LUNA MCFE CAT - Book

CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
Chapter 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

1. General Information
1.1 Before Replacing Devices
Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the following
items before replacing devices (logic unit, logic card, power supply card, inverters, inverter DSP cards, EPS, input unit and
output unit):
- Loose battery connectors
- Abnormal wire harness connections
- Loose connectors
- Broken, bent or loose connector pins
- Dirty connectors
If connectors are dirty, remove and clean connectors.
See "How to clean harness connectors and system components" on page 2-2.
- Ensure that the main harness is not short-circuited to the lift truck body by using the following procedures:
(1) Disconnect battery plug and discharge the inverters and EPS before
working on electrical system
(2) Disconnect connector E-01 of logic unit. Check continuity between

E-01-15(106) and truck body (logic unit installation bolts, etc.)
No continuity Continuity
(3) Normal (4) Repair or replace harness
502882
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a new one.
Be sure to check the above items and replace carefully.
1.2 Connection of The Service Tool
(1) Turn OFF the lift truck power.

(2) Remove cup holder.
(3) Find the connector E-09 to the service tool.
(4) Remove the cover and connect the PC as shown.
(5) Turn ON the lift truck power. 1
(6) Start the service tool software. 2
502883
1. Error code display 2. Cup holder
2-1
1.3 How to Clean Harness Connectors and System Components
(1) Open circuits are often caused by dirty harness

connectors and components. Dust together with
greasy matter forms grime which, in time, penetrates
electrical connections, resulting in loose metal-to-metal
contact or, in the worst case, electrical separation of
surfaces in contact. For this reason, it is essential that
the connectors and components be cleaned at each
periodic inspection and at when servicing the lift truck. 1
Instead of a commonly used solvent, use electronic
parts cleaner (in the manner illustrated on the right).
502884
1. Electronic parts cleaner
Electronic parts cleaner

Three Bond 29B
Note: The cleaner liquid is volatile (evaporates by itself).

All that is required is to throughly wash off the grime with the spray.
There is no need to wipe off the sprayed liquid.
(2) After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray
contact surface activator onto contact surfaces. Install 1
and remove the connector several times to wet the
surfaces thoroughly with the activator liquid. After
coupling up the connector, check to be sure that it is in
locked state.
1) 502885
1) Contact surface activator 1. Electronic parts cleaner
Contact surface activator

Three Bond 2501S (aerosol)
Note: Do not spray too much liquid into the connector.

Cleaner liquid reacts differently with some resins (plastic materials).
2-2
2. List of Error Codes
Error Error name Error Error name

code code
E0 Traction Motor R.H.,Overheating H2 Tilt Lever, Faulty Setting
E1 Traction Motor L.H.,Overheating H3 Attach1 Lever, Faulty Setting
E2 Pump Motor,Overheating H4 Attach 2 Lever, Faulty Setting
E5 Traction Inverter R.H., Overheating (L) Seat Switch, Faulty Setting For Hydraulic
E6 Traction Inverter L.H., Overheating EE FNR Lever Fault
E7 Pump Inverter, Overheating 60 Display Communication Fault
E9 PS Controller, Overheating 61 Logic Card Initialize Failure
14 Traction Moter Current Sensor R.H., Fault 62 Logics Faul
15 Traction Motor R.H., Over-current 63 Traction Inverter R.H., Fault
16 Traction Moter R.H., Stall Timer 64 Traction Inverter L.H., Fault
24 Traction Moter Current Sensor L.H., Fault 65 Pump Inverter Fault
25 Traction Motor L.H., Over-current 67 Input Unit Fault
26 Traction Moter L.H., Stall Timer 68 Output Unit Fault
34 Pump Motor Current Sensor Fault 71 EPS Controller Fault
35 Pump Motor Over-current 72 Contactor Coil Fault
40 Line Contactor Fault 74 Hydraulic Lock Solenoid Fault
41 Steering Contactor Fault 75 Parking Brake Fault
45 Traction Motor R.H., Open 76 PDS Buzzer Fault
46 Traction Motor L.H., Open 78 Battery Voltage Too Low
47 Pump Motor Open 79 Battery Voltage Too High
49 PS Motor Open (Lo) Battery Consumption Too Much
50 Tire Angle Sensor Fault 80 Tilt Angle Sensor Fault
51 Accelerator Sensor Fault 81 Load Sensor Fault
52 Traction Motor R.H., Pulse Input Fault 82 Handle Sensor Fault
53 Traction Motor L.H., Pulse Input Fault A4 PS Motor Current Sensor Fault
54 FC Lever Fault A5 PS Motor Over-current
55 Output Unit Solenoid Fault A7 PS Handle Brake Fault
56 Output Unit Solenoid Current Leak A8 Battery Side Way Exchange Interlock
E FNR Lever or Accelerator, Faulty Setting None Battery Consumption Much
(E) Seat Switch, Faulty Setting For Traction None Brake Oil, Low Level
H1 Lift Lever, Faulty Setting None RTC Battery Low
2-3
3. Troubleshooting
3.1 Traction Motor R.H.,Overheating (E0)
Error code: E0
Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power
Situation
steering operations. Service tool "Alarm status" and "E0" displayed.
Overheating of right side traction motor, faulty right side traction motor or thermal sensor, faulty or open
Possible
harness wiring, faulty right traction inverter DSP card, abnormal power supply of logic unit, brake or parking
cause
brake drag, abnormality in front axle, faulty display unit.
Trigger of
Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F).
the error
Recovers when motor temperature is in range of -20 to 70 °C (-4 to 158 °F).
code
Checks
(1) Let truck cool for 15 minutes

Overheat indicator ON Overheat indicator OFF
(2) Traction motor becomes normal
If problem reoccurs
(3) Disconnect battery plug
Disengage brake and parking brake, and check their
drag
No drag Drag
(4) Adjust brake
(5) Lift front wheels, and disengage parking brake

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

upgrade or to pull large cargo load
Normal
(7) Perform inverter discharging work
(8) Replace right traction (9) Replace right traction

motor motor or front axle
502803
2-4
With service tool
(10) Confirm temperature of right traction motor with

input/output monitor
Less than -20 °C(-4 °F) -20 °C to 70 °C
or more than 70 °C(158 °F) (-4 °F to 158 °F)
Without service tool
(11) Disconnect battery plug (12) Normal

Wait until right traction motor temperature becomes
close to room temperature
(14) Disconnect connector E-14 of right traction motor

speed and thermal sensor. Measure resistance
between E-14-2 and E-14-1 at motor side
2.2kΩ at 70° C(158° F) to
82kΩ at -20 °C (-4° F) Out of range
Thermal
(15) Disconnect connector E-07 of right traction inverter (16) Replace right traction motor
Replace right traction motor
Check continuity between E-07-1 and E-14-1(1)
‫ ޓޓ‬Continuity ‫ޓޓޓޓޓޓޓޓޓ‬ No continuity
Power supply
(17) Check continuity between E-01-3 and E-07-17(10)
Continuity‫ ޓޓޓޓޓޓޓޓ‬No continuity
CAN
(18) Disconnect connector E-02 of logic unit

‫ ޓޓޓޓޓޓޓޓ‬No continuity
Continuity
(19) Connect connector E-01, then turn on power again (20) Repair or replace harness
(21) Measure voltage between E-07-18(11) and

E-07-20(12)
Confirm value is 8 ± 2V
‫ޓޓ‬Normal Abnormal
(23) Ensure all connectors are connected (24) Replace power supply card of logic unit
Then turn on power again
"E0"‫ޓޓޓޓ‬ ‫ޓޓ‬Not "E0"
(25) Disconnect battery plug, then perform Inverter

discharging work
(26) Replace DSP card of (27) Connect connector

right traction inverter securely
502804
2-5
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
E-07 Traction inverter (right)
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
R/B 8V N Battery (-)
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19
E-17 Traction motor (right)

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-6
3.2 Traction Motor L.H.,Overheating (E1)
Error code: E1
Situation
steering operations. Service tool "Alarm status" and "E1" displayed
Overheating of left traction motor, faulty left traction motor or thermal sensor, faulty or open harness wiring,
Possible
faulty left traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
cause
abnormality in front axle, faulty display unit
Trigger of
Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F)
the error
Recovers when motor temperature is in range of -20 to 70 °C (-4 to 158 °F)
code
Checks

(2) on motor becomes normal

If problem reoccurs
Disengage brake and parking brake, and check their
drag
No drag Drag
(4) Adjust brake
(5) Lift front wheels, and disengage parking brake

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

upgrade or to pull large cargo load
Normal
(8) Replace left traction (9) Replace left traction

motor motor or front axle
With service tool
(10) Confirm temperature of left traction motor with

Less than -20 °C(-4 °F) -20 °C to 70 °C
(11) Disconnect battery plug. Wait until left traction motor (12) Normal
temperature becomes close to room temperature
502805
2-7
(14) Disconnect connector E-15 of left traction motor

speed and thermal sensor
Measure resistance between E-15-2 and E-15-1 at
motor side
2.2kΩ at 70°C (158°F) to
82kΩ at -20°C (-4°F) Out of range
Thermal
(15) Disconnect connector E-06 of left traction inverter (16) Replace left traction motor
Continuity No continuity
Power supply
CAN

E-06-20(12)
Confirm value is 8V±2V
Normal Abnormal
The latest data is "E1" Not "E1"

discharging work

left traction inverter securely
502806
2-8
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
E-06 Traction inverter (left)
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
R/L 8V N Battery (-)
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -
E-18 Traction motor (left)

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-9
3.3 Pump Motor,Overheating(E2)
Error code: E2
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power
Situation
Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump
Possible
motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or hydraulic
cause
lines, faulty display unit
Trigger of
Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F).
the error
Recovers when motor temperature is in range of -20 to 70 °C (-4 to 158 °F)
code
Checks

(2) Pump motor becomes normal
If problem reoccurs
(3) Check if truck is operated to lift large cargo load
Normal
(5) Check oil pressure of gear pump and hydraulic lines

Normal Abnormal
(6) Replace pump motor (7) Repair or replace

gear pump or piping
With service tool
(8) Confirm temperature of pump motor with

Less than -20 °C(-4 °F) -20 °C to 70 °C

Wait until pump motor temperature becomes close to
room temperature
(12) Disconnect connector E-16 of pump motor

speed and thermal sensor. Measure resistance
between E-16-2 and E-16-1
2.2kΩ at 70°C (158°F) to
82kΩ at -20°C (-4°F) Out of range
(13) Replace pump motor
502807
2-10
Thermal
(14) Disconnect connector E-05 of pump motor inverter

Power supply
CAN
Check continuity between E-05-14 and E-05-15
(17) Repair or replace harness

E-05-20(12)
Confirm value is 8 ± 2 V
Normal Abnormal
(20) Ensure all connectors are connected. (21) Replace power supply card of logic unit
"E2" Not "E2"

Discharging work

pump motor inverter securely
502808
2-11
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics
E-02 E-05 Pump inverter
CAN 5 W 3 3 Inside Inside

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-12
3.4 Traction Inverter R.H., Overheating (E5)
Error code: E5
Situation
Overheating of right traction inverter, faulty right traction inverter thermal sensor, open harness wiring, faulty
Possible
right traction inverter PC board, abnormal power supply of logic unit, faulty radiation of right traction inverter,
cause
faulty display unit.
Trigger of
Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F). Capacitor temperature is out of
the error
range of -25 °C to 110 °C (-13 °F to 230 °F). Recovers when temperature is in range of -20 to 70 °C (-4 to 158 °F).
code
Checks

(2) Right traction inverter becomes normal

If problem reoccurs
(3) Check if truck is operated on steep upgrade or to pull
large cargo load
Normal
Check thermal paste applied on inverter mounting
Surface
Thermal paste film should be thin and even
Normal Abnormal
(5) Replace right traction (6) Clean mounting

inverter surface,
apply thermal paste,
With service tool then reinstall inverter
(7) Confirm temperature of controller and head capacitor

Without service tool with input monitor
Less than -20 °C(-4 °F) -20 °C to 70 °C
(8) Disconnect battery plug. Wait until inverter (9) Normal

502809
2-13
Thermal
(11) Remove right traction inverter DSP card cover, then
check flat cable looseness or wire breakage
Normal Abnormal
Power supply
(12) Disconnect connector E-07 of right traction inverter (13) Secure harness if loose
Check continuity between E-01-3 and E-07-17(10) Replace inverter if wire breaks
CAN

E-07-20(12)
Normal Abnormal
Then turn on power again‫ޓ‬
"E5" Not "E5"

discharging work

right traction inverter securely
If fault remains
(24) Disconnect battery plug, then perform inverter
discharging work
(25) Replace right traction inverter

(DSP card is normal)
502810
2-14
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-15
3.5 Traction Inverter L.H., Overheating (E6)
Error code: E6
Situation
Overheating of left side traction inverter, faulty left side traction inverter thermal sensor, open harness wiring,
Possible
faulty left traction inverter PC board, abnormal power supply of logic unit, faulty radiation of left side traction
cause
inverter, faulty display unit.
Trigger of
the error
code
Checks

(2) Left traction inverter becomes normal

If problem reoccurs
large cargo load
Normal
surface
Normal Abnormal
(5) Replace left traction (6) Clean mounting

inverter surface, apply thermal
paste, then reinstall
With service tool inverter
(7) Confirm temperature of controller and head

capacitor with input monitor
Less than -20 °C(-4 °F) -20 °C to 70 °C
Without service tool or more than 70 °C(158 °F) (-4 °F to 158 °F)
(8) Disconnect battery plug. Wait until inverter (9) Normal

502811
2-16
Thermal
(11) Remove left traction inverter DSP card cover, then

check flat cable looseness or wire breakage
Normal Abnormal
Power supply
(12) Disconnect connector E-06 of left traction inverter (13) Secure harness if loose
CAN

E-06-20(12)
Normal Abnormal
"E6" Not "E6"

discharging work

left traction inverter securely
If fault remains
discharging work
(25) Replace left traction inverter (DSP card is normal)
502812
2-17
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-18
3.6 Pump Inverter, Overheating (E7)
Error code: E7
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power
Situation
Possible Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter
cause PC board, abnormal power supply of logic unit, faulty radiation of pump inverter, faulty display unit.
Trigger of
the error
code
Checks

