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FOREWORD This Manual (Volume 2) contains diagnosis, service procedures of electrical controller and display of the TOYOTA ELECTRICAL POWERED FORKLIFT 8FBN15 to 30, 50-8FBN15·18·20 series. For maintenance, specifications and repair procedure for the chassis, body and material handling system, refer to Volume 1 (Pub. No. CE349). Please use these manuals for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of January, 2012. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.
SECTION INDEX NAME
SECTION
GENERAL
0
BATTERY
1
CHARGER (OPT)
2
CONTROLLER
3
DISPLAY FUNCTIONS
4
TROUBLESHOOTING
5
FRONT MODULE
6
REAR AXLE
7
STEERING
8
BODY
9
MATERIAL HANDLING SYSTEM
10
MAST
11
CYLINDER
12
SAS-ε FUNCTIONS (OPT)
13
MATCHING
14
APPENDIX
15
Section indicated by solid characters are included in this manual. Section indicated by half-tone characters: Refer to vol. 1 (Pub. No. CE349).
3-1
CONTROLLER Page
GENERAL ........................................................................3-2 COMPONENTS .............................................................3-10
0
BEFORE REPAIR ......................................................... 3-11
1
INSPECTION ................................................................. 3-11
2
CONNECTOR INSPECTION ......................................3-12
3
TO USE SST .................................................................. 3-12
4
INSPECTION ................................................................. 3-12
5
MAIN CONTROLLER ..................................................3-30 REMOVAL·INSTALLATION...........................................3-30
MATERIAL HANDLING AC DRIVER .......................3-33 REMOVAL·INSTALLATION (1 ton series and 50-8FBN20)................................... 3-33
6 7 8 9
REMOVAL·INSTALLATION (2 · 3 ton series, except 50-8FBN20)........................ 3-36
10
DRIVE AC DRIVER ......................................................3-38
11
OCL MEASUREMENT ................................................3-39
12 13 14
3-2
GENERAL MAIN CONTROLLER
G85703001_
Caution: When replacing the main controller,always check the part No.
3-3
CONNECTOR-PIN ASSIGNMENT CN101
CN102
CN103
CN104
0 1 G85703002_
CN101 No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
102 SOLLU+
SOLLU+
UNLOAD, LIFT+
103 SLTFB+
SLTFB+
TILTF, R+
104 FAN+
FAN+
RYR, FAN+
105 VBBT
VBBT
VBBT
106 SLLA2+
SOL1, 4+
SOL1, 4+
107 SLTA1+
SOL2, 3+
SOL2, 3+
108 ---
SOL5+
SOL5+
109 ---
SOL5B
SOL5B
110 ---
SOL5A
SOL5A
111 SA1PL-
SOL3B
SOL3B
112 SA1PS-
SOL3A
SOL3A
113 STPL-
SOL2B
SOL2B
114 STPS-
SOL2A
SOL2A
115 SA2PL-
SOL4B
SOL4B
116 SA2PS-
SOL4A
SOL4A
117 SLPS-
SOL1A
SOL1A
118 SLPL-
SOL1B
SOL1B
119 VBBA (only 3 ton series) VBBA
VBBA
120 VBKY
VBKY
VBKY
121 VRTA+
VRTA+
TILT ANGLE SENSOR POWER SUPPLY
122 ---
VRS+
SWING ANGLE SENSOR POWER SUPPLY
123 VRA-
VRA-
ACCELERATOR SENSOR GND
124 VRTRA+
VRTRA+
TIRE ANGLE SENSOR POWER SUPPLY
125 VRH+
VRH+
HEIGHT SENSOR POWER SUPLLY
126 VRL+
VRL+
LIFT LEVER SENSOR POWER SUPPLY
127 VRA2+
VRA2+
ACCELERATOR SENSOR 2 POWER SUPPLY
128 VRA1+
VRA1+
ACCELERATOR SENSOR 1 POWER SUPPLY
129 VRT+
VRT+
TILT LEVER SENSOR POWER SUPPLY
130 VRAT1+
VRAT1+
ATTACHMENT 1 LEVER SENSOR POWER SUPPLY
131 VRAT2+
VRAT2+
ATTACHMENT 2 LEVER SENSOR POWER SUPPLY
132 ---
VRAT3+
ATTACHMENT 3 LEVER SENSOR POWER SUPPLY
133 POT-
POT-
GND3
134 VRB2+
VRB2+
BRAKE SENSOR 2 POWER SUPPLY
135 VRB1+
VRB1+
BRAKE SENSOR 1 POWER SUPPLY
2 3 4 5 6 7 8 9 10 11 12 13 14
3-4 CN102 No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
67
---
FNDC1
FAN1
68
---
FNDC2
FAN2
69
VBMBSL
VBMBSL
VBMBSOL
70
VBMBSL
VBMBSL
VBMBSOL
71
SOLCOM
SOLCOM
SOLCOM
72
SOLCOM
SOLCOM
SOLCOM
73
SLS+
SLS+
KNOB, MPS+
74
---
OACC3
ACCESSORY 3 (for FORWARD)
75
---
OACC2
ACCESSORY 2 (for REVERSE)
76
LS-
LS-
GND2
77
---
OACC1
ACCESSORY 1 (for BRAKE)
78
---
RY2-
RYR2
79
RY1-
RY1-
RYR1
80
SLS-
SLS-
KNOB-
81
