. [Point 3]
5. Remove the bearing outer race. [Point 4]
6. Remove the inner bearing outer race. [Point 5]
NOTICE
Apply gear oil to the planetary gear and bearing and install them.
Point Operations
[POINT 1]
Disassembly:
Use the SST to remove the idle gear bearing.
SST 979-001/182
SST
SST
Disassembly:
Use the SST to install the idle gear bearing.
SST(1) 979-001/183
SST(2) 979-001/185
SST
S S T(2)
(2)
S S T(1)
SST (1)
[POINT 2]
Reassembly:
Measure the backlash of the planetary gear, idle gear
and ring gear.
Standard: 0.2 mm (0.008 in.) or less
[POINT 3]
Reassembly:
Use the SST to install the oil seal.
SST 979-001/177
SST
[POINT 4]
Disassembly:
SST Use the SST to remove the outer bearing outer race.
SST 979-001/177
Reassembly:
Use the SST to install the outer bearing outer race.
SST
SST 979-001/177
[POINT 5]
Disassembly:
Use the SST to remove the inner bearing outer race.
SST 979-001/177
SST
Reassembly:
Use the SST to install the inner bearing outer race.
SST 979-001/177
8-732 8 REAR AXLE
8 REAR AXLE
8.1 REAR AXLE ASSY ................................................................................ 733
8.2 REAR AXLE HUB .................................................................................. 742
8.3 REAR AXLE CYLINDER ASSY............................................................. 745
8.4 TIRE ANGLE SENSOR ......................................................................... 749
8 REAR AXLE 8-733
8.1 REAR AXLE ASSY
8.1.1 GENERAL
8
8-734 8 REAR AXLE
Tire type Tread pattern Tire size Wheel size Air pressure -
Cushion Smooth, Black - - STD
Cushion non- Smooth 15 x 5 x 111/4
- - OPT
marking Lug
b 7
4 9
c 6
11
4
3
a: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]

b: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]
c: T = 166 to 273 ft·lbf. [265 to 370 N·m]
Removal Procedure
1. Remove the counterweight. (Refer to BODY section)
2. Jack up the lift truck. [Point 1]
3. Remove the hubcap, rear wheel and outer bearing. [Point 2]
4. Remove the outer bearing outer race. [Point 3]
8 REAR AXLE 8-735
5. Remove the inner bearing outer race. [Point 4]

6. Disconnect the piping of the power steering cylinder.
7. Remove the tire angle sensor.
8. Measure the rear axle ASSY starting force. [Point 5]
9. Loosen the rear axle set bolts.
10. Hoist the rear axle temporarily and remove the set bolts. [Point 6]
11. Remove the rear axle.
8
NOTICE
• When the tire angle sensor is removed and installed or replaced, perform matching. (See the PSS
section)
• Apply grease before installation.
Outer bearing Inner bearing Inside rear wheel

STD STSK2520-1 or Daphne grease #2U
Type Cold storage
Esso beacon 325
spec.
Amount 55 to 67
11 to 15 14 to 19
(0.12 to 0.15)
g (lb) (0.024 to 0.033) (0.031 to 0.042)
(Reference)
NOTICE
• After tightening the castle nut, apply lubricant to the castle nut, cotter pin, and the tip of rear axle.
(Use to STSK2520-1, Daphne grease #2U or STSK2520-2)
Point Operations
[POINT 1]
Removal:
Jack up the lift truck at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the lift truck with wooden blocks at
specified points.
8-736 8 REAR AXLE
[POINT 2]
Inspection:
Measure the rear wheel or rear hub (OPT) starting
force.
Standard:
Cushion : 1.3 to 3.42 lbf [5.8 to 15.2 N]
Reassembly:
When installing a claw washer, position it with its
edge facing the rear axle.
(a) Face without edge.
(b) Face with edge.
(a)
(b)
[POINT 3]
Disassembly:
Use a copper bar to remove the outer bearing outer
race.
Reassembly:
SST(2) Use the SST to install the outer bearing outer race.
SST(1) 979-001/184
SST(1) SST(2) 979-001/185
8 REAR AXLE 8-737
[POINT 4]
Disassembly:
Use a copper bar to remove the inner bearing outer
race.
Reassembly:
SST(2) Use the SST to install the inner bearing outer race.
SST(1) 979-001/184
SST(1) SST(2) 979-001/185
[POINT 5]
Inspection:
Measure the rear axle ASSY starting force.
Standard: F = 22.5 to 45.0 lbf. [100 to 200 N]
Installation:
Check the projection of the rear axle from the lock
nut.
Standard: longer than 0.3 in. (8 mm)
Installation:
When the correct value is obtained, securely stake
the lock nut. (Stake the lock nut on the top of corner)
8-738 8 REAR AXLE
[POINT 6]
Removal:
Temporarily hoist the rear axle as shown in the illus-
tration.
2 6
5 7
8
8
a: T = 7.4 to 14.8 ft·lbf. [10 to 20 N·m] (Reference value)
1. Remove the lock nut.
2. Remove the upper bearing.
3. Disconnect the rear axle cylinder W/ holder ASSY and rear axle ASSY.
4. Remove the lower oil seal. [Point 1]
5. Remove the lower bearing outer race. [Point 2]
6. Remove the upper bearing outer race. [Point 3]
8 REAR AXLE 8-739
7. Remove the lower bearing. [Point 4]

8. Remove the oil seal and inner bearing. [Point 5]
Point Operations
[POINT 1] 8
Reassembly:
SST Use the SST to install the oil seal.
SST 979-001/177
[POINT 2]
SST
Disassembly:
Use the SST to remove the lower bearing outer race.
SST 979-001/182
Reassembly:
SST(2) Use the SST to install the lower bearing outer race.
SST(1) 979-005/491
SST(2) 979-001/185
SST(1)
[POINT 3]
Disassembly:
SST Use the SST to remove the upper bearing outer race.
SST 979-001/177
8-740 8 REAR AXLE
Reassembly:
Use the SST to install the upper bearing outer race.
SST(1) 979-001/184
SST(2) SST(2) 979-001/185
SST(1)
[POINT 4]
SST(1) Disassembly:
Use the SST to remove the lower bearing.
SST(1) 979-001/182
SST(2) 979-001/183
SST(2)
Reassembly:
Use the SST to install the lower bearing.
SST 979-001/168
SST
Disassembly:
SST Use the SST to remove the inner bearing.
SST 979-001/182
8 REAR AXLE 8-741
Reassembly:
Use the SST to install the inner bearing.
SST 979-005/490
SST
Reassembly:
SST 979-001/177
SST
8-742 8 REAR AXLE
8.2 REAR AXLE HUB
2 3
1
a
4
1
4
3
a: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]
Removal Procedure
1. Jack up the lift truck. [Point 1]
2. Remove the hub caps.
3. Remove the rear wheel and outer bearing. [Point 2]
4. Remove the oil seal and inner bearing. [Point 3]
NOTICE
Apply grease before installation.
Outer bearing Inner bearing Inside rear wheel

STD STSK2520-1 or Daphne grease #2U
Type Cold storage
Esso beacon 325
spec.
8 REAR AXLE 8-743
Amount 55 to 67
11 to 15 14 to 19
(0.12 to 0.15)
g (lb) (0.024 to 0.033) (0.031 to 0.042)
(Reference)
NOTICE
• After tightening the castle nut, apply lubricant to the castle nut, cotter pin and the tip of rear axle.
(Use to STSK2520-1, Daphne grease #2U or STSK2520-2)
8
Point Operations
[Point 1]
Removal:
Jack up the lift truck at the specified jack-up point.
Jacking up at any other point is very dangerous.
Always support the lift truck with wooden blocks at
specified points.
[Point 2]
Inspection:
Measure the rear wheel or rear hub (OPT) starting
force.
Standard:
Cushion: 1.3 to 3.42 lbf. [5.8 to 15.2 N]
Reassembly:
When installing a claw washer, position it with its
edge facing the rear axle.
(a) Face without edge
(b) Face with edge
(a)
(b)
8-744 8 REAR AXLE
[Point 3]
Disassembly:
Use the SST to remove the inner bearing.
SST 979-001/182
SST
Reassembly:
Use the SST to install the inner bearing.
SST 09316-76008-71
SST
Reassembly:
SST 979-001/177
SST
8 REAR AXLE 8-745
8.3 REAR AXLE CYLINDER ASSY
8
b
a: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]

b: T = 166 to 273 ft·lbf. [265 to 370 N·m]
c: T = 8.9 to 23.6 ft·lbf. [12 to 32 N·m]
Removal Procedure
1. Remove the rear axle ASSY. (Refer to REAR AXLE ASSY)
2. Remove the rear axle cylinder ASSY. [Point 1]
Point Operations
[Point 1]
Installation:
Adjust the installation of the steering cylinder.
8-746 8 REAR AXLE
1. Apply STSK 2520-1 on the rotation portion (both outside and inside) equally until it protrudes from the
edge surfaces of the top and bottom.
2. Set the blue tooth on the rack between the 2 pink teeth on the pinion.
Apply "Moly cote grease D-321RK" equally on more than 180° of area on the rack side of the pinion
teeth.
3. Tighten the lock nut and caulk the lock nut in two places to ensure the starting force of the rear axle. (a)
7.4 to 14.8 ft·lbf. [10 to 20 N·m] (Reference value)
4. Tightening the torque of the frame installation: (b) 166 to 273 ft·lbf. [265 to 370 N·m]
b
8 REAR AXLE 8-747
2
1 8
3
3 5
2 1
1. Remove the steering cylinder end.
2. Remove the piston.
3. Remove the bushing.
4. Remove the rack.
5. Remove the steering torque cylinder. [Point 1]
8-748 8 REAR AXLE
NOTICE
• Apply hydraulic oil to each part before installation.
• Replace O-ring, U-packing and dust seal.
Point Operations
[Point 1]
Inspection:
Measure the steering cylinder bore.
Inside diameter standard: 2.16 in. (55.0 mm)
Wear limit: 2.179 in. (55.35 mm)
8 REAR AXLE 8-749
8.4 TIRE ANGLE SENSOR

a
4
8
b
a: T = 1.0 to 1.2 ft·lbf. [1.4 to 1.6 N·m]

b: T = 7.4 to 11.8 ft·lbf. [10 to 16 N·m]
Removal Procedure
3. Disconnect the wiring connector.
4. Remove the tire angle sensor and joint. [Point 1]
5. Remove the tire angle sensor plate. [Point 2]
7. Remove the joint cover.
8-750 8 REAR AXLE
CAUTION
Align the tapping screw axis and the sensor plate hole straight for installation. If the screw is out of
position, replace the sensor plate with a new one.
When the tapping screw is removed, the sensor plate should be replaced with a new one.
NOTICE
• Make sure to set the tires to the straight traveling position before installing the tire angle sensor.
• Apply MP grease to the inside of the joint cover for installation.
• Perform matching when the tire angle sensor is removed, installed or replaced. (Refer to PSS
section)
Point Operations
[Point 1]
Installation:
After positioning the sensor as shown in the illustra-
tion to the left, rotate it by approx. 110° to align the
holes.
[Point 2]
SST
Installation:
Use the SST to adjust the concentricity of the rear
axle and sensor plate holes.
SST 979-005/494
(a)
(a) The tip of the SST.
1. Temporarily secure the bracket and sensor plate.
2. Securely set the tip of the SST at the hole at the
top of the rear axle shaft and position the bracket
and sensor plate.
3. Securely tighten the bracket and sensor plate bolt
and remove the SST.
Installation:
(a) Apply MP grease to the sensor plate hole of the rear
axle shaft groove.
(a) Groove part.
9 STEERING 9-751
9 STEERING
9.1 GENERAL.............................................................................................. 751
9.2 SPECIFICATIONS................................................................................. 752
9.3 STEERING WHEEL AND MAST JACKET ............................................ 753
9.4 HYDROSTATIC STEERING VALVE ASSY .......................................... 756
9.5 RELIEF PRESSURE INSPECTION AND ADJUSTMENT..................... 765 9
9.1 GENERAL
9-752 9 STEERING
9.2 SPECIFICATIONS
Model
All Models
Item
Steering wheel diameter
11.8 (300)
in. (mm)
Steering wheel play
0.79 to 1.97 (20 to 50)
in. (mm)
Power steering type Hydrostatic steering
Discharge
3.1 [50.0]
cu-in. (in.3) [cc (cm3)]
Rated flow rate
Hydrostatic steering valve 2.6 (10)
US gal / min. (L / min.)
Relief set pressure
1624 to 1697 [11.2 to 11.7]
psi [MPa]
PS valve list
Identification mark With or without solenoid Manufacturer Type
E1 Without solenoid OSPC50LS
Danfoss
E2 With solenoid OSPC50LS_EFU
(a)
E1
(a) Identification mark.

9 STEERING 9-753
9.3 STEERING WHEEL AND MAST JACKET
a
9
3
5
2
2 12
8
10
b 5
2 9 11
c
a: T = 26 ft·lbf. [35 N·m]

b: T = 26.0 to 39.0 ft·lbf. [35.2 to 52.8 N·m]
c: T = 22.0 to 28.6 ft·lbf. [29.8 to 38.8 N·m]
Removal Procedure
2. Remove the instrument panel. (LH, RH, CTR)
3. Remove the steering wheel. [Point 1]
4. Remove the knob for the parking brake lock release lever.
5. Remove the column covers (upper and lower).
6. Disconnect the connectors of the combination switch.
9-754 9 STEERING
7. Remove the combination switch.

8. Remove the parking brake lock release lever.
9. Remove the return spring.
10. Remove the tilt lock mechanism and tilt steering lock release lever. [Point 2]
11. Remove the steering valve set bolts and set the steering valve free.
12. Remove the mast jacket ASSY.
NOTICE
• Apply MP grease to each sliding portion of the tilt lock mechanism and tilt steering lock release
lever.
• Add MP grease to the coupling between the steering shaft and steering valve.
Point Operations
[Point 1]
SST
Removal:
SST 979-001/181
Installation:
Steering wheel installation procedure
1. Before removing the steering wheel, make a posi-
tioning mark at the top of the steering shaft.
2. Apply rubber grease to the sliding portion of the
turn signal switch.
3. Install the steering wheel by referring to the posi-
tioning mark made in (1).
4. Turn the steering wheel after installation. Turning
the steering wheel will automatically position the
three pins of the turn signal switch at the pin
holes of the steering wheel.
9 STEERING 9-755
[Point 2]
Installation:
The lever is attached in ±20° based on the part line in
the column cover.
20°
20°
1
3
1. Remove the snap ring.
2. Remove the steering shaft.
3. Remove the bearing.
4. Remove the direction switch bracket.
9-756 9 STEERING
9.4 HYDROSTATIC STEERING VALVE ASSY
9.4.1 TROUBLESHOOTING
Symptom Probable cause Corrective action
Replace the steering
The steering valve is defective.
valve ASSY.
Replace the inlet section
The steering wheel can- The priority valve is defective.
of OCV.
not be rotated.
The oil pump is defective. Replace the pump ASSY.
The piping connection is wrong. Connect the piping right.
The piping is damaged. Replace the piping ASSY.
valve ASSY.
The priority valve is defective.
of OCV.
The oil leaks in the steering valve, the piping or the Repair or replace the cor-
The steering wheel is
rear axle cylinder. responding part.
hard to turn.
See the corrective action
The oil pressure does not increase.
below.
The steering shaft is damaged.
shaft.
The power steering cylinder rod is bent or the piston Repair or replace the cor-
is sticking. responding part.
Adjust, repair or replace
The relief valve is defective.
the relief valve.
valve ASSY.
The oil pressure does not
rise. The oil leaks in the power steering valve, the piping Repair or replace the cor-
or the rear axle cylinder. responding part.
of OCV.
Replace the knob solen-
The knob solenoid is defective.
oid.
valve ASSY.
The steering wheel does
The tire was worn away. Replace the tire.
not return correctly.
Repair or replace the pip-
The piping is defective.
ing.
valve ASSY.
The lift truck wobbles. The tire was worn away. Replace the tire.
The steering shaft was worn away.
shaft.
The tire moves opposite
to the steering wheel op- The piping is connected in reverse. Connect the piping right.
erating direction.
9 STEERING 9-757
Symptom Probable cause Corrective action

Replace the knob solen-
The knob solenoid is defective.
The knob position is out of oid.
alignment. The oil leaks in the power steering valve, the piping Repair or replace the cor-
or the rear axle cylinder. responding part.
The steering wheel jams Replace the inlet section
occasionally. of OCV.
The steering wheel can- Replace the steering
not stop at the stroke end. valve ASSY.
9
9-758 9 STEERING
4 2
2 5
4
a: T = 22.0 to 28.6 ft·lbf. [29.8 to 38.8 N·m]
Removal Procedure
2. Remove the instrument panel. (LH, RH)
3. Remove the knob for the parking brake lock release lever.
4. Remove the column covers. (upper and lower)
5. Disconnect the piping.
6. Remove the steering valve ASSY.
7. Remove the fitting. [Point 1]
NOTICE
Add MP grease at the coupling between the steering shaft and steering valve.
9 STEERING 9-759
Point Operations
[Point 1]
Reassembly:
Install the fitting with the angle shown in the illustra-
40° 40°
tion to the left.
12° 40° 40° 9

5
b 5
4
3
3 3
2 4
a: T = 17.7 to 26.6 ft-lbf. [24 to 36 N·m]

b: T = 44.3 to 51.7 ft-lbf. [60 to 70 N·m]
NOTICE
Clean dirt off from ports and joints before disassembly and operate in a clean place.
1. Remove the end cover. [Point 1]
2. Remove the gear wheel set, cardan shaft and distributor plate. [Point 2]
9-760 9 STEERING
3. Remove the check valve and steel ball. [Point 3]

4. Remove the sleeve W/spool and bearing. [Point 4]
5. Remove the O-ring, kin-ring and dust seal ring. [Point 5]
6. Remove the relief valve. [Point 6]
Point Operations
[Point 1]
Disassembly:
Make a match mark across the end cover, outer gear,
and valve body.
Disassembly:
When removing each set bolts, be careful not to lose
the steel ball.
Reassembly:
▪ Put a steel ball in the illustrated position before in-
stalling each set bolts.
▪ One out of seven set bolts is a bolt with pin. In-
stall it in the correct position.
9 STEERING 9-761
[Point 2]
Reassembly:
Reassemble the gear wheel set, cardan shaft and
distributor plate.
(a) (a) Parallel
(a)
[Point 3]
Disassembly:
a A steel ball is placed under the pin.
Be careful so as not to lose it.
The cross-section drawing of the ball and pin is illus-
trated at left.
a: Pin
b: Steel ball
Reassembly:
b
Make sure to install the steel ball and pin.
9-762 9 STEERING
[Point 4]
Disassembly:
Extract the spool W/sleeve upward. Otherwise, the
spool cross pin may move during extraction to cause
sticking.
Reassembly:
Set and install the neutral position spring correctly.
Reassembly:
Pay attention to the bearing direction for installation.
(See the figure.)
a: Chamfer
b: Sleeve
Reassembly:
Place the housing with its flanged side facing down
and insert the spool W/sleeve into the housing. Set
the cross pin of the spool horizontal during insertion.
9 STEERING 9-763
[Point 5]
Reassembly:
Install the kin-ring and O-ring correctly.
a: O-ring
b: Kin-ring
NOTICE! For SST No. SJ150-9000-11, please in-

quire at the nearest Danfoss service shop. 9
Reassembly:
1. Turn the steering unit until the bore is horizontal.
Guide the outer part of the assembly tool into the
bore for the spool/sleeve.
2. Apply O-ring and kin-ring with hydraulic oil and

place them on the tool.
3. Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide the
inner part of the tool right to the bottom.
4. Press and turn the O-ring/kin-ring into position in

the housing.
5. Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the
guide from the inner part in the bore.
9-764 9 STEERING
[Point 6]
Disassembly:
Do not remove the relief valve unless it is judged de-
fective. The valve seat cannot be removed.
Measure the screwed-in depth of the relief valve ad-
justing screw before starting disassembly.
Reassembly:
Reassemble by adjusting to the screwed-in depth of
the valve spring retainer measured before disas-
sembly. After installing the steering valve ASSY on
the lift truck, measure the relief pressure. If it is not
within the standard range, adjust it by changing the
screwed-in depth of the retainer.
NOTICE
Wash each part with clean hydraulic oil before assembly.
9 STEERING 9-765
9.5 RELIEF PRESSURE INSPECTION AND

ADJUSTMENT
Step 1 Install an oil pressure gauge.
(a) P port
▪ Disconnect the hose from the P port of the steer-
ing valve, and connect the SST (adapter)
. 9
(b) SST 979-001/170
Install the oil pressure gauge.
Plug size: PT1/8
(a)
(b)
Step 2 Turn the key switch ON, rotate the steering wheel
slowly clockwise and counterclockwise, and inspect
the relief pressure at each stroke end.
Standard: 1624 to 1697 psi [11.2 to 11.7 MPa]
Step 3 If the standard is not satisfied, remove the steering

valve and make an adjustment by turning the relief
valve adjusting screw.
10-766 10 BRAKE
10 BRAKE
10.1 GENERAL.............................................................................................. 766
10.2 SPECIFICATIONS................................................................................. 768
10.3 DISC BRAKE ......................................................................................... 769
10.4 BRAKE AIR BLEEDING ........................................................................ 775
10.5 BRAKING FORCE INSPECTION AND ADJUSTMENT ........................ 775
10.6 BRAKE MASTER CYLINDER ............................................................... 776
10.7 PARKING BRAKE ................................................................................. 779
10.8 PARKING BRAKE INSPECTION AND ADJUSTMENT......................... 780
10.9 BRAKE PEDAL ADJUSTMENT............................................................. 782
10.1 GENERAL
(a) Wheel cylinder (c) Parking cable (e) Motor (g) Brake plate
(b) Lever (d) Drive unit (f) Brake disc
10 BRAKE 10-767
Parking Brake
10
10-768 10 BRAKE
Master Cylinder
10.2 SPECIFICATIONS
Brake type Wet disc brake
Brake disk diameter 108 mm (4.25 in.)
Number of brake disk (Piece × wheel) 3×2
AUTOMATIC TRANSMISSION T-IV or MOBIL
Cooling oil
ATF 3309
Amount of oil (L × wheel) 0.55 × 2
Brake fluid SAE J-1703, DOT-3
10 BRAKE 10-769
10.3 DISC BRAKE
10.3.1 REMOVAL AND INSTALLATION (Outside of brake)
10
8
a
11
10 b
a: T = 151 to 225 ft·lbf. [205 to 305 N·m]

b: T = 27.1 to 40.7 ft·lbf. [36.8 to 55.2 N·m]
c: T = 73.8 to 108 ft·lbf. [100 to 146 N·m]
Removal Procedure
2. Remove mast ASSY. (Refer to mast section)
3. Jack up the lift truck and remove the front wheel.
10-770 10 BRAKE
4. Drain the gear oil.

5. Disconnect the tie rod.
6. Disconnect the PKB brake link.
7. Disconnect the wiring and piping. [Point 1]
8. Remove the reamer bolt the of drive unit bracket.
9. Remove the drive unit W/ drive motor.
10. Remove the drive unit ASSY.
11. Remove the drive motor.
10 BRAKE 10-771
3
10
b
6 1
a: T = 24.2 to 36.3 ft·lbf. [32.8 to 49.2 N·m]

b: T = 6.49 to 12.0 ft·lbf. [8.8 to 16.3 N·m]
Removal Procedure
1. Remove the brake lever.
2. Remove the wheel cylinder.
3. Remove the sun gear and first reduction gear.
4. Remove the retainer.
5. Remove the disc and plate.
6. Remove the pressure pin.
10-772 10 BRAKE
1. Install the pressure pin. [Point 1]
2. Install the brake lever. [Point 2]
3. Install the wheel cylinder.
4. Install the disc and plate. [Point 3]
5. Install the retainer.
6. Install the sun gear and first reduction gear. [Point 4]
7. Adjust the brake lever. [Point 5]
NOTICE
• After installation, perform brake pedal adjustment, air bleeding and matching.
• Do not wear cotton working gloves.
• Never wash Disc.
Point Operations
[POINT 1]
Installation:
(a) Install the disc and plate with arranging each phase
of the oil through hole.
(a) D-ring
(b) Pressure pin
(c) Axle bracket
(b) NOTICE! Pay attention to the installed direction of
the pressure pin.
(c) NOTICE! Apply NPC grease spray to the D-ring
when assemble D-ring to the pressure pin and
axle bracket.
NOTICE! If removing pressure pin, replace the D-
ring.
(a)
[POINT 2]
Installation:
(b) Insert the bush from the side chamfered for lever
hole.
(a) Brake Lever
(b) Bush install direction
(c) Lever hole chamfering
A-A
(c)
A A
10 BRAKE 10-773
[POINT 3]
(a)
Installation:
Install the disc and plate aligning each phase of the
oil through hole.
(a) Disc
(b) Oil through hole (6 places)
(c) Plate
(b) (c) 10
[POINT 4]
Installation:
1. Set the center position by holding on to the disc us-
ing the brake lever.
2. Use the adjusting bolt to hold the disc in place.
3. After that, install the sun gear and first reduction
gear.
[POINT 5]
Installation:
1. Pull the brake lever by force (F).
F = 31.5 to 33.7 lbf. [140 to 150 N]
2. Keep the lever at the "1" status, and set the adjust
bolt (a) clearance between the adjust bolt and axle
bracket "L".
L = 0.079 to 0.091 in. (2.00 to 2.30 mm)
3. Keep the top position of the adjust bolt, and rotate

lever for running-in. Then tighten the nut.
Tighten torque T = 4.06 to 6.12 ft·lbf. [5.5 to 8.3
N·m]
A = 0.768 to 0.992 in. (19.5 to 25.2 mm)
A
T
10-774 10 BRAKE
Inspection of disc and plate

Installation:
1. Pull the brake lever by force (F).
F = 31.5 to 33.7 lbf. [140 to 150 N]
2. Keep the lever at the "1" status, and contact the

adjust bolt to the stopper.
3. If exposed portion "A" is under 0.886 in. (22.5 mm),
inspect the disc and the plate, and replace.
Limit : A = 0.886 in. (22.5 mm)
Disc thickness
Standard : 0.138 in. (3.5 mm)
Limit : 0.130 in. (3.3 mm)
Plate thickness
Standard : 0.079 in. (2.0 mm)
Limit : 0.071 in. (1.8 mm)
NOTICE! If disc and plate is over limit value, re-

place the brake lever and pressure pin.
10 BRAKE 10-775
10.4 BRAKE AIR BLEEDING
NOTICE
Add brake fluid to the reservoir tank during air bleeding to prevent it from becoming insufficient. Per-
form air bleeding with two operators.
1. Bleed air from the brake master cylinder.

• Depress the brake pedal several times to com-
press the air in the piping, and hold that state.
• Loosen the breather plug (a) to discharge air in 10
the piping with the brake fluid, and tighten the
plug immediately before the fluid starts to run
out.
• Repeat steps above until no air bubbles are
seen in the discharged brake fluid.
(a) 2. Bleed air from wheel cylinders RH and LH.
• Operate as described in step 1 above for both
the RH and the LH side.
3. Add brake fluid to the specified level.
• Add brake fluid through the filter provided at the
reservoir tank.
• Add brake fluid up to the staged portion in the
reservoir tank.
10.5 BRAKING FORCE INSPECTION AND ADJUSTMENT

1. Inspect the braking force by means of a brake tester or traveling test.
Braking distance (without load)
• Initial speed of braking mph (km/h) : Max. speed
Braking distance ft. (m) : 16.4 (5.0) or less
10-776 10 BRAKE
10.6 BRAKE MASTER CYLINDER
Removal Procedure
2. Remove the toe board (front and rear) and lower panel.
3. Disconnect the brake side hose from the reservoir tank and drain brake fluid.
5. Remove the push rod clevis pin.
6. Remove the brake master cylinder.
NOTICE
After installation, perform brake pedal adjustment, air bleeding, and matching of the pedal.
10 BRAKE 10-777
10
a: T = 38.3 to 60.8 ft·lbf. [52.0 to 82.4 N·m]
Removal Procedure
1. Turn the boot up and remove the snap ring.
2. Remove the push rod. [Point 1]
3. Remove the piston. [Point 2]
4. Remove the pin and the fluid inlet elbow.
5. Remove the outlet plug and valve.
Point Operations
[POINT 1]
Reassembly:
Temporarily set the push rod length to the illustrated
dimension, and make readjustment after installation.
131 mm (5.16 in)

10-778 10 BRAKE
Reassembly:
Apply rubber grease on the piston cup and the whole
periphery of the cup before reassembly.
10 BRAKE 10-779
10.7 PARKING BRAKE
10
2
6
a : T = 6.7 to 12.5 ft·lbf. [9.1 to 16.9 N·m]
Removal Procedure
2. Remove the tilt steering lock release lever.
3. Remove the column cover.
4. Remove the instrument panel LH.
5. Remove the lower panel.
6. Remove the parking brake release cable from the mast jacket.
7. Remove the parking brake ASSY.
10-780 10 BRAKE
10.8 PARKING BRAKE INSPECTION AND ADJUSTMENT

1. Check the parking brake cable set position.
Standard: A = 0 to 0.08 in. (0 to 2 mm)
2. Apply chassis grease on the portions indicated by
A
arrows.
3. Inspect and adjust the parking brake pedal oper-
ating force.
(a) For RH
(b) For LH
(b) • Measure the operating force.
(a)
·When using SST [979-500/502]
Standard: 23.2 to 26.0 lbf. [103 to 116 N]
·When using a push pull tester (a)

Push the probe of a push-pull tester vertic-
ally into the center of the brake pedal.
SST Standard: 54.0 to 60.7 lbf. [240 to 270 N]
• If the operating force is out of the standard

range, release the parking brake and make ad-
justment at the adjusting portion.
Clockwise turn: Increases the operating force.