(2) Pump inverter becomes normal

If problem reoccurs
(3) Check if truck is operated to lift large cargo load
Normal
Surface
Thermal paste film should be thin and even.
Normal Abnormal
(5) Replace pump (6) Clean mounting

inverter surface,
then
With service tool reinstall inverter
(7) Confirm temperature of controller and head

capacitor with input monitor
Less than -20 °C(- 4 °F) -20 °C to 70 °C

Wait until invertertemperature becomes close to room
temperature
502813
2-19
Thermal
(11) Remove pump inverter DSP card cover, then check
flat cable looseness or wire breakage
Normal Abnormal
Power supply
(12) Disconnect connector E-05 of pump inverter (13) Secure harness if loose
CAN

E-05-20(12)
Normal Abnormal
"E7" Not "E7"

discharging work

pump inverter securely
If fault remains
discharging work
(25) Replace pump inverter (DSP card is normal)
502814
2-20
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-21
3.7 PS Controller,Overheating (E9)
Error code: E9
Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor. Service
Situation
tool "Alarm status" and "E9" displayed.
Possible Overheating of PS controller, faulty PS controller thermal sensor, open harness wiring, faulty PC board,
cause abnormal power supply of logic unit, faulty radiation of left traction inverter, faulty display unit.
Trigger of
the error
code
Checks
(1) Let truck cool for 15 minutes and turn the key off and on
(2) Left traction inverter becomes normal

If problem reoccurs
large cargo load
Normal
Surface
Normal Abnormal
(5) Replace EPS controller (6) Clean mounting

surface,
then reinstall EPS
controller
With service tool
(7) Confirm temperature of controller and head capacitor

with input monitor
Less than -20 °C(- 4 °F) -20 °C to 70 °C
or more than 70 °C(158 °F) (- 4 °F to 158 °F)

Wait until EPS controller temperature becomes close to
room temperature
502815
2-22
Thermal
(11) Check harness looseness or wire breakage

Normal Abnormal
Power supply
(12) Disconnect connector E-08 of left EPS controller (13) Secure harness if loose
Check continuity between E-01-3(10) and E-08-18(10) Replace inverter if wire breaks
Check continuity between E-01-6(12) and E-08-25(12)
CAN

E-08-25(12)
Normal Abnormal
"E9" Not "E9"

discharging work
(22) Replace EPS Controller (23) Connect connector

securely
502816
2-23
E-08
E-02
- 8 7 6 - - - - 1
- 23 5 3 1
21 19 17 15 - - 9 7 17 - 15 14 - - - 10
- 24 - 20 18 - - - - 8 6 4 2
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
Logics
E-02
E-08 EPS controller
CAN 5 W 3
Inside
6 L 4 21 Inside
of of
30 cover case
R/L 12V
5 9 10 P Fuse
R/Y 14V
Power 3 R/B 10
8V
18
N Battery (-)
4 11 1 DSP IMS
B GND 25 card card
6 12 U IUR
11 GND 32 Controller
thermistor
Power card Flat
cable W IWR
E-01
Capacitor
E-01 thermistor
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 - PS motor
W TWR 2
M U TUR 1
E-27
1 2
E-27
501138
2-24
3.8 Traction Motor Current Sensor R.H., Fault (14)
Error code: 14
Display: "14". All lift truck operations inhibited. Line contactor HOLD and ST contactor HOLD.
Situation Traction motor and pump motor operation inhibited. If this fault occurs before ST contactor CLOSE, all
operations inhibited except mast lowering operation.
Faulty traction inverter. (U, V current sensor in traction inverter)
Possible
Faulty DSP card of traction inverter.
cause
Faulty contact or wire breakage of DSP flat cable in traction inverter.
Trigger of
the error When turning ON power, current sensor value is out of -120 A to 120 A .
code
Checks
(1) Disconnect battery plug, then perform inverter discharging work
(2) Follow the inverter testing procedure

Normal Abnormal
(3) Remove DSP cover of traction inverter (4) Replace traction inverter
Check DSP Flat cable for looseness or wire breakage
Normal Abnormal
(5) Replace DSP card of traction inverter (6) Secure DSP flat cable if loose
All power cables connect and turning on power Replace traction inverter if wire breaks
If fault (14) remains
(8) Replace the DSP card with the original card again, then
replace the traction inverter
Please keep the DSP card which is used for inspection
at step (5) because the card is normal
502817
2-25
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-26
3.9 Traction Motor R.H., Over-current (15)
Error code: 15
Faulty traction motor. (Contain the bearing sensor)
Faulty contact or wire breakage of traction motor speed sensor harness.
Possible Faulty traction inverter.
cause Faulty contact or wire breakage of DSP flat cable in traction inverter.
Faulty traction inverter DSP card.
Faulty main harness.
Trigger of
the error Motor current is more than 1105 A (Moment) or 893 A (1 mS) or 829 A (1.6 mS).
code
Checks
(2) Check traction motor body and terminal for burning and small
Normal Abnormal
(4) Replace traction motor

(3) Check motor terminal (U V W phases) for shorting to
the motor body and truck frame
Not shorting shorting
(5) Remove the all cables of motor and traction inverter

terminals (P N U V W )
Check motor terminals for shorting to the motor body
Check the cables for shorting to the frame
(6) Replace traction (7) Replace traction

inverter motor or cables
(8) Confirm cable looseness and improper connections

(U V W phases) for traction inverter and motor
Normal Abnormal
(9) Disconnect battery plug, then perform inverter discharge (10) Secure cable if loose or connect cable correctly
work
Confirm connection of traction motor speed sensor
connector
Normal Abnormal
(11) Connect connector securely
502818
2-27
(12) Disconnect connectors E-07 and CN1

Check continuity between E-07-5 and E-17-1 (6)
(13) Connect all connectors, battery plug and turning on (14) Repair or replace harness
power
Raise wheels off floor
(13) Connect all connectors, battery plug and turning on

power
(15) Driving and check the jerky and change directions at

very low speed
Normal Abnormal
With service tool
(16) Driving and reading ̈Motor speed feedback ̉of
output monitor
Check the value of speed is smooth and not erratic
feedback
Smooth Rough or erratic
(17) Follow the traction inverter testing procedure (18) Replace traction motor
Normal Abnormal
(19) Remove DSP cover of traction inverter and check DSP (20) Replace traction inverter
flat cable for looseness or wire breakage
Normal Abnormal
(24) Replace the DSP card with the original card again,
then replace the traction inverter
(26) Replace the traction inverter ASSY with the original

inverter ASSY again , then replace the traction motor
Please keep the inverter ASSY which is used for
inspection at step (24) because the ASSY is normal
502819
2-28
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-29
3.10 Traction Motor R.H., Stall Timer (16)
Error code: 16
Display: “16”. Traction motor and pump motor operation inhibited. LINE contactor HOLD and ST contactor
Situation
HOLD
Possible Stall current flowed more than 7s right traction motor, faulty right traction inverter current sensor, shorted
cause harness wiring, faulty right traction inverter DSP card, faulty logic unit.
Trigger of
the error 7s is measured while stalling.
code
Checks
(1) Turn off power, then turn on power again

Confirm error code display
No error, problem reoccurs ‫ޓޓޓޓޓޓޓޓ‬ Error code “14”
(2) Check to see if truck is operated with heavy cargo (3) See troubleshooting for code "14"
load or on steps when motor stalls
Normal steeps Heavy load
(4) Disconnect battery plug, then perform inverter (5) Operate under normal condition
discharging work
(6) Disconnect connector E-07 of right traction inverter

and remove DSP cover, then check DSP flat cable for
looseness or wire breakage
Normal Abnormal
Power supply
(7) Disconnect connector E-01 of logic unit (8) Secure harness if loose. Replace right traction
Check continuity between E-01-5 and E-07-16(9) inverter if wire breaks
CAN
Continuity Abnormal and no continuity
(10) Connect connector E-01 to logic unit, then turn on (11) Repair or replace harness
power again

E-07-20(12) Confirm value is 12 ± 1 V
Normal Abnormal
(14) Replace DSP card of right traction inverter (15) Replace power supply card of logic unit
502820
2-30
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-31
3.11 Traction Motor Current Sensor L.H., Fault (24)
Error code: 24
Faulty traction inverter (U, V current sensor in traction inverter).
Possible
cause
Faulty contact or wire breakage of DSP flat cable in traction inverter.
Trigger of
code
Checks

Normal Abnormal
(3) Remove DSP cover of traction inverter (4) Replace traction inverter
Normal Abnormal
replace the traction inverter
502821
2-32
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-33
3.12 Traction Motor L.H., Over-current (25)
Error code: 25
Faulty traction moter. (Contains the bearing sensor)
Faulty contact or wire breakage of traction motor speed sensor harness.
Possible Faulty traction inverter.
cause Faulty contact or wire breakage of DSP flat cable in traction inverter.
Trigger of
code
Checks
(2) Check traction motor body and terminal for burning and small
Normal Abnormal
(3) Check motor terminal (U V W phases) for shorting to (4) Replace traction motor
(5) Remove the all cables of motor and traction inverter

terminals (P N U V W )
Check motor terminals for shorting to the motor body
(6) Replace traction (7) Replace traction

inverter motor or cables
(8) Confirm cable looseness and improper connections

(U V W phases) for traction inverter and motor
Normal Abnormal
(9) Disconnect battery plug, then perform inverter discharge (10) Secure cable if loose or connect cable correctly
work
Confirm connection of traction motor speed sensor
connector
Normal Abnormal
(11) Connect connector securely
(12) Disconnect connectors E-06 and E-18

502822
2-34
(13) Connect all connectors, battery plug and turning on

power
(15) Driving and check the jerky and change directions at

very low speed
Normal Abnormal
With service tool
(16) Driving and reading ̈Motor speed feedback̉ of
output monitor
Check the value of speed is smooth and not erratic
feedback
Smooth Rough or erratic
(17) Follow the traction inverter testing procedure (18) Replace traction motor
Normal Abnormal
(19) Remove DSP cover of traction inverter and check DSP (20) Replace traction inverter
Normal Abnormal
‫ޓޓ‬All power cables connect and turning on power Replace traction inverter if wire breaks
(24) Replace the DSP card with the original card again,
then replace the traction inverter
(26) Replace the traction inverter ASSY with the original

inverter ASSY again, then replace the traction motor
502823
2-35
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-36
3.13 Traction Motor L.H., Stall Timer (26)
Error code: 26
Display: “26”. Traction motor and pump motor operation inhibited. Line contactor HOLD and ST contactor
Situation
HOLD
Possible Stall current flowed more than 7s right traction motor, faulty right traction inverter current sensor, shorted
cause harness wiring, faulty right traction inverter DSP card, faulty logic unit.
Trigger of
the error 7s is measured while stalling.
code
Checks
(1) Turn off power, then turn on power again

Confirm error code display
No error, problem reoccurs Error code "24"
(2) Check to see if truck is operated with heavy cargo (3) See troubleshooting for code "24"
load or on steps when motor stalls
Normal steeps Heavy load
(4) Disconnect battery plug, then perform inverter (5) Operate under normal condition
discharging work
(6) Disconnect connector E-06 of left traction inverter

and remove DSP cover, then check DSP flat cable for
looseness or wire breakage
Normal Abnormal
Power supply
(7) Disconnect connector E-01 of logic unit (8) Secure harness if loose
Check continuity between E-01-5 and E-06-16(9) Replace lefttraction inverter if wire breaks
CAN
Continuity Abnormal and no continuity
power again

E-06-20(12)
Normal Abnormal
(14) Replace DSP card of left traction inverter (15) Replace power supply card of logic unit
502824
2-37
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-38
3.14 Pump Motor Current Sensor Fault (34)
Error code: 34
Faulty pump inverter. (U, V current sensor in pump inverter)
Possible
Faulty pump inverter DSP card.
cause
Faulty contact or wire breakage of DSP flat cable in pump inverter.
Trigger of
code
Checks

Normal Abnormal
(3) Remove DSP cover of pump inverter (4) Replace pump inverter
Normal ‫ޓޓ‬ Abnormal
(5) Replace DSP card of pump inverter (6) Secure DSP flat cable if loose
All power cables connect and turning on power Replace pump inverter if wire breaks
replace the pump inverter
502825
2-39
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-40
3.15 Pump Motor Over-current (35)
Error code: 35
Faulty pump motor. (Contains the bearing sensor)
Faulty pump inverter.
Possible
Faulty contact or wire breakage of DSP flat cable in pump inverter.
cause
Faulty pump inverter DSP card.
Trigger of
code
Checks
(2) Check pump motor body and terminal for burning and small
Normal Abnormal
(3) Check motor terminal (U V W phases) for shorting to (4) Replace pump motor
.
‫ ޓޓ‬Not shorting shorting
(5) Confirm cable looseness and improper connections (6) Remove the all cables of motor and pump inverter
(U V W phases) for pump inverter and motor terminals (P N U V W )
Normal Abnormal Check motor terminals for shorting to the motor body
(7) Secure cable if loose or (8) Replace pump inverter (9) Replace pump motor or
connect cable correctly cables
(10) Follow the pump inverter testing procedure

Normal Abnormal
(11) Remove DSP cover of pump inverter and check DSP (12) Replace pump inverter
Normal Abnormal
(13) Replace DSP card of pump inverter (14) Secure DSP flat cable if loose
All power cables connect and turning on power Replace pump inverter if wire breaks
(16) Replace the DSP card with the original card again ,
then replace the pump inverter
(18) Replace the pump inverter ASSY with the original

inverter ASSY again, then replace the pump motor
502826
2-41
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-42
3.16 Line Contactor Fault (40)
Error code: 40
Break of line fuse.
Faulty line contactor.
Possible Faulty right, left traction inverter or pump inverter.
cause Faulty DSP card in right, left traction inverter.
Faulty logic unit.
Trigger of
the error Inverter voltage data is checked when contactor is closed (400 ms).
code
Checks
(1) Turn off power, turn on power again. Confirm error code display.
Error code " 40 " ( Not Error " 41" ) Error code "41"
(2) Disconnect battery plug, then perform inverter discharging (3) See trouble shooting code "41"
work
Check continuity of the line fuse for inverters
Check continuity of the control line fuse for contactor coil
(4) Block wheels, and remove the traction fuse , pump fuse (5) Replace the failed fuse
and steering fuse
Then confirm line contactor operation in self - diagnosis
step [14 ]
Not operated Operated
(6) Disconnect battery plug , then perform inverter discharging (7) Go to step (14)
work
(8) Check to see if line contactor tip moves smoothly