---
MPS-
SLDM-(MPS-)
82
SLLL-
SLLL-
LIFT-
83
---
SLUL-
UNLOAD-
84
---
SLTBL-
TILTR-
85
SLTFL-
SLTFL-
TILTF-
86
VRA12
VRA12
ATTACHMENT 1 LEVER SENSOR 2
87
VRA11
VRA11
ATTACHMENT 1 LEVER SENSOR 1
88
VRT2
VRT2
TILT LEVER SENSOR 2
89
VRT1
VRT1
TILT LEVER SENSOR 1
90
CSBAT
CSBAT
BATTERY CURRENT SENSOR
91
VRB2
VRB2
BRAKE SENSOR 2 (combined with SW)
92
POT-
POT-
GND4
93
---
CHK5V
5V POWER SUPPLY for CHECK
94
VRA22
VRA22
ATTACHMENT 2 LEVER SENSOR 2
95
VRA21
VRA21
ATTACHMENT 2 LEVER SENSOR 1
96
VRA1
VRA1
ACCELERATOR SENSOR 1
97
VRTRA
VRTRA
TIRE ANGLE SENSOR
98
VRA2
VRA2
ACCELERATOR SENSOR 2
99
VRB1
VRB1
BRAKE SENSOR 1 (combined with SW)
100 ---
VRS
SWING ANGLE SENSOR
101 CSBAT-
CSBAT-
BATTERY CURRENT SENSOR GND
3-5 CN103 No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
32
---
SLSW+
SWING+
33
---
SLSW-
SWING-
34
DGND
DGND
DISPLAY GND
35
KYSAT
KYSAT
KEYSTART
36
N2
N2
N2
37
LS-
LS-
GND4
38
---
SMTSA
SMTSA
39
IPL+
IPL+
SHOCK SENSOR POWER SUPPLY
40
---
CAN2H
CAN2H
41
---
CAN2L
CAN2L
42
CAN1H
CAN1H
CAN1H
43
CAN1L
CAN1L
CAN1L
44
SSTR+
SSTR+
STEERING WHEEL ANGLE SENSOR AND ULTRA SONIC SENSOR POWER SUPPLY (combined use)
45
D7V
D7V
DISPLAY POWER SUPPLY
46
---
CHK15V
15V POWER SUPPLY for CHECK
47
---
CHK33V
3.3V POWER SUPPLY for CHECK
48
VRTA
VRTA
TILT ANGLE SENSOR
49
VRL2
VRL2
LIFT LEVER SENSOR 2
50
IPL2
IPL2
SHOCK SENSOR 2
51
---
SSTMA
SSTMA
52
---
SMTSK
SMTSK
53
---
SSTMK
SSTMK
54
---
OPTSS2
OPTSS2
55
SH2-1
SH2-1
LIFTING HEIGHT SWITCH 2-1
56
SHL
SHL
HEIGHT LIMIT SWITCH
57
VRL1
VRL1
LIFT LEVER SENSOR 1
58
---
SYR
YAW RATE SENSOR
59
VRH
VRH
HEIGHT SENSOR
60
SPLF
SPLF
PRESSURE SENSOR
61
IPL1
IPL1
SHOCK SENSOR 1
62
---
SH2-2
LIFTING HEIGHT SWITCH 2-2
63
STK
STK
AUTOMATIC FORK LEVELING SWITCH
64
---
OLM+
LASER POINTER POWER SUPPLY
65
---
VRA32
ATTACHMENT 3 LEVER SENSOR 2
66
---
VRA31
ATTACHMENT 3 LEVER SENSOR 1 (SWITCH for 4/5-way)
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
3-6 CN104 No.
TERMINAL NAME
CIRCUIT CODE
REMARKS
1
B48V
B48V
B80V(B48V)
2
VBMB
VBMB
VBMB
3
CBAT+
CBAT+
MB, P+
4
N2
N2
N2
5
N2
N2
N2
6
N2
N2
N2
7
---
N2
N2
8
FNDC
MP-
MP-
9
CBAT-
CBAT-
MB-
10
CSBAT+
CSBAT+
BATTERY CURRENT SENSOR POWER SUPPLY
11
---
SYR-
YAW RATE SENSOR GND
12
SPLF+
SPLF+
PRESSURE SENSOR POWER SUPPLY
13
---
SYR+
YAW RATE SENSOR POWER SUPPLY
14
PSACC+
PSACC+
ACCESSORY POWER SUPPLY
15
PSSW+
PSSW+
POWER SUPPLY for MINI LEVER SWITCH (LOAD METER, AUTOMATIC FORK LEVERING and SWITCH for 4/5-WAY SW)
16
---
CHKG
CHKG
17
---
OPT2
OPT2
18
SDM
SDM
SEAT SWITCH
19
DSR
DSR
DIRECTION SWITCH REVERSE
20
SPB
SPB
PARKING BRAKE SWITCH
21
---
OPTSSC
OPTSSC
22
SH1
SH1
LIFTING HEIGHT SWITCH 1
23
SWBK
SWA
SWA
24
SSTRC
SSTRC
STEERING WHEEL ANGLE SENSOR 3 (only SSC combined with SW)
25
---
OPTSS1
OPTSS1
26
DSF
DSF
DIRECTION SWITCH FORWARD
27
---
LSOPT1
LSOPT1
28
SHS
SHS
HEIGHT SELCTOR SWITCH
29
---
BMP
BMP
30
SSTR1
SSTR1
STEERING WHEEL ANGLE SENSOR 1 (only SSC combined with SW)
31
SSTR2
SSTR2
STEERING WHEEL ANGLE SENSOR 2 (only SSC combined with SW)
3-7
DRIVE·MATERIAL HANDLING AC DRIVER 1 ton model Applicable model : 8FBN15 8FBN16 8FBN18
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
Applicable model : 50-8FBN15 50-8FBN18
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
G85703003_
3-8 2 ton model Applicable model : 8FBN20 8FBN25
RH side of vehicle Material Handling AC Driver
Vehicle front side
Drive AC Driver
Applicable model : 50-8FBN20
Material Handling AC Driver
RH side of vehicle
Vehicle front side
Drive AC Driver
G85703004_
3-9 3 ton model Applicable model : 8FBN30
RH side of vehicle Material Handling AC Driver
Vehicle front side
Drive AC Driver
G85703005_
3-10
COMPONENTS
1 1 3 1 1 2
4 *T1 8
7 *T3
5
9 6
10 9
11
13 9
12 *T2
7 *T3
13
8 5 14 G85703013_
* Tightening torque: T = N·m (kgf·cm) [ft·lbf] T1 = 3.85 ~ 7.15 (39.3~ 72.9) [2.84 ~ 5.28] T2 = 1.3 ~ 1.7 (13 ~ 17) [1.0 ~ 1.3] T3 = 12.2 ~ 16.8 (124 ~ 171) [9.00 ~ 12.4] No.
Parts name
QTY
No.