Counterclockwise turn: Decreases the operat-
ing force.
(a)
10 BRAKE 10-781
RELEASE LEVER CABLE ADJUSTMENT

1. Adjust the play of the release lever (b) to 0.0 to
0.2 in. (0.0 to 5 mm) at the tip of the lever using
the release cable adjusting nut (a).
(a)
10
(b)
10-782 10 BRAKE
10.9 BRAKE PEDAL ADJUSTMENT
(b)
(a)
(c)
B
A
C
(d)
(a) Brake master cylinder (c) Push rod

(b) Stopper bolt protrusion (d) Toe board
1. Inspect brake pedal height A. (From toe board to top of pedal)
Standard: A = 132 to 137 mm (5.20 to 5.39 in.) (with pedal pad)
2. Inspect brake pedal play B.
Standard: B = 1 to 5 mm (0.04 to 0.20 in.)
If the standard is not satisfied, make adjustment by changing the master cylinder push rod length.
3. Check the master cylinder push rod play C with the brake pedal in the above state.
Standard: C = 0.5 to 2 mm (0.02 to 0.08 in.)
4. After the adjustment, fully (at 196 N) press the brake pedal and inspect the pedal height D.
Standard: D = 77 mm (3.03 in.) or more
5. After finishing the adjustment, perform the brake matching.
11 BODY & FRAME 11-783
11 BODY & FRAME

11.1 BATTERY HOOD ASSY........................................................................ 783
11.2 COUNTERWEIGHT............................................................................... 785
11.3 OPERATOR’S SEAT ............................................................................. 787
11.4 FUSE REPLACEMENT ......................................................................... 788
11.1 BATTERY HOOD ASSY 11
4 1
5
11-784 11 BODY & FRAME
Removal Procedure
3. Use string to tie the battery hood ASSY W/seat ASSY to the overhead guard rear pillar.
4. Disconnect the wiring of the seat switch.
5. Disconnect the battery hood damper (on the frame side).
6. Close the battery hood.
7. Remove the battery hood hinge set bolt.
8. Remove the battery hood ASSY W/seat ASSY.
11.2 COUNTERWEIGHT
11
7 9 5
5
1
8
a
a: T = 236 to 354 ft·lbf. [320 to 480 N·m]
Removal Procedure
2. Remove the rear cover (item 3).
3. Remove the draw bar (item 7). Temporarily hoist the counterweight by slinging with a wire rope.
4. Remove the counterweight set bolt (item 8).
5. Remove the counterweight (item 9). [Point 1]
NOTICE
Make sure to set the tires to the straight traveling position.
Point Operations
[POINT 1]
Inspection:
Make sure to keep the counterweight balanced when
installing.
11.3 OPERATOR’S SEAT
11
Removal Procedure
1. Disconnect the wiring of the seat switch.
3. Remove the operator's seat set nuts. (Be careful not to drop the operator's seat.)
4. Remove the operator's seat.
11.4 FUSE REPLACEMENT

If a lamp/light does not come on or an electrical device does not function, the corresponding fuse may have
blown. Check the fuse for each device.
F1 Fuse
The F1 fuse is located on the contactor panel inside the battery hood.
F1
Fuse box
Other fuses are located in the fuse box.
1. To access the fuse box, remove the rear cover.
(1)
(1) Rear cover

2. Remove the fuse box cover and remove the fuse by clipping with the fuse clip attached to the fuse box.
11
(3) (2)
(2) Fuse box cover

(3) Fuse clip
F54 F55 F58 F56 F57 F45

F41 F43 F44 F42 F5A F59
F51 F52 F53 F71 F72 F73
F74 F75 F76 F77 F78 F79
F5 F6 F81 F82 F5B F5C
See the fuse assignment table below for the device corresponding to each fuse.
Fuse assignment
Fuse name Capacity Corresponding device
700A (36V spec.)
F1 Drive and pump circuit
600A (48V spec.)
F54 2A Horn relay
F55 2A Horn surge absorber
F58 2A Direction control switch
F56 2A Strobe light, blue light, key off head light off relay
F57 2A Flasher relay
F45 2A Stop lights
Fuse name Capacity Corresponding device

F41 2A Interior light, head light rely, tail light relay, rear working lights
F43 2A Head light (left-hand)
F44 2A Head light (right-hand)
Tail light (left- and right-hand) and clearance lights (left- and
F42 2A
right-hand)
F5A 2A Clamp release interlock
F59 2A
F51 2A Inverter fan 1
F52 2A Inverter fan 2
F53 2A Motor fan
F71 2A Knob solenoid
F72 2A Unload solenoid
F73 2A Lift lock solenoid
F74 2A Forward tilt solenoid
F75 2A Backward tilt solenoid
F76 2A Lift solenoid
F77 2A Tilt solenoid
F78 2A Attachment 1 solenoid
F79 2A Attachment 2 solenoid
F5 10A Controller
F6 10A Controller
F81 10A DC/DC converter (front)
F82 10A DC/DC converter (rear)
F5B 2A Telematics
F5C 2A
WARNING
• Disconnect the battery plug before inspecting the fuse.
• Always replace with a fuse having the same capacity. See the SERVICE DATA section of this manual for
fuse specifications.
• If the replaced fuse blows again, ask your Raymond Sales and Service Center for an inspection.
• When the fuse is being replaced, never short between terminals with a spanner or other tools.
12 MATERIAL HANDLING SYSTEM 12-791
12 MATERIAL HANDLING SYSTEM

12.1 HYDRAULIC CIRCUIT .......................................................................... 792
12.2 REMOVAL • INSTALLATION ................................................................ 793
12.3 NATURAL DROP TEST ........................................................................ 795
12.4 NATURAL FORWARD TEST ................................................................ 795
12.5 OIL LEAK TEST..................................................................................... 796
12
12-792 12 MATERIAL HANDLING SYSTEM
12.1 HYDRAULIC CIRCUIT
6
4
5
3
8
10
11
9
12
1) Lift cylinder 4) Return filter 7) Steering valve 10) Load sensing

2) Oil control valve 5) Priority valve 8) Suction filter 11) Oil pump
3) Tilt cylinder 6) Oil tank 9) Solenoid valve 12) Pump motor
12.2 REMOVAL • INSTALLATION
12.2.1 RETURN FILTER
12
Removal Procedure
2. Remove the toe boards (front and rear) and tilt cylinder cover.
3. Disconnect hoses from the front and rear of the return filter.
4. Remove the return filter.
12.2.2 SUCTION FILTER
Removal Procedure
1. Remove the oil pump ASSY W / fitting. (Refer to Oil pump section.)
2. Remove the tank cover W / suction filter.
3. Remove the suction filter cover.
4. Remove the suction filter.
12.3 NATURAL DROP TEST

1. Set the mast vertical with the standard load on the
forks. Lift the forks 39.3 to 59.1 in. (1 to 1.5 m), and
turn the key switch to OFF.
2. Draw datum lines on the inner and outer masts, 12

and measure the drop in 15 minutes.
Limit: 1.77 in. (45 mm)
12.4 NATURAL FORWARD TEST

1. Set the mast vertical with a standard load on the
forks. Lift the forks about 19.7 in. (50 cm) and turn the
key switch OFF.
2. Measure the tilt cylinder rod extension in 15

minutes.
1 ton series: 0.6 in. (15 mm) or less
2 ton series: 0.8 in. (20 mm) or less
12.5 OIL LEAK TEST
12.5.1 LIFT CYLINDER

1. Set the mast vertical with the standard load on
the forks. Lift the forks 1 to 1.5 m (40 to 59 in.).
2. Slowly tilt the mast fully forward, and turn the key
switch to OFF.
3. After 5 minutes, disconnect the oil control valve to
oil tank hose. Place a measuring cylinder under
the elbow and measure the amount of oil leaking
in one minute.
Standard (at lift port): 0.49 in.3(8 cm3) or less
NOTICE! If the natural drop is big even though the
oil leak amount is within the standard, the lift cyl-
inder packing is defective.
12.5.2 TILT CYLINDER

1. Set the mast in the vertical position with standard
load on the forks. Lift the forks about 19.7 in. (50
cm) and turn the key switch to OFF.
2. After 5 minutes, disconnect the oil control valve to

oil tank hose. Place a measuring cylinder under
the elbow and measure the amount of oil leaking
in one minute.
Standard (total for lift and tilt): 0.98 in.3 (16
cm3) or less
3. The leak amount at the tilt port is equal to the re-

mainder when you subtract the lock amount at
the lift port from the total leak amount of the lift
and tilt cylinder.
NOTICE! If the natural forward tilt is big even
though the oil leak amount is within the standard,
either the tilt lock valve or the tilt cylinder pack-
ing is defective.
13 MAST 13-797
13 MAST
13.1 CHAIN.................................................................................................... 797
13.2 FORK..................................................................................................... 802
13.3 QM MAST ASSY ................................................................................... 803
13.4 TT MAST ASSY .................................................................................... 807
13.5 LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING)................................................. 824
13.1 CHAIN 13
13.1.1 INSPECTION
1. Inspect the chain elongation using the following
procedure:
(a) Chain gauge
(1) Since the measurement scale differs according to
the chain type, set the corresponding scale on the
chain as illustrated.
(2) Check the chain no. of the chain to be inspected,
and check the pin center position.
If the pin center is at the arrow mark on the chain
gauge, it has reached the limit; replace the chain.
N
N
Chain link pitch standard

Pitch No. of links meas-
Mast Type CHAIN No.
in. (mm) ured N
TT 0.75(19.05) BL634 50 13
QM: Front 0.625(15.88) BL534 50 15
QM: Rear 1.0(25.4 ) BL834 80 11
NOTICE
• Perform measurement without removing the chain from the lift truck.
• Inspect elongation over the entire chain length as it may be localized.
13-798 13 MAST
13.1.2 REASSEMBLY
1. Installing direction
Applicable mast and
QM: Inner mast QM: Carriage
section
(a) (a)
Rough sketch
Arrow indicates outside of

Arrow indicates the back of
the lift truck.
the lift truck.
Install with the split pin dir-
Install with the split pin dir-
ecting backward of the lift
ecting outside the lift truck.
truck.
(a) Split pin
2. Chain adjusting nut tightening procedure

(1) Tighten nut (a), (b). T = 50.9 ft-lbf. [69.0 N·m].
However, T = 90.7 ft-lbf. [123.0 N·m] (b) for only QM hard lock nut.
(2) Tighten nuts (c).
(3) Attach the clamp (e) with the bolts (d).
Applicable mast and QM: Lower middle QM: Upper middle
QM: Front cylinder QM: Outer mast
section mast mast
(d)
(e)
(b)
Rough sketch
(a)
13.1.3 ADJUSTMENT
1. Park the lift truck on a flat surface and set the mast in the vertical position.
2. Lower the forks to the ground, and turn the adjusting nut to eliminate any chain sag.
3. Check to see that the chain tension is equal on the left and right sides.
4. Check that the chain is not twisted.
5. Check that the lifting height meets the standard.
6. In the uppermost position, check that the carriage fall-out prevention stopper at the inner mast upper
beam is not in contact with the carriage.
13 MAST 13-799
13.1.4 MAIN LIFT CHAIN ADJUSTMENT (TT)

1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90 cm) block under the free lift cylinder support blocks.
The main lift chain anchors are now accessible.
2. Adjust one chain to achieve the correct upright position when fully lowered.
3. Adjust the other chain to achieve equal chain tension.
4. Raise and lower the mast several times to confirm the adjustments.
13
(a) Chain adjusting nut
13.1.5 MAIN LIFT CHAIN SERVICE (TT)
WARNING
Block the intermediate upright.
1. Raise the inner upright 3 ft. (90 cm). Place a 3 ft. (90 cm) block under the free lift cylinder support cast-
ing, then lower the cylinder support onto the block. The main lift chains should be slack.
2. Remove the cotter pins and pins (a) from the chain anchors (b). Remove the chains.
3. Inspect the chain anchors for cracks. Replace as required.
4. For reassembly, reverse the disassembly procedure. Adjust the chains.
13-800 13 MAST
CAUTION
If chain anchor is secured with a nylon lock nut (c), install a new lock nut when it is necessary to
loosen the chain or remove the anchor.
13.1.6 FREE LIFT CHAIN ADJUSTMENT (TT)

The free lift chains should be adjusted so that when the mast is vertical and the carriage is fully lowered, the
forks are positioned as specified in the table below.
Fork Type Distance Above Floor
Standard 2 in. (5 cm) measured from top of fork at the heel
1. Locate the threaded chain anchors on the front side of the inner upright cross member in front of both
cylinders. Adjust one chain to achieve the correct carriage position when fully lowered.
2. Adjust the other chain to achieve equal chain tension.
3. Raise and lower the mast several times to confirm the adjustments.
13 MAST 13-801
13.1.7 FREE LIFT CHAIN SERVICE (TT)

1. Raise the carriage enough to place a 12 in. (300
mm) block under the carriage, then lower the carriage
onto the block. The free lift chains should be slack.
WARNING! Block the carriage.
2. Remove the cotter pins and pins from the chain an-
chors. Remove the chains.
3. Inspect the chain anchors for cracks. Replace as
required.
4. For reassembly, reverse the disassembly proced-
ure. Adjust the chains.
CAUTION! If chain anchor is secured with a nylon
lock nut, install a new lock nut when it is neces-
sary to loosen the chain or remove the anchor. 13
13-802 13 MAST
13.2 FORK
13.2.1 REMOVAL
1. Raise the forks to approx. 7.9 in. (20 cm) from the
ground.
2. Place a wooden block under the notched section
of the fork rail.
3. Unlock the fork by lifting the fork stopper pin, and
shift the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.
13.2.2 INSTALLATION
13.2.3 INSPECTION
Inspect misalignment of the fork tip ends.
Limit: 0.39 in. (10 mm)
If the limit is exceeded, inspect individual fork bend,
looseness of fork installation, and carriage finger bar
distortion.
13 MAST 13-803
13.3 QM MAST ASSY
13.3.1 MAST ADJUSTMENT (QM)

Lift Roller Adjustment at Mast
1. Inner mast roller and middle mast lower roller clearance adjustment.
13
About the QM mast

Clearance between outer mast and lower middle mast lower roller
Clearance between lower middle mast and upper middle mast lower roller
Clearance between upper middle mast and inner mast roller
(a) Bring into contact
Position where the roller is the closest to the QM mast.
(1) Adjust the mast overlap to approx. 17.7 in. (450 mm).
(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and measure on the
opposite side the clearance between the roller side face and mast at the point where they are the closest.
Standard: A = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.
Shim thickness: 0.020 and 0.039 in. (0.5 and 1.0 mm)
(3) Distribute shims equally to the left and right rollers.
(4) After adjustment, check that mutual mast movement is smooth.
2. Outer mast roller (QM) and middle mast upper roller (QM) clearance adjustment.
13-804 13 MAST
About the QM mast

Clearance between lower middle mast and outer mast roller
Clearance between upper middle mast and lower middle mast upper roller
Clearance between inner mast and upper middle mast upper roller
(1) Adjust the mast overlap to approx. 17.7 in. (450 mm).
(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on the
opposite side the clearance between the roller side face and mast at the point where they are the closest.
Standard: B = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the outer mast roller shim thickness.
Shim thickness: 0.020 to 0.039 in. (0.5 to 1.0 mm)
(3) Distribute shims equally to the left and right rollers.
(4) After adjustment, check that mutual mast movement is smooth.
13 MAST 13-805
Lift and Side Roller Adjustment at the Carriage
13
(a) Lower side roller (c) Bring into contact (e) Carriage
(b) Side roller (d) Bring into contact
(1) For adjustment, raise the carriage fully in case of QM.
(2) Shift the carriage to one side to bring the lower lift roller and side roller into contact with the inner mast,
and measure on the opposite side the clearance between the roller side face and the mast at the point where
they are the closest.
Standard: C = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness. (Distribute shims equally to the left and
right side rollers.)
(3) After the inspection and adjustment in step (2) above, inspect and adjust the side rollers. Bring the side
roller on one side into contact with mast side surface, and measure on the opposite side the clearance
between the side roller and the inner mast side surface.
Standard: D = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.(Distribute shims equally to the left and right
side rollers.)
(4) After the above adjustment, check that the carriage moves smoothly along the entire length of the mast.
13-806 13 MAST
Mast Strip Adjustment

1. Mast strip clearance adjustment
QM mast (a) (b)
(c)
(d)
(e)
E
(f)
NOTICE! Image shows three of the four upright weldments

(a) Intermediate mast (c) Inner mast (e) Outer mast
(b) Upper side roller (d) Bring into contact (f) outward
(1) Lower the inner (or middle) mast fully.
(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller), meas-
ure the clearance between the mast strip and mast.
Standard: E = 0 to 0.024 in. (0 to 0.6 mm)
If the standard is not met, adjust by changing the shim thickness.
(3) After adjustment, check the mast for smooth movement.
13 MAST 13-807
13.4 TT MAST ASSY
13.4.1 MAST REMOVAL AND INSTALLATION
13.4.1.1 REMOVAL AND INSTALLATION (W/CARRIAGE)
13
2 a
7
5
8
b
a : T = 63 to 95 ft·lbf. (86 to 129 N·m)

b : T = 62 to 115 ft·lbf. (84 to 156 N·m)
Removal Procedure
1. Set the mast in the vertical position.
2. Remove the fork. (Refer to Cylinder section)
3. Disconnect the lifting height switch.
4. Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner
mast and operate the lift lever several times to release the residual pressure from the lift cylinder.)
5. Tie the carriage and outer mast tie beam with a wire rope.
6. Slightly hoist the mast.
7. Remove the tilt cylinder front pin. [Point 1]
8. Remove the mast support cap.
13-808 13 MAST
9. Remove the mast ASSY W/carriage.
NOTICE
• Apply chassis grease special to the mast support bushing and mast support cap interior sur-
faces. Apply MP grease to the tilt cylinder front pin.
• Perform shim adjustment of the lift cylinder rod when the mast ASSY, outer mast, inner mast or
either lift cylinder is replaced.
• Adjust the chain tension after installation.
• When the mast is replaced, perform PSS matching after installation.
Point Operations
[POINT 1]
Removal:
Make match marks to clarify the relative positions of
the front pin, stopper plate and lock bolt. Match
marks, however, are unnecessary when the mast or
mast ASSY is replaced as mast tilt angle adjustment
is to be done after replacement.
Removal:
If the fitting is stiff, use the driver for removal.
Inspection:
Measure the mast support bushing thickness.
Limit: 0.039 in. (1.0 mm)
13.4.1.2 PARTIAL REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck with a capacity of at least five tons.
13 MAST 13-809
1. Turn the key switch OFF and disconnect the battery connector.
2. Remove the console and front covers.
3. Remove the forks.
4. Verify that the mast is in a vertical position.
5. Position the lift truck beneath the hoist or lift truck.
6. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist or lift truck.
7. Lift the hoist just enough to take the slack out of the chain or strap.
8. Remove the support cap and retaining bolts from the support pins.
9. Remove the tilt pin assembly retaining hardware and mast support cap. Carefully remove the pivot
blocks from each tilt cylinder clevis, allowing the tilt cylinder to rest on the brake assemblies
13.4.1.3 INSTALLATION AFTER PARTIAL REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity. 13
1. With the mast securely held by a strap or chain, carefully raise the mast until it is vertical.
2. Reconnect the battery connector and turn the key switch ON.
3. Apply chassis grease on the tilt pin before the mast is installed on the lift truck.
4. Slowly extend the tilt cylinders until you are able to install the cylinder front pin, stopper plate, and lock
bolt into each tilt plate.
5. Perform MAST FORWARD/BACKWARD TILT ANGLE ADJUSTMENT in the Cylinder section.
6. Apply chassis grease to the grease nipple after the mast is mounted to the lift truck.
7. Remove the lifting device and any chains/straps used to lift the mast.
8. Bleed the hydraulic system.
NOTICE
• Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check nor-
mal functioning.
• Check the hydraulic oil level and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (Refer to "MAST
FORWARD BACKWARD TILT ANGLE ADJUSTMENT"
9. Install the forks.
13.4.1.4 COMPLETE MAST REMOVAL

NOTE: See also “Partial Removal” procedure which precedes for an alternative means of gaining access to
motors and pumps.
For this procedure, you will need a hoist or lift truck of suitable capacity.
1. Before starting complete removal, perform partial removal steps.
2. Verify that the mast is in a vertical position.
3. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to a hoist.
4. Turn the key switch OFF and disconnect the battery connector.
5. Remove the forks.
6. Lift the hoist just enough to take the slack out the chain or strap.
7. Remove the support cap and retaining hardware from the support pins.
8. Disconnect the main lift and auxiliary hoses. Be careful not to spill hydraulic fluid. Plug/cap each fitting to
prevent contamination from entering the hydraulic system.
9. Use the hoist or other lift truck to lift the mast just enough to allow it to be moved away from the tractor.
13-810 13 MAST
10. Have wood blocks positioned to support the mast off the floor.
11. Carefully lower the mast onto the support blocks with the fork carriage facing down.
(a)
(b)
(c)
(a) Mast support pin (b) Mast support cap

(c) Retaining hardware. 62～113 ft. lb. (84～156 N·m) (4PCS.)
13.4.1.5 INSTALLATION AFTER COMPLETE REMOVAL

NOTE: For this procedure, you will need a hoist or lift truck of suitable capacity.
1. Make sure the pivot bearings are shimmed as they were when the mast was removed.
2. Wrap a chain or lifting strap around the top of the mast. Attach the chains or straps to the lifting device.
3. Slowly lift the mast up and off the wooden blocks.
4. Slowly move the mast towards the lift truck.
5. Carefully engage the mast support pin with the supports on the drive unit.
6. Place the mast support caps over both mast support pins. Install the retaining hardware in both support
caps.
7. Remove C-clamps from upright flange if they were installed during mast reassembly.
8. Reconnect the mast and auxiliary hoses. Torque to correct specification.
9. Apply chassis grease to the grease nipples on the support caps.
10. Follow the procedure for "Installation after Partial Removal".
(a)
(b)
(c)
(a) Mast support pin (b) Mast support cap

(c) Retaining hardware. 62～113 ft. lb. (84～156 N·m) (4PCS.)
13 MAST 13-811
13.4.2 ROLLER BEARING WEAR PAD ADJUSTMENT (TT)

Adjust the roller bearing wear pad spacing, at all locations, as shown.
13
(a)
(a) 0.2 to 0.4 in. (0.008 to 0.016 mm) Clearance

1. Check and adjust the gap at each of the roller bearing wear pads (12 places).
• (4) Carriage bearings
• (2) Inner Tele bearings
• (4) Outer tele bearings
• (2) Mainframe bearings
2. Set the gap (a) between the wear pads and the mast rails by adjusting the set screws.
• A 1/6th inch turn of the set screw is approximately 0.011 in. (0.30 mm) of lateral movement of the wear
pad.
3. Make sure the adjustment of the wear pads keeps the teles centered within each other (left to right).
4. Replace a wear pad if it is excessively worn.
13.4.3 MAST SKEWING

Raise the mast to full height:
▪ If the mast kicks to the right at full extension, the right hand main lift cylinder rod must be shimmed.
▪ If the mast kicks to the left at full extension, the left hand main lift cylinder rod must be shimmed.
13-812 13 MAST
1. Place a 4 x 4 x 12 in. (10 x 10 x 30 cm) wood

block between the intermediate weldment and the
outer weldment cross members. Lower the cross
member onto the block.
2. Remove the cap (a), screw (b), inner(c), and
outer (d) sleeves from the cylinder to be adjusted.
Activate the lower control to allow the cylinder rod
to retract and disengage the cross member.
3. Install shim(s) (e) as necessary.
4. Slowly activate the lift control to allow the cylinder
rod to engage the cross member. Reinstall the
outer and inner sleeves, screw, and cap. Torque
the screw (b) to 55 ft•lb. (74.5 N•m).
5. Repeat steps 1 through 4 until skewing has been
removed.
13.4.4 3-STAGE (TT) MAST SERVICE

Bubbled items in the figures correspond to steps in the associated procedure.
13.4.4.1 DISASSEMBLY
1. Remove the mast assembly from the truck.
2. Reverse the Internal Reeving Installation.
3. Remove the free lift cylinders.
4. Disconnect the free lift chains from the carriage.
5. Disconnect the auxiliary hoses from the carriage bulkheads and plug all fittings.
6. Remove the carriage by sliding it out of the bottom of the inner upright.
7. Remove the main lift chain.
8. Remove main lift chain sheave.
9. Remove fittings and hoses between the mast manifold and main lift cylinders.
10. Remove the main lift cylinders.
11. Remove the mast manifold.
12. Using an overhead hoist, turn the mast over (cross members facing down).
13. Attach an overhead hoist to the inner upright. Remove the inner upright through the top of the intermedi-
ate upright.
14. Attach an overhead hoist to the intermediate upright and remove it through the top of the outer upright.
15. Remove bearing assemblies (if necessary).
13 MAST 13-813
(b) (a) (c) (a) Intermediate Upright

(b) Inner Upright
(c) Outer Upright
13.4.4.2 INSPECTION 13
1. Inspect the wear pads for excessive wear or damage. Wear pads with visible flat spots or cracks should
be replaced.
2. Inspect the roller bearings by turning them on their shafts. Roller bearings with roughness or noticeable
restrictions to turning should be replaced.
3. Inspect the bearing roller stub shafts. If they are damaged or have cracks at the base, the upright must
be replaced or repaired.
4. Inspect the lift chains. Refer to "Mast Chain Inspection".
5. Inspect the outer upright chain anchors.
6. Inspect the inner upright chain anchors.
13-814 13 MAST
13.4.4.3 REASSEMBLY
1. Install small and large roller bearing assemblies in the locations specified. Wear pads should be pushed
in as far as they can go. Set screws should be started but should not be installed far enough to start for-
cing the wear pad out of the roller stud.
2. Lubricate the roller bearing surfaces on the outer, intermediate, and inner uprights.
3. Attach an overhead hoist to the intermediate upright. Install the intermediate upright through the top of
the outer upright.
4. Adjust the wear pad spacing on the roller bearings positioned on the top of the outer upright and at the
bottom of the intermediate upright. This adjustment is made by driving in the adjusting set screw. Spa-
cing between the wear pads and the rails should be between 0.008 and 0.016 in. (0.2 and 0.4 mm) on
both sides. The intermediate upright should be centered within the outer upright.
5. Attach an overhead hoist to the inner upright. Install the inner upright through the top of the intermediate
upright.
6. Adjust the wear pad spacing on the roller bearings positioned on the top of the intermediate upright and
at the bottom of the inner upright. This adjustment is made by driving in the adjusting set screw. Spacing
between the wear pads and the rails should be between 0.008 and 0.016 in. (0.2 and 0.4 mm) on both
sides. The inner upright should be centered within the intermediate upright.
7. Using an overhead hoist, turn the mast over (cross members facing up).
8. Install the mast manifold as shown.
9. Install the main lift cylinders. Refer to Main Lift Cylinder Installation - Mast on Floor.
10. Install fittings and hoses between the mast manifold and main lift cylinders as shown.
11. Install the main lift chain sheave.
12. Install the main lift chain. Refer to Main Lift Chain Service.
13. Install the carriage by sliding it into the bottom of the inner upright.
14. Adjust the wear pad spacing on the roller bearings positioned on either side of the carriage. This adjust-
ment is made by driving in the adjusting set screw. Spacing between the wear pads and the rails should
be between 0.008 and 0.016 in. (0.2 and 0.4 mm) on both sides. The carriage should be centered within
the inner upright.
15. Connect auxiliary hoses to the carriage bulkheads in the correct orientation.
16. Connect the free lift chains to the carriage. Refer to Free Lift Chain Service.
17. Install free lift cylinders. Refer to Free Lift Cylinder Installation - Mast on Floor.
18. Adjust the chains by securing the carriage at the specified dimension from the bottom of the inner upright
with C-clamps clamped on the upright flange. Adjust both chain anchors until they have equal tension
with the carriage in the correct position (minor adjustments will need to be made once the mast is up-
right). Leave the carriage in this position with the C-clamps in place.
19. Route the auxiliary and lift hoses. Refer to Internal Reeving Installation.
13 MAST 13-815
13
13-816 13 MAST
(g) Wear pad adjustment set screw (On all roller

(a) Top of outer upright
bearing assemblies)
(b) Small roller bearing assembly (h) Bottom of inner upright
(c) Mast manifold (i) Large roller bearing assembly
(j) 1" from bottom of carriage to bottom of inner up-
(d) Main lift hoses
right
(e) Top and bottom of intermediate upright (k) Carriage
(f) Main lift chain sheave (l) C-clamp location
13 MAST 13-817
13.4.5 CYLINDER REMOVAL AND INSTALLATION
13.4.5.1 MAIN LIFT CYLINDER REMOVAL - MAST ON FLOOR
13
13-818 13 MAST
1. Remove the mast from the truck. See Complete Mast Removal.
2. Lay the mast face-down on wood blocks. Block under the outer upright so the inner upright is free to
move. The integral side shift must be positioned between the blocks and free to move.
3. Disconnect the cylinder supply hoses from the cylinder inlet ports. Remove the special long fittings from
the cylinder ports and install plugs.
NOTE: Each internal fuse piston holds a compressed spring in place.
4. Remove the cap (a), screw (b), inner sleeve (c), outer sleeve (d), and shims (e) (if present).
5. Remove the two screws securing the cylinder retaining bracket.
6. Remove the cylinder retaining bolt at the bottom of the cylinder.
7. Remove main lift cylinder.
13.4.5.2 MAIN LIFT CYLINDER INSTALLATION - MAST ON FLOOR

For installation, reverse the Removal procedure. In addition:
▪ Torque the screw at the top of the cylinder to 55 ft. lb. (74.5 N·m).
▪ Bleed the system.
13 MAST 13-819
13.4.5.3 FREE LIFT CYLINDER REMOVAL - MAST ON FLOOR
13
13-820 13 MAST
1. Remove the mast from the truck. See Complete Mast Removal.
2. Lay the mast down.
3. Roll the carriage toward the center of the cylinder to slacken the chains and internal reeving hoses.
4. Disconnect the cross-over tube and fittings from the cylinders. Cap the fittings and plug the hose.
5. Remove the free lift hose assembly from the free lift chain sheave assembly (a) by removing the two
bolts.
6. Remove the chain and nut from the free lift chain anchor.
7. Remove the free lift chain sheave assembly from the cylinder.
8. Remove the free lift cylinder bolts (b) connecting the cylinder to the lower mounting blocks.
9. Remove the chain anchor and remove the cylinder from the mast.
13.4.5.4 FREE LIFT CYLINDER INSTALLATION - MAST ON FLOOR