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

[44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)]
Within range Out of range
(10) Disconnect connectors E-04 (11) Replace line contactor

Check continuity betweenE-04-63 and line
contactor coil plus (+)
Check continuity betweenE-04-59 and line
contactor coil plus (-)
(12) Perform inverter discharging work, then replace logic (13) Repair or replacemain Harness
card of logic unit
502827
2-43
(15) Remove DSP cover of all inverters and check DSP flat cable for looseness or wire breakage
Normal‫ޓ‬ Abnormal
(16) Secure DSP flat cable if loose

Replace inverter if wire breaks
(17) Install the line fuse, connect battery plug and tern on
(18) Measure voltage between P and N of traction(right and left) and pump inverters (1 minute max )
Traction inverter Traction inverter Pump inverter

Normal abnormal ( RH) abnormal (LH) abnormal
(19) Replace power cable
(20) Check DC voltage of pump and traction inverters with monitor

These values should be same as battery voltage
Traction inverter value abnormal(RH) Traction inverter value abnormal(LH) Pump inverter value abnormal
(22) Replace DSP card of traction (23) Replace DSP card of traction (24) Replace DSP card of pump
inverter (RH) inverter (LH) inverter
Install all fuses and turning on Install all fuses and turning on Install all fuses and turning on
power power power
If fault (40) remains If fault (40) remains If fault (40) remains
(26) Replace the DSP card with the (27) Replace the DSP card with the (28) Replace the DSP card with the
original card again original card again original card again
Then replace the traction inverter Then replace the traction inverter Then replace the pump inverter
(RH) (LH) Please keep the DSP card which
Please keep the DSP card which Please keep the DSP card which is used for inspection
is used for inspection is used for inspection Because the card is normal
Because the card is normal Because the card is normal
502828
2-44
E-07
19 17 - - - - 7 5 3 1
20 18 16 - - - - 6 4 2
E-06
19 17 - - 11 - 7 5 3 1
20 18 16 - - - 8 6 4 2
E-02 E-05
- 23 5 3 1 - 17 15 - 11 9 - - 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2 20 18 16 14 - - - - 4 2
Logics
E-07
E-02
W 3 3
5 Traction inverter
CAN L (right)
6 4 4 P
E-06
3 3 Traction inverter
4 4 (left) P
E-05
3 3
Logics Pump inverter
EMG P
KEY 4 4
E-04 Control
line fuse
+
63
Line
contactor
59 -
Line fuse
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501142
2-45
3.17 Steering Contactor Fault (41)
Error code: 41
Situation Display: "41". All lift truck operations inhibited. Line contactor OPEN and steering contactor OPEN.
Possible
Faulty steering contactor, faulty main harness, faulty logic unit.
cause
Trigger of
the error Inverter voltage data is checked when contactor is closed (400 mS).
code
Checks
(1) Turn off power, then turn on power again. Confirm error code display

Check continuity of the steering .fuse
Check continuity of the control line fuse for contactor coil
(3) Block wheels and remove the traction fuse, pump fuse, (4) Replace steering fuse
steering fuse
Then confirm pump contactor
operation in self-diagnostics step [15]
Not operated Operated
(6) Check to see if steering contactor tip moves smoothly (7) Go to step (13)
Check steering contactor tip for melting
‫ޓޓޓ‬
Normal Abnormal
(8) Measure resistance of contactor coil

[61Ω at -30 °C(-22 °F) to 91Ω at 80 °C(176 °F)]
Within range Out of range
(9) Disconnect connectors E-04 (10) Replace steering contactor

Check continuity between E-04-63 and Steering
contactor coil plus(+)
Check continuity between E-04-64 and steering
contactor coil minus(-)
(11) Perform inverter discharging work, then replace (12) Repair or replace main harness
logic card of logic unit
(13) Install the steering fuse, connect battery plug and tern on
(14) Measure voltage between P and N of EPS controller (1 minute may)

Normal Abnormal
(15) Disconnect battery plug, then perform inverter (16) Replace power cable
discharging work
(17) Replace EPS controller

502829
2-46
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics
E-02 E-05
W
5 3 3
CAN Pump inverter
L P
6 4 4
Logics EMG
KEY
E-04
FUSE
LINE CON
+
63
Steering
contactor
64 -
Steering
fuse
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501143
2-47
3.18 Traction Motor R.H., Open (45)
Error code: 45
Display: "45". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this
Situation fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line
contactor OPEN and pump contactor CLOSE or OPEN.
Faulty contact or wire breakage of right side traction motor cable, faulty right side traction motor, faulty
Possible contact or wire breakage of right side traction inverter connector, faulty contact of DSP flat cable in right side
cause traction inverter, wire breakage of main harness, faulty logic unit power supply, faulty right side traction
inverter DSP card, and faulty right side traction inverter when restarting after motor shorted.
Trigger of
Motor voltage is abnormal when power is turned ON. Current does not flow when torque instruction is
the error
requested.
code
Checks
(2) Check right traction inverter and motor for cable

looseness and improper contact
Normal ‫ޓޓޓ‬ Abnormal
(3) Disconnect right traction motor cables from inverter (4) Secure cable if loose
Measure resistance of motor cables (U, V and W
phases)
Less than 1 Ω 1 Ω or more
(5) Check connector E-07 of right traction inverter for (6) Measure resistance between terminals of both cable
looseness ends (between U and U, V and V, and W and W)
Normal ‫ޓޓޓ‬ Abnormal Less than 1 Ω 1 Ω or more
(7) Disconnect connector E-07 of right (8) Connect connector securely

traction inverter and remove DSP
cover. Check DSP flat cable for
looseness or wire breakage (9) Replace right traction motor (10) Replace motor cables
Normal Abnormal
Gate power
supply
(11) Disconnect connector E-01 of logic unit (12) Secure DSP flat cable if loose
CAN
(14) Connect connector E-01 to logic unit , then turn on (15) Repair or replace harness
power again
(16) Measure voltage between E-07-16(9) and E-07-20(12)

If fault remains
(20) Perform inverter discharging work, then replace right
traction inverter (DSP card is normal)
502830
2-48
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-49
3.19 Traction Motor L.H., Open (46)
Error code: 46
Faulty contact or wire breakage of left side traction motor cable, faulty left side traction motor, faulty contact or
Possible wire breakage of left side traction inverter connector, faulty contact of DSP flat cable in left side traction
cause inverter, wire breakage of main harness, faulty logic unit power supply card, faulty DSP card of left side traction
inverter, and faulty left side traction inverter when restarting after motor shorted
Trigger of
the error
requested.
code
Checks
(2) Check left traction inverter and motor for cable

(3) Disconnect left traction motor cables from inverter (4) Secure cable if loose
Measure resistance of motor cables
(U, V and W phases)
(5) Check connector E-06 of left traction inverter for (6) Measure resistance between terminals of both cable
looseness ends (between U and U, V and V, and W and W)
Normal ‫ޓޓ‬ Abnormal Less than 1 Ω 1 Ω or more
(7) Disconnect connector E-06 of left traction (8) Connect connector securely
inverter and remove DSP cover
Check DSP flat cable for looseness or wire
breakage (9) Replace left traction motor (10) Replace motor cables
Normal Abnormal
Gate power supply
CAN
power again

If fault remains
(20) Perform inverter discharging work, then replace left
traction inverter (DSP card is normal) 502831
2-50
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-51
3.20 Pump Motor Open (47)
Error code: 47
Situation Display: "47". All lift truck operations inhibited. Line contactor OPEN and pump contactor OPEN.
Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of
Possible pump inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness,
cause faulty logic unit power supply card, faulty pump inverter DSP card, faulty pump inverter, when restarting after
motor shorted.
Trigger of
Motor voltage is abnormal when power is turned ON. Current does not flow when rotational speed instruction
the error
is requested.
code
Checks
(2) Check pump inverter and motor for cable looseness

and improper contact
(3) Disconnect pump motor cables from inverter (4) Secure cable if loose
Measure resistance of motor cables
(U, V and W phases)
(5) Check connector E-05 of pump inverter forlooseness (6) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W)
(7) Disconnect connector E-05 of
Pump inverter and remove DSP (8) Replace motor cables
Cover
Check DSP flat cable for Looseness
or wire breakage
Normal
‫ޓޓޓ‬ Abnormal (9) Replace pump motor (10) Replace motor cables
Gate power supply
CAN
power again

Normal ‫ޓ‬ Abnormal
(18) Replace DSP card of pump inverter (19) Replace power supply card of logic unit
If fault remains
(20) Perform inverter discharging work, then replace
pump inverter (DSP card is normal)
502832
2-52
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-53
3.21 PS Motor Open (49)
Error code: 49
Situation Display: "49". All operations inhibited except mast lowering operation. Line steering contactor OPEN.
Faulty contact or wire breakage of ST motor cable, faulty ST motor, faulty contact or wire breakage of left PS
Possible
controller connector, wire breakage of main harness, faulty logic unit power supply card, when restarting after
cause
motor shorted
Trigger of
the error
requested.
code
Checks
(2) Check EPS controller and motor for cable

Normal Abnormal
(3) Disconnect steering motor cables from EPS controller (4) Secure cable if loose
Measure resistance of motor cables (U and W phases)
(5) Check connector E-08 of EPS controller for looseness (6) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U , and W and W)
Less than 1 Ω ‫ޓޓ‬ 1 Ω or more
(7) Disconnect connector E-08 of EPS (8) Connect connector securely

controller and remove DSP cover
Check DSP flat cable for looseness or
wire breakage (9) Replace left traction motor (10) Replace motor cables
Normal Abnormal
Gate power
supply
Check continuity between E-01-5 and E-08-10(9) Replace EPS controller if wire breaks
CAN
power again

Normal Abnormal
(17) Disconnect battery plug, then perform EPS controller discharging work
(18) Replace EPS controller (19) Replace power supply card of logic unit
502833
2-54
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-04
E-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- 8 7 6 - - - - 1
E-01 17 - 15 14 - - - 10
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
Life L/R
Signal 53 28
E-08 EPS Controller

W 8
CAN 5 3
6 L 4 21
E-02
30
12V
5 L/R 9 10 VG P Fuse
R/Y 14V
Power 3 R/B 18 VL
10
8V DSP N Battery (-)
4 11 1 8V IMS
E-01 B GND
6 12 25 GND U
GND
11 32 GND
R/W V
Fuse 34 LOW
R/Y VE
1 27 W
3 W 24 7 STEERING ANGL 1
G/L 25
4 15 STEERING ANGL 2
2 B 26 24 GND
Y/R
Bk 5 30 17 BRAKE +
Br/Y
6 31 33 BRAKE -
Steering Unit 26 +5V
F-01 14 TIRE ANGL 1
12V
6 TIRE ANGL 2
1 6 23 GND
2 5
3 4
F-01
H-01(3W)
E-38(4W)
27 R/Y 4 Tire angle
Y/B sensor TWR 2
21
B
5
6
M TVR 1
23
R/Y 3 E-27
27
Br
22 2
23
B 1 1 2
3 2 1 E-27
1 2 3
6 5 4
4 5 6
H-01(3W)
E-38(4W) 501145
2-55
3.22 Tire Angle Sensor Fault (50)
Error code: 50
Display: "50". All operations inhibited except mast lowering operation. Line and steering contactor OPEN. Or
Situation
travelling speed limited to 5 km/h.
Possible
Faulty steering sensor, faulty main harness, faulty PS controller.
cause
Trigger of Voltage 4.8 or more, or 0.2 or less
the error 12°of phase difference between A and B
code 36°of fluctuation for 10 ms
Checks
(2) Disconnect connecter E-08 and H-01(3W), E-38(4W)

Check continuity between E-08-26 and H-01(3W)
E-38(4W)-3, E-08-26 and E-01(3W) E-38(4W)-4
(Sensor voltage)
(3) Check continuity between E-08-14 and

H-01(3W) E-38(4W)-2
Check continuity between E-08-6 and
H-01(3W) E-38(4W)-5 (Signal)
(4) Check continuity between E-08-23 and H-01(3W)

E-38(4W)-1, E-08-23 and H-01(3W) E-38(4W)-6(GND)
(6) Replace harness

(5) Connect logic connector and connect battery plug.
Turn on power
Check voltage between H-01(3W) E-38(4W)-3(Power)
and (GND) and check voltage between H-01(3W)
E-38(4W)-4(Power) and 6(GND)
5 V ± 10 % ‫ޓ‬Outside the specified range
(7) Turn off power, turn off battery, and discharge (8) Replace logic power board
Check steering wheel angle sensor linkage
Normal Abnormal
(9) Replace steering wheel angle sensor (10) Repair linkage
If fault remains
(11) Reinstall steering wheel angle sensor just has been
replaced
Replace EPS controller
502834
2-56
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-04
E-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- 8 7 6 - - - - 1
E-01 17 - 15 14 - - - 10
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
Life L/R
Signal 53 28
E-08 EPS Controller

W 8
CAN 5 3
6 L 4 21
E-02
30
12V
R/Y 14V
Power 3 R/B 18 VL
10
4 11 1 8V IMS
E-01 B GND
6 12 25 GND U
GND
11 32 GND
R/W V
Fuse 34 LOW
R/Y VE
1 27 W
G/L 25
2 B 26 24 GND
Y/R
Bk 5 30 17 BRAKE +
Br/Y
6 31 33 BRAKE -
F-01 14 TIRE ANGL 1
12V
6 TIRE ANGL 2
1 6 23 GND
2 5
3 4
F-01
H-01(3W)
E-38(4W)
27 R/Y 4 Tire angle
Y/B sensor TWR 2
21
B
5
6
M TVR 1
23
R/Y 3 E-27
27
Br
22 2
23
B 1 1 2
3 2 1 E-27
1 2 3
6 5 4
4 5 6
H-01(3W)
E-38(4W) 501145
2-57
3.23 Accelerator Sensor Fault (51)
Error code: 51
Possible
Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.
cause
Trigger of
Sensor 1 or 2 output is 0.2 V or lower, or 4.8 V or higher.
the error
Difference in output between sensors 1 and 2 is 0.5 V or more.
code
Checks
(1) Raise front wheels until they clear floor
(3) Check link length of accelerator pedal