Parts name
QTY
1
Bolt
4
8
Bolt
8
2
Bracket
1
9
Bolt
6
3
Bracket
1
10
Bracket
1
4
Bolt
4
11
Fan motor
1
5
AC driver
1
12
Screw
4
6
Main controller
1
13
Sponge
2
7
Nut
11
14
Bracket
1
3-11
BEFORE REPAIR INSPECTION 1
Insulation resistance measurement
Note: Always measure before inspecting the drive/material handling controller and the main controller. (1) Disconnect the battery plug and measure the resistance between battery plug and body.
G85703014_
Measurement terminals Standard:
Controller side of battery plug-body Resistance value depends greatly on the vehicle operating state, place and weather. (Approx. 1MΩ or more)
Some components can be inspected after they are removed from the vehicle, some components can be inspected as installed on the vehicle. Main controller must be inspected as installed on the vehicle since the battery voltage must be applied.
Disassembly Procedure • Overhauling the contactor panel is rarely necessary. In most cases, failed parts is replaced after finding out the cause of the failure from inspection. Therefore, make sure to repair correctly by referring to the figures of configuration and ASSY. • Do not disassemble drive·material handling AC driver and the main controller, as they should be replaced in a form of ASSY.
Caution for part replacement • Observe the specified tightening torque for tightening bolts. Insufficient torque and overlooking of tightening may cause other failure. • When disconnecting the bars and harness, record the connecting location and place tags. When connecting them again, be sure to confirm with the record and tags to prevent incorrect connection. Incorrect connection may cause other failure. • After installation, check that there is no interference of the bar and harness connection with other portion.
3-12
CONNECTOR INSPECTION TO USE SST Use SSTs for quick and accurate measure on the 8FBCU20~32, 8FBCHU25. The check will fail if the connection method is wrong. Since boards may be damaged by incorrect connection, the operation is needed to be careful. Caution: Always unplug the battery plug before SST connection and disconnection. If the battery plug is still connected, various boards may be damaged. Part No.
Purpose
Remarks
09230-13240-71
Measure the voltage or resistance for main controller.
For use CN101 to CN104
09240-13241-71
Measure the voltage for AC driver.
For use CN110 to CN111
INSPECTION When inspecting each board and the cause of the trouble is found, do not immediately replace the board but check the following items. • Abnormality in related harnesses • Looseness of the related connectors • Bending or damage of connector pin and defective contact of any related connector pin. If any of the above is the cause of the trouble and the board is replaced with a new one, the new board will be damaged. Always replace the board after careful inspection. Measurement method and standard list How to read the list
Tester Probe + Tester Probe -
Connecror No. CN101-1 (45, DSF)
Connector No. CN101-26 (51, LS-) Terminal name
Conditions Key switch OFF, DSF ON.
Standard
Remarks
Approx. 0V
Conditions for measurement
Electric Level No. Connector pin No.
G85703015_
3-13
MAIN CONTROLLER CPU board
CN101
CN102
CN103
CN104
G85703016_
Material Handling Lever CN101 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
Remarks
CN101-1 (3, SOLLU+)
CN102-16 (4, SLLL-)
Lift lock solenoid ON Lift lock solenoid OFF
Approx. 11V Approx. 0V
CN101-2 (6, SLTFB+)
CN102-19 (7, SLTFL-)
Tilt forward solenoid ON Tilt forward solenoid OFF
Approx. 11V Approx. 0V
CN101-3 (97, FAN+)
CN104-4 (N2, N2)
-
Approx. 48V
CN101-4 (41, VBBT)
CN104-4 (N2, N2)
-
Approx. 48V
CN101-5 (9, SLLA2+)
CN101-16 (11, SLPS-)
Variation upon changeover from upward to downward lifting
Approx. 0V to 10V
CN101-6 (32, SLTA1+)
CN101-12 (33, STPL-)
Variation upon changeover from forward to backward tilting
Approx. 0V to 10V
CN101-7
-
Unused
-
CN101-8
-
Unused
-
CN101-9
-
Unused
-
CN101-10 (36, SA1PL-)
CN101-6 (32, SLTA1+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
*1
CN101-11 (37, SA1PS-)
CN101-6 (32, SLTA1+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
*1
CN101-12 (33, STPL-)
CN101-6 (32, SLTA1+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
CN101-13 (34, STPS-)
CN101-6 (32, SLTA1+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
CN101-14 (39, SA2PL-)
CN101-5 (9, SLLA2+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
*2
3-14 Connector No. ⇔ Connector No.
Conditions
Standard
Remarks *2
CN101-15 (40, SA2PS-)
CN101-5 (9, SLLA2+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
CN101-16 (11, SLPS-)
CN101-5 (9, SLLA2+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
CN101-17 (10, SLPL-)
CN101-5 (9, SLLA2+)
Resistance measurement with battery plug disconnected
Approx. 7Ω
CN101-18 (99, VFAN)
CN104-4 (N2, N2)
FAN ON
Approx. 30V
CN101-19 (47, VBKY)
CN104-4 (N2, N2)
Key switch OFF Key switch ON
Approx. 0V Approx. 48V
CN101-20 (57, VRTA+)
CN101-32 (51, POT-)
CN101-21
-
CN101-22 (50, VRA-)
-
-
-
CN101-23 (316, VRTRA+)
CN101-32 (51, POT-)
-
Approx. 5V
CN101-24 (219, VRH+)
CN101-32 (51, POT-)
-
Approx. 5V
CN101-25 (28, VRL+)
CN101-32 (51, POT-)
-
Approx. 4.6V
CN101-26 (55, VRA2+)
CN101-32 (51, POT-)
-
Approx. 4.8V
CN101-27 (53, VRA1+)
CN101-32 (51, POT-)
-
Approx. 4.8V
CN101-28 (29, VRT+)
CN101-32 (51, POT-)
-
Approx. 4.6V
CN101-29 (30, VRAT1+)
CN101-32 (51, POT-)
-
Approx. 4.6V
*1
CN101-30 (31, VRAT2+)
CN101-32 (51, POT-)
-
Approx. 4.6V
*2
CN101-31
-
CN101-32 (51, POT-)
-
-
-
CN101-33 (74, VRB2+)
CN101-32 (51, POT-)
-
Approx. 4.8V
CN101-34 (72, VRB1+)
CN101-32 (51, POT-)
-
Approx. 4.8V
Unused
3 ton only
Approx. 5V -
Unused
-
*1: W/ ATT1 *2: W/ ATT2 CN102 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN102-1
-
Unused
-
CN102-2
-
Unused
-
CN102-3 (19, VBMBSL)
CN104-4 (N2, N2)
Key switch OFF Key switch ON
Approx. 0V Battery voltage
CN102-4 (19, VBMBSL)
CN104-4 (N2, N2)
Key switch OFF Key switch ON
Approx. 0V Battery voltage
CN102-5 (17, SOLCOM)
CN104-4 (N2, N2)
Key switch OFF Key switch ON
Approx. 0V Battery voltage
Remarks
3-15 Connector No. ⇔ Connector No.