For installation, reverse the Removal procedure. Bleed the system.
13 MAST 13-821
13.4.5.5 FREE LIFT CYLINDER REMOVAL - MAST ON TRUCK
13
1. Completely lower the carriage. Remove forks or attachment. Make sure the free lift cylinder is completely
retracted. Attach an overhead hoist to the top carriage bar.
WARNING
The carriage must be supported by a block while removing the cylinder to avoid possible injury.
2. Raise the carriage to the center of the cylinder to slacken the chains and internal reeving hoses. Block
the carriage in place using a 4 x 4 x 24 in. (10 x 10 x 60 cm) wood block between the lower carriage bar
and the floor.
3. Remove the bolts connecting the cylinders to the lower mounting blocks.
4. Remove the free lift hose assembly.
5. Remove the chain and nut from the free lift chain anchor.
13-822 13 MAST
6. Remove the free lift chain sheave assembly from the cylinder.
7. Disconnect the cross-over tube and fittings from the cylinders. Cap the fittings and plug the hose.
8. Remove the chain anchors.
9. Remove the cylinder from the mast.
13.4.5.6 FREE LIFT CYLINDER INSTALLATION - MAST ON TRUCK

For installation, reverse the Removal procedure. Bleed the system.
13.4.6 INTERNAL REEVING INSTALLATION

1. Install auxiliary hoses at the carriage fittings.
2. Route auxiliary hoses over the free lift cylinder and through the hose pulley assembly. Attach hose pulley
assembly to the free lift chain sheave assembly.
3. Route auxiliary hoses down the free lift cylinder to the hose clamp. Install hose clamp components
around auxiliary hoses and bolt clamps to the cross-member. Do not tighten.
4. With carriage at its lowest position, pull slack out of the two aux hoses. Mark the hoses at the bottom of
the clamp. Pull the hoses until the distance between the line and the clamp is 1.5 ±0.5 in. (38 ±12 mm).
Tighten the clamp.
5. Route the auxiliary hoses as shown, clamping them at the positions specified with the hose clamps.
6. Attach lift hose (d) to the cross-over tube (c) between the free lift cylinders (e).
7. Clamp the free lift hose (a) and auxiliary hoses (b) into the hose clamp. Make sure the plastic clamps are
arranged as shown. Torque the screws to 50 in. lb. (6 N·m).
8. Route the free lift (a) and aux (b) hoses up to the upper hose pulley assembly. Install the hoses on the
pulleys, then push the pulleys into position so the shaft can engage both pulleys.
9. Assemble the upper hose clamp as shown with the hoses in the clamps, do not tighten.
10. With the mast fully collapsed, pull slack out of the lift hose and two aux hoses. Mark the hoses at the bot-
tom of the clamp. Pull the hoses until the distance between the line and the clamp is 1.5 ±0.5 in. (38 ±12
mm). Tighten the clamp to hold the hoses. Torque the screws to 50 in. lb. (6 N·m).
11. Route hoses as shown over to the main lift cylinder and clamp at equal distances in 3 places on the main
lift cylinder.
12. Attach the lift hose to the mast manifold.
13. Secure the two auxiliary hoses to the fitting on the mast manifold with a cable tie.
14. Raise and lower the mast several times. Make sure the hoses track over the pulleys correctly. The hose
pulley assembly attached to the free lift cylinder should be aligned front to back. If it looks like it is twist-
ing as the free lift cylinder is raised, perform the following adjustment procedure:
(a) Slightly loosen the aux hose fittings at the carriage, allowing the swivel fitting to correct the twist in the
hose.
(b) Tighten the fittings and check the hose pulley assembly for alignment. If necessary, adjust the hose
ends with a slight amount of twist to improve the alignment of the hose pulley assembly.
13 MAST 13-823
13
13-824 13 MAST
13.5 LIFT CYLINDER ROD SHIM ADJUSTMENT

(PREVENTION OF UNEVEN LIFTING)
NOTICE
• For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the
left and right sides due to tolerances of parts, etc.
• Perform inspection and adjustment when any of the following parts are replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY and inner mast SUB-ASSY.
• After adjustment, perform PSS matching. (See section 17.)
1. Inspection method
Slowly raise the inner mast, and observe the stopping
condition of the left and right cylinder rods at the mo-
ment when the inner mast reaches the maximum
height.
(1) Normal case
Both the left and right rods stop almost simultan-
eously with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.
SST 2. Adjustment method
(1) Raise the inner mast, attach the SST to the outer
mast tie beam, and lower the inner mast until it
comes into contact with the
SST 979-001/174
(2) Remove the cylinder rod end set bolt on the side
requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect
the cylinder rod end.
(4) Place shims (a) on the cylinder rod end, and

slowly raise the cylinder rod end into the inner mast.
(5) Install the cylinder rod end set bolt.
(6) Raise the inner mast again for reinspection.
(7) Repeat the inspection and adjustment until the
number of shims is determined.
Shim thickness: 0.020 to 0.039 in.(0.5 to 1.0 mm)
14 CYLINDER 14-825
14 CYLINDER
14.1 REAR LIFT CYLINDER (TT•QM) .......................................................... 825
14.2 VALVE ................................................................................................... 832
14.3 FRONT LIFT CYLINDER (TT, QM) ....................................................... 835
14.4 TILT CYLINDER .................................................................................... 840
14.1 REAR LIFT CYLINDER (TT•QM)
14.1.1 GENERAL
14
Rear Lift Cylinder (TT)
275 PSI
Rear Lift Cylinder (QM)
LH
RH
14-826 14 CYLINDER
Rear Lift Cylinder (TT)
Cylinder type Single-acting type
Cylinder bore
1.77 (45)
in. (mm)
Piston rod outside diameter
1.57 (40)
in. (mm)
Piston seal type U packing
Rod seal type U packing
Others Built-in valve (LH and RH)
Rear Lift Cylinder (QM)

Cylinder bore
2.17 (55)
in. (mm)
1.77 (45)
in. (mm)
Others Built-in valve (LH)
14 CYLINDER 14-827

3 2
10
14
5 10
Removal Procedure
1. Set the mast in the vertical position and fully lower the forks.
3. Hoist the inner mast by slinging with a wire and disconnect the end of each lift cylinder rod. [Point 1]
4. Hoist the inner mast farther so that the lift cylinder ASSY can be removed toward the front of the lift truck.
5. Support the bottom of the inner mast with wooden blocks and fix to the outer mast with string.
6. Remove the hose cover.
7. Disconnect the hose.
8. Remove the lift cylinder bottom end set bolt.
9. Remove the lift cylinder support.
10. Remove the lift cylinder ASSY. [Point 2]
14-828 14 CYLINDER
NOTICE
• Without a load, repeat full-stroke raising and lowering of the cylinder to bleed air and check nor-
mal functioning.
• Check the hydraulic oil level and add if insufficient.
• Inspect lift cylinders for uneven lifting, and make any necessary adjustment. (Refer to "MAST
FORWARD BACKWARD TILT ANGLE ADJUSTMENT"
Point Operations
[POINT 1]
Removal:
Perform shim adjustment at the lift cylinder rod end to
prevent uneven lifting by lift cylinders LH and RH.
Record which cylinder the adjustment is made and
also the number of shims used.
[POINT 2]
Installation:
Temporarily fasten the cylinder support, and eliminate
any clearance between the cylinder support and outer
mast by shim (a) insertion after connecting the rod
end.
(The shim thickness should be slightly greater than
the clearance)
14 CYLINDER 14-829
(a) 2
14
4
a (TT): T = 180 to 200 ft·lbf. [244 to 271 N·m]

a (QM): T = 200 to 220 ft·lbf. [271 to 298 N·m]
1. Remove the valve (LH).
2. Remove the cylinder cover. [Point 1]
3. Remove the piston rod. [Point 2]
4. Remove seals on the piston side. [Point 3]
14-830 14 CYLINDER
NOTICE
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the cylinder cover on the part shown in the below illustration
(a)
(b)
(c)
and reassemble it.
(a) 1/3 to 1/2 of circumference (b) 2 ridges (c) 2 to 3 ridges
Point Operations
[POINT 1]
Disassembly / Reassembly:
If the cylinder cover is a U-groove type, use the SST.
SST SST 979-001/175
[POINT 2]
Installation:
Measure the piston rod outside diameter.
Standard:
TT mast: 1.574 in. (40 mm)
QM: 45 mm (1.77 in.)
Limit:
TT mast: 1.5716 in. (39.92 mm)
QM: 1.7685 in. (44.92 mm)
Installation:
Measure the bend of the piston rod.
Limit: 0.079 in. (2.0 mm)
14 CYLINDER 14-831
Reassembly:
SST Use a cylinder rod (a) and insertion guide (SST) to re-
(a) assemble the cylinder (b).
SST 979-005/504
(b)
[POINT 3]
Inspection:
Measure the lift cylinder bore.
Standard:
TT:1.77 in. (45 mm)
14
QM: 2.17 in. (55mm)
Limit:
TT: 1.7795 in. (45.20 mm)
QM: 2.1791 in. (55.35 mm)
14-832 14 CYLINDER
14.2 VALVE
QM
TT
14 CYLINDER 14-833
14.2.1 REMOVAL AND INSTALLATION for QM
7
a 3 14
6
a (QM): T = 43.5 to 53.9 ft·lbf. [59 to 73 N·m]
Removal Procedure
2. Hoist the inner mast. [Point 1]
3. Remove the front hose cover and load sensor bracket.
4. Remove the lift cylinder (LH) bottom end set bolt.
5. Loosen the lift cylinder (LH) support set bolt.
6. Disconnect the hose.
7. Remove the valve.
14-834 14 CYLINDER
Point Operations
[POINT 1]
SST
SST Removal:
Hoist the inner (middle) mast by slinging with wire,
set the SST on the inner (middle) mast tie beam, and
lower the inner mast until it comes into contact with
the SST.
SST 979-001/174
14 CYLINDER 14-835
14.3 FRONT LIFT CYLINDER (TT, QM)
14.3.1 GENERAL
Front Lift Cylinder (TT)
275 PSI
14
Front Lift Cylinder (QM)
Front Lift Cylinder (TT)
Cylinder bore
1.968 (50)
in. (mm)
1.654 (42)
in. (mm)
14-836 14 CYLINDER

Others Built-in valve (LH and RH)
Front Lift Cylinder (QM)
Cylinder bore
2.76 (70)
in. (mm)
2.00 (50.8)
in. (mm)
Others Built-in valve

Removal Procedure
1. Remove the carriage W/ fork.
3. Remove the front lift cylinder.
NOTICE
After installing the lift cylinder, follow the steps below.
• Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.
• Check the hydraulic oil level, and add if insufficient.
• Adjust the lift chain tension equally on the left and right sides.
14 CYLINDER 14-837
6
3,4
14
5
2
1. Remove the chain wheel support.
2. Remove the cylinder cover. [Point 1]
4. Remove the wear ring and U packing.
5. Remove the check valve.
6. Remove the valve from the cylinder. [Point 3]
14-838 14 CYLINDER
NOTICE
• Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the cylinder cover on the part shown in the below illustration to re-
assemble it.
(a)
(b)
(c)
• Fill the cylinder with the specified amount of hydraulic oil through the cylinder top opening be-
fore installing the cylinder cover.
Filling amount : 3.66 in.3( 60 cm3)
(a) 1/3 to 1/2 of circumference

(b) 2 ridges
(c) 2 to 3 ridges
Point Operations
[POINT 1]
If the cylinder cover is a U-groove type, use the SST.
SST SST 979-001/175
[POINT 2]
Installation:
Standard:
TT: 1.654 in. (42 mm)
QM: 2.00 in. (50.8 mm)
Limit:
TT: 1.650 in. (41.92 mm)
QM: 1.9969 in. (50.72 mm)
Installation:
Limit: 0.079 in. (2.0 mm)
14 CYLINDER 14-839
[POINT 3]
Installation:
Standard:
TT: 1.968 in. (50 mm)
QM: 2.76 in. (70 mm)
Limit:
TT: 1.980 in. (50.3 mm)
QM: 2.7697 in. (70.35 mm)
14
14-840 14 CYLINDER
14.4 TILT CYLINDER
14.4.1 GENERAL
14.4.2 SPECIFICATION
Cylinder type Double-acting type
Cylinder bore
2.76 (70)
in. (mm)
1.18 (30)
in. (mm)
14 CYLINDER 14-841

9
8
3 7
3 14
Removal Procedure
1. Remove the toe board (front and rear) and tilt cover.
2. Remove the instrument panel.
3. Remove the fender cover and step.
4. Slightly hoist the mast.
5. Disconnect the hose. (After releasing the residual pressure in the tilt cylinder by operating the tilt lever
several strokes)
6. Disconnect the tilt angle sensor link. (RH)
7. Remove the tilt cylinder front pin. [Point 1]
8. Remove the tilt cylinder rear pin.
9. Remove the tilt cylinder ASSY.
14-842 14 CYLINDER
NOTICE
• Apply MP grease to the insertion portions of the tilt cylinder front and rear pins before installa-
tion.
• After installation, slowly tilt the mast forward and backward a few times to check normal function-
ing.
• Check the hydraulic oil level, and add if insufficient.
• After installation, perform PSS matching. (Refer to PSS section.)
Point Operations
[POINT 1]
Removal:
Make match marks to clarify the relative positions of
the front pin, stopper plate and lock bolt. Match
marks, however, are unnecessary when the mast or
mast ASSY is replaced as mast tilt angle adjustment
needs to be done after replacement.
[POINT 2]
Removal:
If the fitting is stiff, use the driver for removal.
14 CYLINDER 14-843
1 5
a T=284~421
(2900~4300)
[210~311]
14
a: T = 260 ft·lbf. [353 N·m]

b: T = 322 ft·lbf. [436 N·m]
1. Remove the Fitting.
2. Loosen the rod guide. [Point 1]
3. Extract the piston rod W/piston.
4. Remove the tilt cylinder. [Point 2]
5. Remove the bushing.
6. Remove the piston.
7. Remove the rod guide.
14-844 14 CYLINDER
NOTICE
• Apply MP grease or hydraulic oil to the packing, O-ring, and dust seal lip portion.
• Apply sealant (979-001/156) to the threaded portion of the rod guide before reassembly.
Point Operations
[POINT 1]
SST SST 979-001/175
[POINT 2]
Inspection:
Standard: 2.76 in. (70.0 mm)
Limit: 2.770 in. (70.35 mm)
Reassembly:
SST Use a cylinder rod insertion guide (SST) to reas-
semble the cylinder rod (a) to the cylinder (b).
SST 979-001/176
(b)
(a)
[POINT 3]
Installation:
Standard: 1.18 in. (30.0 mm)
Limit: 1.178 in. (29.92 mm)
Installation:
Limit: 0.039 in. (1.0 mm)
14 CYLINDER 14-845
14.4.5 MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT

(ADJUSTMENT OF UNEVEN TILTING)
NOTICE
• Adjust the mast forward and backward tilt angles (uneven tilting) when the tilt cylinder and mast
ASSY are replaced or overhauled.
• After adjustment, perform PSS matching. (Refer to PSS section.)
1. Inspect the forward and backward tilt angle and uneven lifting amount.
Standard:
Mast forward tilt angle: Standard set angle -0.6° to +1.6°
Mast backward tilt angle: Standard set angle -0.8° to +0.6°
Uneven lifting amount: 1 mm (0.04 in.) or less 14
2. If the standard is not satisfied, adjust it.
(a)
Tilt the mast forward, loosen the nut that holds the rod, then adjust the mast tilt angle and uneven lifting
by adjusting the screw engagement margin between the rod and the joint. (To adjust the screw engage-
ment margin, position a wrench to the 2-faced section on the rod and turn the rod.)
(a) Eccentric direction
CAUTION! Do not turn the rod when it is in the forward most tilt position (or the backward most
tilt position) (Turn it with the mast slightly before forward most tilt position).
3. After adjusting, tighten the nut to fix the rod.
15-846 15 OIL PUMP
15 OIL PUMP
15.1 GENERAL.............................................................................................. 846
15.2 REMOVAL AND INSTALLATION .......................................................... 847
15.3 DISASSEMBLY, INSPECTION AND REASSEMBLY ........................... 849
15.4 TEST METHOD ..................................................................................... 852
15.1 GENERAL
Vehicle model All model

Oil pump name Single gear pump
SMG300A21A3H1-L726
Oil pump type
(Shimadzu)
Drive system Direct motor drive
Delivery (at speed: 1800 rpm, pres-
L (US gal) /min 36.8 (9.72)
sure: 17.2 MPa)
Theoretical discharge cm3 (in3) /rev 21.8 (1.330)
15 OIL PUMP 15-847
15.2 REMOVAL AND INSTALLATION
1 15
6
5
a
a: T = 18 to 24 ft·lbf. [24 to 33 N·m]
Removal Procedure
2. Remove the toe board (front and rear) and tilt cover.
3. Remove the return filter set bolt and set the filter free.
4. Disconnect the pump outlet hose at the oil pump side.
5. Remove the oil pump set bolts.
6. Disconnect the pump inlet hose at the oil pump side.
7. Remove the oil pump ASSY W/ fitting.
15-848 15 OIL PUMP
NOTICE
• Apply grease at the spline section of the oil pump before installation.
Grease shall be "MOLIPASTE 500" of SUMIKO JUNKATSUZAI CO LTD,"HELME COAT TX-168" of
NIHON HERMETICS CO LTD,"G-N METAL ASSEMBLY PASTE of DOW CORNING CORP. Or equi-
valent ones. (molybdenum disulfide lubricants-rate of content:min 10%).
• Clean the flange that meets the motor before installation.
15 OIL PUMP 15-849
15.3 DISASSEMBLY, INSPECTION AND REASSEMBLY

4
a
5
15
a: T = 35.5 to 42.7 ft·lbf. [48.1 to 57.9 N·m]
1. Make match marks between the front cover and body.
2. Fix the mounting parts of front cover with body side up to the vice.
3. Remove the four bolts, body, back-up, figure 3 gasket and side plate. [Point 1]
4. Remove the drive gear, driven gear and side plate. [Point 2]
5. Remove the oil seal. [Point 3]
1. Put the body on the worktable with its hole for the gear up.
2. Reassemble the parts in order as the upper illustration. [Point 4]
3. Invert the assembled pump so the front cover is down and fix the mounting parts to the vice.
4. Tighten 4 bolts evenly by 35.5 to 42.7ft·bf. [48.1 to 57.9 N·m] torque.
5. Invert the assembled pump again so the front cover is up. Fix the body to the vice.
6. Remove the oil seal. [Point 5]
NOTICE
• Wash each part, blow dry with compressed air, and apply hydraulic oil before installation.
• Always use new seals for reassembly.
15-850 15 OIL PUMP
Point Operations
(b) [POINT 1]
Inspection:
(a) The bushing inner surface should not be roughened
and should not be worn to the extent that the metal
on the rear side is visible.
Disassembly:
Since the pair of side plates, figure 3 gaskets, and
back-ups are assembled in different directions, put a
tag on each pair to distinguish where the part is used.
(a) Lubrication groove
(b) Bushing
Inspection:
The side plate surface in contact with gears should
(a)
not be worn beyond the limit shown at left.
(b) (a) Wear limit: 0.0059 in. (0.15 mm) or less
(b) Surface in contact with gears
(d) (e) (c) Groove of figure 3 gaskets
(d) Discharge port
(e) Suction port
(c) (f) Erosion by cavitation around this portion
(f) (g) Strong contact around here
(g)
Inspection:
(b) Inspect the body inner surface for the wipe mark.
(a)
Standard:
(c) Wipe depth: 0.0004 to 0.0024 in. (0.010 to 0.060
mm)
(a) Wipe depth 0.0004 to 0.0024 in. (0.010 to 0.060
mm)
(b) Discharge port
(c) Suction port
(d) (d) wipe mark
[POINT 2]
Inspection:
Check the gear side surface for wear and the tooth
flanks for roughening.
Standard:
(a) Shaft diameter limit: 0.78 in. (19.85 mm)
Tooth width limit: 1.11 in. (28.30 mm)
(a) Shaft diameter
(b) Tooth width
(b)
15 OIL PUMP 15-851
Disassembly:
Make match marks on the tooth flanks of the drive
and driven gears.
(a)
(a) Drive gear
(b) Front cover
(c) Driven gear
(c)
(b)
[POINT 3]
Inspection:
1. Check that there is no wear (that makes edge
rounded portion invisible) or damage at oil seal
(a) lip.
2. Check that the figure 3 gasket is not damaged. 15
3. Check that the O-ring is not damaged.
4. Check that seals are not swollen.
(b) (a) Oil seal
(b) Figure 3 gasket
[POINT 4]
(a) Disassembly:
Fix the figure 3 gasket and back-up to the side plate
by using grease to prevent them from being twisted
or caught (The figure 3 gasket has a small dent for
back-up).
Reassembly:
Fix the drive gear and driven gear by matching each
(b) mark.
(a) Figure 3 gasket
(b) Back-up
[POINT 5]
(a) Reassembly:
Fill the dent between the main lip and dust lip of oil
seal with grease.
(a) Dust lip
(b) (b) Grease filling
(c) Main lip
(c)
15-852 15 OIL PUMP
15.4 TEST METHOD

A bench test should be conducted for strict testing, but as it is generally impossible in practical service oper-
ation, install the oil pump on the lift truck and judge the oil pump discharge performance by operating the cyl-
inder.
▪ Check that the battery charge is sufficient by observing the battery charge indicators.
▪ Check that the oil control valve set relief pressure is as specified. (Refer to Oil control valve section)
▪ Measure the time of full stroke of the lift cylinder with the hydraulic oil temperature at 50 ~ 55°C (122 ~
131°F) and calculate the lifting speed. However, due to soft start by material handling chopper circuit, lift-
ing speed is 10 ~ 20 mm/sec (2.0 ~ 3.9 fpm) lower than the value obtained from the table. The lifting
speed can be calculated more accurately by measuring the full stroke operation time excluding the soft
start period.
The lifting speed may differ depending on the conditions of the battery, hydraulic oil temperature and mast
adjustment.
The values below are based on a certain condition.
Lifting speed (reference value)

36V
fpm (mm / sec)
C35S
Model C30 C40
C35
Mast Mode No load Load No load Load No load Load
H 115 (585) 73 (370) 115 (585) 69 (350) 115 (585) 64 (325)
P 97 (495) 64 (325) 97 (495) 61 (310) 97 (495) 58 (295)
TT
S 78 (395) 53 (270) 78 (395) 51 (260) 78 (395) 49 (250)
E 72 (365) 48 (245) 72 (365) 45 (230) 72 (365) 43 (220)
H 120 (610) 95 (485) 120 (610) 94 (475) 120 (610) 92 (465)
P 103 (525) 83 (420) 103 (525) 81 (410) 103 (525) 79 (400)
QM
S 82 (415) 68 (345) 82 (415) 67 (340) 82 (415) 66 (335)
E 76 (385) 62 (315) 76 (385) 60 (305) 76(385 ) 59 (300)
48V
fpm (mm / sec)
C35S
Model C30 C40
C35
Mast Mode No load Load No load Load No load Load
H 118 (600) 89 (450) 118 (600) 87 (440) 118 (600) 84 (425)
P 109 (555) 73 (370) 109 (555) 69 (350) 109 (555) 66 (335)
TT
S 96 (490) 61 (310) 96 (490) 57 (290) 96 (490) 53 (270)
E 88 (445) 59 (300) 88 (445) 54 (275) 88 (445) 52 (265)
H 123 (625) 105 (535) 123 (625) 103 (525) 123 (625) 102 (520)
P 115 (585) 94 (475) 115 (585) 92 (465) 115 (585) 90 (455)
QM
S 102 (520) 81 (410) 102 (520) 79 (400) 102 (520) 77 (390)
E 93 (470) 75 (380) 93 (470) 73 (370) 93 (470) 72 (365)
16 OIL CONTROL VALVE 16-853
16 OIL CONTROL VALVE

16.1 OIL CONTROL VALVE (Mechanical controlled valve) .......................... 854
16.2 OIL CONTROL VALVE (Solenoid controlled valve) .............................. 867
16.3 CONTROL VALVE LEVER ASSY ......................................................... 881
16.4 RELIEF PRESSURE ADJUSTMENT .................................................... 883
16.5 MANUAL DOWN VALVE....................................................................... 885
16.6 TROUBLESHOOTING........................................................................... 886
16
16-854 16 OIL CONTROL VALVE
16.1 OIL CONTROL VALVE (Mechanical controlled

valve)
16.1.1 GENERAL
X1 X3 X4
S X2 C2
C4
P
CF
X1 T1
X4 C5
C1 C3
X2 X3
T2
LS
Inlet section (X1-X1)
(a)
(b)
(c)
16
(c) Unloading valve (Unloading

(a) Priority valve (b) Relief valve
SOL)
Lift section (X2-X2)
(b)
(a)
(c)
(d)
(a) Lift lock valve (Lift lock SOL) (c) Manual down valve
(b) Flow regulator valve (d) Lift spool
Tilt section (X3-X3)
(b)
(a)
(c) (e)
(d)
(a) Tilt control valve (Tilt control SOL) (c) Backward tilt switch (e) Tilt spool
(b) Backward tilt lock valve (Backward tilt lock SOL) (d) Forward tilt switch
Attachment section (X4-X4)
(a)
(a) Attachment spool

Solenoid Connector Diagram
(a)
(b)
16
(a) SOL (ON-OFF) (b) T-SW

Hydraulic Circuit Diagram

(f)
T2 LS R
(g)
(a)
P
CF
(b)
(c) (h)
(d)
S
C1
(e)
C2
C3
C4
C5
T1
(a) Unloading valve (Unloading SOL) (d) Manual down valve (g) Gauge port
(b) Relief valve (e) Tilt control valve (Tilt control SOL) (h) Flow regulator valve
(c) Lift lock valve (Lift lock SOL) (f) Priority valve
Model All model
Type Add-on type
Lift 2494 [17.2]
Relief pressure
Tilt
psi [MPa] 1987 [13.7]
ATT
Flow regulator flow rate
50
L / min
ATT flow rate list

Tuning level Flow rate (L / min)
8 63
7 54
6 45
5 37 16
4 28
3* 20
2 16
1 13
* : Factory preset is level "3"
Lowering speed specification (36V / 48V)

mm / sec (fpm)
Model All model

Mast Mode No load Load
TT All 480 (94) 490 (96)
QM All 485 (95) 500 (98)
8
7
7
3
Removal Procedure
3. Remove the floor mat and rear toe board.
4. Remove the accelerator clamp set bolt and disconnect the connector of accelerator pedal.
5. Remove the front toe board.
7. Remove the instrument panel (RH).
8. Remove the wire harness bracket.
9. Disconnect the wiring.
11. Disconnect the lever rod.
12. Slightly hoist the oil control valve ASSY.
13. Remove the oil control valve ASSY W/bracket. [Point 1]
14. Remove the oil control valve ASSY.
15. Remove the fitting and load sensor. [Point 2]
NOTICE
• Apply chassis grease special to the oil control valve lever linkage.
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (Refer to PSS sec-
tion.)
Point Operations
[Point 1]
Removal:
For the removal of the oil control valve ASSY W/ 16
bracket for fourth-way, use a hoist.
Installation:
▪ Tightening torque
T = 17.7 ft·lbf. [24.0 N•m]
▪ For the reassembly of the oil control valve ASSY
W/ bracket for fourth-way, use a hoist.
[Point 2]
Installation:
Reassemble the fitting and the load sensor.
▪ Standard : Refer to the following table.
Standards
Port Application Tightening torque (ft·lbf. [N•m])
P ALL 55 to 60 [74 to 82]
Fitting: 24 to 27 [32 to 36]
S (Pressure sensor) ALL
Sensor: 16 to 19 [22 to 26]
C1 ALL 41 to 46 [56 to 62]
C2 ALL
C3 ALL
C4 ALL
C5 ALL
C6 4 way
C7 4 way
24 to 27 [32 to 36]
A ALL
OUT ALL
LS ALL
PS return ALL
Oil-pressure check port ALL
T2 ALL
NOTICE
• Work in a clean location.
• Carefully handle parts. Individual parts are finished with high precision.
1. Remove the lift lock SOL and flow regulator valve. [Point 1]
2. Remove the lift spool. [Point 2]
3. Remove the tilt control SOL. [Point 3]
4. Remove the backward tilt lock SOL. [Point 4]
5. Remove the tilt limit switch and spring cover. [Point 5]
6. Remove the tilt spool. [Point 6]
7. Remove the unload SOL. [Point 7]
8. Remove the priority valve. [Point 8]
10. Remove the attachment valve.
11. Remove the rod bolt.
12. Remove the housing.
Inspection and Reassembly Procedure

NOTICE
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reas-
sembly.
Point Operations
[Point 1]
Removal:
Put match marks on the solenoid to prevent installing
in the wrong position.
Installation:
Align match marks for reassembly.
Inspection:
1
2 3
4 Check the lift lock solenoid for continuity.
Measurement terminal 2 ⇔ 6: Continuity exists.
9.4 to 10.4 Ω (at 20°C [68°F])
16
5 6 7 8
Installation:
▪ Check for contamination and clean the filter.
▪ Carefully reassemble to prevent incorrect installa-
tion of each solenoid spool, etc.
[Point 2]
Removal / Installation:
(b)
Remove / Install the compression spring to the lift
spool.
a: SST 979-005/495
Use the SST after attaching a washer (b).
(a)
[Point 3]
1
2 3
4 Inspection:
Check the tilt solenoid for continuity.
9.4 to 10.4 Ω (at 20°C [68°F])
5 6 7 8
Installation:
Check for contamination and clean the filter.
Installation:
▪ Check for contamination and clean the orifice.
tion of each solenoid spool.
[Point 4]
2 3
1 4 Inspection:
Check the backward tilt lock SOL for continuity.
5 6 9.8 to 10.8 Ω (at 20°C [68°F])
7 8
Installation:
[Point 5]
Inspection:
Check the tilt limit switch for continuity.
2 1
Forward tilting side (measurement terminals 1 ⇔
2):
No continuity when the switch is pressed. 16
4 3
Backward tilting side (measurement terminals 3
⇔ 4):
No continuity when the switch is pressed.
Be careful not to mistake the forward and backward
tilt limit switches.
[Point 6]
Removal / Installation:
(b)
Remove / Install the compression spring to the tilt
spool.
a: SST 09610-10161-71
Use the SST after attaching a washer (b).
(a)
[Point 7]
Inspection:
2 3
1 4 Check the unload solenoid for continuity.
5 6
9.4 to 10.4 Ω (at 20°C [68°F])
7 8
Installation:
[Point 8]
Installation:
Check for contamination and clean the orifice.
Installation:
16.2 OIL CONTROL VALVE (Solenoid controlled valve)
16.2.1 GENERAL
X3 X4
X2 16
S C2
X1
C4
P
CF
R1
X1 T1
C5
C1 C3
X4
X2 X3
T2
LS
(a)
(b)
(a) Priority valve (b) Relief valve
(c)
(d)
(b) (a)
(a) Proportion SOL (c) Lift lock valve (Lift lock SOL)
(b) Proportion SOL (d) Manual down valve
(c)
16
(b) (a)
(c) Tilt control valve (Tilt control