Normal Abnormal
(4) Perform inverter discharging work (5) Adjust accelerator pedal linkage
(6) Disconnect connectors E-19 and E-02 of logic unit

(Sensor voltage)

Check continuity between E-02-23(54) and E-19-5(54)
Without With service tool
service tool (9) Repair or replace harness
(10) Replace accelerator pedal
If fault remains
(12) Reinstall accelerator pedal, then replace logic card of

logic unit
(13) Connect connector E-19 and E-02 Turn on power and check voltage between E-19-3(55) and E-19-5(54)
5V Not 5 V
(14) Turn off power. Short-circuit E-19-3(55) and

E-19- 6(52), E-19-2(53)
Turn on power and check accelerator voltage with service tool
5V Not 5 V
(15) Turn off power

Open E-19-3(55) and E-19-6(52), E-19-2(53)
Short -circuit E-19-5(54) and E-19-6(52), E-19-2(53)
Turn on power and check accelerator voltage with service tool
0V Not 0 V
(16) Replace accelerator pedal (17) Disconnect battery plug
(18) Replace logic card of logic unit
502835
2-58
E-19
- 2 3
4 5 6
Accelerator
E-19
21 L 53 2
R/Y 5V
24 55 3
W 6
ACCEL ANGLE 20 52
B GND
23 54 5
Logics
E-02
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501144
2-59
3.24 Traction Motor R.H., Pulse Input Fault (52)
Error code: 52
Faulty contact of right side traction inverter connector, faulty connection of right side traction motor connector
Possible and cable, faulty 12V input voltage of right side traction inverter, faulty contact or wire breakage of right side
cause traction motor speed sensor harness, faulty right side traction inverter DSP card, faulty right side traction motor
speed sensor.
Trigger of
the error Motor rotation speed is more than 6000 rpm.
code
Checks
(2) Check to see if right traction motor cables (U,V and W

phases) are connected to right traction inverter properly
Normal Abnormal
(3) Check to see if connector E-07 of right traction (4) Connect cables properly
inverter is fastened securely
Normal Abnormal
(5) Check to see if connector E-17 of right traction (6) Fasten connector securely
motor speed sensor is fastened securely
Normal Abnormal
Sensor
(7) Disconnect connectors E-07 and E-17 (8) Fasten connector securely
Power supply
CAN
power again

Normal ‫ ޓޓޓ‬Abnormal
If fault remains
(17) Perform inverter discharging work, then replace Right
traction motor (DSP card is normal)
502836
2-60
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-61
3.25 Traction Motor L.H., Pulse Input Fault (53)
Error code: 53
Faulty contact of left side traction inverter connector, faulty connection of left side traction motor connector
Possible and cable, faulty 12V input voltage of left side traction inverter, faulty contact or wire breakage of left side
cause traction motor speed sensor harness, faulty left side traction inverter DSP card, faulty left side traction motor
speed sensor.
Trigger of
the error Motor rotation speed is more than 6000 rpm.
code
Checks
(2) Check to see if left traction motor cables (U, V and W

phases) are connected to left traction inverter properly
(3) Check to see if connector E-06 of left traction inverter is (4) Connect cables properly
fastened securely
(5) Check to see if connector E-18 of left traction motor (6) Fasten connector securely
speed sensor is fastened securely
Sensor
(7) Disconnect connectors E-06 and E-18 (8) Fasten connector securely
Power supply
CAN
power again

Normal Abnormal
If fault remains
(17) Perform inverter discharging work, then replace left
traction motor (DSP card is normal)
502837
2-62
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-63
3.26 FC Lever Fault (54)
Error code: 54
Situation Display: "54". Related lever operation inhibited. Normal traction motor and power steering operations.
Possible Faulty lift FC control lever, faulty tilt FC control lever, faulty attachment 1 and 2 FC control levers, faulty main
cause harness, faulty input unit.
Trigger of
the error FC control lever voltage is out of range of 0.1 V to 4.9 V.
code
Checks
(1) Operate all FC control levers to find faulty FC control lever

Attachment 2: 4-valve specification only
Attachment 1 and 2: Inspect by checking pump motor running sound if attachment is not installed
Found Not found, with service tool
(2) Find faulty FC control lever with FC input / output Monitor

FC control lever voltage should be 2.5 ± 0.2 V if it is not operated
(3) Turn off power Note : -100 % equal 0.25 V

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

Replace FC control lever

discharging work
(6) Disconnect connector E-12 of input unit. Disconnect connectors H-04 to H-07 of FC control levers (FC-IN harness)
Lift Tilt Attachment 1 Attachment 2
(7) Check continuity between (8) Check continuity between (9) Check continuity between (10) Check continuity between
E-12-25 and H-04-2(S026), E-12-27 and H-05-2(S024), E-12-29 and H-06-2(S022), E-12-31 and H-07-2(S020),
E-12-26 and H-04-4(S025), E-12-28 and H-05-4(S023), E-12-30 and H-06-4(S021), E-12-32 and H-07-4(S019),
E-12-23 and H-04- 5(A084) E-12-23 and H-05-5(A072) E-12-23 and H-06-5(A073) E-12-23 and H-07-5(A074)
and and and and
E-12-24 and H-04-1(G021) E-12-24 and H-05-1(G020) E-12-24 and H-06-1(G019) E-12-24 and H-07-1(G018)
Continuity No continuity Continuity No continuity Continuity No continuity Continuity No continuity
(11) Replace input unit (12) Repair or replace harness (FC-IN harness)
If fault remains
discharging work
(14) Reinstall input unit and replace harness

(FC-IN harness)
502838
2-64
E-02
Logics
E-02 - 23 5 3 1
21 19 17 15 - - 9 7
4 6 - 24 - 20 18 - 6 4 2
- - - 8
3 5 CAN
E-01
Power cord
10 3 E-01
15 13 11 9 - 5 3 -
12 6 Power
16 14 12 10 - 6 4 -
B 1
R/Y
2
W FC-IN harness
7 FC control lever
L E-12 H-04
8 A084 5
R/B 5V
H-04
23 S026 2
Lift
Input Y/W S025 4 5 4 - 2 1
unit 25 G021 1
W/Y H-05
26 A072 5
R/Y H-05
S024 2 Tilt
27
S023 4 5 4 - 2 1
Y/R
28 G020 1
Y/B H-06
29 A073 5
H-06
B/Y S022 2 Attachment 1
30 4 5 4 - 2 1
S021
1
31 L/Y G019
H-07
Y/L A074 5
32 Attachment 2 H-07
S020 2
24 B
GND
S019 4 5 4 - 2 1
G018 1
E-12
31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
501147
2-65
3.27 Output Unit Solenoid Fault (55)
Error code: 55
Situation Display: "55". Related lever operation inhibited. Normal traction motor and power steering operations.
Possible Faulty lift solenoid, faulty tilt solenoid, faulty attachment 1 and 2 solenoids, faulty main harness, faulty output
cause unit.
Trigger of
the error When signal is outputted, current is out of range of 0.16 A to 1.9 A.
code
Checks
(1) Operate all FC control levers to find faulty solenoid

Attachment 2: 4-valve specification only
Attachment 1 and 2: Inspect by checking pump motor running sound if attachment is not installed
Found Not found,with service tool
(2) Find faulty solenoid with FC input / output monitor

Solenoid current should flow when FC control lever is
operated

discharging work
(4) Disconnect connector E-11 of output unit. Disconnect connectors E-28 to E-35 of solenoids (FC-OUT harness)
Lift Tilt Attachment 1 Attachment 2
(5) Check continuity between (6) Check continuity between (7) Check continuity between (8) Check continuity between
E-11-21 and E-28-1(1), E-11-24 and E-29-1(4), E-11-27 and E-30-1(7), E-11-30 and E-31-1(10),
E-11-23 and E-28-2(3), E-11-26 and E-29-2(6), E-11-29 and E-30-2(9), E-11-32 and E-31-2(12),
E-11-22 and E-32-1(2) and E-11-25 and E-33-1(5) and E-11-28 and E-34-1(8) and E-11-31 and E-35-1(11) and
E-11-23 and E-32-2(3) E-11-26 and E-33-2(6) E-11-29 and E-34-2(9) E-11-32 and E-35-2(12)
Continuity No continuity Continuity No continuity Continuity No continuity Continuity No continuity
(9) Measure resistance of solenoid coil (10) Repair or replace harness (FC-OUT harness)
[13 Ω at -30 °C(-22 °F) to 24 Ω at 80 °C (176 °F)]
Normal Abnormal
(11) Check short circuit between E-11-21(1), E-11-22(2) and E-11-23(3) (12) Replace related solenoid
Check short circuit between E-11-24(4), E-11-25(5) and E-11-26(6)
Check short circuit between E-11-27(7), E-11-28(8) and E-11-29(9)
Check short circuit between E-11-30(10), E-11-31(11) and
E-11-32(12)
Not shorted Shorted
(13) Replace output unit (14) Repair or replace harness (FC-OUT harness)
502839
2-66
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Power card Logics

E-11 Power CAN
E-01 3 6 6 5 E-02
- - 31 29 27 25 23 21 R/Y B W L
- - 32 30 28 26 24 22
Output unit
E-11
Output unit
31 32 30 28 29 27 25 26 24 22 23 21 20 19 14 13
E-10
Br/W
W/B
G/W
G/W
Br/B
Br/R
W/R
L/W
G/B
G/R
L/B
E-10
19 - - 13 - - - - 3 1
12 11 12 10 9 8 9 7 6 5 6 4 3 2 3 1
20 - - 14 - - - - 4 2
2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
ATT2B ATT2A ATT1B ATT1A TILTB TILTA LIFTB LIFTA

E-35 E-31 E-34 E-30 E-33 E-29 E-32 E-28
Solenoid coils
E-35 E-31 E-34 E-30 E-33 E-29 E-32 E-28
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
501150
2-67
3.28 Output Unit Solenoid Current Leak (56)
Error code: 56
Possible Faulty lift solenoid, faulty tilt solenoid, faulty attachment 1 and 2 solenoids, faulty main harness, faulty output
cause unit.
Trigger of
the error When signal is not outputted, current is more than 0.18 A.
code
Checks
(2) Disconnect connector E-11 of output unit

Disconnect connectors E-28 to E-35 of solenoids
(3) Check short circuit between all pin patterns[E-11-21(1) to E-11-32(12)]

Not shorted Shorted
(4) Measure solenoid coil resistance (5) Repair or replace harness

[13 Ω at -30 °C(-22 °F) to 24 Ω at 80 °C(176 °F)]
Normal ‫ޓ‬ Abnormal
(6) Replace output unit (7) Replace related solenoid
502840
2-68
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Power card Logics

E-11 Power CAN
E-01 3 6 6 5 E-02
- - 31 29 27 25 23 21 R/Y B W L
- - 32 30 28 26 24 22
Output unit
E-11
Output unit
31 32 30 28 29 27 25 26 24 22 23 21 20 19 14 13
E-10
Br/W
W/B
G/W
G/W
Br/B
Br/R
W/R
L/W
G/B
G/R
L/B
E-10
19 - - 13 - - - - 3 1
12 11 12 10 9 8 9 7 6 5 6 4 3 2 3 1
20 - - 14 - - - - 4 2
2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
ATT2B ATT2A ATT1B ATT1A TILTB TILTA LIFTB LIFTA

E-35 E-31 E-34 E-30 E-33 E-29 E-32 E-28
Solenoid coils
E-35 E-31 E-34 E-30 E-33 E-29 E-32 E-28
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
501150
2-69
3.29 FNR Lever or Accelerator, Faulty Setting (E)
Error code: E
Display: "E". Traction motor operation inhibited. Normal pump and power steering operations. Line contactor
Situation
OPEN.
Key switch turned on while direction lever was either in forward or reverse position, key switch turned on while
Possible
accelerator pedal was depressed, seat switch turned off during running, faulty direction lever switch, faulty
cause
accelerator sensor, faulty main harness, faulty logic unit.
Trigger of Detects following signal when turning ON power.
the error Direction lever: F or R
code Accelerator sensor voltage: More than 0.9 V
Checks
(1) Move direction lever to neutral, and release accelerator pedal
If fault remains
(2) Turn off power. Move direction lever to neutral, release

accelerator pedal, then turn on power again

With service tool
(3) Confirm SUO #47 setting (4) Disconnect connector E-02 or B-01
Correct Incorrect If B-01 is disconnected , short circuit B-01-1 and B-01-3
(5) Set SUO #47 with (6) Turn on power

service tool Not "E" "E"
(7) Check direction lever and accelerator sensor operations (8) Connect connector E-02 or B-01
with input/output monitor
(9) Refer to troubleshooting
for code "51"
(10 ) Turn off power
(Check faulty unit if found with service tool )
Direction lever Accelerator sensor
(11) Refer to error code "51"
(12) Disconnect connector E-19 of direction lever Turn on

power
Normal (E)
(13) Replace direction lever (14) Disconnect connectors E-03 and E-02 of logic unit
(15) Check short circuit between E-03-15(21) and

E-03-36(104), pump inverter N terminal and
E-03-37(103)
Not shorted Shorted
(16) Disconnect battery plug (17) Repair or replace

main harness
(18) Replace Logic card of logic unit
502841
2-70
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
E-03
A-01
- - 37 35 33 - - -
- - 38 36 34 32 - 28
4 - - - - - - 4
8 - 6 - - 6 - 8
Back buzzer
Logics (female) (male)
E-04 and E-03 A-01
G/W
Forward 37 62 8 F
Br Direction
Reverse 36 61 6 R lever
B/W GND 106
GND 43 4 N
Accel idle
switch
Pump inverter
N terminal
Accelerator
Logics E-19
E-02 L
53 2
5V R/Y
+ 5V 24 55 3
ACCEL ANGLE 1 W 6
20 52
GND GND B 5
23 54
ACCEL ANGLE 2 21
E-02 - 2 3
4 5 6
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - 6 4 2 E-19
- - - 8
E-12
B-01 Input unit