Conditions Key switch OFF Key switch ON
Standard
CN102-6 (17, SOLCOM)
CN104-4 (N2, N2)
CN102-7 (329, SLS+)
CN102-14 (330, SLS-)
CN102-8
-
Unused
-
CN102-9
-
Unused
-
CN102-10 (51, LS-)
-
CN102-11
-
Unused
-
CN102-12
-
Unused
-
CN102-13 (335, RY-)
CN104-4 (N2, N2)
CN102-14 (330, SLS-)
CN102-7 (329, SLS+)
CN102-15
-
CN102-16 (4, SLLL-)
CN101-1 (3, SOLLU+)
CN102-17
-
Unused
-
CN102-18
-
Unused
-
CN102-19 (7, SLTFL-)
CN101-2 (6, SLTFB+)
CN102-20 (25, VRA12)
CN102-26 (51, POT-)
Attachment 1 lever in the neutral position Attachment 1 lever in the forward to backward position
CN102-21 (24, VRA11)
CN102-26 (51, POT-)
Attachment 1 lever in the neutral position Attachment 1 lever in the forward to backward position
CN102-22 (23, VRT2)
CN102-26 (51, POT-)
Tilt lever in the neutral position Tilt lever in the forward to backward position
CN102-23 (22, VRT1)
CN102-26 (51, POT-)
Tilt lever in the neutral position Tilt lever in the forward to backward position
CN102-24 (304, CSBAT)
CN102-35 (305, CSBAT-)
CN102-25 (73, VRB2)
CN102-26 (51, POT-)
CN102-26 (51, POT-)
-
CN102-27
-
CN102-28 (27, VRA22)
CN102-26 (51, POT-)
Remarks
Approx. 0V Battery voltage
Knob position correcting solenoid ON Knob position correcting solenoid OFF
-
Approx. 11V Approx. 0V
-
Key switch OFF Key switch ON
Approx. 48V Approx. 36V
Resistance measurement with battery plug disconnected
Approx. 10Ω
Unused
-
Resistance measurement with battery plug disconnected
Resistance measurement with battery plug disconnected
Key switch OFF, Resistance variation when brake pedal fully depressed Unused Attachment 2 lever in the neutral position Attachment 2 lever in the forward to backward position
Approx. 10Ω
Approx. 10Ω Approx. 2.3V Approx. 0.5V to 4V
*1
Approx. 2.3V Approx. 0.5V to 4V
*1
Approx. 2.3V Approx. 0.5V to 4V Approx. 2.3V Approx. 0.5V to 4V Approx. 2.5V Approx. 0.9V to 2.9V
Except for models with 50-
Approx. 2.3V Approx. 0.5V to 4V
*2
3-16 Connector No. ⇔ Connector No.
Conditions
Standard Approx. 2.3V
CN102-29 (26, VRA21)
CN102-26 (51, POT-)
Attachment 2 lever in the neutral position Attachment 2 lever in the forward to backward position
CN102-30 (52, VRA1)
CN102-26 (51, POT-)
Key switch OFF, Resistance variation when Approx. 0.5V to 3.8V accelerator pedal fully depressed
CN102-31 (317, VRTRA)
CN102-26 (51, POT-)
Tire in neutral position
CN102-32 (54, VRA2)
CN102-26 (51, POT-)
Key switch OFF, Resistance variation when Approx. 0.9V to 4.1V accelerator pedal fully depressed
CN102-33 (71, VRB1)
CN102-26 (51, POT-)
Key switch OFF, Resistance variation when brake pedal fully depressed
CN102-34
-
CN102-35 (305, CSBAT-)
-
Unused
Approx. 0.5V to 4V
Remarks *2
Approx. 2.0V
Approx. 0.6V to 2.6V
Except for models with 50-
-
-
*1: W/ ATT1 *2: W/ ATT2 CN103 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN103-1
-
Unused
-
CN103-2
-
Unused
-
CN103-3 (14, DGND)
-
CN103-4 (42, KYSAT)
CN104-4 (N2, N2)
CN103-5 (N2, N2)
-
-
-
CN103-6 (51, LS-)
-
-
-
CN103-7
-
CN103-8 (300, IPL+)
CN102-26 (51, POT-)
CN103-9
-
Unused
-
CN103-10
-
Unused
-
CN103-11 (145, CAN1H)
-
Immeasurable
-
CN103-12 (146, CAN1L)
-
Immeasurable
-
CN103-13 (311, SSTR+)
CN103-6 (51, LS-)
-
Approx. 14V
CN103-14 (16, D7V)
CN103-3 (14, DGND)
-
Approx. 6.5V
CN103-15
-
Unused
-
CN103-16
-
Unused
-
CN103-17 (56, VRTA)
CN102-26 (51, POT-)
Key switch OFF Key switch ON
Approx. 0V Battery voltage
Unused
-
Variation upon changeover from forward to backward tilting
Approx. 5V
Approx. 1V to 4V
Remarks
3-17 Connector No. ⇔ Connector No.