(a) Proportional SOL (b) Proportional SOL
SOL)
(b) (a)
(a) Proportional SOL (b) Proportional SOL

Solenoid Connector Diagram
SOL-b
SOL-a
(c)
(c) SOL (ON-OFF)

Hydraulic Circuit Diagram

(f)
T2 LS R1
CF
(a)
b1 a1
16
(b)
(c) S
C1
(d)
b2 a2
(e)
C2
C3
b3 a3
C4
C5
T1 R2
(e) Tilt control valve (Tilt control

(a) Relief valve (c) Flow regulator valve
SOL)
(b) Lift lock valve (Lift lock SOL) (d) Manual down valve (f) Priority valve
Model All model
Type Add-on type
Lift 2494 [17.2]
Relief pressure
Tilt
psi [MPa] 1987 [13.7]
ATT
Flow regulator flow rate
50
L / min
ATT flow rate list

Tuning level Flow rate (L / min)
8 63
7 54
6 45
5 37
4 28
3* 20
2 16
1 13
* : Factory preset is level "3"
Lowering speed specification (36V / 48V)

mm / sec (fpm)
Model All model

Mast Mode No load Load
TT All 480 (94) 490 (96)
QM All 485 (95) 500 (98)
8
7
16
7
3
Removal Procedure
4. Remove the accelerator clamp set bolt and disconnect the connector of accelerator pedal.
8. Remove the wire harness bracket.
9. Disconnect the wiring.
11. Slightly hoist the oil control valve ASSY.
12. Remove the oil control valve ASSY W/bracket. [Point 1]
13. Remove the oil control valve ASSY.
14. Remove the fitting and load sensor. [Point 2]
NOTICE
• After installation, check the hydraulic oil level, and if the level is too low, add more hydraulic oil.
• Perform matching when the load sensor is removed and installed or replaced. (Refer to PSS sec-
tion.)
• The solenoid controlled valve starting current is set up by turning for every section.
Do not carry out position change of a wire harness and a connector.
Point Operations
[Point 1]
Removal:
For the removal of the oil control valve ASSY W/
bracket for fourth-way, use a hoist.
Installation:
▪ Tightening torque
T = 17.7 ft-lbf. [24.0 N•m]
▪ For the reassembly of the oil control valve ASSY
W/ bracket for fourth-way, use a hoist.
[Point 2]
Installation:
Reassemble the fitting and load sensor.
▪ Standard : Refer to the following table.
Standards
Port Application Tightening torque (ft-lbf. [N•m])
P ALL 55 to 60 [74 to 82]
Fitting: 24 to 27 [32 to 36]
S (Pressure sensor) ALL
Sensor: 16 to 19 [22 to 26]
C1 ALL 41 to 46 [56 to 62]
C2 ALL
C3 ALL
C4 ALL
C5 ALL
C6 4 way
C7 4 way
24 to 27 [32 to 36]
A ALL
OUT ALL
LS ALL
PS return ALL 16
Oil-pressure check port ALL
T2 ALL
NOTICE
• Work in a clean location.
• Carefully handle parts. Individual parts are finished with high precision.
1. Remove the lift lock SOL and flow regulator valve. [Point 1]
2. Remove the tilt control SOL. [Point 2]
3. Remove the proportional SOL (a). [Point 3]
4. Remove the proportional SOL (b). [Point 4]
5. Remove the lift spool, tilt spool and attachment spool.
6. Remove the priority valve. [Point 5]
8. Remove the rod bolt, and then remove the housing.
Inspection and Reassembly Procedure

NOTICE
Clean each part thoroughly, remove dirt with compressed air, and apply hydraulic oil before reas-
sembly.
Point Operations
[Point 1]
Removal:
Put match marks on the solenoid to prevent installing
in the wrong position.
Installation:
Align match marks for reassembly.
Inspection:
2
3 Check the lift lock solenoid for continuity.
9.4 to 10.4 Ω (at 68°F [20°C])
6
5
Installation:
tion of each solenoid spool, etc.
16
[Point 2]
2
3 Inspection:
Check the tilt solenoid for continuity.
6 9.4 to 10.4 Ω (at 68°F [20°C])
5
Installation:
Installation:
▪ Check for contamination and clean the orifice.
[Point 3]
1 2 3 Inspection:
Check the proportional solenoid (a) for continuity.
5 6 7 Measurement terminal 2 ⇔ 6: Continuity exists.
(3way)
6.5 to 7.2 Ω (at 68°F [20°C])
[Point 4]
1 2 3
Inspection:
Check the proportional solenoid (b) for continuity.
5 6 7 Measurement terminal 2 ⇔ 6: Continuity exists.
(3way)
6.5 to 7.2 Ω (at 68°F [20°C])
[Point 5]
Installation:
Check for contamination and clean the orifice.
[Point 6]
Installation:
16
16.2.5 I-Q PLATE

The oil control valve installed on the lift truck requires setting of the starting current level.
The starting current is the current drawn by the oil control valve when the main spool starts to move.
By setting the starting current level, it is possible to attain a smoother load handling movement.
For the standard setting value of the starting current, refer to the I-Q plate attached on the oil control valve or
the label attached to the harness.
If there is no information about the standard setting value or if the load handling movement is not smooth
after setting with a certain setting value, decide the standard setting value as follows:
1. Set the starting current level to level 1.
2. Operate the load handling lever slowly.
3. Check the lever position when the mast or the attachment starts to move.
4. To make the play between that lever position and the neutral position smaller, raise the setting value.
5. Repeat the procedure 2 to 4.
For each of the following cases, it is necessary to change the starting current level settings.
1. When replacing the oil control valve ASSY.
2. When replacing the oil control valve sections.
3. When disassembly, cleaning, or parts replacement of the oil control valve.
4. When replacing the main controller.
Perform the setting using the display.

For detailed setting procedure, refer to the section DISPLAY for MATCHING OCV (3 OCV) .
(a)
SOL-b
SOL-a
(b) (c)
When replacing the oil control valve as an ASSY or as a block, remove the label that is attached to the har-
ness.
(a) Plate (b) Current level (c) SOL (ON_OFF)
NOTICE
1. If the level of the I-Q starting current was not entered correctly, it will not perform to the predeter-
mined level.
2. When a new lift truck is delivered or the oil control valve is replaced, make sure to record the I-Q
starting current level. The I-Q starting current level can be checked on the display, the I-Q plate, or
the I-Q label.
16.3 CONTROL VALVE LEVER ASSY

10
16
Removal Procedure
4. Remove the accelerator clamp set bolt and disconnect the connector of the accelerator pedal.
8. Disconnect the lever rod.
9. Remove the set bolt.
10. Remove the control valve levers. [Point 1]
NOTICE
Apply molybdenum disulfide grease on the control valve lever links.
Point Operations
[Point 1]
Installation:
Check the knob switch for continuity.
16.4 RELIEF PRESSURE ADJUSTMENT
NOTICE
• Always adjust the relief pressure as described below. Avoid hasty adjustment since it may cause
high pressure generation that may result in damage to the oil pump and other hydraulic devices.
• Before starting adjustment, check if the no-load maximum rpm is as specified.

2. Remove the lower panel and toe board.
3. Install an oil pressure gauge. [Point 1]
4. Set the adjusting screw A and adjusting sleeve B of the relief valve as described "Point Operations".
[Point 2]
5. Turn the key switch ON, and check for oil leaks and abnormal noise.
6. Install the toe board.
7. Close the battery hood. 16
8. Adjust the lift side relief pressure. [Point 3]
9. Adjust the tilt side relief pressure. [Point 4]
Point Operations
[Point 1]
Inspection:
Remove the oil-pressure detecting plug installed on
the left side of the oil control valve, and install the oil
(a) pressure gauge there.
Plug size: 9/16-18UNF
Fitting size: 9/16-18UNF × PF1/4
Fitting (a): 979-005/513
9/16-18 UNF
[Point 2]
(b)
(a) 1. Loosen lock nut (b). After fully tightening adjust-
ing screw (a) once, loosen it by 1 to 2 turns.
(c) 2. Loosen the lock nut (d), and position adjusting
screw (c) to the following dimension.
A A = 1.06 in. (27.0 mm)
(d)
[Point 3]
1. Set the seat switch to ON. (Operate with two
workers with one sitting on the seat.)
2. Operate the lift lever to lift the forks fully.
3. Operate the lift lever to the lifting side. Gradually
tighten adjusting sleeve B to make the oil pres-
sure in the relief state satisfy the standard in the
table on the next page, and fix the sleeve position
by tightening lock nut (d).
[Point 4]
1. Set the seat switch ON.
2. Operate the tilt lever to tilt the mast fully back-
ward.
3. Operate the tilt lever to the backward side.
Gradually tighten adjusting screw A to make the
oil pressure in the relief state satisfy the standard
in the table below, and fix the sleeve position by
tightening lock nut (b).
4. Tighten the lock nut and re-check the oil pres-
sure.
Standards:
Relief pressure
Lift
2494 to 2567 psi [17.2 to 17.7 MPa]
Tilt / ATT
1987 to 2059 psi [13.7 to 14.2 MPa]
16.5 MANUAL DOWN VALVE

(a)
16
(a) Manual down valve

▪ Tightening torque: T = 23.59 ft-lbf. [32.0 N•m]
If the forks do not lower due to a malfunction or other cause, loosen the manual down valve to lower the
forks in emergencies.
When loosening the manual down valve, do not rotate it more than one full turn.
After making repairs, tighten it securely.
16.6 TROUBLESHOOTING
Operation Symptom Probable cause Corrective action
• Check the priority valve piston. This part is re-
movable.
The steering
The priority valve pis- • Check the priority valve piston is not dam-
wheel cannot be
ton is stuck. aged.
rotated
• Check the priority valve piston is not contam-
inated.
• Check the priority valve piston is not dam-
Priority valve piston aged.
During steering malfunction. • Check the priority valve piston is not contam-
operation inated.
• Check the priority valve spring is not broken.
The steering
Insufficient spring force • Check the seat surface of the spring is not
wheel is hard to
is applied by the prior- worn out.
rotate
ity valve spring. • Check the seat surface of the stopper is not
worn out.
Contamination is stuck
• Check that the priority valve orifice is not con-
in the priority valve ori-
taminated.
fice (3).
• Check the relief main plunger. This part is re-
movable.
Relief valve main plun-
• Check the relief main plunger is not damaged.
ger is open and stuck.
• Check the relief main plunger is not contamin-
ated.
The relief valve is set
at the wrong setting • Check the relief pressure.
pressure.
Manual down valve is
• Check the manual down valve is tightened.
loose.
During lift opera- Load pressure detec-
Cannot lift tion circuit check valve • Not possible to inspect.
tion
(2) is closed and stuck.
• Check the lift by-pass check valve and lift lock
Lift by-pass check plunger. This part is removable.
valve (1) and the lift • Check the lift by-pass check valve and lift lock
lock plunger are closed plunger is not damaged.
and stuck. • Check the lift by-pass check valve and lift lock
plunger is not contaminated.
• Check the load check valve. It is removable.
Load check valve (12) • Check the load check valve is not damaged.
is closed and stuck. • Check the load check valve is not contamin-
ated.

• Check the relief valve main plunger is not
Relief valve main plun- damaged.
ger malfunction. • Check the relief valve main plunger is not
contaminated.
Insufficient spring force • Check the relief valve main plunger spring is
is applied by the relief not broken.
valve main plunger • Check the seat surface of the spring is not
spring. worn out.
Too small lap of relief • Check for any damage or contamination on
During lift opera- Lifting speed is main plunger. the relief main plunger.
tion slow The relief valve is set
pressure.
• Check the manual down valve is tightened.
loosen.
• Check for contamination in the load pressure
in the load pressure
detection circuit (2).
detection circuit. 16
Check valve (2) mal-
• Not possible to inspect.
function.
• Check the lift by-pass check valve is not dam-
Lift by-pass check aged.
valve (1) malfunction. • Check the lift by-pass check valve is not con-
taminated.
• Check the lift lock plunger is not damaged.
Lift lock plunger mal-
• Check the lift lock plunger is not contamin-
function.
ated.
• Check the load check valve is not damaged.
Load check valve (12)
During lift opera- Lifting speed is • Check the load check valve is not contamin-
malfunction.
tion slow ated.
Contamination is at-
tached to the lift SOL • Check for contamination in the lift SOL filter.
filter.
• Check for contamination in the priority valve
into the priority valve
orifice.
orifice (31).
Relief valve spring (A)
• Check the relief valve spring (A).
is damaged.

• Check the lift lock plunger. This part is remov-
able.
Lift lock plunger is
closed and stuck.
ated.
• Check for contamination in the lift lock plunger
into the lift lock plunger
orifice.
orifice (5).
• Check the operation sound of the lift lock SOL
by the following procedure. *MASK MENU >
Lift lock SOL is closed
ANALYZER > ACTIVE TEST > LIFT LWR SOL
During lift opera- and stuck.
Cannot lower > ON - OFF (Lift lowering SOL forced opera-
tion tion).
Lowering operation de-
tection limit switch is
• Check limit switch continuity.
damaged.
• Check for contamination in the lift lock valve
in the lift lock valve pi-
pilot circuit.
lot circuit (4)
filter.
Lift lock plunger mal-
• Check for contamination in the lift lock plun-
function.
ger.
• Check for contamination in the lift lock plunger
in the lift lock plunger
orifice.
orifice (5).
• Check the operation sound of the lift lock SOL
by the following procedure. *MASK MENU >
Lift lock SOL malfunc- ANALYZER > ACTIVE TEST > LIFT LWR SOL
tion. > ON - OFF (Lift lowering SOL forced opera-
tion)
• Check for contamination attached to the filter.
During lift opera- Lowering speed in the lift lock valve pi- • Not possible to inspect.
tion is slow lot circuit (4).
• Check the flow regulator valve is not dam-
Flow regulator valve aged.
piston malfunction. • Check for contamination in the flow regulator
valve.
The flow regulator • Check the flow regulator valve piston spring is
valve piston spring is not broken.
applying insufficient • Check the seat surface (6) of the spring is not
spring force. worn out.
filter.
is damaged.

• Check the relief valve main plunger. This part
is removable.
Relief valve main plun- • Check the relief valve main plunger is not
ger is open and stuck. damaged.
contaminated.
During tilt opera- Cannot tilt for- pressure.
tion ward • Check the tilt control valve plunger. This part
is removable.
Tilt control valve plun-
• Check the tilt control valve plunger is not
ger is closed and
damaged.
stuck.
• Check the tilt control valve plunger is not con-
taminated.
• Check for contamination in the tilt control
in the tilt control valve
valve plunger orifice.
plunger orifice (7). 16
• Check the operational sound of the tilt SOL by
moving the lever after the key switch is turned
ON.
Tilt SOL is stuck and
• Check the operation sound of tilt SOL by the
closed.
following procedure. *MASK MENU > ANA-
LYZER > ACTIVE TEST > TILT SOL > ON -
OFF (Tilt SOL forced operation)
valve pilot circuit.
pilot circuit (8).
During tilt opera- Cannot tilt for- Load pressure detec-
tion ward tion circuit check valve
(25) is closed and
stuck.
• Check the load check valve. This part is re-
movable.
• Check the load check valve with no damage.
is closed and stuck.
• Check the load check valve without any con-
taminations.
tached to the lift SOL • Check for contamination in the tilt SOL filter.
filter.

contaminated.
spring. worn out.
main plunger. the relief main plunger.
During tilt opera- Tilt forward
tion speed is slow The relief valve is set
pressure.
Tilt control valve mal- damaged.
function. • Check the tilt control valve plunger is not con-
taminated.
into the tilt control • Check for contamination in the tilt control
valve plunger orifice valve plunger orifice.
(7).
following this procedure. *MASK MENU > ANA-
Tilt SOL malfunction. LYZER > ACTIVE TEST > TILT SOL > ON -
• Check for contamination in the filter.
• Check for contamination are not in the tilt con-
trol valve pilot circuit.
pilot circuit (8).
During tilt opera- Tilt forward in the load pressure
detection circuit.
tion speed is slow detection circuit (25).
Load pressure detec-
tion circuit check valve • Not possible to inspect.
(25) malfunction.
• Check the load check valve is not contamin-
malfunction.
ated.
tached to the lift SOL • Check for contamination in the tilt SOL filter.
filter.

is removable.
contaminated.
pressure.
tion circuit check valve
During tilt opera- Cannot tilt back- (25) is closed and
tion ward stuck.
movable.
ated. 16
tached to the tilt SOL • Check for contamination in the tilt SOL filter.
filter.
pilot circuit (8).
contaminated.
spring. worn out.
pressure.
During tilt opera- Tilt backward Contamination is stuck
tion speed is slow in the load pressure
detection circuit.
tion circuit check valve • Not possible to inspect.
(25) malfunction.
malfunction.
ated.
tached to the tilt SOL • Check for contamination in the tilt SOL filter.
filter.
pilot circuit (8).

• Check the lift lock plunger seat is not dam-
Lift lock plunger seat is aged.
damaged. • Check the lift lock plunger seat is not contam-
inated.
able.
open and stuck.
ated.
• Check the lift lock plunger spring is not
Insufficient spring force
broken.
is applied by the lift
• Check the seat surface of the spring is not
lock plunger spring.
worn out.
• Check the lift by-pass check valve seat is not
Lift by-pass check damaged.
valve seat is damaged. • Check the lift by-pass check valve seat is not
contaminated.
Key switch is Natural drop is • Check the lift by-pass check valve plunger.
OFF large This part is removable.
Lift by-pass check
• Check the lift by-pass check valve plunger is
valve plunger is open
not damaged.
and stuck.
not contaminated.
Insufficient spring force • Check the lift by-pass check valve spring is
is applied by the lift by- not broken.
pass check valve • Check the seat surface of the spring is not
spring. worn out.
• Check the manual down valve is tight.
loose.
Lift lock SOL seat is
damaged.
• Check the operational sound of the lift lock
SOL by following this procedure. *MASK
Lift lock SOL is open
MENU > ANALYZER > ACTIVE TEST > LIFT
and stuck.
LWR SOL > ON - OFF (Lift lowering SOL
forced operation)

• Check the tilt control valve plunger seat is not
Tilt control valve plun- damaged.
ger seat is damaged. • Check the tilt control valve plunger seat is not
contaminated.
• Check the tilt control valve plunger. This part
is removable.
Tilt control valve plun- • Check the tilt control valve plunger is not
taminated.
Insufficient spring force • Check the tilt control valve plunger spring is
Key switch is Natural tilt for- is applied by the tilt not broken.
OFF ward is large control valve plunger • Check the seat surface of the spring is not
spring. worn out.
is applied by the tilt
• Check spring force by pushing.
control valve check ball
spring. 16
Tilt SOL seat is dam-
aged.
Tilt SOL is open and following this procedure. *MASK MENU > ANA-
stuck. LYZER > ACTIVE TEST > TILT SOL > ON -
contaminated.
is removable.
taminated.
Forward tilt auto- is applied by the tilt not broken.
Does not stop
matic leveling control valve plunger • Check the seat surface of the spring is not
automatically
stop spring. worn out.
is applied by the tilt
• Check spring force by pushing.
spring.
aged.

ger malfunction. • Check the tilt control valve plunger is not con-
taminated.
is removable.
Backward tilting taminated.
Speed is fast
speed regulation • Check the operational sound of the tilt SOL by
operating the lever after the key switch is
turned ON.
Tilt SOL is stuck and
• Check the operation sound of the tilt SOL by
closed.
following this procedure. *MASK MENU > ANA-
LYZER > ACTIVE TEST > TILT SOL > ON -
pilot circuit (8).
is removable.
contaminated.
During ATT op- ATT does not pressure.
eration move Load pressure detec-
tion circuit check valve
(26) is closed and
stuck.
movable.
ated.

contaminated.
spring. worn out.
During ATT op- ATT movement at the wrong setting • Check the relief pressure.
eration is slow pressure.
in the load pressure
detection circuit.
tion circuit check valve • Not possible to inspect. 16
(26) malfunction.
malfunction.
ated.
is damaged.
Lifting does not Unload valve (D) is
• Check the unload valve(D).
stop closed and stuck.
able.
open and stuck.
ated.
• Check the operational sound of the lift lock
SOL by following this procedure. *MASK
Lift lock SOL is open
MENU > ANALYZER > ACTIVE TEST > LIFT
and stuck.
LWR SOL > ON - OFF (Lift lowering SOL
During Operator forced operation)
Presence Sensor
operation Lowering does • Check the lift by-pass check valve seat is not
not stop Lift by-pass check damaged.
valve seat is damaged. • Check the lift by-pass check valve seat is not
contaminated.
• Check the lift by-pass check valve plunger.
This part is removable.
Lift by-pass check
valve plunger is open
not damaged.
and stuck.
not contaminated.
Lift lock SOL seat is
damaged.

contaminated.
is removable.
taminated.
is applied by the tilt not broken.
Tilt forward does control valve plunger • Check the seat surface of the spring is not
not stop spring. worn out.
During Operator Insufficient spring force
Presence Sensor is applied by the tilt
operation • Check spring force by pushing.
spring.
aged.
Unload valve (D) is
• Check the unload valve (D).
closed and stuck.
Tilt backward Unload valve (D) is
does not stop closed and stuck.
ATT does not Unload valve (D) is
stop closed and stuck.
(31)
(3)
(A)
(D)
16
(A) Spring (3) Orifice

(D) Unload valve (31) Priority valve
(20)
(19)
(12)
(6)
(1)
(2)
(14)
(17)
(16)
(5)
(18)
(15)
(6)
(1) Check valve (5) Orifice (12) Load check valve (15) O-ring (17) SOL spool (19) SOL spool
(2) Check valve (6) Seat surface (14) Sleeve (16) O-ring (18) Pilot circuit (20) Pilot circuit
(24)
(23)
(13)
16
(25)
(25)
(21)
(7)
(22)
(8)
(7) Orifice (13) Load check valve (22) Pilot circuit (24) Pilot circuit
(8) Pilot circuit (21) SOL spool (23) SOL spool (25) Check valve
(29)
(28)
(27)
(26)
(28)
(29)
(26) Check valve (27) Load check valve (28) SOL spool (29) Pilot circuit
Hydraulic Circuit diagram
T2 CF LS R1
P1
(12)
b1
a1
S
16
(4) C1
b2
a2
C2
C3
b3
a3
C4
C5
T1 R2
(4) Pilot circuit (12) Load check valve

I-Q plate
(a)
(30)
(a) Plate (30) Current level

17 PSS FUNCTIONS 17-903
17 PSS FUNCTIONS
17.1 GENERAL (PSS)................................................................................. 904
17.2 FOR REPAIR WORK.......................................................................... 907
17.3 TILT ANGLE SENSOR....................................................................... 908
17.4 LOAD SENSOR.................................................................................. 909
17.5 SPEED SENSOR ............................................................................... 910
17.6 MAST LIFTING HEIGHT SWITCH ..................................................... 911
17.7 TIRE ANGLE SENSOR ...................................................................... 911
17.8 MATCHING......................................................................................... 912
17.9 GENERAL (Operator Presence Sensor) ............................................ 915
17.10 CONTROL SPECIFICATION............................................................. 918
17.11 RENEWAL OF PSS CAUTION LABEL ............................................. 920 17
17-904 17 PSS FUNCTIONS
17.1 GENERAL (PSS)
17.1.1 System configuration

17.1.2 Name and Feature of Each Component
17.1.2.1 Name of Each Component
17
No. Name No. Name

1 Height switch 9 Forward switch
2 Tilt angle sensor 10 Reverse switch
3 Tilt lever switch 11 Vehicle speed sensor *1
4 Lift lever angle sensor 12 Tilt forward lock valve
5 Load sensor 13 Tilt backward lock valve
6 Automatic fork leveling control switch 14 Lift lock valve
7 Tire angle sensor 15 Drive motor *2
8 Accelerator pedal angle sensor 16 Main controller
*1: The lift truck speed is detected by the motor speed sensors via the drive motor driver.
*2: The drive motor is driven by the drive motor driver.
17.1.2.2 Feature of Each Component

No. Name Feature
The limit switch installed on the outer mast detects the height of the in-
1 Height switch ner mast. Then it is determined whether the lift height is on the lower
stage or upper stage with respect to the specified height.
The angle sensor installed on the right tilt cylinder detects the mast tilt
2 Tilt angle sensor angle by measuring the position of the tilt cylinder considering the rear
pin as axis of rotation.
The tilt lever switch installed on the oil control valve detects the tilting
3 Tilt lever switch
operation.
The lift lever angle sensor detects the lifting operation. It is installed on
4 Lift lever angle sensor
the oil control valve.
The pressure sensor installed in the hydraulic circuit of the lift detects
5 Load sensor the load.
It is mounted on the oil control valve.
Automatic fork leveling control This switch that is installed on the tilt lever is used to automatically
6
switch level the fork.
The sensor installed at the center of the rotational axis of the rear axle
7 Tire angle sensor
detects the steered angle of the tire.
This sensor measures the angle of depression of the accelerator
Accelerator pedal angle
8 pedal. The response to accelerator operation is limited by traveling
sensor
control.
The forward switch in the direction lever detects the operation to drive
9 Forward switch forward. The direction lever is installed on the left side of the handle
post or on the armrest.
The reverse switch in the direction lever detects the operation to drive
10 Reverse switch
backward. The installed location is the same as the forward switch.
The lift truck speed is detected by the motor speed sensors via the
11 Vehicle speed sensor *1 drive motor driver.
The motor speed sensors are installed on the drive motor.
The solenoid installed on this valve changes the oil passage of the tilt
12 Tilt forward lock valve and stops tilt forward by switching the applied voltage from the control-
ler.
13 Tilt backward lock valve and stops tilt backward by switching the applied voltage from the con-
troller.
The solenoid installed on this valve interrupts the oil passage from the
14 Lift lock valve lift cylinder to the oil tank and stops the forks lowering by switching the
applied voltage from the controller.
15 Drive motor *2 The drive motor drives the front wheels of the lift truck.
*1: The lift truck speed is detected by the motor speed sensors via the drive motor driver.
17.2 FOR REPAIR WORK

Before starting PSS repair, make sure you fully understand the PSS functions.
CAUTION
Always disconnect the battery terminal before the inspection or servicing of electrical parts.
1. Preparation for repair work

(1) Avoid washing the lift truck as much as possible; for cleaning, blow compressed air. If washing with
water is required, avoid water jet washing. Always blow compressed air to remove water after washing.
(2) Transport the controller in a packed state, and keep it packed until installation. Never transport it in an
exposed state. Make sure not to drop or apply impact to the controller.
(3) If matching is required after repair, park the lift truck on a flat surface in advance.
(4) Prepare necessary tools, testers (analog tester).
2. During repair work

(1) Never use an impact wrench for removing or installing the main controller. Full care should be taken
not to drop the main controller by mistake. Avoid impact from dropping that may damage parts inside.
(2) Do not turn the key switch to ON or OFF carelessly while the sensor wiring is disconnected. Key
switch ON in this state may cause an error and the error code will be stored in the controller. Error codes
17
cannot be cleared. When the stored error codes exceed ten, the oldest one is cleared from the controller.
Therefore necessary repair information becomes unavailable.
(3) Do not drive the lift truck during matching, as PSS function is disabled.
(4) If the hydraulic piping is disconnected, apply a cap to each fitting and hose to keep dirt off.
(5) When the oil control valve lift lock unlocking bolt is loosened, always tighten it to the specified torque
and return the bolt to the original state after the end of repair.
(6) Tighten the set bolts of respective functional parts to the specified torque.
(7) No adjustment is necessary for each sensor at the time of installation, but make sure to perform
matching after the installation.
(8) When disconnecting a connector, do not pull it at the harness.
(9) When inspecting the harness, make sure to avoid damaging the connector terminals.
(10) Positioning of the low- and high-lifting heights described in the troubleshooting section are as fol-
lows.
Classification How to distinguish

Low lifting height Fully lowered to height with lifting height switch MH1 (Less than approx. 2 m)
High lifting height Height with lifting height switch MH2-1 (Approx. 2 m or more)
3. Emergency Action
If the mast fails to lower during lowering operation, it
(a)
can be lowered manually as follows:
Loosen the manual down valve (a) gradually until the
mast starts to lower. After repair, do not forget to re-
tighten the manual down valve. If forgotten, the lift
speed becomes remarkably delayed.
Tightening torque: T = 23.59 ft-lbf. [32.0 N·m]
17.3 TILT ANGLE SENSOR
1
a
a : T = 5.8 to 13.4 ft·lbf. [7.8 to 18.2 N·m]
Removal Procedure
1. Disconnect the tilt angle sensor link.
2. Remove the toe boards (front and rear).
4. Disconnect the connector.
5. Remove the tilt angle sensor.
NOTICE
• Perform matching if the tilt angle sensor is removed or replaced or the tilt angle sensor link is ad-
justed in length or replaced. (Refer to PSS section)
• For installation, apply MP grease on sliding section of the end.
• Spread thread locking compound (P/N 990-403) on screw.
• Hold both parts rigidly to avoid damaging end.
17.4 LOAD SENSOR
2
a 17
a (Load sensor) : T = 16.2 to 19.2 ft·lbf. [22 to 26 N·m]
Removal Procedure
1. Disconnect the connector from the load sensor.
2. Remove the load sensor.
NOTICE
• When the load sensor is replaced, proceed with the matching procedure. (Refer to Display sec-
tion)
• Do not use open type tool, in fixing pressure sensor to oil control valve. (Use box type wrench)
17.5 SPEED SENSOR
Removal Procedure
1. Remove the mast ASSY.
2. Remove the toe boad.
4. Diconnect the speed sensor connector.
5. Remove the speed sensor.
17.6 MAST LIFTING HEIGHT SWITCH
(a)
(b)
17
a : T = 12.0 to 27.9 ft·lbf. (16.2 to 37.8 N·m)

b : T = 5.8 to 13.4 ft·lbf. (7.8 to 18.2 N·m)
Removal Procedure
1. Remove the lower cover.
2. Disconnect the connector.
3. Remove the mast lifting height switch.
17.7 TIRE ANGLE SENSOR