L/R
F 2 18
W/L
N 1 19
Joystick box G/B
(option) R 4 20
G/R 14
GND 3
B-01 NEG
1 2 E-12
3 4
31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
501160
2-71
3.30 Seat Switch, Faulty Setting for Traction (E)
Error code: (E)

Display: "(E)" flashes. Traction motor operation inhibited. Normal pump and power steering operations. Line
Situation
contactor OPEN.
Possible Operator is not seated, seat switch turned OFF during running, improper seat suspension adjustment, faulty
cause seat switch, faulty main harness, faulty logic unit.
Trigger of
the error Detects seat switch opening when turning ON power or while running.
code
Checks
(1)
If this fault occurred If this fault occurred when
during running turning on power
(2) Stop truck, then move direction lever to neutral

Sit properly in operator's seat and release accelerator
pedal
If fault remains ‫ޓޓޓ‬ Normal
(3) Fail-safe function
(4) Turn off power

Sit on seat, then turn on power again
If fault remains
(5) Turn off power
(6) Adjust seat suspension

If fault remains ‫ޓޓޓ‬ Normal
(7) Faulty seat switch position
(9) Disconnect connector C-02, then short-circuit

between terminals C-02-3 and C-02-2
Turn on power again
If fault remains Normal
(10) Disconnect battery plug, then perform inverter (11) Replace seat switch
discharging work

Check continuity between C-02-2 and E-04-43(64)
(13) Replace logic card of logic unit (14) Repair or replace main harness
502842
2-72
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
Logics
E-03
0/12V
32
0/12V
33
C-02
Seat belt switch W/B 57 Logics
1
Seat switch Y/L E-04
3 58
B GND
43 GND
2 64
C-02 E-04
63 61 43
3 2 1 1 2 3 59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
(female) (male)
501161
2-73
3.31 Lift Lever, Faulty Setting (H1)
Error code: H1
Display: "H1" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
Situation occurs when turning ON power. Pump contactor CLOSE if this fault occurs during pump operation and then
OPEN if lift truck stops.
Possible Key switch turned ON while operating lift lever, faulty lift control lever or lift switches 1 and 2, faulty main
cause harness, faulty logic unit, faulty input unit.
Trigger of
Detects lift control lever signal of CAN when turning ON power (FC specification). Detects lift microswitch 1 or
the error
2 when turning ON power (MC specification).
code
Checks
(1)
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(2) Sit on seat, then stop pump motor operation

(4) Turn off power

Sit on seat, then turn on power again without lift
operation
If fault remains ‫ ޓޓ‬Error code "54" or "67" or"(L)"
(5) Turn off power (6) Refer to error code

"54", "67" or "(L)"
FC specification
MC (7) Change lift control lever to other normal control lever

specification Not changed ‫ޓ‬ Error changed
(8) Disconnect connector E-36 of microswitch (9) Repair or replace (10) Replace lift control
Sit on seat, then turn on power again FC-IN harness lever
If fault remains ‫ޓޓ‬ Normal
(11) Disconnect battery plug, then perform inverter (12) Replace lift switch 1 or 2
discharging work

Check short circuit between E-36-1 and E-36-6
Continuity, Not shorted No continuity, Shorted
(14) Disconnect battery plug (15) Repair or replace main harness
502843
2-74
E-12
H-04
5 4 - 2 1 31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
FC specification
H-04 FC-IN harness E-12
5 54
5V R/B 23
Lift 2 Y/W 25 Input
control lever 4 W/Y 26 unit
1 55
GND B 24
MC specification
Logics
E-36 E-04
Lift 1 2 67 W/L 51
GND
6
1 B
Lift 2
64 43
68
L/W 52
E-04
E-36
E-04
3 2 1 1 2 3
6 5 4 4 5 6
63 61 43
59 - 55 53 51 49 - -
(female) (male) 64 62 60 - 56 - 52 50 48 - 44
501162
2-75
3.32 Tilt Lever, Faulty Setting (H2)
Error code: H2
Possible Key switch turned on while operating tilt lever, faulty tilt control lever or tilt switch, faulty main harness, faulty
cause logic unit, faulty input unit.
Trigger of
Detects tilt control lever signal of CAN when turning ON power (FC specification). Detects tilt microswitch
the error
when turning ON power (MC specification).
code
Checks
(1)

(4) Turn off power

Sit on seat, then turn on power again without tilt
operation
If fault remains Error code "54" or "67" or "(L)"

"54", "67" or "(L)"
FC specification
(7) Change tilt control lever to other normal control lever

Not changed Error changed
MC
specification
(8) Disconnect connector E-36 of microswitch (9) Repair or replace (10) Replace tilt control
Sit on seat, then turn on power again FC-IN harness lever
(11) Disconnect battery plug, then perform inverter (12) Replace tilt switch
discharging work

Continuity, Not shorte No continuity , Shorted
502844
2-76
E-12
H-05
31 29 27 25 23 21 19 - - - - - 7 - - 1
5 4 - 2 1 32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
FC specification
5V R/B
5 54 5 23
Tilt 2 R/Y 27 Input
control lever 4 Y/R 28 unit
1 GND
6
B 24
MC specification Logics
E-36 E-04
3 Br/W
Tilt 66 50
B
6 64 43
GND
E-04
63 61 43
E-36 59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
3 2 1 1 2 3
6 5 4 4 5 6
(female) (male)
501163
2-77
3.33 Attachment 1 Lever, Faulty Setting (H3)
Error code: H3
Possible Key switch turned ON while operating attachment 1 lever, faulty attachment 1 control lever or attachment 1
cause switch, faulty main harness, faulty logic unit, faulty input unit.
Trigger of
Detects attachment 1 control lever signal of CAN when turning ON power (FC specification). Detects
the error
attachment 1 microswitch when turning ON power (MC specification).
code
Checks
(1)

(4) Turn off power. Sit on seat, then turn on power

again without attachment 1 operation
(5) Turn off power (6) "Refer to error code

"54", "67" or "(L)"
FC specification
(7) Change attachment 1 control lever to other normal

control lever
MC Not changed Error changed
specification
(8) Disconnect connector E-36 of microswitch (9) Repair or replace (10) Replace attachment
Sit on seat, then turn on power again FC-IN harness 1 control lever
(11) Disconnect battery plug, then perform inverter (12) Replace attachment 1 switch
discharging work

502845
2-78
E-12
H-06
31 29 27 25 23 21 19 - - - - - 7 - - 1
5 4 - 2 1 32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
FC specification
FC-IN harness
H-06 E-12
5V R/B 23
5 54 5
Attachment 1 2 Y/B 29 Input
control lever B/Y unit
4 30
1 55
GND
6 B 24
MC specification
E-36 Logics
E-04
GND B
6 64 43
Aux 1
0/12V Y/L
4 83 49
E-36 E-04
3 2 1 1 2 3
6 5 4 4 5 6 63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
(female) (male)
501164
2-79
3.34 Attachment 2 Lever, Faulty Setting (H4)
Error code: H4
Possible Key switch turned ON while operating attachment 2 lever, faulty attachment 2 control lever or attachment 2
cause switch, faulty main harness, faulty logic unit, faulty input unit.
Trigger of
Detects attachment 2 control lever signal of CAN when turning ON power (FC specification). Detects
the error
attachment 2 microswitch when turning ON power (MC specification).
code
Checks
(1)

(4) Turn off power. Sit on seat, then turn on power again
without attachment 2 operation

"54", "67" or "(L)"
MC FC specification
specification
(7) Disconnect connector E-36 of microswitch (8) Change attachment 2 control lever to other normal
Sit on seat, then turn on power again control lever
If fault remains Normal Not changed Error changed
(9) Repair or replace (10) Replace attachment

FC-IN harness 2 control lever
(11) Disconnect battery plug, then perform inverter (12) Replace attachment 2 switch
discharging work

502846
2-80
E-12
H-07
5 4 - 2 1 31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
FC specification
5V R/B
5 23
Attachment 2 L/Y 31 Input
2
control lever Y/L unit
4 32
1 GND B 24
MC specification
E-36 Logics
E-04
GND B
6 64 43
Aux 2 0/12V G/W 48
5 121
E-36
E-04
3 2 1 1 2 3
6 5 4 4 5 6
63 61 43
(female) (male) 59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501165
2-81
3.35 Seat Switch, Faulty Setting for Hydraulic (L)
Error code: (L)

Display: "L" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault
Possible Operator not seated, seat switch turned OFF during pump motor operation, improper seat suspension
cause adjustment, faulty seat switch, faulty main harness, faulty logic unit.
Trigger of
the error Detects seat switch opening when turning ON power or during pump operation.
code
Checks
(1)
turning on power turning on power

(4) Turn off power

Sit on seat, then turn on power again
If fault remains
(5) Turn off power
(6) Adjust seat suspension

(7) Faulty seat switch position
(9) Disconnect connector C-02, then short-circuit

between terminals C-02-2 and C-02-3
Turn on power again
(10) Disconnect battery plug, then perform inverter (11) Replace seat switch
discharging work

502847
2-82
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
Logics
E-03
0/12V
32
0/12V
33
C-02
Seat belt switch W/B 57 Logics
1
Seat switch Y/L E-04
3 58
B GND
43 GND
2 64
C-02 E-04
63 61 43
3 2 1 1 2 3 59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
(female) (male)
501161
2-83
3.36 FNR Lever Fault (EE)
Error code: EE
Situation Gear of lever changes to NEUTRAL status, thus travel is inhibited.
Possible
Lever fault, harness fault, logic unit fault
cause
Trigger of All FNRs are ON (armrest FNR)
the error All FNRs are OFF
code Both FRs are ON (normal or foot direction)
Checks
Other than armrest FNR

(1) Disconnect battery plug and discharge
(2) Disconnect E-03, E-04, and A-01 harnesses

Place FNR lever in neutral.
Open‫ޓޓޓޓޓޓ ޓ ޓޓ‬short
(3) Connect A-01 (4) Replace harness

Open ‫ ޓޓޓޓޓޓ ޓޓ ޓ‬short
(5) Replace logic card of login unit (6) Replace FNR lever
Armrest FNR
(7) Disconnect battery plug and discharge
(8) Disconnect E-12 and B-01

Place FNR lever in neutral
With tester, check continuity between:
E-12-18 and E-12-14
E-12-19 and E-12-14
E-12-20 and E-12-14
Open short
‫ޓޓޓ‬ ‫ޓޓޓޓޓ‬
(9) Check continuity between B-01-1 and E-12-19

(10) Connect B-01 (11) Replace harness

With FNR lever in neutral,
check continuity between E-12-18 and E-12-14 and
check continuity between E-12-20 and E-12-14
With FNR lever in position other than neutral,
check continuity between E-12-19 and 14
Open‫ ޓޓޓޓޓޓޓ ޓޓ‬short
(12) With FNR lever in neutral (13) Replace FNR lever

(14) Replace logic card of logic unit (15) Replace harness

502848
2-84
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
E-03
A-01
- - 37 35 33 - - -
- - 38 36 34 32 - 28
4 - - - - - - 4
8 - 6 - - 6 - 8
Logics Back buzzer
(female) (male)
E-04 and E-03 A-01
G/W
Forward 37 62 8 F
Br Direction
Reverse 36 61 6 R lever
GND 43 B/W GND GND 106
4 N
Accel idle
switch
Pump inverter
N terminal
E-12
B-01 Input unit

L/R
F 2 18
W/L
N 1 19
Joystick box G/B
(option) R 4 20
G/R GND
GND 3 14
B-01 NEG
1 2 E-12
3 4
31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
502260
2-85
3.37 Display Communication Fault (60)
Error code: 60
Display: "60".
Situation
Normal lift truck operation All lift truck operations inhibited
Possible Faulty main harness, faulty display unit, faulty logic
Faulty logic unit
cause unit.
Trigger of
Communication is impossible. Display unit hour
the error Communication is impossible.
meter is abnormal.
code
Checks

discharging work
(2) Check connection of display connector
CAN
(3) Disconnect connector E-02 and H-03
Check continuity between E-02-5 and H-03-9(3)
Check continuity between E-02-6 and H-03-10(4)
Continuity ‫ ޓޓޓޓޓޓ‬No continuity
(4) Connect E-02 (5) Replace harness

Measure resistance between H-03-9 and10
(harness side)
120ǡ± 5㧑‫ޓޓޓޓޓޓޓޓޓ‬ Not
(6) Measure resistance between H-03-9 and 10 (7) See troubleshooting for code E " 65"
(displace side)
120ǡ± 5 㧑‫ޓޓޓޓޓޓޓޓޓ‬ Not
(8) Connect H-03 and disconnect E-02 (9) Replace display

Measure resistance between E-02-5 and 6
(harness side)
60ǡ± 5 㧑‫ޓޓޓޓޓޓޓޓޓޓ‬ Not
(10) Check to see if these are shorted to other signal (11) Replace harness
cables
Not shorted Shorted
(12) Replace display unit
If fault remains
(13) Disconnect battery plug, then perform inverter (14) Repair or replace harness
discharging work
502849
2-86
E-01 E-21
15 13 11 9 - 5 3 - 2 1
16 14 12 10 - 6 4 -
E-21 Key switch
Power card 105 2