Conditions Lift lever in the neutral position Lift lever in the forward to backward position
Standard Approx. 2.3V Approx. 0.5 to 4V
CN103-18 (21, VRL2)
CN102-26 (51, POT-)
CN103-19 (302, IPL2)
CN102-26 (51, POT-)
CN103-20
-
Unused
-
CN103-21
-
Unused
-
CN103-22
-
Unused
-
CN103-23
-
Unused
-
CN103-6 (51, LS-)
Key switch OFF, mast in uppermost position Key switch OFF, mast in lowermost position
Approx. 0V
CN103-24 (91, SH2-1)
CN103-6 (51, LS-)
Key switch OFF, mast height switch ON Key switch OFF, mast height switch OFF
Approx. 0V
CN103-25 (221, SHL) CN103-26 (20, VRL1)
CN102-26 (51, POT-)
CN103-27
-
CN103-28 (220, VRH)
CN102-26 (51, POT-)
Resistance variation when raising and lowering the lift
CN103-29 (59, SPLF)
CN102-26 (51, POT-)
Forks on the ground Approx. 1V or less Resistance variation when raising Approx. 0.5V to 4.5V and lowering the lift with a load
CN103-30 (301, IPL1)
CN102-26 (51, POT-)
CN103-31
-
CN103-32 (70, STK)
CN103-6 (51, LS-)
CN103-33
-
Unused
-
CN103-34
-
Unused
-
CN103-35
-
Unused
-
-
Lift lever in the neutral position Lift lever in the forward to backward position Unused
Approx. 2V
Approx. 5V
Approx. 5V Approx. 2.3V Approx. 0.5 to 4V -
Unused Key switch OFF, automatic fork leveling switch ON Key switch OFF, automatic fork leveling switch OFF
Approx. 0.5 to 4.3V
Approx. 2V Approx. 0V Approx. 5V
Remarks
3-18 CN104 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
-
Battery voltage
CN104-1 (41, B48V) (18, B80V)
CN104-4 (N2, N2)
CN104-2 (44, VBMB)
CN104-4 (N2, N2)
Key switch OFF Key switch ON
Approx. 0V Battery voltage
CN104-3 (1, CBAT+)
CN104-9 (2, CBAT-)
Key switch ON Key switch OFF
Approx. 11V Approx. 0V
CN104-4 (N2, N2)
-
-
-
CN104-5 (N2, N2)
-
-
-
CN104-6 (N2, N2)
-
-
-
CN104-7
-
CN104-8 (98, FNDC)
-
CN104-9 (2, CBAT-)
CN104-3 (1, CBAT+)
CN104-10 (303, CSBAT+)
CN102-35 (305, CSBAT-)
CN104-11
-
CN104-12 (58, SPLF+)
CN102-26 (51, POT-)
CN104-13
-
CN104-14 (334, PSACC+)
CN104-4 (N2, N2)
-
Approx. 14V
CN104-15 (60, PSSW+)
CN104-4 (N2, N2)
-
Approx. 14V
CN104-16
-
Unused
-
CN104-17
-
Unused
-
CN104-18 (67, SDM)
CN103-6 (51, LS-)
Key switch OFF, seat switch ON Key switch OFF, seat switch OFF
Approx. 0V Approx. 5V
CN103-6 (51, LS-)
Key switch OFF, direction switch backward Key switch OFF, direction switch neutral
Approx. 0V
CN104-19 (46, DSR)
CN103-6 (51, LS-)
Key switch OFF, parking brake switch release Key switch OFF, parking brake switch lock
Approx. 0V
CN104-20 (66, SPB)
CN104-21
-
CN104-22 (90, SH1)
CN103-6 (51, LS-)
Unused
-
Resistance measurement with battery plug disconnected Unused
Approx. 20Ω Approx. 5V -
Unused
Approx. 5V -
Unused Mast in uppermost position, key switch OFF Mast raising, key switch OFF
Approx. 5V
Approx. 5V
Approx. 0V Approx. 5V
Remarks
3-19 Connector No. ⇔ Connector No.
Conditions
Standard
Remarks
Approx. 0V Approx. 5V
Only for models with 50-
CN104-23 (65, SWBK)
CN103-6 (51, LS-)
Key switch OFF, brake not operated Key switch OFF, brake operated
CN104-24 (314, SSTRC)
CN103-6 (51, LS-)
Steering operation
CN104-25
-
CN104-26 (45, DSF)
CN103-6 (51, LS-)
CN104-27
-
CN104-28 (68, SHS)
CN103-6 (51, LS-)
CN104-29
-
CN104-30 (312, SSTR1)
CN103-6 (51, LS-)
Steering operation
Approx. 0V to 5V
CN104-31 (313, SSTR2)
CN103-6 (51, LS-)
Steering operation
Approx. 0V to 5V
Unused Key switch OFF, direction switch forward Key switch OFF, direction switch neutral Unused Key switch OFF, load switch ON Key switch OFF, load switch OFF Unused
Approx. 0V to 5V Approx. 0V Approx. 5V Approx. 0V Approx. 5V -
3-20
DRIVE AC DRIVER
CN110 and CN111
8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 23 22 21 20 19 18 17 16 G85703017_
CN110 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN110-1
-
-
-
CN110-2 (14, CANGND)
( N1)
-
Approx. 0V
CN110-3 (80, SSD2)
(N1, N1)
-
L: Approx. 0.5V or H: Approx. 1.5V
CN110-4 (79, SSD1)
(N1, N1)
-
L: Approx. 0.5V or H: Approx. 1.5V
CN110-5
-
-
-
CN110-6 (78, SSD+)
(N1, N1)
-
Approx. 12V
CN110-7
-
-
-
CN110-8 (42, KYSAT)
(N1, N1)
-
Battery voltage
CN110-9
-
-
-
CN110-10 (146, CAN1L)
-
CN110-11
-
-
-
CN110-12
-
-
-
CN110-13
-
-
-
CN110-14
-
-
-
CN110-15
-
-
-
CN110-16
-
-
-
CN110-17 (145, CAN1H)
-
CN110-18
-
-
-
CN110-19
-
-
-
CN110-20
-
-
-
CN110-21
-
-
-
CN110-22 (87, STDM)
(N1, N1)
-
Approx. 0V
CN110-23 (86, STDM+)
(N1, N1)
-
Approx. 0.2 to 3.0V
Immeasurable
-
Immeasurable
-
Remarks
3-21
MATERIAL HANDLING AC DRIVER CN111 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN111-1
-
-
-
CN111-2 (14, CANGND)
(N1)
-
Approx. 0V
CN111-3
-
-
-
CN111-4 (82, SSP1)
(N1, N1)
-
L: Approx. 0.5V or H: Approx. 1.5V
CN111-5
-
-
-
CN111-6 (81, SSP+)
(N1, N1)
-
Approx. 12V
CN111-7
-
-
-
CN111-8 (42, KYSAT)
(N1, N1)
-
Approx. 48V
CN111-9
-
-
-
CN111-10 (146, CAN1L)
-
CN111-11 (152, SETP-)
(N1, N1)
CN111-12 (152, SETP1)
(N1, N1)
-
Approx. 0V
CN111-13
-
-
-
CN111-14
-
-
-
CN111-15
-
-
-
CN111-16
-
-
-
CN111-17 (145, CAN1H)
-
CN111-18
-
-
-
CN111-19
-
-
-
CN111-20
-
-
-
CN111-21
-
-
-
CN111-22 (89, STPM)
(N1, N1)
-
Approx. 0V
CN111-23 (88, STPM+)
(N1, N1)
-
Approx. 0.2 to 3.0V
Immeasurable
Approx. 0V
Immeasurable
-
Remarks
3-22
CONTACTOR PANEL ASSY
1 · 2 ton
3 ton
CN128
CN137
CN143
CN136
CN137
CN143
CN136
CN127
CN142
CN127
CN127
CN128
CN142
CN136
CN137
G85703018_
CN127 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
-
-
CN127-1
-
CN127-2 (97, RY+)
N1 terminal (N1, N1)
CN127-3
-
-
-
CN127-4
-
-
-
CN127-5
-
-
-
CN127-6 (19, VBMBSL)
N1 terminal (N1, N1)
CN127-7
-
CN127-8 (17, SOLCOM)
N1 terminal (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
Apply the negative probe to the N1 terminal to measure voltage. Apply the negative probe to the N1 terminal to measure voltage.