About tire angle sensor, refer to REAR AXLE section.
17.8 MATCHING
17.8.1 GENERAL
Each function is controlled by using the sensors and each signal voltage at standard lift truck condition
stored in the controller at the time of shipment. Therefore, a MATCHING (updating of the signal voltage of a
sensor at standard lift truck condition) is required when performing maintenance on a section or replacing
parts related to the sensor.
For the accelerator sensor used for drive functions, the signal voltage values at accelerator fully released,
accelerator fully closed are stored, respectively, in the controller to control based on these values. When ser-
vicing these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the
standard lift truck condition) is necessary.
For the tilt angle, load and tire angle sensors used for PSS functions, the signal voltage values under the
mast vertical, no load, tire straight and lift truck horizontal are stored respectively at the time of shipment, in
the controller to control based on these values. When servicing or replacing these sensors, MATCHING (up-
dating the sensor signal voltage value in the standard lift truck condition) is necessary. Also, matching is
needed for the tilt angle sensor when the lift truck posture has changed excessively, and for the load sensor
when the load under no load condition (no load on fork) is changed because of addition or removal of any at-
tachment or fork, replacement of mast or change of fork length.
Each lever angle sensor for material handling lever function is controlled based on the memory of signal
voltage values in the neutral position stored in the controller at the time of shipment. When servicing these
sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard lift
truck condition) is necessary.
It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer
reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the
tire size or type is changed according to “Tire Data List”.
Matching Items and Prerequisite for Implementation

1. DRIVE
plementation
Accelerator sensor output value with fully released ac-
1 ACCEL OFF *1, *2
celerator position to the controller.
Accelerator sensor output value with fully stepped accel-
2 ACCEL ON *1, *2
erator position to the controller.
Brake sensor output value with fully released brake posi-
3 BRAKE OFF *1, *16
tion to the controller.
Brake sensor output value at the start point of wet-brake
4 BRAKE ACT *1, *16
activation to the controller.
2. PSS
plementation
Tilt angle sensor output value with fork in the horizontal
1 TILT LEVEL *1, *3, *4, *7, *8, *9
position to the controller.
Tilt angle sensor output value at the mast vertical posi-
*1, *3, *4, *5, *7, *8,
2 TILT FWD LIMIT tion and the load sensor output value without load to the
*9
controller.
Tire angle sensor output value while the lift truck is trav-
3 TIRE POSITION *1, *6
eling straight to the controller.
4 MAST TYPE The mast type is stored *8, *14
3. LEVER
plementation
Lift lever angle sensor output value in the lift lever neut-
1 LEVER 1 *1, *10
Tilt lever angle sensor output value in the tilt lever neut-
2 LEVER 2 *1, *11
3 LEVER 3 tachment (1) lever neutral position is stored in the con- *1, *12
troller.
4 LEVER 4 tachment (2) lever neutral position is stored in the con- *1, *13
troller.
4. TIRE DATA
plementation
1 TIRE DATA The tire data according to the tire size is stored. *1, *15
Prerequisite content for implementation 17
*1: When replacing the main controller
*2: When removing/installing or replacing the accelerator sensor
*3: When removing/installing or replacement the tilt angle sensor
*4: When length change or replacement of the tilt angle sensor rod
*5: When removing/installing or replacing the load sensor
*6: When removing/installing or replacing the tire angle sensor or the sensor cover
*7: When installing or changing the attachment or forks
*8: When removing/installing or replacing the mast
*9: When removing/installing or replacing the tilt cylinder
*10: When replacing the lift lever angle sensor
*11: When replacing the tilt lever angle sensor
*12: When replacing the attachment (1) lever angle sensor
*13: When replacing the attachment (2) lever angle sensor
*14: When replacing the multi-function display
*15: When the tire size or the type is changed
*16: When removing/installing or replacing the brake sensor
*17: When replacing the oil control valve
17.8.2 STANDARD STATE OF VEHICLE

If the surface on which matching is to be performed is slanted, error occurs to the standard state. Select a
level floor without irregularity for matching.
NOTICE
The finishing accuracy of the floors for factories, warehouses and buildings in general calls for the
floor inclination to be 0.5° or under. Therefore, matching on these floors is not affected. Do not per-
form matching on a floor that is inclined over 0.5° for draining purpose.
[POINT 1]
TT/QM Fork stop position with automatic leveling and
forward tilting limit position
▪ Set the lift truck in the following condition so as to
have the tilt angle sensor signal voltage value
stored with the mast held vertical to the floor sur-
face: Load sensor
No-load standard load
▪ Set the lift truck in the following condition so as to
100 mm have the load sensor signal voltage value stored
(3.93 in) under no-load condition:
Standard:
ment, including forks or attachments, moun-
ted as specified.
▪ The lift truck should be with no load on level
ground.
▪ For TT/QM mast: The rear lift cylinders should
be raised to a height of approximately 3.93 in.
(100 mm).
▪ Park the lift truck on a level surface. Position
the mast perpendicular to the floor. Press 1
for 2 seconds or more.
▪ In special cases that the execution of "the
other procedure" is specified, the mast should
be lifted to the top and the hydraulic oil con-
trol valve should be relieved.
Tire straight traveling position check
Signal voltage of the tire angle sensor in tire straight
travel position is stored. Tire straight travel position is
the condition in which driving the lift truck 16 ft. (5 m)
with the steering wheel fixed causes the center of the
lift truck to stay within 2.0 in. (50 mm) to the left and
right of the line.
NOTICE
• Keep the forks or attachment installed on the lift truck.
• Set the mast vertical from a backward tilted position (not from the forward tilted position).
• In case of a detachable attachment, keep the attachment installed on the lift truck.
17.8.3 CAUTIONS ON MODIFYING VEHICLES

When replacing the mast
▪ When the mast is replaced, the mast harness has to be replaced with one suitable for the new lift-
ing height.
▪ When placing an order for a mast ASSY, check the need for sensors (lifting height switch, load
sensor, mast harness, and other PSS-replaced parts) and place an order accordingly.
▪ Make sure to perform matching after replacement. (Refer to Display section)
Other functional parts

▪ Refer to the oil control valve section for the OCV solenoid 1, 2, backward and forward tilt switch,
and tilt lever knob button.
▪ For the inspection of functional parts, refer to the troubleshooting section.
17.9 GENERAL (Operator Presence Sensor)
17.9.1 System Configuration
17
17.9.2 Name and Feature of Each Component
17.9.2.1 Name of Each Component
No. Name No. Name

1 Height switch 10 Attachment 2 lever angle sensor
2 Load sensor 11 Tilt forward lock valve
3 Seat switch 12 Tilt backward lock valve
4 Accelerator pedal angle sensor 13 Lift lock valve
5 Forward switch 14 Unload valve
6 Reverse switch 15 Multi-function display
7 Lift lever angle sensor 16 Drive motor
8 Tilt lever switch 17 Main controller
9 Attachment 1 lever angle sensor
17.9.2.2 Feature of Each Component

No. Name Feature
The limit switch installed on the outer mast detects the height of the in-
1 Height switch ner mast. Then it is determined whether the lift height is on the lower
stage or upper stage with respect to the specified height.
The pressure sensor installed in the hydraulic circuit of the lift detects
2 Load sensor the load.
It is mounted on the oil control valve.
This limit switch is built into the seat, and detects the operator sitting
3 Seat switch
on the seat.
Accelerator pedal angle The sensor installed on the accelerator pedal unit detects the stepped-
4
sensor on angle of it.
The forward switch in the direction lever detects the operation to drive
forward.
5 Forward switch The direction lever is installed on the left side of the handle post or on
the armrest.
The reverse switch in the direction lever detects the operation to drive
6 Reverse switch backward. 17
The installed location is same as the forward switch.
The lift lever angle sensor detects the lift operation.
7 Lift lever angle sensor
It is installed on the oil control valve.
The tilt lever switch installed on the oil control valve detects the tilt op-
8 Tilt lever switch
eration.
The attachment 1 lever angle sensor detects the operation of the at-
Attachment 1 lever angle
9 tachment 1.
sensor
The attachment 2 lever angle sensor detects the operation of the at-
Attachment 2 lever angle
10 tachment 2.
sensor
11 Tilt forward lock valve and stops tilt forward by switching the applied voltage from the control-
ler.
12 Tilt backward lock valve and stops tilt backward by switching the applied voltage from the con-
troller.
The solenoid installed on this valve interrupts the oil passage from the
13 Lift lock valve lift cylinder to the oil tank and stops forks lowering by switching the ap-
plied voltage from the controller.
This valve bypasses the oil pressure, supplied from the oil pump to the
14 Unload valve oil control valve, to the oil tank by switching of the applied voltage from
the controller.
This indicator on the multi-function display is turned on while the seat
Multi-function display Oper-
switch is turned off. The onboard buzzer on the multi-function display
15 ator Presence Sensor indic-
sounds by the specified pattern when the seat switch is turned off or
ator Onboard buzzer
"return to neutral warning" is activated.
In the normal operation, the drive motor drives the front wheels.
16 Drive motor *1 When the travel Operator Presence Sensor is activated, the drive mo-
tor acts as the regenerative brake and reduce the freewheeling.
17.10 CONTROL SPECIFICATION

1. Traveling Operator Presence Sensor functions
▪ When the controller detects the seat switch being turned off for 2 seconds, the traveling power is inter-
rupted by interrupting the voltage supply to the forward and reverse drive valve with control of the for-
ward interrupt relay and the reverse interrupt relay.
▪ Travel Operator Presence Sensor is released by returning the direction lever to the neutral position and
turning on the seat switch.
Moreover, the lift truck must be returned to neutral and the accelerator pedal released, if the operator left
the seat when traveling in the forward or reverse direction.
NOTICE
Traveling Operator Presence Sensor is not a brake. Engage the parking brake all the time when leav-
ing the lift truck.
2. Material handling Operator Presence Sensor system

▪ When the controller detects the seat switch has been turned off for 2 seconds, all the load-handling oper-
ations are restricted by the valve control.
▪ The lock valve restricts lowering. The tilt control valve and tilt backward lock valve restrict tilting. The un-
load valve shuts off the hydraulic oil supply and restricts lifting and attachment operations.
▪ The hydraulic function Operator Presence Sensor has been released by turning the lift down lever to the
neutral position and turning on the seat switch.
3. Operator Presence Sensor operation information function

▪ When the controller detects that the seat switch is turned off, the buzzer sounds for 1 second and the
Operator Presence Sensor indicator shows up on the display in advance of Operator Presence Sensor
activation.
▪ If the operator notices it and is seated again within 2 seconds, the Operator Presence Sensor will not ac-
tivate. In order to know that the Operator Presence Sensor is operating, the Operator Presence Sensor
indicator stays on as long as the seat switch is turned off.
4. Return-to-neutral warning
Traveling
▪ Once the travel Operator Presence Sensor is activated, the buzzer sounds continuously when the seat
switch is turned on until the direction lever is returned to the neutral position and the accelerator pedal is
released. This sound informs the operator that the lift truck is still in the travel Operator Presence Sensor
condition.
Hydraulic function
▪ On all models, once hydraulic function Operator Presence Sensor is activated, and when the seat switch
is turned on without returning all the hydraulic control levers to the neutral position, the sound informs the
operator that the hydraulic function Operator Presence Sensor is not released.
5. Parking brake OFF warning

▪ The buzzer sounds when the operator leaves the seat with the parking brake released.
▪ The buzzer sounds when the operator turns off the key switch with the parking brake released.
17
17.11 RENEWAL OF PSS CAUTION LABEL

The warning instructions on the PSS caption label affixed to each truck must always agree with the PSS fea-
tures that particular model owns. You must be very strict about changing the PSS warning label when a
modification is made to your lift truck that changes the PSS system.
Notice that the caution label must be changes in the following cases:
The selective function of the mast Function or Turn Control was switched to either Validation or Invalidation.*
(*See Option Set for the switching method.)
1. Case of Switching "Mast Function" or "Turn Control" Valid / Invalid."
(1) (2)
Valid Invalid
(1) (2)
(1) (2)
Valid Invalid
(3) (4)
Valid Invalid
(3) (4)
(3) (4)
Valid Invalid
Label (1) has the following PSS features: Label (2) has the following PSS features:
▪ Turn speed control "VALID". ▪ Turn speed control "INVALID".
▪ Mast tilt forward angle control "VALID". ▪ Mast tilt forward angle control "VALID".
Label (3) has the following PSS features: Label (4) has the following PSS features:
▪ Turn speed control "VALID". ▪ Turn speed control "INVALID".
▪ Mast tilt forward angle control "INVALID". ▪ Mast tilt forward angle control "INVALID".
2. Case of Mast Installation for Mast-Less Spec. models.
When you install a mast to a mast-less model, make sure the specification features with the mast as-
sembled.
Take note that the correct caution label must be chosen to be affixed to the lift truck.
The correct label can be found from the labels numbered (1) - (4) in the illustration.
18 APPENDIX 18-921
18 APPENDIX
18.1 SST LIST ............................................................................................... 921
18.2 SERVICE STANDARDS........................................................................ 924
18.3 CONNECTOR LOCATION .................................................................... 930
18.4 CONNECTOR DRAWING ..................................................................... 945
18.1 SST LIST

Illus- Part Section
Part
tra- Nam
No. 2 3 4 6 7 8 9 10 13 14 16
tion e
Pulle
rB
979- set
001/ ex- О
157 ten- 18
sion
tool
Rea
mer
979-
bolt
001/ О
re-
164
move
r
Tran
smis-
sion
and
979- trans-
005/ fer О
490 bear-
ing
re-
pla-
cer
Front
axle
hub
979- inner
005/ bear- О
491 ing
re-
pla-
cer
Front
axle
979- bear-
001/ ing О
168 re-
pla-
cer
18-922 18 APPENDIX
Illus- Part Section

Part
tra- Nam
No. 2 3 4 6 7 8 9 10 13 14 16
tion e
Steer-
ing
warm
979-
bear-
005/ О
ing
492
re-
pla-
cer
979-
Pulle
001/ О
r
170
Tool,
979- park-
005/ ing О
502 brak
e
Tire
979- angle
005/ sens О
494 or set
tool
Oil
con-
trol
valve
979- sprin
005/ g re- О
495 move
r and
re-
pla-
cer
Inner
979-
mast
001/ О О
stop-
174
per
Cyl-
inder
cap
979- re-
001/ move О
175 r and
re-
pla-
cer
979- Deep
001/ sock О
173 et
Sprin
g pin
979-
tool
001/ О О
re-
177
move
r
18 APPENDIX 18-923
Illus- Part Section

Part
tra- Nam
No. 2 3 4 6 7 8 9 10 13 14 16
tion e
979- Pulle
001/ r C О О О
181 set
979- Pulle
001/ r B О О О
182 set
Re-
979-
pla-
001/ О О О
cer
183
set
Re-
979-
pla-
001/ О
cer
184
No.2
979-
Hand
001/ О О
le set
185
Bat- 18
979-
tery
005/ О
hang
496
er
979- Tube
005/ , oil О
555 level
18-924 18 APPENDIX
18.2 SERVICE STANDARDS
18.2.1 BATTERY
Item All models
1.280 (at 20°C)
Specific gravity upon perfect charging
1.150 (at 20°C)

Specific gravity upon end of discharge
Voltage upon end of discharge 36V 32.0

V 48V 42.5
Insulation resistance
1 or more
MΩ
18.2.2 DRIVE MOTOR

Item All models
Stator ASSY insulation resistance
Standard: 100 or more
MΩ
Motor cable continuity
Standard: 0
Ω
Thermo-sensor resistance
Standard: Approx. 11 to 15 (at 20°C)
kΩ
18.2.3 PUMP MOTOR

Item All models
Clearance between the end frame and
0.43 to 0.50
rpm sensor Standard:
(10.8 to 12.8)
in. (mm)
Stator ASSY insulation resistance
Standard: 100 or more
MΩ
Motor cable continuity
Standard: 0
Ω
Thermo-sensor resistance
Standard: Approx. 11 to 15 (at 20°C)
kΩ
18.2.4 DRIVE UNIT & FRONT AXLE

Item All models
Hub starting force
Standard: 6.12 to 14.1 [27.2 to 62.9]
lbf. [N]
Tightening torque ft·lbf. [N·m]
Gear case set bolt Standard: 73.8 to 108 [100 to 146]
Hub lock nut Standard: Refer to DRIVE UNIT section
18 APPENDIX 18-925
18.2.5 REAR AXLE

Item All models
Rear axle ASSY
Rear axle ASSY starting force 22.5 to 45.0
Standard:
lbf. [N] [100 to 200]
STD (Cushion): 1.3 to 3.4 [5.8 to 15.2]
Rear Wheel starting force
Standard: OPT (Pneumatic): 3.3 to 8.8
lbf. [N]
[15 to 39]
Rear axle cylinder
Rear axle cylinder bore Standard: 2.16 (55.0)
in. (mm) Limit 2.179 (55.35)
Rear axle ASSY lock nut Standard: 7 to 15 [10 to 20]
Rear axle cylinder set bolt Standard: 166 to 273 [265 to 370]
Tire angle sensor set bolt Standard: 1.4 to 1.6 [1.0 to 1.2]
Tire angle sensor cover set bolt Standard: 7.4 to 11.8 [10 to 16]
18
18.2.6 STEERING
Item All models
Steering wheel play
Standard: 0.79 to 1.97 (20 to 50)
in. (mm)
Hydrostatic steering valve ASSY
Relief set pressure
Standard: 1624 to 1697 [11.2 to 11.7]
psi [MPa]
Tightening torqueft·lbf. [N·m]
Steering wheel set nut Standard: 18.4 to 33.2 [25 to 45]
18.2.7 BRAKE
Item All models
Wet brake
Brake disk thickness Standard: 0.138 (3.5)
in. (mm) Limit 0.130 (3.3)
Brake plate wheel thickness Standard: 0.079 (2.0)
in. (mm) Limit 0.071 (1.8)
Brake pedal
Brake pedal height (no pad)
Standard: 5.20 to 5.39 (132 to 137)
in. (mm)
Brake pedal play
Standard: 0.04 to 0.20 (1 to 5)
in. (mm)
Parking Brake
Parking brake cable set position
Standard: 0 to 0.08 (0 to 2)
in. (mm)
Parking brake operating force Standard: Refer to BRAKE section
18-926 18 APPENDIX
18.2.8 FRAME
Item All models
Counterweight
Counterweight set bolt Standard: 236 to 354 [320 to 480]
18.2.9 MATERIAL HANDLING SYSTEM

Item
Natural drop test
Natural drop
Limit 1.77 (45)
in. (mm)
Natural forward tilt test
Natural forward tilt 1 ton series Standard: 0.59 (15) or less
in. (mm) 2 ton series Limit 0.79 (20) or less
Oil leak test
Lift cylinder oil leak amount
Standard: 8 (0.49) or less
in.3 (cm3)
Tilt cylinder oil leak amount (total for lift and tilt)
Standard: 0.98 (16) or less
in.3 (cm3)
18.2.10 MAST
Item
Mast adjustment (QM MAST)
Inner mast roller clearance
Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Mast rollers
Outer mast roller clearance
Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Middle and lower lift roller clearance
Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Carriage rollers
Side roller clearance
Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Mast strip to inner mast clearance
Standard: 0 to 0.024 (0 to 0.6)
in. (mm)
Mast strip thickness
Limit 0.059 (1.5)
in. (mm)
Fork
Fork front end misalignment
Limit 0.39 (10)
in. (mm)
63 to 115
Mast support cap set bolt Standard:
[84 to 156]
89 to 129
Back rest set bolt Standard:
[62 to 115]
Chain adjusting nut Standard: Refer to MAST section
18 APPENDIX 18-927
18.2.11 CYLINDER
Item
Rear Lift cylinder (TT)
Piston rod outside diameter Standard: 1.574 (40)
in. (mm) Limit 1.5716 (39.92)
Cylinder bore Standard: 1.77 (45)
in. (mm) Limit 1.7795 (45.2)
Piston rod bend
Standard: 0.08 (2.0)
in. (mm)
Rear Lift cylinder (QM)
Piston rod outside diameter Standard: 1.77 (45)
in. (mm) Limit 1.7685 (44.92)
Cylinder bore Standard: 2.17 (55)
in. (mm) Limit 2.1791 (55.35)
Piston rod bend
Standard: 0.08 (2.0)
in. (mm)
Front cylinder (TT) 18
Piston rod outside dia- Standard: 1.654 (42)
in. (mm)
meter Limit 1.650 (41.92)
Standard: 1.968 (50)
Cylinder bore in. (mm)
Limit 1.980 (50.3)
Piston rod bend in. (mm) Standard: 0.08 (2.0)
Front cylinder (QM)
Piston rod outside dia- Standard: 2.0 (50.8)
in. (mm)
meter Limit 1.9969 (50.72)
Standard: 2.76 (70)
Limit 2.7697 (70.35)
Tilt cylinder
Standard: 1.1811 (30)
Piston rod outside diameter in. (mm)
Limit 1.1780 (29.92)
Standard: 2.7559 (70)
Limit 2.7697 (70.35)
TT: 225 (166) [2290]
Lift cylinder cover Standard:
QM: 200 to 220 [271 to 298]
TT: 21.4 to 28.8
[29.0 to 39.0]
valve Standard:
QM: 43.5 to 53.9
[59 to 73]
Tilt cylinder piston castle nut Standard: 322 [436]
Tilt cylinder cover Standard: 260 [353]
18-928 18 APPENDIX
18.2.12 OIL PUMP

Item
Oil pump assy
Side plate thickness
Limit 0.006 (0.15)
in. (mm)
Gear shaft outside diameter
Limit 0.78 (19.85)
in. (mm)
Body inside surface wipe depth
Standard: 0.0004 to 0.0024 (0.010 to 0.060)
in. (mm)
18.2.13 OIL CONTROL VALVE

Item
Oil control valve
2494 to 2567
Lift Standard:
Relief set pressure [17.2 to 17.7]
psi [KPa] 1987 to 2059
Tilt Standard:
[13.7 to 14.2]
18.2.14 PSS
Item
5.8 to 13.4
Tilt angle sensor set bolt Standard:
[7.8 to 18.2]
16.2 to 19.2
Load sensor Standard:
[22 to 26]
Lifting height switch ASSY set bolt Standard: Refer to PSS section
18 APPENDIX 18-929
18.3 CONNECTOR LOCATION

• FR STAY and MAST
• CABLES
• INSTRUMENT PANEL
• TOE BOARD No.1
• TOE BOARD No.2
• RR BODY No.1
• RR BODY No.2
SYMBOLS WIRE NAME
A BODY MAIN WIRE
B FR STAY WIRE
C TEN KEY WIRE
D BODY SUB NO.1 WIRE
E STOP LAMP SWITCH WIRE
F MAST WIRE
G C/V WIRE
H RR UPR WIRE 18
I HOOD WIRE (MINI LEVER)
J HOOD SUB WIRE
K DC/DC WIRE
L CLAMP INTERLOCK WIRE
18-930 18 APPENDIX
18.3.1 FR STAY and MAST

18 APPENDIX 18-931
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18
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18-932 18 APPENDIX
18 APPENDIX 18-933
18.3.2 CABLES
㻯㻭㻮㻸㻱㻿
18
REFER TO RR BODY No.2
REFER TO TOE BOARD No.2

18-934 18 APPENDIX
18.3.3 INSTRUMENT PANEL

㻵㻺㻿㼀㻾㼁㻹㻱㻺㼀㻌㻼㻭㻺㻱㻸㻭㻮㻻㻰㼅㻌㻹㻭㻵㻺㻌㼃㻵㻾㻱㻯㼀㻱㻺㻌㻷㻱㼅㻌㼃㻵㻾㻱
㻖㻝㻌㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻛㻶㻻㼅㻌㻿㼀㻵㻯㻷㻰㻮㻻㻰㼅㻌㻿㼁㻮㻌㻺㻻㻚㻝㻌㼃㻵㻾㻱㻱㻿㼀㻻㻼㻌㻸㻭㻹㻼㻌㻿㼃㻵㼀㻯㻴㻌㼃㻵㻾㻱

㻖㻞㻌㻯㻻㼃㻸㻌㻸㻱㼂㻱㻾
㻯㻺㻝㻥㻯㻺㻣
㻯㻺㻠
㻯㻺㻟
㻯㻺㻤㻤㻖㻞㻯㻺㻟㻟
㻯㻺㻝㻜㻯㻺㻟㻜
㻯㻺㻝㻝㻣㻖㻞
㻯㻺㻤㻡
㻯㻺㻞㻝㻟㻖㻞
㻯㻺㻝㻣㻜
㻖㻞㻯㻺㻠㻢
㻯㻺㻥㻤
㻯㻯㻺㻝㻣㻤
㻯㻺㻝㻣㻡
㻯㻺㻝㻠㻢
㻯㻺㻝㻣㻠㻯㻺㻞㻠㻠
㻯㻺㻝㻡㻯㻺㻞㻥㻱㻯㻺㻝㻣㻞

㻯㻺㻝㻣㻢
㻯㻺㻝㻣㻟
㻯㻺㻡
㻯㻺㻝㻞
㻰
㻯㻺㻠㻣
㻯㻺㻞㻝
㻯㻺㻞㻞㻯㻺㻝㻣㻣
㻯㻺㻤㻥
㻭
㻯㻺㻣㻜
㼇㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻛㻶㻻㼅㻌㻿㼀㻵㻯㻷㼉㼇㼃㻛㻻㻌㻱㻹㻱㻾㻳㻱㻺㻯㼅㻌㻿㼃㼉
㻯㻺㻤㻤㻖㻝
㻯㻺㻤㻣㻖㻝
㻯㻺㻟㻜㻝㻯㻺㻝㻣㻢
㻯㻺㻣㻤㻖㻝
18 APPENDIX 18-935
㻯㻺㻟㻴㻻㻾㻺㻌㻿㼃㻯㻺㻝㻣㻠㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻝
㻯㻺㻠㻷㻱㼅㻌㻿㼃㻯㻺㻝㻣㻡㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴㻞
㻯㻺㻡㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻯㻺㻝㻣㻢㻱㻹㻱㻾㻳㻱㻺㻯㼅㻌㻿㼃
㻯㻺㻣㼀㼁㻾㻺㻒㻸㼀㻌㻿㼃㻔㻸㻴㻌㻰㻵㻾㻕㻯㻺㻝㻣㻣㻲㻾㻌㻿㼀㻭㼅㻌㻸㻴
㻯㻺㻝㻜㻰㻵㻾㻱㻯㼀㻵㻻㻺㻌㻿㼃㻔㻸㻴㻌㻰㻵㻾㻕㻯㻺㻝㻣㻤㼀㻱㻺㻌㻷㻱㼅
㻯㻺㻝㻞㻲㻸㻭㻿㻴㻱㻾㻌㻾㻱㻸㻭㼅㻯㻺㻞㻝㻟㻵㻺㼀㻱㻾㻸㻻㻯㻷㻌㻾㻸㼅㻌㻔㻯㻻㼃㻸㻕
㻯㻺㻝㻡㻼㻷㻮㻌㻿㼃㻯㻺㻞㻠㻠㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴
㻯㻺㻝㻥㻿㼀㻱㻱㻾㻵㻺㻳㻌㻿㻿㻾㻯㻺㻟㻜㻝㻿㻴㻻㻾㼀㻌㻯㻻㻺㻺
㻯㻺㻞㻝㻴㻻㻾㻺㻌㻗
㻯㻺㻞㻞㻴㻻㻾㻺㻌㻙
㻯㻺㻞㻥㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻔㻗㻕
㻯㻺㻟㻜㻿㼀㻻㻼㻌㻸㻼㻌㻿㼃㻔㻙㻕
㻯㻺㻟㻟㼀㻱㻺㻌㻷㻱㼅
18
㻯㻺㻠㻢㼀㻭㻵㻸㻌㻸㻼㻌㻾㻱㻸㻭㼅
㻯㻺㻠㻣㻰㻵㻭㻳㻺㻻㻿㻵㻿
㻯㻺㻣㻜㻰㻵㻿㻼㻸㻭㼅
㻯㻺㻣㻤㻯㻛㼂㻌㻼㼁㻸㻸㻌㻿㻻㻸㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻤㻡㻺㼀㻾㻸㻌㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻤㻢㼀㻵㻸㼀㻌㻭㻺㻳㻌㻿㻿㻾
㻯㻺㻤㻣㻯㻛㼂㻌㻼㼁㻿㻴㻌㻿㻻㻸㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻤㻤㻯㻛㼂㻌㻿㻻㻸
㻯㻺㻤㻥㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻥㻤㻿㼀㻱㻱㻾㻵㻺㻳㻌㻿㻻㻸
㻯㻺㻝㻝㻣㻯㻛㼂㻌㻿㻿㻾㻌㻿㼁㻮
㻯㻺㻝㻠㻢㻝㻞㼂㻌㻼㼃㻾㻌㻿㼁㻼㻼㻸㼅
㻯㻺㻝㻣㻜㻭㼀㼀㻌㻭㻯㼀㻌㻿㼃㻌㻔㻯㻻㼃㻸㻕
㻯㻺㻝㻣㻞㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴㻝
㻯㻺㻝㻣㻟㻲㻾㻌㻿㼀㻭㼅㻌㻾㻴㻞
18-936 18 APPENDIX
18.3.4 TOE BOARD No.1