R/B
E-01 86 1
Battery + C-08
C-08
13 105
3 10 A 2 1
4 4 3
Fuse holder
E-37
2 5 H-02 (MC)
(FC)
2 1 1 2
(female) (male)
Emetrgency SW
H-02 2 1 E-37
(MC)
(FC)
3 2 1 1 2 3
7 6 5 4 4 5 6
7
10 9 8 8 9 10
(female) (male) Emetrgency SW
Logics
H-03
E-02 Battery voltage R/W
105 1
WB 3 9 W
CAN 5
Display
L L
CAN 6 4 10
15 L B/W
GND 4
106
16 H-03
E-01 10 9 - - - - 4 - - 1
Power card
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501151
2-87
3.38 Logic Card Initialize Failure (61)
Error code: 61
Situation Display: "61". All lift truck operations inhibited. Line contactor OPEN and ST contactor OPEN.
Possible Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
cause faulty logic unit.
Trigger of
Setup Option data is in abnormal setting range. MC specification is set at #43 while CAN data is received from
the error
input unit or output unit.
code
Checks
(1) Turn off power, then turn on power in Setup Option Group3 setting
(2) Set Setup Option Group 3 data

Confirm that SUO #43 and 50 have been set up correctly and their combination
with output unit and input unit is correct
(3) Set Setup Option default data
(4) Turn on power
If fault remains
(5) With service tool, set Setup Option Group 3 data
(6) With service tool, set Setup Option default data
If fault remains
(10) With service tool, set Setup Option default data
Tilt horizon Function

Enable Disable
FC Input Input
output output
output -
MC
502850
2-88
3.39 Logics Fault (62)
Error code: 62
Possible
Faulty EEPROM data, faulty logic unit.
cause
Trigger of
ROM/RAM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different
the error
from check data.
code
Checks
(1) Turn off power, then turn on power in Setup Option Group3 setting
(2) Set Setup Option Group 3 data
(3) Set Setup Option default data
(4) Turn on power in "RUN" mode

Error code "61"
If fault remains "62"
(5) Disconnect battery plug, then perform inverter (6) See troubleshooting for code "61"
discharging work

Set Setup Option default data
502851
2-89
3.40 Traction Inverter R.H., Fault (63)
Error code: 63
operations inhibited except lowering the mast.
Faulty main harness or connector E-07 comes off.
Possible (Communication between logic unit and traction inverter.)
cause Faulty logic unit.
Display fault
Traction inverter is connected as pump inverter
Trigger of (E-07-9 is connected to GND or installed pump DSP card).
the error ROM SUM value of traction inverter is different from check data.
code RAM of traction inverter is faulty
Communication between logic unit and traction inverter is impossible.
Checks
(2) Remove DSP cover, then remove connector E-07

Check the contact face both of connector E-07on harness side and-E 07 on inverter side
Connect connector E-07 and tuning on power
(4) Disconnect connector E-01

Check no continuity between E-01-3 and E-01-6 Check no continuity between E-01-3 and E-01-11
No Continuity Continuity
14 V, 8 V
power supply
(5) Disconnect connector E-07 and E-01 of logic unit. (6) Repair or replace main harness
Continuity No Continuity
CAN
(Already disconnected. E-07 and E01)
(8) (Already disconnected. E-01, E-02 and E-07) (9) Repair or replace main harness
Resistance between
E-02-5(3) and E-02-6(4)of harness side connectors
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(10) Perform CAN check of

Pump inverter Fault (65)
502852
2-90
(11) Connect connector E-07of traction inverter

Resistance between E-02-5(3) and E-02-6(4) of
harness side connectors
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(12) Replace DSP card of

traction inverter
(13) Check E-07-8 and E-07-9 that pin is not inserted in

No Yes
(14) Disconnect connector E-07 (15) Repair or replace main harness

Connect connector E-01 and E-02 to logic unit, then
turn on power again

Measure voltage between E-07-17(10) and E-07-20(12)
Confirm value is from 14 ± 2 V
Normal Abnormal
(18) Replace DSP card of traction inverter (19) Replace power supply card of logic unit
If fault remains
(20) Disconnect E-03, E-04, E-05, E-06, E-07, E-08

Reconfirm step (16) after power on
Normal Abnormal
(21) After step (17), (22) Repair or replace main

Connect E-07 harness
Reconfirm step (16)
Normal Abnormal
(23) After step (17), (24) Replace DSP of

Connect E-06 Traction inverter Right
Reconfirm step (16)
Normal Abnormal

Connect E-05 Traction inverter Left
Reconfirm step (16)
Normal Abnormal
(27) After step (17), (28) Replace DSP of Pump

Connect E-08 inverter
Reconfirm step (16)
Normal Abnormal
(29) Replace Logics Unit (30) Replace DSP EPS

controller
502853
2-91
E-02 E-07
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - - - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - - 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9
Power card Flat
11 cable W IWR
E-01 Br/R 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 - GND B
16 14 12 10 - 6 4 -
19

5 3 Speed
sensor W TWR
4
8
2
M V TVR
7 U TUR
6 1 Thermal
2 2 sensor
1 1 341Ω 150°C [302°F]
E-14 125kΩ -30°C [-22°F]
1 2
1 2
3 4
E-14
E-17
501135
2-92
3.41 Traction Inverter L.H., Fault (64)
Error code: 64
Possible (Communication between logic unit and traction inverter).
Display fault.
Traction inverter is connected as pump inverter.
Trigger of (E-06-9 is connected to GND or installed pump DSP card.)
the error ROM SUM value of traction inverter is different from check data.
code RAM of traction inverter is faulty.
Checks

Check the contact face both of connector E-06 on harness side and E-06 on inverter side

14V, 8V
power supply
(5) Disconnect connector E-06 and E-01 of logic unit (6) Repair or replace main harness
CAN
(9) Repair or replace main harness

(8) (Already disconnected E-01, E-02 and E-06)
Resistance between
E-02-5(3) and E-02-6(4)of harness side connectors
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(10) Perform CAN check of

Pump inverter Fault (65)
(11) Connect connector E-06of traction inverter

Measure resistance of CAN with connector E-02
disconnected
Resistance between E-02-5(3) and E-02-6(4) of
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(12) Replace DSP card of

traction inverter
502854
2-93

Confirm value is from 14 ± 2 V
Normal Abnormal
(17) Replace DSP card of traction inverter (18) Replace power supply card of logic unit
If fault remains

Normal Abnormal

Reconfirm step (15)
Normal Abnormal

Reconfirm step (15)
Normal Abnormal

Reconfirm step (15)
Normal Abnormal

Reconfirm step (15)
Normal Abnormal

controller
502855
2-94
E-02 E-06
- 23 5 3 1
21 19 17 15 - - 9 7 19 17 - - 11 - 7 5 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 - - - 8 6 4 2
Logics
E-02
CAN 5 W 3
L Inside Inside
6 4 3 of of
4 cover case
5 R/L 12V
9 16 P Fuse
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IUR
11 GND 8
V IVR
9 Flat
Power card
11 cable W IWR
E-01 Br/W 1
B 2
E-01 12V R/Y 5
W/B 6
L/B 7
15 13 11 9 - 5 3 -
GND B 19
16 14 12 10 - 6 4 -

16 3 Speed
sensor W TWR
2
17
4
M V TVR
18 U TUR
15 1 Thermal
14 2 sensor
13 1 341Ω 150°C [302°F]
E-15 125kΩ -30°C [-22°F]
1 2
3 4 1 2
E-18 E-15
501136
2-95
3.42 Pump Inverter Fault(65)
Error code: 65
Possible (Communication between logic unit and traction inverter).
Display fault
Pump inverter is connected as traction inverter.
Trigger of (E-05-9 is connected to GND or installed traction DSP card.)
the error The value of pump inverter ROM SUM is different from check data.
code Pump inverter RAM is faulty.
Checks


Check no continuity between E-01-3 and E-01-6
‫ޓޓޓޓޓޓޓޓޓޓޓޓ‬
14V, 8V
power supply
(5) Disconnect connector E-05 and E-01 of logics Unit
Continuity ‫ޓޓޓޓޓޓޓޓޓޓޓޓ‬ No Continuity
CAN
(6) Disconnect connector E-02 of logics Unit
(Already disconnected E-05 and E-01)
‫ޓޓ‬
Continuity ‫ޓޓޓޓ‬ No continuity
(7) Repair of replace main harness
(8) Resistance between E-02-5 and E-02-6 of harness side connectors

120 ǡ ± 5 % Other than 120 ǡ ± 5 %
(9) Measure resistance of CAN for Pump inverter (10) Perform CAN check of Display communication
DSP card Fault (60)
Resistance between E-05-3 and E-05-4 of DSP card
side connectors
120 ǡ ± 5 % Other than 120 ǡ ± 5 %
(11) Replace DSP card of pump inverter

502856
2-96
(12) Connect connector E-05 of pump inverter

Resistance between E-02-5 and E-02-6 of harness
side connectors
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(13) Check E-05-8 that pin is not inserted in (14) Replace DSP card of pump inverter
No‫ ޓޓޓޓޓޓ ޓޓޓ‬Yes

(15) Disconnect connecter E-05
turn on power again
(17) Measure voltage between E-05-18and E-05-20(12)

Voltage should be is 8 ± 2 V
Measure voltage between E-05-17 and E-05-20(12)
Voltage should be is 14 ± 2 V
Normal‫ޓޓޓޓޓ‬ ‫ ޓޓޓޓޓ‬Abnormal
If fault remains

Normal Abnormal

Reconfirm step (17)
Normal Abnormal

Reconfirm step (17)
Normal Abnormal

Reconfirm step (17)
Normal Abnormal

Reconfirm step (17)
Normal Abnormal

controller
502857
2-97
E-02 E-05
- 23 5 3 1
21 19 17 15 - - 9 7 - 17 15 - 11 9 - - 3 1
- 24 - 20 18 - - - - 8 6 4 2
20 18 16 14 - - - - 4 2
Logics

6 L 4 4 of of
cover case
14
15
5 R/L 12V Fuse
9 16 P
R/Y 14V
Power 3 17
10
4 11 18 DSP IMS
B GND 20 card card
6 12 U IU
GND
11 8
V IV
9 Flat
Power card
E-01 11 cable W IW
Br/B
1
E-01 GND B
2
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
Pump motor
W PW
M V PV
U PU
E-16
Thermal
37 2 sensor
36 1 341Ω 150°C [302°F]
125kΩ -30°C [-22°F]
1 2
E-16
501137
2-98
3.43 Input Unit Fault (67)
Error code: 67
Possible
Faulty remote input unit, faulty main harness, faulty logic unit.
cause
Trigger of
The input unit ROM/RAM SUM value is different from check data. Communication with input unit is impossible.
the error
SUO #43 (Hydraulic Control Selection) is incorrect.
code
Checks
(1)
Without service tool ‫ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓ‬
With service tool
(2) Check input unit status with FC input / output monitor

Normal‫ޓޓޓޓ ޓޓޓޓޓޓ‬Error
(3) Turn off power (4) Disconnect battery plug, then replace input unit
(5) Disconnect connector E-12 of input unit, then measure voltage between E-12-1(12) and E-12-2(10)
Normal‫ޓޓޓޓޓޓޓޓޓޓޓޓ‬ Abnormal
(6) Disconnect battery plug, then perform inverter (7) Turn off power, then disconnect connector H-02 of
discharging work harness and connector H-02 of FC-IN harness
(8) Disconnect connector E-02 of logic unit (9) Measure voltage between H-02-07(12) and H-02-10(10)
Check continuity between E-12-7 and E-02-5(3) Confirm value is 14 ± 2 V
Check continuity between E-12-8 and E-02-6(4) Normal‫ޓޓޓޓޓޓޓޓޓޓޓޓ‬ Abnormal
‫ޓޓޓޓޓޓޓޓޓ ޓޓ‬
(10) Replace input unit (11) Repair or replace (12) Disconnect battery
FC-IN harness plug, then perform
inverter
discharging work
(13) Disconnect connector H-02of FC-IN harness (14) Check continuity between E-01-3 and H-02-10(10)
Check continuity between H-02-1 and E-02-5(3) Check continuity between E-01-6 and H-02-7(12)
Check continuity between H-02-4 and E-02-6(4) ‫ޓޓޓޓޓޓޓޓޓޓޓޓ‬
(17) Replace power (18) Repair or replace

(15) Repair or replace (16) Repair or replace supply card of logic main harness
FC-IN harness main harness unit
502858
2-99
E-12
31 29 27 25 23 21 19 - - - - - 7 - - 1
32 30 28 26 24 - 20 18 - 14 - - 8 - - 2
H-02 E-01
3 2 1 1 2 3
15 13 11 9 - 5 3 -
7 6 5 4 4 5 6
7
10 9 8 8 9 10 16 14 12 10 - 6 4 -
(female) (male)
FC-IN Power card

E-12 harness H-02 E-01
B GND
1 12 7 12 6
Input R/Y10 14V
unit 2 10 10 3
W 0 to 5V
7 3 1 3
L 0 to 5V
4 Logics
8 4 4
E-02
5
CAN
6
Harness
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501152
2-100
3.44 Output Unit Fault (68)
Error code: 68
Possible
Emergency switch opened, faulty remote output unit, faulty main harness, faulty logic unit.
cause
Trigger of Emergency switch is detected. ROM/RAM SUM value of output unit is different from check data.
the error Communication with output unit is impossible. SUO #43 (Hydraulic Control Selection) is incorrect. SUO #50
code (Tilt Horizon Function) is incorrect.
Checks
(1) Check emergency switch

Not pushed ‫ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓ‬
Pushed
(2) Release emergency switch
(3) Checks
Without service tool ‫ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓ‬
With service tool
(4) Check output unit status with FC input /output monitor