Approx. 48V
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V 1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
Remarks
3-23 CN128 connector basic conditions (3 ton series only) (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN128-1
-
-
-
CN128-2
-
-
-
CN128-3 (1, CBAT+)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
Approx. 80V
CN128-4 (1, CBAT+)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
Approx. 80V
CN128-5 (1, CBAT+)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
Approx. 80V
CN128-6 (1, CBAT+)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
Approx. 80V
CN128-7
-
CN128-8 (99, VFAN)
N1 (N1, N1)
Fan ON Apply the negative probe to the N1 terminal to measure voltage.
Approx. 30V
CN128-9 (99, VFAN)
N1 (N1, N1)
Fan ON Apply the negative probe to the N1 terminal to measure voltage.
Approx. 30V
CN128-10 (99, VFAN)
N1 (N1, N1)
Fan ON Apply the negative probe to the N1 terminal to measure voltage.
Approx. 30V
CN128-11 (99, VFAN)
N1 (N1, N1)
Fan ON Apply the negative probe to the N1 terminal to measure voltage.
Approx. 30V
CN128-12
-
-
-
Remarks
-
-
CN136 connector basic conditions (battery plug connected, key switch OFF) Connector No. ⇔ Connector No.
Conditions
Standard
CN136-1 (101, FLP)
P2 (P2, P2)
Battery plug disconnected, and the CN136 connector disconnected
Approx. 0 Ω
CN136-2 (41, B48V)
P2 (P2, P2)
Battery plug disconnected, and the CN136 connector disconnected
Approx. 0 Ω
CN136-3 (1, CBAT+)
CN136-4 (2, CBAT-)
Apply the negative probe to the CN136-3 to measure voltage.
Approx. 11 Ω
CN136-4 (2, CBAT-)
CN136-3 (1, CBAT+)
Battery plug disconnected, and the CN136 connector disconnected
Approx. 20 Ω
CN136-5 (44, VBMB)
P3 (P3, P3)
Battery plug disconnected, and the CN136 connector disconnected
Approx. 0 Ω
CN136-6 (19, VBMBSL)
P3 (P3, P3)
Battery plug disconnected, and the CN136 connector disconnected
Approx. 0 Ω
CN136-7 (42, KYSAT)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
CN136-8 (42, KYSAT)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
Remarks
3-24 CN137 connector basic conditions (battery plug connected, key switch OFF) Connector No. ⇔ Connector No. CN137-1 (303, CSBAT+)
CN137-2 (305, CSBAT-)
CN137-2 (305, CSBAT-)
-
CN137-3 (304, CSBAT)
CN137-2 (305, CSBAT-)
Conditions Apply the negative probe to the CN137-2 to measure voltage. Apply the negative probe to the CN137-2 to measure voltage. Drive motor, pump motor, all auxiliary machines OFF
Standard
Remarks
Approx. 5V -
Approx. 2.5V
CN142 connector basic conditions (battery plug connected, key switch OFF) Connector No. ⇔ Connector No.
Conditions
Standard
CN142-1 (P3, P3)
CN142-2 (15, RCP)
Battery plug disconnected, and CN142 disconnected
Approx. 20 Ω
CN142-2 (15, RCP)
-
Battery plug disconnected, and CN142 disconnected
-
CN142-3
-
Battery plug disconnected, and CN142 disconnected
-
Remarks
CN143 connector basic conditions (battery plug connected, key switch OFF) Connector No. ⇔ Connector No.
Conditions
Standard
CN143-1 (42, KYSAT)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
CN143-2 (42, KYSAT)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
CN143-3
-
-
-
CN143-4
-
-
-
CN143-5 (15, RCP)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
CN143-6 (15, RCP)
N1 (N1, N1)
Apply the negative probe to the N1 terminal to measure voltage.