㼀㻻㻱㻌㻮㻻㻭㻾㻰㻌㻺㼛㻚㻝㻭㻮㻻㻰㼅㻌㻹㻭㻵㻺㻌㼃㻵㻾㻱㻳㻯㻛㼂㻌㼃㻵㻾㻱
㻯㻺㻝㻝㻡
㻯㻺㻢㻯㻺㻝㻝㻣
㻯㻺㻡㻢㻳
㻯㻺㻥㻝㻯㻺㻝㻝㻥
㻯㻺㻞㻢
㻯㻺㻝㻟㻟
㻯㻺㻝㻞㻜
㻯㻺㻤㻢
㻯㻺㻝㻞㻟
㻯㻺㻝㻝㻤
㻯㻺㻡㻡㻯㻺㻝㻞㻝㻯㻺㻝㻞㻞
㻯㻺㻡㻠
㻭
㻯㻺㻥㻜
㻯㻺㻡㻟
㻯㻺㻡㻞㻯㻺㻝㻣㻥
㻯㻺㻝㻤㻟
18 APPENDIX 18-937
㻯㻺㻢㻮㻾㻭㻷㻱㻌㻿㻿㻾
㻯㻺㻞㻢㻭㻯㻯㻱㻸㻌㻿㻿㻾
㻯㻺㻡㻞㻰㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾㻌㻾㻴
㻯㻺㻡㻟㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻝㻌㻾㻴
㻯㻺㻡㻠㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻞㻌㻾㻴
㻯㻺㻡㻡㻼㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾
㻯㻺㻡㻢㻼㻹㻌㻿㻼㻰㻌㻿㻿㻾
㻯㻺㻤㻢㼀㻵㻸㼀㻌㻭㻺㻳㻌㻿㻿㻾
㻯㻺㻥㻜㻹㻭㻿㼀㻌㻿㻿㻾
㻯㻺㻥㻝㻼㻾㻱㻿㻿㻌㻿㻿㻾
㻯㻺㻝㻝㻡㻸㻵㻲㼀㻌㻸㼂㻾
㻯㻺㻝㻝㻣㻯㻛㼂㻌㻿㻿㻾㻌㻿㼁㻮
㻯㻺㻝㻝㻤㻹㻻㼀㻻㻾㻌㻲㻭㻺 18
㻯㻺㻝㻝㻥㻭㼀㼀㻝㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻞㻜㻭㼀㼀㻞㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻞㻝㻰㻹㻌㼀㻱㻹㻼㻌㻿㻿㻾㻌㻸㻴
㻯㻺㻝㻞㻞㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻝㻌㻸㻴
㻯㻺㻝㻞㻟㻰㻹㻌㻿㻼㻰㻌㻿㻿㻾㻞㻌㻸㻴
㻯㻺㻝㻟㻟㻱㼆㻌㻼㻱㻰㻭㻸
㻯㻺㻝㻣㻥㻵㻺㼀㻱㻾㻸㻻㻯㻷㻌㻿㻻㻸
㻯㻺㻝㻤㻟㼀㻱㻸㻱㻹㻭㼀㻵㻯㻿
18-938 18 APPENDIX
18 APPENDIX 18-939
18.3.5 TOE BOARD No.2

㼀㻻㻱㻌㻮㻻㻭㻾㻰㻌㻺㼛㻚㻞
㻯
㻮
㼂㻵㻱㼃㻌㻭
㼁㼃
㼂㼂
㼃㼁
18
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻸㻴㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻾㻴
㼂㻵㻱㼃㻌㻮㼂㻵㻱㼃㻌㻯
㻼㼁㻹㻼㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻯㻻㻺㻺㻱㻯㼀㻻㻾㻌㻯㻭㻮㻸㻱
18-940 18 APPENDIX
18.3.6 RR BODY No.1

[MINI LEVER / JOY STICK LEVER]
㻾㻾㻮㻻㻰㼅㻌㻺㼛㻚㻝 A BODY MAIN WIRE
㻯㻺㻝㻢㻝㻯㻺㻝㻣㻜
H RR UPR WIRE
㻯㻺㻝㻢㻡
I HOOD WIRE(MINI LEVER) 㻯㻺㻝㻢㻢
㻯㻺㻝㻢㻞
J HOOD SUB WIRE
*1 L/LED
*2 LED 㻯㻺㻝㻢㻟
㻯㻺㻝㻣㻝
㻯㻺㻝㻢㻠
㻯㻺㻟㻝 *2
㻯㻺㻝㻤㻡
㻯㻺㻟㻢
㻯㻺㻟㻝 *1 㼍
㻯㻺㻟㻠 *1 I
㻯㻺㻟㻠 *2
㻯㻺㻡㻤
㻯㻺㻣㻟
㻯㻺㻟㻞
㻯㻺㻝㻞㻡 H
㻯㻺㻟㻤
㼍
㻯㻺㻠㻟
㻯㻺㻠㻠
㻯㻺㻟㻣
㻯㻺㻣㻡
㻯㻺㻣㻢㻯㻺㻞㻟
㼎
㻯㻺㻞㻠㻢
㻯㻺㻣㻣
㻯㻺㻞㻟㻣
㻯㻺㻝㻝㻞
㻯㻺㻞㻠㻯㻺㻞㻟㻤
㻯㻺㻥㻣㻯㻺㻞㻡㻜
㻯㻺㻞㻝㻣
A 㻯㻺㻝㻝㻟
㻯㻺㻞㻝㻞㼎
㻯㻺㻞㻜㻤
㻯㻺㻠㻜
㻯㻺㻞㻜㻣
㻯㻺㻞㻝㻜
㻯㻺㻞㻝㻝
18 APPENDIX 18-941
㻯㻺㻞㻟㻮㻭㻯㻷㻌㻮㼁㼆㼆㻱㻾
㻯㻺㻞㻠㻲㼃㻰㻌㻯㻴㻵㻹㻱
㻯㻺㻟㻝㻾㻾㻌㻯㻻㻹㻮㻵㻌㻸㻴㻌㻛㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵㻌㻸㻴
㻯㻺㻟㻞㻾㻾㻌㻴㻻㻾㻺㻌㻿㼃
㻯㻺㻟㻠㻾㻾㻌㻯㻻㻹㻮㻵㻌㻾㻴㻌㻛㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵㻌㻾㻴
㻯㻺㻟㻢㻿㻹㻭㻾㼀㻌㻭㻸㻭㻾㻹
㻯㻺㻟㻣㻾㻾㻌㼁㻼㻾㻌㻹㻭㻵㻺
㻯㻺㻟㻤㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻠㻜㻴㻻㻾㻺㻾㻱㻸㻭㼅
㻯㻺㻠㻟㻴㻻㻻㻰㻌㻿㼁㻮
㻯㻺㻠㻠㻿㻱㻭㼀㻌㻿㼃
㻯㻺㻡㻤㻿㼀㻾㻻㻮㻱㻌㻸㻭㻹㻼
㻯㻺㻣㻟㼃㻻㻾㻷㻵㻺㻳㻌㻸㻭㻹㻼㻌㻿㼃
㻯㻺㻣㻡㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕
㻯㻺㻣㻢㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕㻌
㻯㻺㻣㻣㻴㻻㻻㻰㻔㻹㻵㻺㻵㻌㻸㻱㼂㻱㻾㻕㻌
㻯㻺㻥㻣㼀㻵㻾㻱㻌㻭㻺㻳㻸㻱㻌㻿㻿㻾 18
㻯㻺㻝㻝㻞㻵㻺㼂㻌㻲㻭㻺㻝
㻯㻺㻝㻝㻟㻵㻺㼂㻌㻲㻭㻺㻞
㻯㻺㻝㻞㻡㼃㻻㻾㻷㻵㻺㻳㻌㻸㻼
㻯㻺㻝㻢㻝㻺㼀㻾㻸㻌㼀㻵㻸㼀㻌㻿㼃
㻯㻺㻝㻢㻞㻸㻵㻲㼀㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻟㼀㻵㻸㼀㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻠㻭㼀㼀㻝㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻡㻭㼀㼀㻞㻌㻸㼂㻾㻌㻿㻿㻾
㻯㻺㻝㻢㻢㻰㻵㻾㻱㻯㼀㻵㻻㻺㻌㻿㼃㻔㻭㻾㻹㻰㻵㻾㻕
㻯㻺㻝㻣㻜㻭㼀㼀㻌㻭㻯㼀㻌㻿㼃㻔㻹㻵㻺㻵㻕
㻯㻺㻝㻣㻝㻭㻾㻹㻾㻱㻿㼀㻌㻴㻻㻾㻺㻌㻿㼃
㻯㻺㻝㻤㻡㻮㻸㼁㻱㻌㻸㻵㻳㻴㼀
㻯㻺㻞㻜㻣㻷㻱㼅㻌㻻㻲㻲㻌㻴㻛㻸㻌㻾㻸㼅
㻯㻺㻞㻜㻤㻿㻻㻸㻵㻰㻌㻿㼀㻭㼀㻱㻌㻾㻸㼅㻌㻝
㻯㻺㻞㻝㻜㻴㻱㻭㻰㻌㻸㻼㻌㻾㻸㼅
㻯㻺㻞㻝㻝㻴㻱㻭㻰㻌㻸㻼㻌㻾㻸㼅㻌㻸㻴
㻯㻺㻞㻝㻞㻭㻯㻯㻱㻿㻿㻻㻾㼅㻌㻾㻱㻸㻭㼅
㻯㻺㻞㻝㻣㻿㼁㻾㻳㻱㻌㻷㻵㻸㻸㻱㻾
㻯㻺㻞㻟㻣㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻞㻟㻤㻰㻯㻛㻰㻯㻌㻲㻻㻾㻌㻸㻱㻰㻌㻾㻾㻌㻯㻻㻹㻮㻵
㻯㻺㻞㻠㻢㻝㻞㼂㻌㻼㻻㼃㻱㻾㻌㻿㼁㻼㻼㻸㼅
㻯㻺㻞㻡㻜㻲㼁㻿㻱㻌㻴㻻㻸㻰㻱㻾
18-942 18 APPENDIX
18.3.7 RR BODY No.2

㻾㻾㻮㻻㻰㼅㻌㻺㼛㻚㻞 A BODY MAIN WIRE K DC/DC WIRE
㻯㻻㻺㻺㻱㻯㼀㻻㻾㻌㻯㻭㻮㻸㻱㻯㻺㻝㻜㻝
㻯㻺㻝㻜㻞
㻯㻺㻞㻜
㻯㻺㻝㻠㻥㻯㻺㻝㻜㻟
K
㻯㻺㻝㻝㻜㻯㻺㻝㻜㻥
㻯㻺㻝㻝㻝
㻯㻺㻝㻜㻠
N2 N2 N2
WR WL W
VR VL V
UR UL 㻯㻺㻝㻠㻤 U
P4
P1 㻯㻺㻞㻜㻜
㻯㻺㻞㻜㻝
㻯㻺㻝㻞㻣㻯㻺㻝㻠㻠
㻯㻺㻝㻞㻥
㻯㻺㻞㻜㻥㻯㻺㻝㻠㻣
A 㻯㻺㻝㻟㻢㻯㻺㻝㻟㻤㻯㻺㻞㻜㻟
㻯㻺㻝㻟㻜
㻯㻺㻝㻟㻣㻯㻺㻞㻜㻞
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻾㻴
㻰㻾㻵㼂㻱㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱㻌㻸㻴㻼㼁㻹㻼㻌㻹㻻㼀㻻㻾㻌㻯㻭㻮㻸㻱
18 APPENDIX 18-943
㻯㻺㻞㻜㻱㻭㻾㼀㻴
㻯㻺㻝㻜㻝㻯㻼㼁㻌㻝
㻯㻺㻝㻜㻞㻯㻼㼁㻌㻞
㻯㻺㻝㻜㻟㻯㻼㼁㻌㻟
㻯㻺㻝㻜㻠㻯㻼㼁㻠
㻯㻺㻝㻜㻥㻰㻾㻵㼂㻱㻌㻵㻺㼂㻌㻸㻴
㻯㻺㻝㻝㻜㻰㻾㻵㼂㻱㻌㻵㻺㼂㻌㻾㻴
㻯㻺㻝㻝㻝㻼㼁㻹㻼㻵㻺㼂
㻯㻺㻝㻞㻣㻹㻵㻺㻵㻸㻱㼂㻱㻾㻌㻿㻻㻸㻌㻾㻸㼅
㻯㻺㻝㻞㻥㻵㻹㻼㻭㻯㼀㻌㻿㻿㻾㻌㻝
㻯㻺㻝㻟㻜㻵㻹㻼㻭㻯㼀㻌㻿㻿㻾㻌㻞
㻯㻺㻝㻟㻢㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻝
㻯㻺㻝㻟㻣㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻞
㻯㻺㻝㻟㻤㻯㻻㻺㼀㻭㻯㼀㻻㻾㻌㻟
㻯㻺㻝㻠㻠㻰㻯㻛㻰㻯
㻯㻺㻝㻠㻣㻰㻯㻛㻰㻯
㻯㻺㻝㻠㻤㻼㻠 18
㻯㻺㻝㻠㻥㻺㻞
㻯㻺㻞㻜㻜㻯㻭㻺㻌㻶㻛㻯㻌㻝
㻯㻺㻞㻜㻝㻯㻭㻺㻌㻶㻛㻯㻌㻞
㻯㻺㻞㻜㻞㻯㻭㻺㻌㻶㻛㻯㻌㻟
㻯㻺㻞㻜㻟㻯㻭㻺㻌㻶㻛㻯㻌㻠
㻯㻺㻞㻜㻥㻿㻻㻸㻵㻰㻌㻿㼀㻭㼀㻱㻌㻾㻱㻸㻭㼅㻌㻞
18-944 18 APPENDIX
18.4 CONNECTOR DRAWING

CN3 HORN SW
CN7 TURN&LT SW (LH DIR)
1 1 6 5 4 3 2 1 1 2 3 4 5 6
2 2 14 13 12 11 10 9 8 7 7 8 9 10 11 12 13 14
TAB REC TAB REC

NO P C J NO P C J NO P C J NO P C J
1 118 - HO+ 1 118 L-Y J2 1 - - - 1 - - -
2 N2 - HO- 2 N2 W-B J10 2 - - - 2 - - -
3 - - - 3 - - -
CN4 KEY SW
4 - - - 4 - - -
5 - - - 5 - - -
2 1 1 2
6 - - - 6 - - -
4 3 3 4
7 116 - BT 7 116 LG CN46-3
TAB REC 8 115 - BH 8 115 P J28
NO P C J NO P C J 9 N2 - T 9 N2 W-B J7
1 41 - AM 1 41 G J5 10 - - - 10 - - -
2 - - - 2 - - - 11 N2 - EL 11 N2 W-B J7
3 - - - 3 - - - 12 109 - TL 12 109 G-Y J26
4 43 - IG 4 43 B-Y J3 13 110 - TB 13 110 L-O CN12-2

14 108 - TR 14 108 R-Y J24
CN5 STOP LP SW
CN10 DIRECTION SW (LH DIR)
2 1 1 2
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
TAB REC
NO P C J NO P C J TAB REC
1 111 Y SWST(COM) 1 111 R-L CN37-6 NO P C J NO P C J
2 490 B-Y SWST(NC) 2 490 GR-R CN250-12 1 - - - 1 - - -
CN6 BRAKE SSR

2 103 - DSBU 2 103 R-W CN23-1
3 120 - DSFO 3 120 Y-R CN24-1
6 5 4 3 2 1 1 2 3 4 5 6 4 46 - DSR 4 46 B-O CN104-19

5 45 - DSF 5 45 GR-R CN104-26
6 51 - LS- 6 51 BR J14
TAB REC
7 495 - VBKY 7 495 B-Y J15
NO P C J NO P C J
8 495 - VBKY 8 495 B-Y J15
1 74 - VRB2+ 1 74 BR-R CN101-33
9 - - - 9 - - -
2 51 - POT- 2 51 G J9
10 - - - 10 - - -
3 73 - VRB2 3 73 Y-R CN102-25
11 - - - 11 - - -
4 71 - VRB1 4 71 Y-B CN102-33
12 - - - 12 - - -
5 72 - VRB1+ 5 72 L-O CN101-34
13 - - - 13 - - -
6 50 - VRA- 6 50 B-O J18
14 - - - 14 - - -
15 - - - 15 - - -
16 - - - 16 - - -
17 - - - 17 - - -
18 - - - 18 - - -
18 APPENDIX 18-945
CN12 FLASHER RELAY CN19 STEERING SSR
2 1 1 2 2 1 1 2
4 3 3 4 3 4 5 6
6 5 4 3
TAB REC
1 N2 - FRY- 1 N2 W-B J10 NO P C J NO P C J
2 110 - FRY 2 110 L-O CN7-13 1 311 - SSTR+ 1 311 P-L CN103-13
3 - - - 3 - - - 2 51 - LS- 2 51 B J19
4 494 - FRY+ 4 494 B-Y CN250-10 3 312 - SSTR1 3 312 B-Y CN104-30
4 313 - SSTR2 4 313 L-W CN104-31
CN14 FR COMBI 5 314 - SSTRC 5 314 G-Y CN104-24
6 - - - 6 - - -
2 1 1 2
4 3 3 4 CN23 BACK BUZZER
TAB REC 1 1
NO P C J NO P C J 2 2
1 108 - LF+ 1 108 R-Y CN172-2
2 N2 - LF- 2 N2 W-B CN173-2 TAB REC
3 N2 - LC- 3 N2 W-B CN173-3 NO P C J NO P C J
4 104 - LC+ 4 104 G-R CN173-1 1 103 - BZ+ 1 103 R-W CN10-2,37-4,75-6,208-4
2 N2 - BZ- 2 N2 W-B J8
CN15 PKB SW 18
CN24 FWD CHIME
3 2 1 1 2 3
1 1
2 2
TAB REC
1 66 R NO 1 66 G-W CN177-1 NO P C J NO P C J
2 - - - 2 - - - 1 120 - CHI+ 1 120 Y-R CN10-3,75-2
3 51 B COM 3 51 B CN177-5 2 N2 - CHI- 2 N2 W-B J8
CN16 HEAD LAMP CN26 ACCEL SSR
2 1 1 2 6 5 4 3 2 1 1 2 3 4 5 6
TAB REC TAB REC

1 102 - LH+ 1 102 R-G CN172-1 1 55 - VRA2+ 1 55 GR-R CN101-26
2 N2 - LH- 2 N2 W-B CN172-3 2 51 - POT- 2 51 G J9

3 54 - VRA2 3 54 BR-Y CN102-32
CN16 HEAD LAMP (LED)
4 52 - VRA1 4 52 BR-R CN102-30
5 53 - VRA1+ 5 53 BR-W CN101-27
2 1 1 2 6 50 - VRA- 6 50 B-O J18
TAB REC
NO P C J NO P C J
1 102 - LH+ 1 102 R-G CN172-1
2 N2 - LH- 2 N2 W-B CN172-3
18-946 18 APPENDIX
CN31 RR COMBI LH CN33 TEN KEY
3 2 1 1 2 3
5 4 3 2 1 1 2 3 4 5
6 5 4 4 5 6
10 9 8 7 6 6 7 8 9 10
TAB REC
NO P C J NO P C J
1 104 - TL 1 104 G-R J49 TAB REC
2 - - - 2 - - - NO P C J NO P C J
3 111 - STL+ 3 111 R-L J45 1 160 - ITKY1 1 160 B-Y CN178-5
4 - - - 4 - - - 2 161 - ITKY2 2 161 R-B CN178-4
5 109 - TRN 5 109 G-Y CN37-9 3 162 - ITKY3 3 162 G CN178-3
6 N2 - E 6 N2 W-B J46 4 165 - OTKY2 4 165 R-Y CN178-2
5 167 - LEDTKY1 5 167 G-Y CN178-1
CN31 LED RR COMBI LH
6 163 - IPSTKY1 6 163 W-L CN178-10
7 169 - TGND 7 169 GR-R CN178-9
8 164 - OTKY1 8 164 L-O CN178-8
2 1 1 2 9 166 - OTKY3 9 166 GR-L CN178-7
10 168 - LEDTKY2 10 168 L-B CN178-6
4 3 3 4
CN34 RR COMBI RH
6 5 5 6
3 2 1 1 2 3
6 5 4 4 5 6
TAB REC
NO P C J NO P C J
TAB REC
1 203 - DSBU 1 203 W-B J48 NO P C J NO P C J
2 211 - STL+ 2 211 R-L J45 1 104 - TL 1 104 G-R J49
3 204 - TL 3 204 G-R J49 2 - - - 2 - - -
4 - - - 4 - - - 3 111 - STL+ 3 111 R-L J45
5 209 - TRN 5 209 G-Y CN37-9 4 103 - DSBU 4 103 R-W J48
6 N2 - E 6 N2 W-B J46 5 108 - TRN 5 108 R-Y CN37-8
6 N2 - E 6 N2 W-B J46
CN32 RR HORN SW
CN34 LED RR COMBI RH
2 1 1 2
2 1 1 2
TAB REC
NO P C J NO P C J
4 3 3 4
1 N2 W-B J46 1 N2 W-B HRS-
2 118 L-Y CN37-5 2 118 L-Y HRS+
6 5 5 6
TAB REC
NO P C J NO P C J
1 203 - DSBU 1 203 R-W J48
2 211 - STL+ 2 211 R-L J45
3 204 - TL 3 204 G-R J49
4 - - - 4 - - -
5 208 - TRN 5 208 R-Y CN37-8
6 N2 - E 6 N2 W-B J46
18 APPENDIX 18-947
CN36 SMART ALARM CN37 DC/DC FOR LED RR COMBI CN38

2 1 1 2
TAB REC 5 4 3 2 1 1 2 3 4 5
NO P C J NO P C J
1 103 - BZ+ 1 103 R-W J48,CN37-3 10 9 8 7 6 6 7 8 9 10
2 N2 - BZ- 2 N2 W-B J46
CN37 RR UPR MAIN
TAB REC
NO P C J NO P C J
1 101 L CN73-1 1 101 L CN37-1
5 4 3 2 1 1 2 3 4 5
2 493 B-Y J47 2 493 B-Y CN37-2
10 9 8 7 6 6 7 8 9 10 3 198 R-W CN36-1 3 198 R-W CN37-3,J56

4 203 R-W J48 4 203 R-W CN238-1
5 118 L-Y CN32-2 5 118 L-Y CN37-5
6 211 R-L J45 6 211 R-L CN238-2
7 204 G-R J49 7 204 G-R CN238-3
TAB REC
NO P C J NO P C J 8 208 R-Y CN34-5 8 208 R-Y CN238-5
1 101 L CN73-1 1 101 L J16 9 209 G-Y CN31-5 9 209 G-Y CN238-4
2 493 B-Y J47 2 493 B-Y J27 10 N2 W-B J46 10 N2 W-B CN238-6
3 198 R-W CN36-1 3 198 R-W CN208-4

CN40 HORN RELAY
18
4 103 R-W J48 4 103 R-W CN23-1
5 118 L-Y CN32-2 5 118 L-Y J2 2 1 1 2
6 111 R-L J45 6 111 R-L CN5-1 4 3 3 4
7 104 G-R J49 7 104 G-R J25
8 108 R-Y CN34-5 8 108 R-Y J24 TAB REC
9 109 G-Y CN31-5 9 109 G-Y J26 NO P C J NO P C J
10 N2 W-B J46 10 N2 W-B J8 1 491 - COIL+ 1 491 G-B CN250-2

2 41 - SW+ 2 41 G-R J11
CN37 DC/DC FOR LED RR COMBI 3 118 - COIL- 3 118 L-Y J2
4 48 - SW- 4 48 L-O J20
CN43 HOOD
5 4 3 2 1 1 2 3 4 5
2 1 1 2
10 9 8 7 6 6 7 8 9 10
TAB REC
NO P C J NO P C J
TAB REC 1 67 L-O CN104-18 1 67 L-O CN44-2
NO P C J NO P C J
2 51 BR J14 2 51 BR CN44-1
1 101 L CN38-1 1 101 L J16
2 493 B-Y CN38-2 2 493 B-Y J27 CN44 SEAT SW
3 198 R-W CN38-3 3 198 R-W CN208-4

2 1 1 2
4 103 R-W CN237-1 4 103 R-W CN23-1
5 118 L-Y CN38-5 5 118 L-Y J2 TAB REC
6 111 R-L CN237-2 6 111 R-L CN5-1 NO P C J NO P C J
7 104 G-R CN237-3 7 104 G-R J25 1 51 - SDM- 1 51 BR CN43-2
8 108 R-Y CN237-5 8 108 R-Y J24 2 67 - SDM+ 2 67 L-O CN43-1
9 109 G-Y CN237-4 9 109 G-Y J26
10 N2 W-B CN237-6 10 N2 W-B J8
18-948 18 APPENDIX
CN46 TAIL LP RELAY CN53 DM SPD SSR1 RH
2 1 1 2
2 1 1 2
4 3 3 4
TAB REC
1 117 - COIL+ 1 117 GR CN211-1 NO P C J NO P C J
2 487 - SW+ 2 487 L-Y CN250-20 1 76 - SSDR1 1 76 Y CN110-14
3 116 - COIL- 3 116 LG CN7-7 2 75 - SSDR+ 2 75 L CN202-3
4 104 - SW- 4 104 G-R J25
CN47 DIAGNOSIS
1 2 3 4 5 6
6 5 4 3 2 1 CN54 DM SPD SSR2 RH
7 8 9 10 11
11 10 9 8 7
12 13 14 15 16 17 2 1 1 2
17 16 15 14 13 12
TAB REC TAB REC

NO P C J NO P C J
NO P C J NO P C J
1 - - - 1 - - -
1 77 - SSDR2 1 77 LG CN110-13
2 - - - 2 - - -
2 75 - SSDR+ 2 75 L CN202-4
3 N2 - GND 3 N2 W-B J10
4 486 - FLP 4 486 B-W J4
5 - - - 5 - - -
6 - - - 6 - - -
7 - - - 7 - - -
8 145 - CAN1H 8 145 R-L CN200-8 CN55 PM TEMP SSR
9 146 - CAN1L 9 146 L-Y CN200-11
10 - - - 10 - - -
11 - - - 11 - - -
2 1 1 2
12 334 - PSACC+ 12 334 L-O CN104-14,201-1
13 - - - 13 - - -
TAB REC
14 - - - 14 - - -
NO P C J NO P C J
15 - - - 15 - - -
1 89 - STPM 1 89 R-W CN111-10
16 - - - 16 - - -
2 88 - STPM+ 2 88 GR CN111-9
17 - - - 17 - - -
CN52 DM TEMP SSR RH
2 1 1 2 CN56 PM SPD SSR
2 1 1 2
TAB REC
NO P C J NO P C J
1 85 - STDMR 1 85 R-W CN110-10
TAB REC
2 84 - STDMR+ 2 84 GR CN110-9
NO P C J NO P C J
1 82 - SSP1 1 82 G CN111-14
2 81 - SSP+ 2 81 R-L CN111-15
18 APPENDIX 18-949
CN58 STROBE LAMP CN70 DISPLAY
2 1 1 2
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
TAB REC 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
NO P C J NO P C J
1 493 - LS+ 1 493 B-Y J47,CN37-2
2 N2 - LS- 2 N2 W-B J46
CN62 COMPARTMENT LIGHT SW

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8 TAB REC
NO P C J NO P C J
1 - - - 1 - - -
TAB REC 2 - - - 2 - - -
NO P C J NO P C J
3 169 - TGND 3 169 GR-R CN178-9
1 112 - SW+ 1 112 G-Y CN63-1
4 14 - DGND 4 14 W-G CN103-3
2 - - - 2 - - -
5 16 - D7V 5 16 Y-B CN103-14
3 - - - 3 - - -
6 162 - ITKY3 6 162 G CN178-3
4 - - - 4 - - -
7 - - - 7 - - -
5 - - - 5 - - -
8 160 - ITKY1 8 160 B-Y CN178-5
6 - - - 6 - - -
7 101 - SW- 7 101 L CN244-2
9 166 - OTKY3 9 166 GR-L CN178-7
18
10 165 - OTKY2 10 165 R-Y CM178-2
8 - - - 8 - - -
11 164 - OTKY1 11 164 L-O CN178-8
CN63 COMPARTMENT LIGHT 12 167 - LEDTKY1 12 167 G-Y CN178-1

13 - - - 13 - - -
2 1 1 2 14 - - - 14 - - -
15 146 - CAN1L 15 146 W CN200-12
TAB REC 16 145 - CAN1H 16 145 L CN200-9

NO P C J NO P C J 17 - - - 17 - - -
1 112 - LCM+ 1 112 G-Y CN62-1 18 486 - VBKY 18 486 B-W J4
2 N2 - LCM- 2 N2 W-B CN244-1 19 168 - LEDTKY2 19 168 L-B CN178-6
20 161 - ITKY2 20 161 R-B CN178-4
21 163 - IPSTKY1 21 163 W-L CN178-10
22 - - - 22 - - -
23 - - - 23 - - -
24 - - - 24 - - -
25 - - - 25 - - -
26 - - - 26 - - -
27 - - - 27 - - -
28 - - - 28 - - -
29 - - - 29 - - -
30 - - - 30 - - -
31 - - - 31 - - -
32 - - - 32 - - -
33 - - - 33 - - -
34 - - - 34 - - -
35 - - - 35 - - -
36 N2 - N1 36 N2 W-B J7
18-950 18 APPENDIX
CN73 WARKING LAMP SW CN77 HOOD (MINI LEVER)
2 1 1 2
6 5 4 3 2 1 1 2 3 4 5 6
13 12 11 10 9 8 7 7 8 9 10 11 12 13
TAB REC
NO P C J NO P C J
1 101 - SW+ 1 101 L CN37-1 TAB REC
2 107 - SW- 2 107 Y-G CN125-1 NO P C J NO P C J
1 28 V-W CN101-25 1 28 V-W CN162-4
CN75 HOOD (MINI LEVER)
2 20 V-R CN103-26 2 20 V-R CN162-3
3 21 V-G CN103-18 3 21 V-G CN162-2
4 51 GR J68 4 51 GR J51
5 29 R-Y CN101-28 5 29 R-Y CN163-4
4 3 2 1
1 2 3 4 6 22 R-W CN102-23 6 22 R-W CN163-3
8 7 6 5 7 23 R-L CN102-22 7 23 R-L CN163-2

5 6 7 8 8 30 R-G CN101-29 8 30 R-G CN164-4
9 24 R-B CN102-21 9 24 R-B CN164-3
10 25 P-L CN102-20 10 25 P-L CN164-2
11 31 P-G CN101-30 11 31 P-G CN165-4
TAB REC
12 26 P-B CN102-29 12 26 P-B CN165-3
NO P C J NO P C J
13 27 L-Y CN102-28 13 27 L-Y CN165-2
1 495 B-Y J15 1 495 B-Y CN166-8
2 120 Y-R CN24-1 2 120 Y-R CN166-3
CN78 C/V PULL SOL
3 45 GR-R CN104-26 3 45 GR-R CN166-5
4 - - - 4 - - -
5 495 B-Y J15 5 495 B-Y CN166-7
4 3 2 1 1 2 3 4
6 103 R-W CN23-1 6 103 R-W CN166-2
7 46 B-O CN104-19 7 46 B-O CN166-4
8 7 6 5 5 6 7 8
8 - - - 8 - - -
CN76 HOOD (MINI LEVER)

TAB REC
NO P C J NO P C J
1 10 B-Y CN101-17 1 10 - SLPL-
5 4 3 2 1 1 2 3 4 5 2 33 W-G CN101-12 2 33 - STPL-

3 36 W-R CN101-10 3 36 - SA1PL-
10 9 8 7 6 6 7 8 9 10 4 39 Y-B CN101-14 4 39 - SA2PL-
5 481 G-W J62 5 481 - SLPL+
6 482 L J63 6 482 - STPL+
7 483 L J64 7 483 - SA1PL+
TAB REC 8 484 G-W J65 8 484 - SA2PL+