Normal ‫ ޓޓޓޓޓ ޓޓޓޓޓ‬Error
(5) Turn off power (6) Disconnect battery plug, then replace output unit
Turn off power
(7) Disconnect connector E-10 of output unit, then Measure

voltage between E-10-20(10) and E-10-19(12)
Normal ‫ ޓޓޓޓޓޓޓޓޓޓ‬Abnormal
(8) Disconnect battery plug, then perform inverter (9) Disconnect battery plug, then perform inverter
discharging work discharging work
(10) Disconnect connector E-02 of logic unit (11) Check continuity between E-01-3 and E-10-20(10)
Check continuity between E-02-5 and E-10-13(3) Check continuity between E-01-6 and E-10-19(12)
Check continuity between E-02-6 and E-10-14(4) Continuity‫ ޓޓޓޓޓޓޓޓޓ‬No continuity
‫ޓޓޓޓޓޓޓ ޓޓޓޓ‬
(12) Replace power supply (13) Repair or replace
card of logic unit main harness
(14) Replace output unit (15) Repair or replace main harness
502859
2-101
E10 E-01
19 - - 13 - - - - 3 1 15 13 11 9 - 5 3 -
20 - - 14 - - - - 4 2 16 14 12 10 - 6 4 -
Power card
E-10 E-01 E-02
R/Y 10 14V
20 3
Output - 23 5 3 1
B GND 21 19 17 15 - - 9 7
19 12 6 - 24 - 20 18 - 6 4 2
unit - - - 8
W
13 3 5
CAN
L
14 4 6
E-21
Logics
E-02 2 1
3 105
4 105 E-21 Key switch
105 2
R/B
86 1
Battery + C-08
C-08
3 10 A 2 1
4 4 3
Fuse holder
E-37
2 5 H-02 (MC)
(FC)
2 1 1 2
(female) (male)
Emetrgency SW
H-02 2 1 E-37
(MC)
(FC)
2 1 1 2 3
6 5 4 4 5 6 7
10 9 8 8 9 10
(female) (male) Emetrgency SW
501153
2-102
3.45 EPS Controller Fault (71)
Error code: 71
Display: "71". All operations inhibited except mast lowering operation. Line steering contactor OPEN. Traveling
Situation
speed limited to 5 km/h.
(Communication between logic unit and traction inverter.)
Possible
Faulty logic unit.
cause
Display fault.
PS Controller fault.
ROM SUM value of pump inverter is different from check data.
Trigger of
RAM of pump inverter is faulty.
the error
Communication between logic unit and PS controller is impossible.
code
No life signal is inputted.
Checks
(2) Remove connector E-08


‫ ޓޓޓޓޓޓޓ‬Continuity
No Continuity ‫ޓ‬
14V, 8V
power supply
(5) Disconnect connector E-08 and E-01 of logics Unit
CAN
(6) Disconnect connector E-02 of logics Unit
‫ޓޓ‬
Continuity ‫ޓޓޓޓ‬ No continuity
(7) Resistance between E-02-5(3) and E-02-6(4) of harness (8) Repair or replace harness
side connectors
60 ǡ ± 5 % Other than 60 ǡ ± 5 %
(10) Perform CAN check of Pump inverter Fault (65)

(9) Connect connector E-08 of EPS controller
Measure resistance of CAN with connector E-02
disconnected
Resistance between E-02-5(3) and E-02-6 (4) of
60 ǡ ± 5 % Other than 60 ǡ ± 5 %

502860
2-103
(12) Disconnect E-08

‫ޓޓޓޓޓޓޓޓ‬
(13) Check E-08-9 that pin is not inserted in (14) Replace harness
No‫ޓޓޓޓޓޓޓޓޓޓ‬Yes
(15) Disconnect connecter E-02 (16) Repair or replace harness

turn on power again

Confirm value is From 14 ± 2 V
Normal ‫ޓޓޓޓޓޓޓ‬ Abnormal
(19) Replace EPS controller (20) Replace power supply card of logic unit
If fault remains

Normal Abnormal

Reconfirm step (17)
Normal Abnormal

Reconfirm step (17)
Normal Abnormal

Connect E-05 Traction inverter Left.
Reconfirm step (17)
Normal Abnormal

Reconfirm step (17)
Normal Abnormal

controller
502861
2-104
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-04
E-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- 8 7 6 - - - - 1
E-01 17 - 15 14 - - - 10
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
Life L/R
Signal 53 28
E-08 EPS Controller

W 8
CAN 5 3
6 L 4 21
E-02
30
12V
R/Y 14V
Power 3 R/B 18 VL
10
4 11 1 8V IMS
E-01 B GND
6 12 25 GND U
GND
11 32 GND
R/W V
Fuse 34 LOW
R/Y VE
1 27 W
G/L 25
2 B 26 24 GND
Y/R
Bk 5 30 17 BRAKE +
Br/Y
6 31 33 BRAKE -
F-01 14 TIRE ANGL 1
12V
6 TIRE ANGL 2
1 6 23 GND
2 5
3 4
F-01
H-01(3W)
E-38(4W)
27 R/Y 4 Tire angle
Y/B sensor TWR 2
21
B
5
6
M TVR 1
23
R/Y 3 E-27
27
Br
22 2
23
B 1 1 2
3 2 1 E-27
1 2 3
6 5 4
4 5 6
H-01(3W)
E-38(4W) 501145
2-105
3.46 Contactor Coil Fault (72)
Error code: 72
Possible
Faulty line contactor, faulty pump contactor, faulty main harness, faulty logic unit.
cause
Trigger of
the error By short circuit detection signal of logic card.
code
Checks
(1)
Without service tool With service tool
(2) Find faulty contactor (line contactor or steering

contactor) with input/output monitor
(4) Check line contactor or Steering contactor (Check faulty contactor if found with service tool)
Line contactor‫ޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓޓ‬ Steering contactor
(5) Remove coil side terminals of line contactor (6) Remove coil side terminals of steering contactor
Disconnect connector E-04 of logic unit Disconnect connector E-04 of logic unit
(7) Check short circuit between coil terminal plus(+) and (8) Check short circuit between coil terminal plus(+) and
minus (-) of harness minus (-) of harness
Not shorted ‫ޓޓޓޓޓ‬Shorted Shorted‫ ޓޓޓޓޓޓޓ‬Not shorted
(10) Measure coil resistance (11) Measure coil resistance

[44 Ω at -30 °C (-22 °F) to 66 Ω at 80 °C (176 °F)] [61 Ω at -30 °C (-22 °F) to 91 Ω at 80 °C (176 °F)]
Abnormal‫ޓޓޓޓޓޓ‬Normal Normal ‫ ޓޓޓޓޓޓ‬Abnormal
(12) Replace line contactor (13) Replace logic card of logic unit (14) Replace Steering contactor
502862
2-106
EMG
KEY
Fuse
-
Line contactor
63 R/W 105 70
+
W/L
59
64 Br/R
Logics 73 -
E-04
Steering contactor
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501154
2-107
3.47 Hydraulic Lock Solenoid Fault (74)
Error code: 74
Display: "74". Pump motor operation inhibited. Normal traction motor operation and power steering
Situation
operation.
Possible
Faulty lift lock valve, faulty main harness, faulty logic unit.
cause
Trigger of
code
Checks

Disconnect connector E-13 of lift lock valve
(3) Check short circuit between E-13-1 and E-13-2 of harness side
Shorted‫ޓޓޓޓޓ‬ ‫ޓ‬ ‫ ޓ‬Not shorted
(4) Repair or replace main harness (5) Check short circuit between E-13-1 and E-13-2 lift lock
valve side connectors
Measure coil resistance
[7.9 Ω at -30 °C (-22 °F) to 11.8 Ω at 80 °C (176 °F)] (MC)
[22.1 Ω at -30 °C (-22 °F) to 37.6 Ω at 80 °C (176 °F)] (FC)
Normal ‫ޓ‬ ‫ޓޓޓ‬Abnormal
(6) Replace logic card of (7) Replace lift lock valve

logic unit
502863
2-108
Key Switch
R/W
Harness B
Logics E-13
E-04
Y
105 1 Lift
lock
61 W/G 72 B
2 valve
E-04 E-13
63 61 43 1 2
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501155
2-109
3.48 Parking Brake Fault (75)
Error code: 75
Possible
Faulty parking brake coil, faulty main harness, faulty logic unit.
cause
Trigger of
code
Checks
(1)
Without service tool With service tool
(2) Find Parking brake with input/output monitor
(4) Disconnect connector E-04 of logic unit (Check faulty valve if found with service tool)
PKB PKB2
(5) Disconnect connector E-04 of logic Unit (6) Disconnect connector E-04of logic Unit
Disconnect connector E-23 of PKB Disconnect connector of PKB
(7) Check short circuit between E-23-1(301) and (8) Check short circuit between E-23-3(302) and
E-23-2(303) of harness side E-23-4(304) of harness side
Not shorted ‫ޓ‬ ‫ޓޓޓ‬Shorted Shorted ‫ޓ‬ ‫ ޓޓޓ‬Not shorted
(10) Check short circuit between unload valve side (11) Check short circuit between lift lock valve side
connectors connectors
Measure coil resistance Measure coil resistance
[13.5 Ω at -30 °C (-22 °F) to 25.3 Ω at 80 °C (176 °F)] [13.5 Ω at -30 °C (-22 °F) to 25.3 Ω at 80 °C (176 °F)]
Shorted ‫ޓޓޓޓ‬ Not shorted Normal ‫ ޓޓޓޓޓޓ‬Abnormal
(12) Replace PKB 1 (13) Replace logic card of logic unit (14) Replace PKB 2
502864
2-110
E-23
4 3 2 1 1 2 3 4
(female) (male)
Key Switch
Logics E-23
E-04
R/W 105 1 301 PKB1
60 Y/W 71 2 303 (L)
R/W 3
105 302 PKB2
62 Y/B (R)
71 4 304
44 PDS buzzer Key Switch
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
501569
2-111
3.49 PDS Buzzer Fault (76)
Error code: 76
Situation Display: "76". All operations available except for the buzzer.
Possible
Faulty PDS buzzer, faulty main harness, faulty logic unit.
cause
Trigger of
the error Short circuit detection signal of logic card.
code
Checks
(2) Disconnect connector of PDS buzzer

Check circuit between R1 and R2 of side
Not shorted Shorted
(4) Check short circuit between R1 and R2 or PDS buzzer

Not shorted Shorted
(5) Replace PDS buzzer
(6) Disconnect connector of E-03 and E-04 of Logics

Check short circuit between E-03-34 and R/W of key switch
Check short circuit between E-04-44 and R/W of key switch
Not shorted Shorted
502865
2-112
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
Logics
E-03
Rrlay Rrlay
R/W Key Switch
34 R/Y PDS buzzer L/Y
R1 R2
44
Logics
E-04
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
502542
2-113
3.50 Battery Voltage Too Low (78)
Error code: 78
Possible Faulty or discharged battery, low voltage battery, improper battery voltage setting (Setup Option #41),
cause improper battery voltage adjustment setting (Setup Option #46), faulty main harness, faulty logic unit.
Trigger of
Corrected battery voltage is too low. Battery voltage is corrected by #46 value.
the error
36 V battery: less than 30 V 48 V battery: less than 42 V
code
Checks

Measure battery voltage with multimeter
36 V battery: 34 to 42 V, 48 V battery: 45 to 60 V Abnormal
(2) Turn on power in Setup Option Group 3 setting (3) Charge battery or replace with proper battery
(4) Set #46 of Setup Option Group 3
(5) Turn off power and turn on power again
If fault remains
discharging work

Check continuity between E-02-19(105) and E-01-14
(8) Perform inverter discharging work, then replace logic (9) Repair or replace main harness
card of logic unit
502866
2-114
EMG
KEY
R/W
19 105 Fuse
Logics
E-02
E- 02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501154
2-115
3.51 Battery Voltage Too High (79)
Error code: 79
Possible Faulty or highly charged battery, high voltage battery, improper battery voltage setting (Setup Option #41),
cause improper battery voltage adjustment setting (Setup Option #46), faulty logic unit.
Trigger of
Corrected battery voltage is too high. Battery voltage is corrected by #46 value.
the error
36 V battery: more than 42 V 48 V battery: more than 60 V
code
Checks

Measure battery voltage with multimeter
36 V battery : 34 to 42 V, 48 V battery : 45 to 60 V Abnormal
(2) Turn on power in Setup Option Group 3 setting (3) Replace with proper battery
(4) Set #46 of Setup Option Group 3
(5) Turn off power and turn on power again
If fault remains

discharging work
(7) Perform inverter discharging work , then replace logic

card of logic unit
502867
2-116
EMG
KEY
R/W
19 105 Fuse
Logics
E-02
E- 02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501154
2-117
3.52 Battery Consumption Too Much (Lo)
Error code: (Lo)

Display: "Lo" flashes. Battery low indicator ON. All lift truck operations inhibited. Line contactor OPEN and
Situation
pump contactor OPEN.
Possible
Extremely consumed battery, faulty main harness, faulty logic unit.
cause
Trigger of
the error Corrected battery voltage is less than 22 V. Battery voltage is corrected by #46 value.
code
Checks
(2) Check battery voltage

22 V or more Less than 22 V
If fault remains
(3) Perform inverter discharging work (4) Charge battery or replace with new battery
(5) Disconnect connector E-01 and E-04

502871
2-118
EMG
KEY
R/W
19 105 Fuse
Logics
E-02
E- 02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501154
2-119
3.53 Tilt Angle Sensor Fault (80)
Error code: 80
Tilt mechanism for securing horizontal operation disabled.
Situation
All other operations are available.
Possible
Tilt angel sensor fault, harness fault, logic unit fault
cause
Trigger of
the error Tilt angle sensor is more than 4.9V, or less than 0.1 V.
code
Checks
(2) Disconnect E-02 or E-03 cable of logic and tilt angle sensor
Check continuity between E-02-26 and Tilt Angle Sensor-1(Power)
Check continuity between E-03-29 and Tilt Angle Sensor-2(Output)
Check continuity between E-02-25 and Tilt Angle Sensor-3(GND)

Normal Abnormal
(4) Connect logic connector E-02 and E-03 and

connect battery plug Turn on power
Check voltage between Sensor-1(Power) and
Sensor-3(GND)
5 V ± 10 % Outside acceptable range
(5) Turn off power, turn off battery and discharge (6) Replace harness
Replace tilt angle sensor
If fault remains
(7) Reinstall tilt angle sensor just has been replaced and (8) Replace logic power board
replace logic card of logic unit
502868
2-120
E-01
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-02
25 23 5 3 1
21 19 17 15 - - 9 7
26 24 - 20 18 - - - - 8 6 4 2
E-03
- - 37 35 33 - 29 -
- - 38 36 34 32 - 28
Logics
Tilt Angle Sensor E-02 and E-03
5V
1 26
2 29
GND 25
3
R/W 4 +5
10 46
W/R
9 45 2 +VL
B 1 GND
11 44
B 3 GND
12 100
E-01 E-02 Logics