1·2 ton series: Approx. 48V 3 ton series: Approx. 80V
Remarks
3-25
DISPLAY
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 G85703019_
CN70 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN70-1 (128, CH7V)
CN70-2 (130, CGND)
-
Appeox. 6.3 V
CN70-2 (130, CGND)
-
-
-
CN70-3 (169, TGND)
-
-
-
CN70-4 (14, DGND)
-
-
-
CN70-5 (16, D7V)
CN70-4 (14, DGND)
-
Approx. 6.3V
CN70-6 (162, ITKY3)
CN70-3 (169, TGND)
-
Approx. 5V
CN70-7
-
CN70-8 (160, ITKY1)
CN70-3 (169, TGND)
CN70-9 (166, OTKY3)
-
CN70-10 (165, OTKY2)
Unused
Remarks
*2
*1 *2
Approx. 5V
*1 *2
Immeasurable
-
*2
-
Immeasurable
-
*2
CN70-11 (164, OTKY1)
-
Immeasurable
-
*2
CN70-12 (167, LEDTKY1)
CN70-3 (169, TGND)
Approx. 0V
*1 *2
CN70-13
-
Unused
-
CN70-14
-
Unused
-
CN70-15 (146, CAN1L)
-
Immeasurable
-
CN70-16 (145, CAN1H)
-
Immeasurable
-
CN70-17
-
Unused
-
CN70-18 (43, VBKY)
CN70-36 (N1, N1)
-
Approx. 48V
*2 *3
CN70-19 (168, LEDTKY2)
CN70-3 (169, TGND)
-
Approx. 3V
*1 *2
CN70-20 (161, ITKY2)
CN70-3 (169, TGND)
-
Approx. 5V
*1 *2
CN70-21 (163, IPSTKY1)
CN70-3 (169, TGND)
-
Approx. 5V
*1 *2
-
-
3-26 Connector No. ⇔ Connector No.
Conditions
Standard
CN70-22 (123, SW1)
CN70-4 (14, DGND)
-
Approx. 5V
CN70-23 (122, SW2)
CN70-4 (14, DGND)
-
Approx. 5V
CN70-24 (121, SW3)
CN70-4 (14, DGND)
-
Approx. 5V
CN70-25 (129, CHAC)
CN70-4 (14, DGND)
-
Approx. 5V
CN70-26 (140, SLLT)
CN70-4 (14, DGND)
-
L: approx. 1.8 V or H: approx. 2.7 V
CN70-27
-
-
-
CN70-28 (139, SWTT)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-29 (125, LD3)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-30 (126, LD2)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-31 (127, LD1)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-32 (124, LD4)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-33 (132, CHMS)
CN70-4 (14, DGND)
-
Approx. 0V
CN70-34
-
-
-
CN70-35
-
-
-
CN70-36 (N1, N1)
-
-
-
*1 PIN CODE ENTRY SYSTEM *2 Multifunction display/ DX only *3 Cold storage specification only
Remarks
*2 *3
3-27
TEN-KEY (W/ PIN code entry system)
CN33
5
4
3
2
1
10
9
8
7
6 G85703020_
CN33 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN33-1 (160, ITKY1)
CN33-7 (169, TGND)
-
Approx. 5V
CN33-2 (161, ITKY2)
CN33-7 (169, TGND)
-
Approx. 5V
CN33-3 (162, ITKY3)
CN33-7 (169, TGND)
-
Approx. 5V
CN33-4 (165, OTKY2)
-
CN33-5 (167, LEDTKY1)
CN33-7 (169, TGND)
-
Approx. 0V
CN33-6 (163, IPSTKY1)
CN33-7 (169, TGND)
-
Approx. 5V
CN33-7 (169, TGND)
-
-
-
CN33-8 (164, OTKY1)
-
Immeasurable
-
CN33-9 (166, OTKY3)
-
Immeasurable
-
CN33-10 (168, LEDTKY2)
CN33-7 (169, TGND)
Immeasurable
-
-
Approx. 3V
Remarks
3-28
CHARGER SWITCH BOX (OPTION)
CN69
6
5
4
3
2
1
12 11 10 9
8
7 G85703021_
CN69 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN69-1 (132, CHMS)
CN69-3 (130, CGND)
-
Approx. 0V
CN69-2 (129, CHAC)
CN69-3 (130, CGND)
-
Approx. 5V
CN69-3 (130, CGND)
CN69-3 (130, CGND)
-
-
CN69-4 (128, CH7V)
CN69-3 (130, CGND)
-
Approx. 6.3V
CN69-5 (121, SW3)
CN69-3 (130, CGND)
-
Approx. 5V
CN69-6 (122, SW2)
CN69-3 (130, CGND)
-
Approx. 5V
CN69-7 (123, SW1)
CN69-3 (130, CGND)
-
Approx. 5V
CN69-8 (124, LED4)
CN69-3 (130, CGND)
-
Approx. 0V
CN69-9 (125, LED3)
CN69-3 (130, CGND)
-
Approx. 0V
CN69-10 (126, LED2)
CN69-3 (130, CGND)
-
Approx. 0V
CN69-11 (127, LED1)
CN69-3 (130, CGND)
-
Approx. 0V
CN69-12
-
Unused
*1: This connector is not used in 8FBN model, but wire harness is connected.
-
Remarks
*1
*1
3-29
TRANSFORMER
CN68
2
1 G85703022_
CN68 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No.
Conditions
Standard
CN68-1 (139, SWTT)
CN68-2 (14, DGND)
-
Approx. 0V
CN68-2 (14, DGND)
-
-
-
Remarks
BATTERY ELECTROLYTE LEVEL SENSOR
CN35 1
G85703023_
CN35 connector basic conditions (battery plug connected, key switch ON) Connector No. ⇔ Connector No. CN35-1 (140, SLLT)
CN70-4 (14, DGND)
Conditions Connected with display
Standard L: approx. 1.8V or H: approx. 2.7V
Remarks
3-30
MAIN CONTROLLER REMOVAL·INSTALLATION Removal Procedure Rear cover
Controller upper cover Bolt
1
Turn the key switch OFF and disconnect the battery plug.
2
Remove the rear cover.
3
Open the battery hood and remove the controller upper cover. (bolt: 4 pcs.)
4
Remove the rear pillar cover LH.
5
Remove the rear pillar cover RH.
6
Remove the battery guard (upper).
Bolt G85703006_
LH cover
Bolt Clip
LH RH cover Bolt
Clip
RH
G85703007_
Battery guard
G85703008_
3-31
Bolt
7
P1*T P2*T
*Tightening torque: T = N·m (kgf·cm) [ft·lbf] T = 11.2 ~ 16.8 (114 ~ 171) [8.26 ~ 12.4]
P4*T
Bolt
Bolt
Disconnect the harness and cable from the contactor panel.