NO P C J NO P C J
1 60 P-L CN104-15 1 60 P-L J53
CN85 NTRL TILT SW
2 N2 W-B J8 2 N2 W-B CN171-1

3 - - - 3 - - - 2 1 1 2
4 - - - 4 - - -
5 - - - 5 - - -
6 68 B-R CN104-28 6 68 B-R CN170-3 TAB REC
NO P C J NO P C J
7 118 L-Y J2 7 118 L-Y CN170-2
1 51 BR J14 1 51 - LS-
8 70 B-L CN103-32 8 70 B-L CN161-3
2 70 B-L CN103-32 2 70 - STK
9 51 BR J14 9 51 BR J52
10 - - - 10 - - -
18 APPENDIX 18-951
CN86 TILT ANG SSR CN88 C/V SOL <MINI LEVER>
3 2 1 1 2 3
3 2 1 1 2 3
TAB REC 6 5 4 4 5 6
NO P C J NO P C J
1 57 - VRTA+ 1 57 L-Y CN101-20
2 56 - VRTA 2 56 Y-R CN103-17 TAB REC
3 51 - POT- 3 51 G J9 NO P C J NO P C J
1 - - - 1 - - -
CN87 C/V PUSH SOL
2 477 V CN250-36 2 477 - SLLL+
3 479 Y-R CN250-38 3 479 - SLTFL+
4 3 2 1 1 2 3 4 4 - - - 4 - - -
5 4 B-Y CN102-16 5 4 - SLLL-
6 7 W CN102-19 6 7 - SLTFL-
8 7 6 5 5 6 7 8
CN89 TILT SW
TAB REC
2 1 1 2
NO P C J NO P C J
1 11 B-W CN101-16 1 11 - SLPS- 4 3 3 4
2 34 W-L CN101-13 2 34 - STPS-
3 37 G-B CN101-11 3 37 - SA1PS- 18
4 40 B-R CN101-15 4 40 - SA2PS-
TAB REC
5 481 G-W J62 5 481 - SLPS+
NO P C J NO P C J
6 482 L J63 6 482 - STPS+
1 22 R-W CN102-23 1 22 - VRT1
7 483 L J64 7 483 - SA1PS+
2 51 GR J13 2 51 - LS-
8 484 G-W J65 8 484 - SA2PS+
3 23 R-L CN102-22 3 23 - VRT2
4 51 GR J13 4 51 - LS-
CN88 C/V SOL
CN90 MAST SSR
4 3 2 1 1 2 3 4
3 2 1 1 2 3
8 7 6 5 5 6 7 8
TAB REC
NO P C J NO P C J
TAB REC 1 51 B CN92-1 1 51 B J19

NO P C J NO P C J 2 91 W CN92-3 2 91 W CN103-24
1 478 V CN250-34 1 478 - SLUL+ 3 90 R CN92-2 3 90 R CN104-22
2 477 V CN250-36 2 477 - SLLL+
3 479 Y-R CN250-38 3 479 - SLTFL+
CN91 PRESS SSR
4 8 G CN102-18 4 8 - SLTBL-
5 5 W-L CN102-17 5 5 - SLUL- 1 1
6 4 B-Y CN102-16 6 4 - SLLL-
7 7 W CN102-19 7 7 - SLTFL- 2 2
8 480 Y-R CN250-40 8 480 - SLTBL+
3 3
TAB REC
NO P C J NO P C J
1 58 - SPLF+ 1 58 Y-R CN104-12
2 59 - SPLF 2 59 Y-G CN103-29
3 51 - POT- 3 51 G J9
18-952 18 APPENDIX
CN92 HEIGHT SW CN101 CPU1
3 2 1 1 2 3
7 6 5 4 3 2 1
TAB REC 17 16 15 14 13 12 11 10 9 8
NO P C J NO P C J
27 26 25 24 23 22 21 20 19 18
1 51 B CN90-1 1 51 - LS-
34 33 32 31 30 29 28
2 90 R CN90-3 2 90 - SH1
3 91 W CN90-2 3 91 - SH2-1
CN97 TIRE ANGLE SSR 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
3 2 1 1 2 3
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
TAB REC
NO P C J NO P C J
TAB REC
1 51 - POT- 1 51 GR J13,J68
NO P C J NO P C J
2 317 - VRTRA 2 317 L-R CN102-31
1 3 - SOLLU+ 1 3 G-B J32
3 316 - VRTRA+ 3 316 L-W CN101-23
2 6 - SLTFB+ 2 6 G-W J33
CN98 STEERING SOL 3 97 - FAN+ 3 97 R-W CN127-3

4 41 - VBBT 4 41 G J5
2 1 1 2 5 9 - SLLA2+ 5 9 Y-R J67
6 32 - SLTA1+ 6 32 Y-L J66
TAB REC 7 - - - 7 - - -
NO P C J NO P C J 8 - - - 8 - - -
1 330 - SLS- 1 330 W-L CN102-14 9 - - - 9 - - -
2 485 - SLS+ 2 485 R CN250-32 10 36 - SA1PL- 10 36 W-R CN78-3
11 37 - SA1PS- 11 37 G-B CN87-3
CN99 CLAMP LOCK VALVE
12 33 - STPL- 12 33 W-G CN78-2
13 34 - STPS- 13 34 W-L CN87-2
2 1 1 2
14 39 - SA2PL- 14 39 Y-B CN78-4
15 40 - SA2PS- 15 40 B-R CN87-4
TAB REC
16 11 - SLPS- 16 11 B-W CN87-1
NO P C J NO P C J
17 10 - SLPL- 17 10 B-Y CN78-1
1 113 G-W CN179-1 1 113 - SLIL+
18 - - - 18 - - -
2 N2 W-B CN179-2 2 N2 - SLIL-
19 43 - VBKY 19 43 B-Y J3
20 57 - VRTA+ 20 57 L-Y CN86-1
21 - - - 21 - - -
22 50 - VRA- 22 50 B-O J18
23 316 - VRTRA+ 23 316 L-W CN97-3
24 - - - 24 - - -
25 28 - VRL+ 25 28 V-W CN117-1,77-1
26 55 - VRA2+ 26 55 GR-R CN26-1
27 53 - VRA1+ 27 53 BR-W CN26-5
28 29 - VRT+ 28 29 R-Y CN77-5
29 30 - VRAT1+ 29 30 R-G CN117-4,77-8
30 31 - VRAT2+ 30 31 P-G CN117.3,77-11
31 - - - 31 - - -
32 51 - POT- 32 51 G J9
33 74 - VRB2+ 33 74 BR-R CN6-1
34 72 - VRB1+ 34 72 L-O CN6-5
18 APPENDIX 18-953
CN102 CPU2 CN103 CPU3
7 6 5 4 3 2 1 6 5 4 3 2 1
19 18 17 16 15 14 13 12 11 10 9 8 16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 27 26 25 24 23 22 21 20 19 18 17
35 34 33 32 31 30 29 28 35 34 33 32 31 30 29 28
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16
20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 28 29 30 31 32 33 34 35
TAB REC TAB REC

1 98 - FNDC1 1 98 V-Y J23 1 - - - 1 - - -
2 99 - FNDC2 2 99 G-R CN118-2 2 - - - 2 - - -
3 19 - VBMBSL 3 19 Y-B J21,J61 3 14 - DGND 3 14 W-G CN70-4
4 19 - VBMBSL 4 19 Y-B J21,J61 4 42 - KYSAT 4 42 R-Y J22
5 17 - SOLCOM 5 17 G-W CN127-7 5 N2 - N2 5 N2 W-B CN200-1 18
6 17 - SOLCOM 6 17 G-W CN127-6 6 51 - LS- 6 51 B J19
7 329 - SLS+ 7 329 R-G CN250-31 7 - - - 7 - - -
8 333 - OACC3 8 333 G CN209-2 8 300 - IPL+ 8 300 L-B CN203-1
9 332 - OACC2 9 332 R CN208-2 9 - - - 9 - - -
10 51 - LS- 10 51 BR J14 10 - - - 10 - - -
11 - - - 11 - - - 11 145 - CAN1H 11 145 GR-R CN200-7
12 - - - 12 - - - 12 146 - CAN1L 12 146 P-B CN200-10
13 335 - RY1 13 335 LG CN127-5 13 311 - SSTR+ 13 311 P-L CN19-1
14 330 - SLS- 14 330 W-L CN98-1 14 16 - D7V 14 16 Y-B CN70-5
15 - - - 15 - - - 15 - - - 15 - - -
16 4 - SLLL- 16 4 B-Y CN88-6,88-5 16 - - - 16 - - -
17 5 - SLUL- 17 5 W-L CN88-5 17 56 - VRTA 17 56 Y-R CN86-2
18 8 - SLTBL- 18 8 G CN88-4 18 21 - VRL2 18 21 V-G CN117-6,77-3
19 7 - SLTFL- 19 7 W CN88-7,88-6 19 302 - IPL2 19 302 V-Y CN130-2
20 25 - VRA12 20 25 P-L CN117-10,77-10 20 - - - 20 - - -
21 24 - VRA11 21 24 R-B CN117-5,77-9 21 - - - 21 - - -
22 23,62 - VRT2,SWTR 22 23 R-L CN89-3,77-7 22 - - - 22 - - -
23 22,61 - VRT1,SWTF 23 22 R-W CN89-1,77-6 23 - - - 23 - - -
24 304 - CSBAT 24 304 L-O CN138-3 24 91 - SH2-1 24 91 W CN90-2
25 73 - VRB2 25 73 Y-R CN6-3 25 - - - 25 - - -
26 51 - POT- 26 51 GR J13,J68 26 20 - VRL1 26 20 V-R CN117-2,77-2
27 - - - 27 - - - 27 - - - 27 - - -
28 27 - VRA22 28 27 L-Y CN117-9,77-13 28 - - - 28 - - -
29 26 - VRA21 29 26 P-B CN117-8,77-12 29 59 - SPLF 29 59 Y-G CN91-2
30 52 - VRA1 30 52 BR-R CN26-4 30 301 - IPL1 30 301 W-L CN129-2
31 317 - VRTRA 31 317 L-R CN97-2 31 - - - 31 - - -
32 54 - VRA2 32 54 BR-Y CN26-3 32 70 - STK 32 70 B-L CN85-2,76-8
33 71 - VRB1 33 71 Y-B CN6-4 33 - - - 33 - - -
34 - - - 34 - - - 34 - - - 34 - - -
35 305 - CSBAT- 35 305 B-O CN138-2 35 - - - 35 - - -
18-954 18 APPENDIX
CN104 CPU4 CN109 DRIVE INV LH
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
7 6 5 4 3 2 1
15 14 13 12 11 10 9 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23
17 16 15 14 13 12 11 10 9 8
TAB REC
25 24 23 22 21 20 19 18 NO P C J NO P C J
31 30 29 28 27 26 1 - - - 1 - - -
2 - - - 2 - - -
3 - - - 3 - - -
4 - - - 4 - - -
1 2 3 4 5 6 7
5 - - - 5 - - -
8 9 10 11 12 13 14 15 16 17 6 - - - 6 - - -
18 19 20 21 22 23 24 25 7 - - - 7 - - -
8 42 - KYSAT 8 42 R-Y J22
26 27 28 29 30 31
9 86 - STDML+ 9 86 GR CN121-2
10 87 - STDML 10 87 R-W CN121-1
TAB REC
11 - - - 11 - - -
NO P C J NO P C J
12 - - - 12 - - -
1 41 - B48V 1 41 G J5
13 80 - SSDL2 13 80 R CN123-1
2 44 - VBMB 2 44 R-B J29
14 79 - SSDL1 14 79 R-B CN122-1
3 1 - CBAT+ 3 1 G-R J17
15 78 - SSDL+ 15 78 LG CN203-5
4 N2 - N2 4 N2 W-B CN200-2
16 146 - CAN1L 16 146 G CN203-7
5 N2 - N2 5 N2 W-B CN200-3
17 145 - CAN1H 17 145 GR CN203-10
6 N2 - N2 6 N2 W-B CN200-4
18 - - - 18 - - -
7 - - - 7 - - -
19 - - - 19 - - -
8 - - - 8 - - -
20 - - - 20 - - -
9 2 - CBAT- 9 2 LG-B CN136-1
21 - - - 21 - - -
10 303 - CSBAT+ 10 303 GR-L CN138-1
22 - - - 22 - - -
11 - - - 11 - - -
23 - - - 23 - - -
12 58 - SPLF+ 12 58 Y-R CN91-1
13 - - - 13 - - -
14 334 - PSACC+ 14 334 L-O CN200-5
15 60 - PSSW+ 15 60 P-L CN76-1
16 - - - 16 - - -
17 - - - 17 - - -
18 67 - SDM 18 67 L-O CN43-1
19 46 - DSR 19 46 B-O CN10-4,75-7,133-3
20 66 - SPB 20 66 G-W CN117-1
21 - - - 21 - - -
22 90 - SH1 22 90 R CN90-3
23 - - - 23 - - -
24 314 - SSTRC 24 314 G-Y CN19-5
25 - - - 25 - - -
26 45 - DSF 26 45 GR-R CN10-5,75-3,133-2
27 - - - 27 - - -
28 68 - SHS 28 68 B-R CN76-6
29 - - - 29 - - -
30 312 - SSTR1 30 312 B-Y CN19-3
31 313 - SSTR2 31 313 L-W CN19-4
18 APPENDIX 18-955
CN110 DRIVE INV RH CN111 PUMP INV
8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8
15 14 13 12 11 10 9 9 10 11 12 13 14 15 15 14 13 12 11 10 9 9 10 11 12 13 14 15
23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23 23 22 21 20 19 18 17 16 16 17 18 19 20 21 22 23
TAB REC TAB REC

1 - - - 1 - - - 1 - - - 1 - - -
2 - - - 2 - - - 2 - - - 2 - - -
3 - - - 3 - - - 3 - - - 3 - - -
4 - - - 4 - - - 4 - - - 4 - - -
5 - - - 5 - - - 5 - - - 5 - - -
6 - - - 6 - - - 6 152 - SETP1 6 152 G-R CN111-23
7 150 - SETDR0 7 150 G-R 110-23 7 - - - 7 - - -
8 42 - KYSAT 8 42 R-Y J22 8 42 - KYSAT 8 42 R-Y J22
9 86 - STDMR+ 9 84 GR CN52-2 9 88 - STPM+ 9 88 GR CN55-2
10 85 - STDMR 10 85 R-W CN52-1 10 89 - STPM 10 89 R-W CN55-1
11 - - - 11 - - - 11 - - - 11 - - -
12 - - - 12 - - - 12 - - - 12 - - -
13 77 - SSDR2 13 77 LG CN54-1 13 - - - 13 - - -
14 76 - SSDR1 14 76 Y CN53-1 14 82 - SSP1 14 82 G CN56-1
15 75 - SSDR+ 15 75 LG CN203-3 15 81 - SSP+ 15 81 R-L CN56-2
16 146 - CAN1L 16 146 L CN203-8 16 146 - CAN1L 16 146 V CN202-11 18
17 145 - CAN1H 17 145 W CN203-11 17 145 - CAN1H 17 145 P CN202-8
18 - - - 18 - - - 18 - - - 18 - - -
19 - - - 19 - - - 19 - - - 19 - - -
20 - - - 20 - - - 20 - - - 20 - - -
21 - - - 21 - - - 21 - - - 21 - - -
22 - - - 22 - - - 22 - - - 22 - - -
23 150 - SETDR- 23 150 G-R CN110-7 23 152 - SETP- 23 152 G-R CN111-6
CN112 INV FAN1
2 1 1 2
TAB REC
NO P C J NO P C J
1 474 R CBAT+ 1 474 L-B CN250-26
2 98 B FNDC1 2 98 V-Y J23
CN113 INV FAN2
2 1 1 2
TAB REC
NO P C J NO P C J
1 475 R CBAT+ 1 475 P CN250-28
2 98 B FNDC1 2 98 V-Y J23
18-956 18 APPENDIX
CN115 LIFT LVR CN120 ATT2 LVR SSR
4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4
TAB REC TAB REC

1 51 - POT- 1 51 GR J41 1 51 - POT- 1 51 GR J41
2 21 - VRL2 2 21 V-G CN117-6 2 27 - VRAT22 2 27 L-Y CN117-9
3 20 - VRL1 3 20 V-R CN117-2 3 26 - VRAT21 3 26 P-B CN117-8
4 28 - VRL+ 4 28 V-W CN117-1 4 31 - VRAT2+ 4 31 P-G CN117-3
CN117 HOOD1 CN121 DM TEMP SSR LH
2 1 1 2
5 4 3 2 1 1 2 3 4 5
10 9 8 7 6 6 7 8 9 10 TAB REC
NO P C J NO P C J
1 87 - STDML 1 87 R-W CN109-10
2 86 - STDML+ 2 86 GR CN109-9
TAB REC CN122 DM SPD SSR1 LH

NO P C J NO P C J
1 28 V-W CN101-25 1 28 V-W CN115-4
2 1 1 2
2 20 V-R CN103-26 2 20 V-R CN115-3
3 31 P-G CN101-30 3 31 P-G CN120-4
4 30 R-G CN101-29 4 30 R-G CN119-4
TAB REC
5 24 R-B CN102-21 5 24 R-B CN119-3 NO P C J NO P C J
6 21 V-G CN103-18 6 21 V-G CN115-2 1 79 - SSDL1 1 79 R-B CN1109-14
7 51 GR J13 7 51 GR J41 2 78 - SSDL+ 2 78 G CN202-1
8 26 P-B CN102-29 8 26 P-B CN120-3
9 27 L-Y CN102-28 9 27 L-Y CN120-2 CN123 DM SPD SSR2 LH
10 25 P-L CN102-20 10 25 P-L CN119-2
2 1 1 2
CN118 MOTOR FAN
2 1 1 2
TAB REC
NO P C J NO P C J
TAB REC
1 80 - SSDL2 1 80 R CN109-13
NO P C J NO P C J
2 78 - SSDL+ 2 78 G CN202-2
1 476 - CBAT+ 1 476 B-W CN250-30
2 99 - FNDC2 2 99 G-R CN102-2
CN125 WORKING LP
CN119 ATT1 LVR SSR

2 1 1 2
4 3 2 1 1 2 3 4
TAB REC TAB REC

1 51 - POT- 1 51 GR J41 1 107 - LW+ 1 107 Y-G CN73-2
2 25 - VRAT12 2 25 P-L CN117-10 2 N2 - LW- 2 N2 W-B J46
3 24 - VRAT11 3 24 R-B CN117-5
4 30 - VRAT1+ 4 30 R-G CN117-4
18 APPENDIX 18-957
CN127 MINI LEVER SOL RLY CN137 CONTACTOR2
1 1
7 6 5 4 3 2 1 1 2 3 4 5 6 7
3 2 2 3
TAB REC TAB REC

1 19 - VBMBSL 1 19 Y-B J61 1 P2 GR J6 1 P2 W FLP
2 19 - VBMBSL 2 19 Y-B J61 2 P2 G-Y CN250-49 2 P2 R VBBT
3 97 - RY1+ 3 97 R-W CN101-3 3 19 Y-B J21 3 19 B VBMBSL
4 - - - 4 - - -
5 335 - RY1- 5 335 LG CN102-13
CN138 CONTACTOR3
6 17 - SOLCOM 6 17 G-W CN102-6

3 2 1 1 2 3
7 17 - SOLCOM 7 17 G-W CN102-5
CN129 IMPACT SSR1 TAB REC

NO P C J NO P C J
3 2 1 1 2 3 1 303 R CSBAT+ 1 303 GR-L CN104-10

2 305 BR CSBAT- 2 305 B-O CN102-35
3 304 W CSBAT 3 304 L-O CN102-24
TAB REC
NO P C J NO P C J CN144 DC/DC
1 51 - POT- 1 51 G J9
2 301 - IPL1 2 301 W-L CN103-30
2 1 1 2 18
3 300 - IPL+ 3 300 L-B CN202-6
4 3 3 4
CN130 IMPACT SSR2
3 2 1 1 2 3
TAB REC
NO P C J NO P C J
TAB REC 1 233 - IN- 1 233 W-R CN147-2
NO P C J NO P C J 2 232 - IN+ 2 232 L-R CN250-54
1 51 - POT- 1 51 G J9 3 235 - OUT- 3 235 B J31
2 302 - IPL2 2 302 V-Y CN103-19 4 234 - OUT+ 4 234 R-W CN250-55
3 300 - IPL+ 3 300 L-B CN202-5
CN146 12V PWR SUPPLY
CN133 EZ PEDAL
2 1 1 2
3 2 1 1 2 3
TAB REC
NO P C J NO P C J
TAB REC 1 236 R J30 1 236 - -
NO P C J NO P C J 2 235 B J31 2 235 - -
1 51 R NC 1 51 BR J14
2 45 W NO 2 45 GR-R CN104-26 CN147 DC/DC
3 46 W NO 3 46 B-O CN104-19
2 1 1 2
CN136 CONTACTOR1
TAB REC
1 1 NO P C J NO P C J
3 2 2 3 1 231 Y-R CN250-53 1 231 Y-R CN148
2 233 W-R CN144-1 2 233 W-R CN149
TAB REC
NO P C J NO P C J
1 2 B CBAT- 1 2 LG-B CN104-9
2 1 R CBAT+ 2 1 G-R J17
3 P3 L VBMB 3 P3 R-G CN250-51
18-958 18 APPENDIX
CN161 NTRL TILT SW CN166 DIRECTION SW (ARM DIR)
2 1 1 2 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
3 3 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18
TAB REC
NO P C J NO P C J
TAB REC
NO P C J NO P C J
1 60 - PSSW+ 1 60 P-L J53
1 - - - 1 - - -
2 51 - LS- 2 51 BR J52
2 103 - DSBU 2 103 R-W CN75-6
3 70 - STK 3 70 B-L CN76-8
3 120 - DSFO 3 120 Y-R CN75-2
CN162 LIFT LVR SSR 4 46 - DSR 4 46 B-O CN75-7
5 45 - DSF 5 45 GR-R CN75-3
4 3 2 1 1 2 3 4 6 51 - LS- 6 51 BR J52
7 495 - VBKY 7 495 B-Y CN75-5
TAB REC 8 495 - VBKY 8 495 B-Y CN75-1
NO P C J NO P C J
9 - - - 9 - - -
1 51 - POT- 1 51 GR J51
10 - - - 10 - - -
2 21 - VRL2 2 21 V-G CN77-3
11 - - - 11 - - -
3 20 - VRL1 3 20 V-R CN77-2
12 - - - 12 - - -
4 28 - VRL+ 4 28 V-W CN77-1
13 - - - 13 - - -
CN163 TILT LVR SSR

14 - - - 14 - - -
15 - - - 15 - - -
4 3 2 1 1 2 3 4 16 - - - 16 - - -
17 - - - 17 - - -
TAB REC 18 - - - 18 - - -
NO P C J NO P C J
1 51 - POT- 1 51 GR J51
CN170 ATT ACT SW (COWL)
2 23 - VRT2 2 23 R-L CN77-7

3 22 - VRT1 3 22 R-W CN77-6 2 1 1 2
4 29 - VRT+ 4 29 R-Y CN77-5
CN164 ATT1 LVR SSR TAB REC

NO P C J NO P C J
4 3 2 1 1 2 3 4 1 496 B-R CB213-2 1 496 - SW+
2 114 BR CN213-1 2 114 - SW-
TAB REC
NO P C J NO P C J CN170 ATT ACT SW (MINI)
1 51 - POT- 1 51 GR J51
2 25 - VRAT12 2 25 P-L CN77-10 2 1 1 2
3 24 - VRAT11 3 24 R-B CN77-9 3 3
4 30 - VRAT1+ 4 30 R-G CN77-8
TAB REC
CN165 ATT2 LVR SSR
NO P C J NO P C J
1 60 - IG 1 60 P-L J53
4 3 2 1 1 2 3 4
2 51 - E 2 51 BR J52
3 68 - + 3 68 B-R CN76-6
TAB REC
NO P C J NO P C J
1 51 - POT- 1 51 GR J51
2 27 - VRAT22 2 27 L-Y CN77-13
3 26 - VRAT21 3 26 P-B CN77-12
4 31 - VRAT2+ 4 31 P-G CN77-11
18 APPENDIX 18-959
CN171 ARMREST HORN SW CN176 EMERGENCY SW
2 1 1 2
2 1 1 2
TAB REC
NO P C J NO P C J
TAB REC 1 41 B SWE+ 1 41 G-R J11
NO P C J NO P C J
2 41 W SWE- 2 41 G J5
1 N2 W-B CN76-2 1 N2 - SW-
2 118 L-Y CN76-7 2 118 - SW+ CN177 BODY SUB
CN172 FR STAY RH1
2 1 1 2 4 3 2 1
3 3 1 2 3 4
8 7 6 5
5 6 7 8
TAB REC
NO P C J NO P C J
1 106 R-G CN16-1 1 106 R-G CN210-4
2 108 R-Y CN14-1 2 108 R-Y J24
TAB REC
3 N2 W-B CN16-2 3 N2 W-B J7 NO P C J NO P C J
1 66 G-W CN15-1 1 66 G-W CN104-20
CN173 FR STAY RH2
2 109 G-Y CN174-2 2 109 G-Y J26
2 1 1 2 3 - - - 3 - - - 18
4 102 R-G CN174-1 4 102 R-G CN211-4
3 3
5 51 B CN15-3 5 51 B J19
6 104 G-R CN175-1 6 104 G-R J25
TAB REC
7 - - - 7 - - -
NO P C J NO P C J
8 N2 W-B J40 8 N2 W-B J7
1 104 G-R J25 1 104 G-R CN14-4
2 N2 W-B J7 2 N2 W-B CN14-2
CN178 TEN KEY
3 N2 W-B J7 3 N2 W-B CN14-3
CN174 FR STAY LH1
2 1 1 2 5 4 3 2 1 1 2 3 4 5
3 3 10 9 8 7 6 6 7 8 9 10
TAB REC
NO P C J NO P C J
1 102 R-G CN16-1 1 102 R-G CN177-4
2 109 R-Y CN14-1 2 109 G-Y CN177-2
TAB REC
NO P C J NO P C J
3 N2 W-B CN16-2 3 N2 W-B J40
1 167 G-Y CN70-12 1 167 G-Y CN33-5
CN175 FR STAY LH2 2 165 R-Y CN70-10 2 165 R-Y CN33-4

3 162 G CN70-6 3 162 G CN33-3
2 1 1 2 4 161 R-B CN70-20 4 161 R-B CN33-2
3 3 5 160 B-Y CN70-8 5 160 B-Y CN33-1

6 168 L-B CN70-19 6 168 L-B CN33-10
TAB REC 7 166 GR-L CN70-9 7 166 GR-L CN33-9

NO P C J NO P C J 8 164 L-O CN70-11 8 164 L-O CN33-8
1 104 G-R CN177-6 1 104 G-R CN14-4 9 169 GR-R CN70-3 9 169 GR-R CN33-7
2 N2 W-B J40 2 N2 W-B CN14-2 10 163 W-L CN70-21 10 163 W-L CN33-6
3 N2 W-B J40 3 N2 W-B CN14-3
18-960 18 APPENDIX
CN179 INTERLOCK SOL TAB
2 1 1 2
TAB REC
NO P C J NO P C J
1 113 G-W CN213-4 1 113 G-W CN99-1
CN200 CN201
CAN J/C1 REC CAN J/C2
2 N2 W-B J10 2 N2 W-B CN99-2
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
CN183 TELEMATICS
NO P C J NO P C J
1 N2 W-B CN103-5 1 334 L-O CN47-12
3 2 1 1 2 3
2 N2 W-B CN104-4 2 334 L-O CN209-1
3 N2 W-B CN104-5 3 N2 W-B CN20-1
6 5 4 4 5 6
4 N2 W-B CN104-6 4 N2 W-B CN183-6
5 334 L-O CN104-14 5 N2 W-B CN20-2
TAB REC 6 334 L-O CN208-1 6 N2 W-B CN183-3
NO P C J NO P C J 7 145 GR-R CN103-11 7 146 LG-B CN202-10
1 440 R-B CN209-4 1 - - - 8 145 R-L CN47-8 8 146 BR CN183-5
2 - - - 2 - - - 9 145 L CN70-16 9 146 - -
3 N2 W-B CN201-6 3 - - - 10 146 P-B CN103-12 10 145 LG-R CN202-7
4 145 BR-W CN201-11 4 - - - 11 146 L-Y CN47-9 11 145 BR-W CN183-4
5 146 BR CN201-8 5 - - - 12 146 W CN70-15 12 145 - -
6 N2 W-B CN201-4 6 - - -
TAB
CN185 BLUE LIGHT
2 1 1 2
TAB REC
NO P C J NO P C J CN202 CN203
CAN J/C3 REC CAN J/C4
1 N2 - LB- 1 N2 W-B J46
2 493 - LB+ 2 493 B-Y J47
1 2 3 4 5 6 1 2 3 4 5 6
7 8 9 10 11 12 7 8 9 10 11 12
NO P C J NO P C J
1 78 G CN122-2 1 300 L-B CN103-8
2 78 G CN123-2 2 - - -
3 75 L CN53-2 3 75 LG CN110-15
4 75 L CN54-2 4 - - -
5 300 L-B CN130-3 5 78 LG CN109-15
6 300 L-B CN129-3 6 - - -
7 145 LG-R CN201-10 7 146 G CN109-16
8 145 P CN111-17 8 146 L CN110-16
9 - - - 9 - - -
10 146 LG-B CN201-7 10 145 GR CN109-17
11 146 V CN111-16 11 145 W CN110-17
12 - - - 12 - - -
18 APPENDIX 18-961
CN207 KEY OFF H/L RLY CN211 HEAD LP RLY LH
2 1 1 2 2 1 1 2
4 3 3 4 4 3 3 4
TAB REC TAB REC
1 493 - COIL+ 1 493 B-Y J27 1 117 - COIL+ 1 117 GR CN46-1,210-1
2 101 - SW+ 2 101 L J16 2 488 - SW+ 2 488 Y-G CN250-16
3 N2 - COIL- 3 N2 W-B J8 3 115 - COIL- 3 115 P J28
4 117 - SW- 4 117 GR CN210-1 4 102 - SW- 4 102 R-G CN177-4
CN208 SOLID STATE RLY1 CN212 ACCESSARY RELAY
2 1 1 2
3 2 1 1 2 3 4 3 3 4
6 5 4 4 5 6 TAB REC
NO P C J NO P C J
1 44 - COIL+ 1 44 R-B J29
2 41 - SW+ 2 41 G-R J11
TAB REC
3 N2 - COIL- 3 N2 W-B J8
NO P C J NO P C J
4 105 - SW- 4 105 G-W J12
1 334 - PSACC+ 1 334 L-O CN200-6
2 332 - OACC2 2 332 R CN102-9
CN213 INTERLOCK RLY (COWL)
18
3 - - - 3 - - -
4 103 - LBU+ 4 103 R-W CN37-3,23-1 2 1 1 2
5 - - - 5 - - - 4 3 3 4
6 472 - B48V 6 472 G-W CN250-24
TAB REC
CN209 SOLID STATE RLY2 NO P C J NO P C J
1 114 - COIL+ 1 114 BR CN170-2
2 496 - SW+ 2 496 B-R CN170-1,250-22
3 2 1 1 2 3 3 N2 - COIL- 3 N2 W-B J10
4 113 - SW- 4 113 G-W CN179-1
6 5 4 4 5 6
CN218 SURGE KILLER CN217
TAB REC 2 1 1 2
NO P C J NO P C J
1 334 - - 1 334 L-O CN201-2
TAB REC
2 333 - - 2 333 G CN102-8
NO P C J NO P C J
3 - - - 3 - - -
1 48 B CN219-2 1 48 L-O J20
4 440 - - 4 440 R-B CN183-1
2 492 B CN219-1 2 492 G-Y CN250-4
5 - - - 5 - - -
6 473 - - 6 473 G-W CN250-58
CN210 HEAD LP RLY
2 1 1 2
4 3 3 4
TAB REC
NO P C J NO P C J
1 117 - COIL+ 1 117 GR CN207-4,211-1,J16,172-1
2 489 - SW+ 2 489 BR CN250-18
3 115 - COIL- 3 115 P J28
4 106 - SW- 4 106 R-G CN172-1
18-962 18 APPENDIX
CN250 FUSE HOLDER
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
CN237 DC/DC FOR LED RR COMBI
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60
3 2 1 1 2 3
6 5 4 4 5 6 NO P C J NO P C J
1 41 G-R J11 31 329 R-G CN102-7
2 491 G-B CN40-1 32 485 R CN98-2
TAB REC 3 41 G-R J11 33 3 G-B J32
NO P C J NO P C J
4 492 G-Y CN217-2 34 478 V CN88-1
1 103 - BUIN 1 103 R-W J56
5 105 G-W J12 35 3 G-B J32
2 111 - STLIN 2 111 R-L CN37-6
6 495 B-Y J15 36 477 V CN88-2
3 104 - TLIN 3 104 G-R CN37-7
7 105 G-W J12 37 6 G-W J33
4 109 - TRNLIN 4 109 G-Y CN37-9
8 493 B-Y J27 38 479 Y-R CN88-3
5 108 - TRNRIN 5 108 R-Y CN37-8
9 105 G-W J12 39 6 G-W J33
6 N2 - GNDIN 6 N2 W-B CN37-10
10 494 B-Y CN12-4 40 480 Y-R CN88-8
CN238 DC/DC FOR LED RR COMBI 11 P2 GR J6 41 9 Y-R J67