Power card
501157
2-121
3.54 Load Sensor Fault (81)
Error code: 81
Pitch control and tilt mechanism to secure horizontal operation are disabled.
Situation
All other operations are available.
Possible
Load weight sensor fault, harness fault, logic unit fault
cause
Trigger of
the error Load weight sensor is more than 4.9 V, or less than 01 V.
code
Checks
(2) Disconnect cable of logic and load weight sensor


Normal Abnormal
(5) Replace harness

(4) Connect logic connector E-02 and E-03 and connect
battery plug
Turn on power
Check voltage between E-20-3(Power) and
E-20-1(GND)
(6) Turn off power, turn off battery and discharge (7) Replace logic card of logic unit
Replace load weight sensor
If fault remains
(8) Reinstall the load weight sensor just has been replaced
and replace logic card of logic unit
502869
2-122
E-02
E-20 - 23
21 19 17 15 - - 9 7
5 3 1
- 24 - 20 18 - - - - 8 6 4 2
1 2 3
Logics
E-20 E-02
R/Y 55
5V
24
3
Br
2 56 23
B GND
1 54 28
Logics
E-03
E-03
- - 37 35 33 - - -
- - 38 36 34 32 - 28
501158
2-123
3.55 Handle Sensor Fault (82)
Error code: 82
Display: "82". All operations inhibited except mast lowering operation. Line steering contactor OPEN. Travelling
Situation
speed limited to 5 km/h.
Possible
Steering wheel unit fault, harness fault, power steering controller fault
cause
Trigger of
One cycle of steering wheel angle input is not within the range between 4 to 6.67 ms.
the error
Steering wheel angle input difference between A and B phase is more than 8 degrees.
code
Checks
(2) Disconnect cable of ESP controller and steering wheel

unit sensor
Check continuity between E-08-26 and F-01-1(27)
(3) Connect power steering controller connector and (4) Replace harness
connect battery plug
Turn on power
Check voltage between F-01-1(Power) and
F-01-2(GND)
(5) Turn off power, turn off battery and discharge (6) Replace logic power board
Replace steering wheel unit
502870
2-124
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-04
E-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- 8 7 6 - - - - 1
E-01 17 - 15 14 - - - 10
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
Life L/R
Signal 53 28
E-08 EPS Controller

W 8
CAN 5 3
6 L 4 21
E-02
30
12V
R/Y 14V
Power 3 R/B 18 VL
10
4 11 1 8V IMS
E-01 B GND
6 12 25 GND U
GND
11 32 GND
R/W V
Fuse 34 LOW
R/Y VE
1 27 W
G/L 25
2 B 26 24 GND
Y/R
Bk 5 30 17 BRAKE +
Br/Y
6 31 33 BRAKE -
F-01 14 TIRE ANGL 1
12V
6 TIRE ANGL 2
1 6 23 GND
2 5
3 4
F-01
H-01(3W)
E-38(4W)
27 R/Y 4 Tire angle
Y/B sensor TWR 2
21
B
5
6
M TVR 1
23
R/Y 3 E-27
27
Br
22 2
23
B 1 1 2
3 2 1 E-27
1 2 3
6 5 4
4 5 6
H-01(3W)
E-38(4W) 501145
2-125
3.56 PS Motor Current Sensor Fault (A4)
Error code: A4
Display: "A4". All lift truck operations inhibited. Line contactor OPEN and ST contactor OPEN.
Situation
All operations inhibited except mast lowering operation.
Possible
Power steering controller.
cause
Trigger of
the error When turning ON power, current sensor value is out of -120A.
code
Checks
502872
2-126
E-08
E-02
- 8 7 6 - - - - 1
- 23 5 3 1
21 19 17 15 - - 9 7 17 - 15 14 - - - 10
- 24 - 20 18 - - - - 8 6 4 2
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
Logics
E-02
E-08 EPS controller
CAN 5 W 3
Inside
6 L 4 21 Inside
of of
30 cover case
R/L 12V
5 9 10 P Fuse
R/Y 14V
Power 3 R/B 10
8V
18
N Battery (-)
4 11 1 DSP IMS
B GND 25 card card
6 12 U IUR
thermistor
Power card Flat
cable W IWR
E-01
Capacitor
E-01 thermistor
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 - PS motor
W TWR 2
M U TUR 1
E-27
1 2
E-27
501138
2-127
3.57 PS Motor Over-current (A5)
Error code: A5
Display: "A5". All lift truck operations inhibited. Line contactor OPEN and ST contactor OPEN.
Situation
  
Faulty PS motor. (Contains the bearing sensor)
Faulty contact or wire breakage of PS motor speed sensor harness.
Possible Faulty PS inverter.
cause Faulty contact or wire breakage of DSP flat cable in PS inverter.
Faulty DSP card of PS inverter.
Trigger of
code
Checks
(2) Check EPS motor body and terminal for burning and small
Normal Abnormal
(3) Check motor terminal (U W phases) for shorting to the (4) Replace EPS motor
motor body and truck frame
(5) Confirm cable looseness and improper connections (6) Remove the all cables of motor and traction inverter
(U W phases) for EPS controller and motor terminals (P N U W )
Normal Abnormal Check motor terminals for shorting to the motor body
(7) Secure cable if loose or

connect cable correctly (8) Replace EPS controller (9) Replace EPS motor or
cables
(10) Steering and check the jerky at very low speed

Normal Abnormal
(11) Replace EPS (12) Replace EPS moter

controller
502873
2-128
E-08
E-02
- 8 7 6 - - - - 1
- 23 5 3 1
21 19 17 15 - - 9 7 17 - 15 14 - - - 10
- 24 - 20 18 - - - - 8 6 4 2
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
Logics
E-02
E-08 EPS controller
CAN 5 W 3
Inside
6 L 4 21 Inside
of of
30 cover case
R/L 12V
5 9 10 P Fuse
R/Y 14V
Power 3 R/B 10
8V
18
N Battery (-)
4 11 1 DSP IMS
B GND 25 card card
6 12 U IUR
thermistor
Power card Flat
cable W IWR
E-01
Capacitor
E-01 thermistor
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 - PS motor
W TWR 2
M U TUR 1
E-27
1 2
E-27
501138
2-129
3.58 PS Handle Brake Fault (A7)
Error code: A7
Situation Steering wheel reaction force disabled, and travelling speed limited to 5 km/h.
Possible
Steering wheel unit fault, harness fault, power steering controller fault
cause
Steering wheel reaction force brake current FB is 1.2A or more.
Trigger of
the error Steering wheel reaction force brake command value > 0.2A and current FB < 0.16A
code
Overcurrent detected by overcurrent detection circuit.
Checks
(2) Disconnect Connecter E-08 of EPS controller and F-01

steering wheel
unit sensor
Continuity Not Continuity
(4) Replace harness

(3) Connect F-01
Measure resistance betweenE-08-17 andE -08-33
8.0 Ω at -30°(-22°F) to 14.9 Ω at 80°(-176°F)
Within the range Outside the range
(5) Replace power steering controller (6) Replace steering wheel unit
502874
2-130
E-02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
E-04
E-08
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- 8 7 6 - - - - 1
E-01 17 - 15 14 - - - 10
25 24 23 - 21 - - 18
34 33 32 - 30 - - - 26
15 13 11 9 - 5 3 -
16 14 12 10 - 6 4 -
E-04
Life L/R
Signal 53 28
E-08 EPS Controller

W 8
CAN 5 3
6 L 4 21
E-02
30
12V
R/Y 14V
Power 3 R/B 18 VL
10
4 11 1 8V IMS
E-01 B GND
6 12 25 GND U
GND
11 32 GND
R/W V
Fuse 34 LOW
R/Y VE
1 27 W
G/L 25
2 B 26 24 GND
Y/R
Bk 5 30 17 BRAKE +
Br/Y
6 31 33 BRAKE -
F-01 14 TIRE ANGL 1
12V
6 TIRE ANGL 2
1 6 23 GND
2 5
3 4
F-01
H-01(3W)
E-38(4W)
27 R/Y 4 Tire angle
Y/B sensor TWR 2
21
B
5
6
M TVR 1
23
R/Y 3 E-27
27
Br
22 2
23
B 1 1 2
3 2 1 E-27
1 2 3
6 5 4
4 5 6
H-01(3W)
E-38(4W) 501145
2-131
3.59 Battery Side Way Exchange Interlock (A8)
Error code: A8
Display: "A8". All lift truck operations inhibited. Line contactor HOLD and ST contactor HOLD.
Possible
Side-mounted interlock switch faulty, harness fault, logic unit fault
cause
Trigger of
the error Battery interlock switch is ON.
code
Checks
(2) Check connection of side- mount battery interlock switch connector

Normal Abnormal
Normal type
(3) Connect the connector
Side-mount battery
(4) Check for Interference between battery cover and switch
No interference Interference
(5) Reinstall cover and switch
(6) Disconnect connector E-04 cable of logic and side - mount battery switch
Check continuity between E-04-56 and Interlock SW(Br/B)
Check continuity between E-04-43 and Interlock SW(B)
Normal type
(7) Replace harness.
Side-mount battery
(8) Manually change side-mount battery switch to batteryavailable status and check continuity on interlock switch
side
Check continuity of interlock SW connector at both ends
(9) Replace logic card of logic unit (10) Replace switch
502875
2-132
E-04
63 61 43
59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
Logics
Side-mount battery
E-04
Br/B 5V
107 56
B
64 43
Interlock SW
Logics
Top-mount battery E-04
Br/B 5V
107 56
B 64 43
Interlock SW
501159
2-133
3.60 Battery Consumption Much
Error code: None

Battery low indicator flashes. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
Situation
and power steering operations.
Possible Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness,
cause faulty logic unit.
Trigger of
Corrected battery voltage is less than 25 V.
the error
Battery voltage is corrected by #46 value.
code
Checks
(2) Check battery voltage

25 V or more Less than 25 V
(3) Set #46 of Setup Option Group (4) Charge battery or replace with new battery
If fault remains
(6) Disconnect connector E-01 and E-04

502876
2-134
EMG
KEY
R/W
19 105 Fuse
Logics
E-02
E- 02
- 23 5 3 1
21 19 17 15 - - 9 7
- 24 - 20 18 - - - - 8 6 4 2
501154
2-135
3.61 Brake Oil, Low Level
Error code: None

Situation Brake fluid icon displayed. All operations available.
Possible
Brake fluid switch fault, harness fault, power steering controller fault
cause
Trigger of
the error Brake fluid SW is ON.
code
Checks
(2) Check brake fluid level

Normal ‫ ޓޓޓޓޓޓ ޓޓ‬Too low
(3) Check brake fluid switch installed condition (4) Add brake fluid
‫ ޓޓޓޓޓޓޓޓޓ‬Abnormal
Normal
(5) Disconnect cable of EPS controller and steering wheel (6) Reinstall brake fluid switch
angle sensor
Check continuity between P3-38 and P 25-1
Check continuity between P3-43 and P 25-2
(7) Replace brake fluid SW (8) Repair or replace main harness
If fault remains
(9)Reinstall brake fluid SW just has been replaced and
replace logic card of logic unit.
502877
2-136
E-03 E-04
63 61 43
- - 37 35 33 - - - 59 - 55 53 51 49 - -
64 62 60 - 56 - 52 50 48 - 44
- - 38 36 34 32 - 28
Logics Logics
E-03 E-04
38 43
GND
Br/B B
63 64
C-01 C-01
2 1
C-01
1
2
501139
2-137
3.62 RTC Battery Low
Error code: None

Situation Hour meter is flashing.
Possible
Battery voltage for calendar IC is low.
cause
Trigger of
the error Signal from calendar IC.
code
Checks
502878
2-138

LUNA MCFE CAT - Book

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CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

Chapter 2 TROUBLESHOOTING FOR CONTROL CIRCUITS

(2) Disconnect connector E-01 of logic unit. Check continuity between

(3) Normal (4) Repair or replace harness

(1) Turn OFF the lift truck power.

(1) Open circuits are often caused by dirty harness

Electronic parts cleaner

Note: The cleaner liquid is volatile (evaporates by itself).

(2) After checking the connector for continuity, wash it as

Contact surface activator

Note: Do not spray too much liquid into the connector.

Error Error name Error Error name

(1) Let truck cool for 15 minutes

(2) Traction motor becomes normal

(4) Adjust brake

(5) Lift front wheels, and disengage parking brake

(6) Check if truck is operated on steep

(7) Perform inverter discharging work

(8) Replace right traction (9) Replace right traction

With service tool

(10) Confirm temperature of right traction motor with

(11) Disconnect battery plug (12) Normal

(13) Perform inverter discharging work

(14) Disconnect connector E-14 of right traction motor

(18) Disconnect connector E-02 of logic unit

(21) Measure voltage between E-07-18(11) and

(22) Disconnect battery plug

(25) Disconnect battery plug, then perform Inverter

(26) Replace DSP card of (27) Connect connector

E-17 Traction motor (right)

(1) Let truck cool for 15 minutes

(2) on motor becomes normal

(4) Adjust brake

(5) Lift front wheels, and disengage parking brake

(6) Check if truck is operated on steep

(7) Perform inverter discharging work

(8) Replace left traction (9) Replace left traction

(10) Confirm temperature of left traction motor with

(13) Perform inverter discharging work

(14) Disconnect connector E-15 of left traction motor

(21) Measure voltage between E-06-18(10) and

(22) Disconnect battery plug

(25) Disconnect battery plug, then perform Inverter

(26) Replace DSP card of (27) Connect connector

E-18 Traction motor (left)

(1) Let truck cool for 15 minutes

(2) Pump motor becomes normal

(3) Check if truck is operated to lift large cargo load

(4) Perform inverter discharging work

(5) Check oil pressure of gear pump and hydraulic lines

(6) Replace pump motor (7) Repair or replace

(8) Confirm temperature of pump motor with

(9) Disconnect battery plug (10) Normal

(11) Perform inverter discharging work

(12) Disconnect connector E-16 of pump motor

(13) Replace pump motor

(14) Disconnect connector E-05 of pump motor inverter

(17) Repair or replace harness

(19) Disconnect battery plug