12 490 GR-R CN5-1 42 481 G-W CN87-5
13 P2 GR J6 43 32 Y-L J66
3 2 1 1 2 3 14 101 L J16 44 482 L CN87-6
15 P2 GR J6 45 32 Y-L J66
6 5 4 4 5 6 16 488 Y-G CN211-2 46 483 L CN87-7
17 P2 GR J6 47 9 Y-R J67
18 489 BR CN210-2 48 484 G-W CN87-8
TAB REC 19 P2 GR J6 49 P2 G-Y CN137-2
NO P C J NO P C J
20 487 L-Y CN46-2 50 41 G-R J11
1 203 R-W CN38-4 1 203 - BUOUT
21 105 G-W J12 51 P3 R-G CN136-3
2 211 R-L CN38-6 2 211 - STLOUT
22 496 B-R CN213-2 52 44 R-B J29
3 204 G-R CN38-7 3 204 - TLOUT
23 41 G-R J11 53 231 Y-R CN147-1
4 209 G-Y CN38-9 4 209 - TRNLOUT
24 472 G-W CN208-6 54 232 L-R CN144-2
5 208 R-Y CN38-8 5 208 - TRNROUT
25 1 G-R J17 55 234 R-W CN144-4
6 N2 W-B CN38-10 6 N2 - GNDOUT
26 474 L-B CN112-1 56 236 R J30
CN244 FR STAY RH 27 1 G-R J17 57 68 G-R J11

28 475 P CN113-1 58 - G-W CN209-6
2 1 1 2 29 1 G-R J17 59 43 B-Y J3
30 476 B-W CN118-1 60 486 B-W J4
TAB REC
NO P C J NO P C J CN300 SHORT CONN CN301 SHORT CONN
1 N2 W-B J10 1 N2 W-B CN63-2
2 101 L J16 2 101 L CN62-7 2 1 2 1
4 3
CN246 12V PWR SUPPLY TAB
TAB NO P C J
2 1 1 2 NO P C J 1 41 G CN301-2
1 - - - 2 41 G CN301-1
TAB REC 2 101 GR CN300-4
NO P C J NO P C J
3 - - -
1 236 R J30 1 235 - -
4 117 GR CN300-2
2 235 B J31 2 236 - -
18 APPENDIX 18-963
BODY MAIN
J8 J1 J10 CN3-1 J2 CN37-5 CN4-4 J3 CN250-59 CN47-4 J4 CN250-60

CN76-7
CN40-3 CN101-19 CN70-18
(N2, W-B) (118, L-Y) (43, B-Y) (486, B-W)
CN4-1 CN250-15 CN7-9 CN23-2 CN6-2

CN250-13 CN250-17 CN177-8 CN7-11 CN20-1 CN24-2 CN130-1 CN26-2
CN101-4 J5 CN176-2 CN250-11 J6 CN250-19 CN172-3 J7 CN20-2 J1 J8 CN37-10 CN129-1 J9 CN86-3

CN173-2 CN70-36 CN76-2 CN207-3 CN91-3
CN104-1 CN137-1 CN173-3 CN212-3 CN101-32
(41, G) (P2, GR) (N2, W-B) (N2, W-B) (51, G)
CN3-2 CN40-2 CN250-5 CN89-2 CN10-6

J1 CN12-1 CN250-57 CN176-1 CN250-7 CN89-4 CN76-9 CN133-1
CN244-1 J10 CN22-1 CN250-50 J11 CN212-2 CN212-4 J12 CN250-9 CN117-7 J13 CN97-1 CN102-10 J14 CN43-2
CN213-3 CN47-3 CN250-23 CN250-1
CN179-2 CN250-3 CN250-21 CN102-26 CN85-1
(N2, W-B) (41, G-R) (105, G-W) (51, GR) (51, BR) 18
CN75-1 CN37-1 CN104-3 CN177-5
CN75-5 CN207-2 CN250-25
CN250-6 CN244-2 CN250-29 CN101-22 CN90-1
(495, B-Y) (101, L) (1, G-R) (50, B-O) (51, B)
CN110-1
CN21-1 CN102-3 CN111-1 CN112-2 CN7-14
(48, L-O) (19, Y-B) (42, R-Y) (98, V-Y) (108, R-Y)
CN46-4
CN177-6 CN7-12 CN250-8 CN210-3 CN104-2
(104, G-R) (109, G-Y) (493, B-Y) (115, P) (44, R-B)
CN250-56 J30 CN246-1 CN144-3 J31 CN246-2 CN250-35 J32 CN101-1 C0101-2 J33 CN250-39
CN146-1 CN146-2 CN250-33 CN250-37
(236, R) (235, B) (3, G-B) (6, G-W)

18-964 18 APPENDIX
BODY MAIN
CN102-3
CN102-4
CN127-2 CN87-5 CN87-6 CN87-7 CN87-8
(19, Y-B) (481, G-W) (482, L) (483, L) (484, G-W)
CN101-6 J66 CN250-43 CN101-5 J67 CN250-41 CN77-4 J68 CN97-1
CN250-45 CN250-47 CN102-26
(32, Y-L) (9, Y-R) (51, GR)
BODY MAIN SUB C/V SSR
CN174-3 CN115-1
CN177-8 J40 CN175-2 CN120-1 J41 CN117-7
CN175-3 CN119-1
(N2, W-B) (51, GR)
RR UPR MAIN
CN31-6 CN31-1
CN185-1 CN32-1 CN34-1
CN58-2 CN36-2
CN37-6 CN37-10 CN185-2 CN37-4 CN37-7
(111, R-L) (N2, W-B) (493, B-Y) (103, R-W) (104, G-R)
CN37-4 J56 CN237-1
CN38-3
(103, R-W)
HOOD
CN77-4 CN161-2
CN162-1
CN165-1 J51 CN163-1 CN76-9 J52 CN166-6 CN76-1 J53 CN170-1
CN164-1 CN170-2 CN161-1
(51, GR) (51, BR) (60, P-L)

1237640A
Printed in the USA

LEVER CONT. UNIT
COMPARTMENT COMPARTMENT
LIGHT SW LIGHT
DISPLAY
SW
TEN KEY
SSR
SW
<COWL LEVER>
DIRECTION
HORN SW
STEERING
TURN&LT
TAB TAB TAB TAB CN62 TAB TAB CN63
REC REC REC REC TAB CN33 TAB REC REC
NTRL TILT ATT ACT REC
CN10 CN3 CN19 CN7 REC
SW SW HEAD LP
CN70
FLASHERRLY
TAIL LAMP RLY
I/LOCK RLY
FLASHER
KEY
TAB
REC
CN4 SW CLEARANCE
STEERING
SOL CN98
TAB TAB TAB
REC REC REC
TAB
REC
CN85 CN170 CN12 CN46 CN213 TAB
CONNECTING DIAGRAM
REC REC CN14 TAB REC

REC CN16
TAB TAB CN178 REC REC CN146
TAB TAB
HEAD LP
FLASHER
CLEARANCE
CN244 CN172 CN173
REC TAB REC
STOP LAMP SW EMERGENCY <COWL LEVER> TAB REC TAB
TAB SW
REC TAB CN89 TAB CN88 TAB CN117 TAB
COM
NC
NO
CN16 REC CN5 REC REC REC
TAB
CN14
REC
TAB
REC
CN176
(48,L-O) CN21
TILT
PKB SW DIAGNOSIS
SW H CN47
CN115
TAB
REC
(N1,W-B) CN22 CN120
CN174 CN175 CN119

TAB REC
TAB TAB TAB

REC REC REC
REC TAB
TAB CN15
REC
C/V
SOL
CN177
TAB
REC
HEIGHT SW
CN92 <EZ PEDAL> NC RVS
COM VRAD BRAKE PRESS ACCEL VRAD NO SW
NO SSR SSR SSR COM
REC
TAB
TILT ANG VRAT
NC TAB TAB TAB SSR
REC REC CN91 REC CN26 CN133 NC FWD
CN6 NO SW TAB
REC
TAB
COM
REC
CN86
CN90
TAB
REC
CLAMP LOCK
VALVE CN99 CN179
BATT
REC
TAB
REC
TAB
CN121 CN52
MOTOR
TAB
REC
TAB
REC
FAN
CN122 CN53
DRIVE DRIVE
TAB
TAB
MOTOR MOTOR
LH CN123 RH CN54
TAB
REC REC
TAB
REC REC
SPD2 SPD1 TEMP

SPD2 SPD1 TEMP
W V U W V U
CN118 TAB SEAT
REC
SW
TAB
REC
CN55
CN183
TAB
REC
TEMP
CN56
PUMP
SPD
TAB
REC
MOTOR TAB CN44
REC
CN601 CN603
W V U CN129 J/C J/C
REC
TAB
REC
TAB
IMPACT N2 VBKY
TAB
REC
SSR1
CN202 CN203 CN200 CN201 CN602 CN604
CN144 CAN CAN IMPACT J/C J/C

REC
TAB
TAB
REC
REC
TAB
TAB
REC
REC
TAB
REC
TAB
J/C J/C HORN DISP

TAB
REC
SSR2 12V PWR

DC/DC SUPPLY
TAB
REC
CN130
CN43 TAB
REC
<FR & RR CHIME>
<MINI LEVER> TAB CN246
REC
RY1
TAB
REC
CN208 CHI
CN127 REC
TAB
CN101 REC TAB REC
TAB REC CN111 REC CN109 REC CN110
REC TAB TAB REC TAB TAB TAB
CN147 PUMP INV DRIVE INV LH DRIVE INV RH CN209 TAB
CN104 SOLID REC
(48,Y-R) CN136 REC CN217
CN148 STATE CONTACTOR TAB REC CHI
+ + + BZ
RLY1 TAB
P1 CN138 CN218
CPU U U U
TAB TAB TAB TAB
REC REC REC REC
SOLID
V V V STATE TAB TAB TAB TAB
REC REC REC REC
RLY2
CN24 CN23 CN24 CN23
W W W
(48,W-R) CN113 (48,W-B)
CN149 INV CN20
- - -
TAB
N2 N2
REC
FAN1
N2
CN112
(N1,B) CN219
(N1,B) CN219
INV CN210 CN211 CN212 CN207 CN40

TAB
REC REC REC REC REC SRG

REC
FAN2
CN75 CN76 CN77 CN97 TAB TAB TAB TAB TAB KILLER
TAB TAB TAB TIRE
VRAH ANG
REC CN37
REC REC REC
REC
TAB
TAB
LP
LP
OFF
KEY
SSR
RLY
RLY
<MINI LEVER> CN37

HEAD
RLY
HEAD
RLY LH
ACC
H/L RLY
HORN
REC
CN37 TAB
FUSE HOLDER TAB CN32 CN237
TAB
REC
REC
CN250
DC/DC
REC TAB
TAB REC
REC REC REC CN238

CN36 REC REC CN185 CN73 REC CN125 REC
TAB CN31 TAB CN58 TAB TAB TAB TAB TAB CN34
CN38 REC
CN37 TAB <LED RR COMBI LAMP>
FLASHER STOP BACK BACK STOP FLASHER
RR HORN SW
TAIL UP UP TAIL
WORKING
SMART BLUE
BEACON LAMP
ALRM LIGHT WORKING
LAMP
LAMP SW
<MINI LEVER>
NTRL ATT
TAB TAB TAB TILT SW DIRECTION ACT SW
CN75 REC CN76 REC CN77 REC
LIFT TILT SW ATT1 ATT2
LEVER LEVER LEVER LEVER
CN78 TAB CN87 TAB CN88 TAB
REC REC REC
TAB TAB TAB TAB TAB TAB TAB

REC REC REC REC REC REC REC
TILT CN162 CN163 CN161 CN166 CN164 CN165 CN170
SW
<MINI LEVER>
ARMREST
HORN SW
REC
TAB
C/V
SOL CN171
4-698
4-699
ELECTRIC WIRING DIAGRAM
P1 P2
FOR MINI LEVER
MB P3
(P3, R-G)
F6
P4
F1
F53
F52
F51
SWK FOR MINI LEVER FOR COWL LEVER
SWE (OPT) RYMS
(476, B-W)
(475, P)
(474, L-B)
(P2, G-Y) (41, G-R) (41, G) (43, B-Y) ACCEL BRAKE
F5
VRA2 VRB2 LIFT LEVER TILT LEVER
CONTACTOR PANEL (P2, GR) ATT1 LEVER ATT2 LEVER
VRL1 VRL2 VRT1 VRT2
BATT VRTA VRAT11 VRAT12 VRAT21 VRAT22
PIN CODE ENTRY (OPT) FAN3 FAN2 FAN1 SWTF SWTR
36V (48V)
VRTRA
SPLF IPL1 IPL2
VRA1 VRB1 SH SPB
EMERGENCY SW LESS
SSTR
RYAC
FOR COWL LEVER
(22, R-W)
(61, R-W)
(29, R-Y)
(23, R-L)
(62, R-L)
(105, G-W)
CSBAT+ (303, GR-L)
VRA1+ (53, BR-W)

VRA2+ (55, GR-R)
VRA1 (52, BR-R)
VRB2+ (74, BR-R)

VRA2 (54, BR-Y)
IPL1 (301, W-L)
VRTRA+ (316, L-W)
(313, L-W)
CSBAT- (305, B-O)
(314, G-Y)
CSBAT (304, L-O)
IPL2 (302, V-Y)
(312, B-Y)
VRTRA (317, L-R)
IPL+ (300, L-B)
(311, P-L)
SOLCOM (17, G-W)
SOLCOM (17, G-W)
SPB (66, G-W)

(97, R-W)
VRL+ (28, V-W)

RY1 (335, LG)
VRA12 (25, -P-L)

FNDC2 (99, G-R)
VRAT1+ (30, R-G)

CBAT- (2, LG-B)
VRA- (50, B-O)
SPLF (59, Y-G)
VRL2 (21, V-G)
VRAT2+ (31, P-G)

(44, R-B)
VRB2 (73, Y-R)
VRTA (56, Y-R)
SPLF+ (58, Y-R)
VRL1 (20, V-R)
VRA11 (24, R-B)

(43, B-Y)
VBMBSL (19, Y-B)

VBMBSL (19, Y-B)
FNDC1 (98, V-Y)
VRB1+ (72, L-O)

VRB1 (71, Y-B)
VRA21 (26, P-B)

VRTA+ (57, L-Y)
VRA22 (27, L-Y)
POT- (51, GR)

CBAT+ (1, G-R)
SH2-1 (91, W)
(41, G)
(41, G)
POT- (51, G)
SH1 (90, R)
LS- (51, B)
F5A
F45
F44
F43
F42
F41
F56
KEY OFF H/L OFF (OPT)
(496, B-R)
(101, L) (493, B-Y)
(490, GR-R)
VBBT
B48V
VBKY
VBMB
FAN+
VRT+
VRT1
VRT2
SSTRC
SSTR2
SSTR1
SSTR+
RYKH
(489, BR)
(488, Y-G)
(487, L-Y)
LS
MAIN CONTROLLER
(117, GR)
ACT
LB
PASCC+
(3, G-B) SOLLU+

(32, Y-L) SLTA1+
(6, G-W) SLTBL+

(9, Y-R) SLLA2+
(37, G-B) SA1PS-
(40, B-R) SA2PS-
(60, P-L) PSSW+

OACC2
(36, W-R) SA1PL-
(39, Y-B) SA2PL-

(145, GR-R) CAN1H
(8, G) SLTBL-
(7, W) SLTFL-
(42, R-Y) KYSAT
(146, P-B) CAN1L
(4, B-Y) SLLL-

(34, W-L) STPS-
(14, W-G) DGND

(11, B-W) SLPS-
(33, W-G) STPL-
(5, W-L) SLUL-

(10, B-Y) SLPL-
(329, R-G) SLS+
(330, W-L) SLS-
(67, L-O) SDM

(46, B-O) DSR
(68, B-R) SHS
(45, GR-R) DSF

(70, B-L) STK
(16, Y-B) D7V

(51, BR) LS-
F55
F54
N2
N2
N2
N2
(N2, W-B)
(N2, W-B)
(N2, W-B)
(N2, W-B)
(492, G-Y)
(491, G-B)
(334, L-O)
(114, BR)
RYH
F71
F72
F73
F74
F75
(332, R)
SA
F76
F79
F77
F78
(479, Y-R)
(480, Y-R)
STK DSF DSR SDM
(478, V)
(477, V)
(485, R)
RYIL
(481, G-W) (482, L) (483, L) (484, G-W) STK ACT
SWST SWCM SWW RYHR RYHL RYTL
F5C
F57
F58
F59
(48, L-O)
(118, L-Y)
(494, B-Y)
(495, B-Y)
(472, G-W)
(486, B-W)
(113, G-W)
RYF DSBU
RYBU SLPL SLPS STPL STPS SA1PL SA1PS SA2PL SA2PS SLS SLUL SLLL SLTFL SLTBL
(111, R-L)
(112, G-Y)
(107, Y-G)
(106, R-G)
(102, R-G)
(115, P)
(104, G-R)
(116, LG)
SLIL
FOR MINI LEVER FOR COWL LEVER FOR COWL LEVER FOR MINI LEVER
(110, L-O)
H
(103, R-W)
LCM LW SWF
DGND
D7V
(146, W) CAN1L
12V POWER (145, L) CAN1H DISPLAY
SWL SUPPLY
LEDTKY1
LEDKTY2
IPSTKY1
EZ PEDAL
OKTY1
OTKY2
OTKY3
(OPT)
TGND
ITKY1
ITKY2
ITKY3
(236, R)
(109, G-Y)
(108, R-Y)
48V
F81
N1
(231, Y-R)
LHR LHL
H T SWHR SWHA SWH
STEP- (152, G-R)

(150, G-R)
(145, GR)
(89, R-W)
(87, R-W)
(85, R-W)
KYSAT (42, R-Y)

(42, R-Y)
(79, R-B)
(42, R-Y)
(81, R-L)
(88, GR)
(86, GR)
(145, W)
(84, GR)
F82
(146, G)
(78, LG)
(75, LG)
(77, LG)
(146, V)
(145, P)
(146, L)
LSTR LSTL
(82, G)
(80, R)
(76, Y)
LBUR LBUL BZ CHI SSDL SSDR SSP
OUT+ (234, R-W)
IN- (233, W-R)

IN+ (232, L-R)
LFL LFR P41 P4
(169, GR-R)
LTL LCL
(166, GR-L)
OUT- (235, B)
(163, W-L)
(167, G-Y)
(161, R-B)
(165, R-Y)
(160, B-Y)
(164, L-O)
(168, L-B)
P7 U P71 U U P14 U
STEP2
CAN1L
CAN1H
STPM+
STPM
SSP1
SSP+
KYSAT
CAN1L
CAN1H
STDML+
STDML
SSDL1
SSDL+
SSDL2
SETDR-
SETDR1
KYSAT
CAN1L
CAN1H
STDMR+
STRMR
SSDR1
SSDR+
SSDR2
STDMR
U U
STDML
(162, G)
STPM
V P8 V ACMDL V P81 V ACMDR V P15 V ACMP
LTR LCR LFLR LFRR W P9 W W P91 W W P16 W
ACMDDL ACMDDR ACMDP
TEN KEY
DC/DC
N1
PIN CODE ENTRY (OPT)
VBKY (486, B-W)

PSACC+ (334, L-O)
CAN1H (145, R-L)

GND (N2, W-B)
CAN1L (146, L-Y)
BATT BATTERY SLTFL SOLENOID, TILT, FORWARD LOCK VRAT21 VARIABLE RESISTOR, ATT2, NO.1 BZ BUZZER RYHR RELAY, HEAD LAMP, RH
MB CONTACTOR, BATTERY SLTBL SOLENOID, TILT, BACKWARD LOCK VRAT22 VARIABLE RESISTOR, ATT2, NO.2 CHI CHIME RYTL RALAY, TAIL LAMP
F FUSE SLIL SOLENOID, CLAMP INTERLOCK H HORN RYF RELAY, FLASHER
STK SWITCH, TILT KNOB SA SURGE ABSORBER RYH RELAY, HORN
ACMDL AC MOTOR, DRIVE, LH SLPL SOLENOID, LIFT PULL ACT SWITCH, ATT CLAMP INTERLOCK RYAC RELAY, ACCESSORY DIAGNOSIS
ACMDR AC MOTOR, DRIVE, RH SLPS SOLENOID, LIFT PUSH DSF DIRECTION SWITCH, FORWARD LHL LAMP, HEAD LH RYIL RELAY, CLAMP INTERLOCK
ACMP AC MOTOR, PUMP STPL SOLENOID, TILT PULL DSR DIRECTION SWITCH, REVERSE LHR LAMP, HEAD RH RYMS RELAY, MINI LEVER SOLENOID
ACMDDL AC MOTOR DRIVER, DRIVE, LH STPS SOLENOID, TILT PUSH SWS SWITCH, SEAT LCL LAMP, CLEARANCE LH RYKH RELAY, KEY OFF H/L OFF
ACMDDR AC MOTOR DRIVER, DRIVE, RH SA1PL SOLENOID, ATT1 PULL SH SWITCH, HEIGHT LCR LAMP, CLEARANCE RH RYBU RELAY, BACK-UP
ACMDP AC MOTOR DRIVER, PUMP SA1PS SOLENOID, ATT1 PUSH SPB SWITCH, PARKING BRAKE LTL LAMP, TAIL LH
SA2PL SOLENOID, ATT2 PULL SWE SWITCH, EMERGENCY LTR LAMP, TAIL RH FR&RR CHIME MOTION ALARM DC/DC FOR LED RR COMBI
EZ PEDAL (OPT)
(472, G-W)
SSDL SENSOR, SPEED, DRIVE, LH SA2PS SOLENOID, ATT2 PUSH SWK SWITCH, KEY LFL LAMP, FLASHER LH
(332, R)
SSDR SENSOR, SPEED, DRIVE, RH SWTF SWITCH, TILT FR LFR LAMP, FLASHER RH
(495, B-Y)
(495, B-Y)
SSP SENSOR, SPEED, PUMP VRA1 VARIABLE RESISTOR, ACCEL, NO.1 SWTR SWITCH, TILT RR LFLR LAMP, FLASHER LH RR RYBU
STDML SENSOR, TEMPERATURE DRIVE, LH VRA2 VARIABLE RESISTOR, ACCEL, NO.2 SWST SWITCH, STOP LAMP LFRR LAMP, FLASHER RH RR
(334, L-O)
DSBU DSFO DSBU IN DC/DC OUT
STDMR SENSOR, TEMPERATURE DRIVE, RH VRB1 VARIABLE RESISTOR, BRAKE, NO.1 SWCM SWITCH, COMPARTMENT LIGHT LSTL LAMP,STOP LH
36V (48V) 12V
STPM SENSOR, TEMPERATURE PUMP VRB2 VARIABLE RESISTOR, BRAKE, NO.2 SWW SWITCH, WORKING LAMP LSTR LAMP,STOP RH (103, R-W) BACK-UP BACK-UP (203, R-W)
SPLF SENSOR, PRESSURE LIFT VRTA VARIABLE RESISTOR, TILT ANGLE SWL SWITCH, LIGHT LBUL LAMP, BACK-UP LH (111, R-L) STOP STOP (211, R-L)
(104, G-R) TAIL TAIL (204, G-R)
SSTR SENSOR, STEERING VRTRA VARIABLE RESISTOR, TIRE ANGLE SWF SWITCH, FLASHER LBUR LAMP, BACK-UP RH (109, G-Y) TURN L TURN L (209, G-Y)
(45, GR-R)
(103, R-W)
(120, Y-R)
(103, R-W)
(198, R-W)
(108, R-Y) TURN R TURN R (208, R-Y)
(46, B-O)
IPL1 SENSOR, IMPACT, NO.1 VRL1 VARIABLE RESISTOR, LIFT, NO.1 SWH SWITCH, HORN LW LAMP, WORKING
(51, BR)
(N2, W-B) GND GND (N2, W-B)
IPL2 SENSOR, IMPACT, NO.2 VRL2 VARIABLE RESISTOR, LIFT, NO.2 SWHA SWITCH, HORN ARMREST LCM LAMP, COMPARTMENT
VRT1 VARIABLE RESISTOR, TILT, NO.1 SWHR SWITCH, HORN RR LS LAMP, STROBE LBUR LBUL BZ
SLS SOLENOID, STEERING VRT2 VARIABLE RESISTOR, TILT, NO.2 DSFO DIRECTION SWITCH, FORWARD OPT LB LAMP, BLUE
SLUL SOLENOID, UNLOAD VRAT11 VARIABLE RESISTOR, ATT1, NO.1 DSBU DIRECTION SWITCH, BACK-UP CHI
DSR
DSF
LS
SLLL SOLENOID, LIFT LOCK VRAT12 VARIABLE RESISTOR, ATT1, NO.2 RYHL RELAY, HEAD LAMP, LH

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Maintenance Manual

Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck

Model: Serial Numbers:

Publication: 1237640A Issued: 26 May 2017

©2017 The Raymond Corporation.

1.1 LIFT TRUCK EXTERIOR VIEW 1

1.2 LIFT TRUCK MODELS

1.3 FRAME NUMBER

1.4 HOW TO USE THIS MANUAL 1

1.4.1 EXPLANATION METHOD

13.2.1 REMOVAL AND INSTALLATION

* Step Nos. are partially sometimes

2. Matters omitted from this manual

Standard: Values showing allowable range in inspection and adjustment.

1.5 OPERATING TIPS 1

1.5.1 JACK-UP POINT

(a) Jack-up point

1.5.2 HOISTING THE VEHICLE 1

1.6 STANDARD BOLT & NUT TIGHTENING TORQUE

1.6.1 BOLT STRENGTH TYPE IDENTIFICATION METHOD 1

Hexagon flange bolt No mark 4T

Hexagon head bolt Two protruding lines 5T

Hexagon flange bolt Two protruding lines 6T

Hexagon head bolt Three protruding lines 7T

Hexagon head bolt Four protruding lines 8T

IDENTIFICATION BY PART NO.

1.6.2 TIGHTENING TORQUE TABLE

ft-lbf. N•m ft-lbf. N•m

1.7 PRECOAT BOLTS 1

2. Method for reuse of precoat bolts

1.8 HIGH PRESSURE HOSE FITTING TIGHTENING

1.9 RECOMMENDED LUBRICANT QUANTITY AND

1.10 LUBRICATION CHART 1

○: Inspection and addition

1. Mast strip 8. Steering rack and pinion gear

1.11 PERIODIC MAINTENANCE TABLE

Inspection Period Every

Inspection Period Every

Inspection Period Every

Inspection Period Every

1.12 PERIODIC REPLACEMENT TABLE 1

2.1 Battery Compartment Size and Necessary Weights

2.2 SERVICE STANDARDS

Specific gravity upon end of discharge

2.2.1 Battery list

Installed Battery Battery Case

Installed Battery Battery Case

Battery Overdischarge Warning

Low Remaining Battery Charge Warning

Deposition of freed Fouled terminal or

Short circuit Electrolyte leakage and reduction Loosened or corroded connection

2.5 BATTERY ASSY

2.5.1 REMOVAL AND INSTALLATION

2. Battery electrolyte specific gravity inspection

The specific gravity of the electrolyte at 68°F (20°C)

* How to use the hydrometer

3. Insulation resistance inspection

2.5.3 REPLACING BATTERY PLUG TERMINAL

2. Insert a screwdriver (c) from the terminal side (a), push

4. Crimping method: When crimping cables, never bend the