Note: The number of harness and cable to be disconnected varies depending on vehicle models. Check that all harnesses and cables are disconnected before removing the bolts. 8
Remove the bolt.
G85703009_
Note: Use a 25cm long extension.
G85703012_
9
Remove the contactor panel.
Note: The parts installed on the contactor panel vary depending on vehicle models.
G85703010_
10 Disconnect the connector and remove the bolts. Then remove the main controller. Main controller Bolt
Bolt
Connector Bolt Bolt
G85703011_
3-32 Note: When replacing the main controller, it requires initial setups as follows. Before replacing the main controller, refer to TUNING and OPTION SET in section 4 DISPLAY FUNCTION and make a note of initial setting values. After replacing the main controller, configure the setting for each function with initial setting values. Also, refer to MATCHING in section 4 DISPLAY FUNCTION and perform matching.
Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
3-33
MATERIAL HANDLING AC DRIVER REMOVAL·INSTALLATION (1 ton series and 50-8FBN20)
Bolt
Bolt
Material handling AC driver
Bolt
Bolt
G85703024_
Removal Procedure 1
Service bolt
Disconnect the harness and cables from the terminals of the material handling AC driver, which is indicated by the arrows in the illustration. Tightening torque: T = N·m (kgf·cm) [ft·lbf] T = 11.2 ~ 16.8 (114 ~ 171) [8.26 ~ 12.4]
2
G85703025_
Remove the bolts. (4 pieces)
3-34 3
Remove the AC driver from the rear frame, using service bolt. (adjustment bolt)
Note: Service bolt can be installed into a hole, which is indicated in the illustration. 4
Insert a tool between the AC driver and the rear frame and remove the AC driver.
G85703026_
Service bolt specification M8 × 1.25 Size: Length: more than 40mm
A
A - A section
A
Service bolt
G85703027_
Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
3-35 Note: Remove silicone grease applied on the top surface of the rear frame and the under surface of the AC driver.
Material handling AC driver
G85703028_
Note: • When installing the material handling AC driver on the rear frame, apply appropriate amount of silicone grease on the under surface of the AC driver. Also, apply silicone grease on the under surface of the drive AC driver. (Only for models with 50-) (Silicone grease may also be applied on the surface of the rear frame.) • Use either one of the following types of silicone grease. KS-609 (Shin-Etsu Chemical Co.,Ltd.) FLOIL G-600 (KANTO KASEI Ltd.) • Apply threadlocker (LOCTITE 243) to the bolts when tightening the AC driver. • Remove excess grease after installing the AC drivers.
3-36
REMOVAL·INSTALLATION (2 · 3 ton series, except 50-8FBN20) Bolt
Bolt
Bolt
Bolt
Material handling AC driver
G85703029_
Material handling AC driver
Removal Procedure 1
Disconnect the harness and cables from the terminals of the material handling AC driver, which is indicated by the arrows in the illustration. Tightening torque: T = N·m (kgf·cm) [ft·lbf] T = 11.2 ~ 16.8 (114 ~ 171) [8.26 ~ 12.4]
Frame
2
Remove the bolts. (4 pieces)
3
Insert a tool into the notched portion under the AC driver, and remove the AC driver from the rear frame.
G85703030_
Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.
3-37 Note: Remove silicone grease applied on the top surface of the rear frame and the under surface of the AC driver.
G85703031_
Note: • When installing the material handling AC driver on the rear frame, apply appropriate amount of silicone grease on the under surface of the AC driver. (Silicone grease may also be applied on the surface of the rear frame.) • Use either one of the following types of silicone grease. KS-609 (Shin-Etsu Chemical Co.,Ltd.) FLOIL G-600 (KANTO KASEI Ltd.) • Apply threadlocker (LOCTITE 243) to the bolts when tightening the AC driver. • Remove excess grease after installing the AC drivers.
3-38
DRIVE AC DRIVER Removal·Installation Procedure For the removal·installation procedure, see the procedure of the material handling AC driver.
3-39
OCL MEASUREMENT [For drive circuit] 1
Preparation before measurement (1) Load the forklift so that it is within the rated capacity, and position it so that the fork tip is facing a wall or steel pole. Be sure to place a piece of wood between the fork tip and the wall.
G85703032_
(2) Turn on the SST by pressing the POWER key on the unit. SST 09140-13130-71
G85703033_
(3) Press the MODE key twice to switch to the AC+DC A measurement mode.
G85703034_
3-40 (4) After pressing the SHIFT key, press the SAMPL key to set the display update rate to “SLOW”.
G85703035_
(5) After pressing the SHIFT key, press the CLEAR key to start zero point adjustment. (Pressing the CLEAR key makes the “ADJ” indicator flash and switches the unit to zero point adjustment mode. When the “ADJ” indicator stays on after flashing, zero point adjustment is completed.)
G85703036_
2
Measurement work (1) Set the clamp sensor of the SST on the motor cable.
Note: Set the clamp sensor so that the cable is positioned in the center of the clamp with the clamp sensor aligned perpendicular to the cable.
G85703037_
3-41 (2) Turn on the key switch and set the direction switch to “Forward”. Gradually depress the accelerator pedal to full throttle and hold there. The SST will start measurement automatically. Note: • The SST start measurement automatically as soon as forward motion starts. Be sure to wait for approximately 20 seconds before reading the measurement value. “O.L.” (Overflow alert) may be displayed during the first 10 seconds, or the displayed value may not be stable for a while. G85703038_
• If the measurement value is not stable after approximately 20 seconds, retry measurement by pressing the SHIFT key down then the PEAK/Hz key to enable filter setting as shown in the illustration. • Measurement can be done in this mode (AC+DC A mode, Display update mode: SLOW) also. However, when using other modes, motor current frequency in forward motion is only 10 Hz or below and current measurement cannot be obtained. OCL Standard Value: Model
Current (A)
50-8FBN15,18
295 ~ 390
50-8FBN20
290 ~ 385
8FBN15,16,18
325 ~ 425
8FBN20,25
405 ~ 520
8FBN30
295 ~ 390
[For pump circuit] G85703039_
The OCL value of the pump circuit cannot be measured because of the following reason: In the material handling system the relief valve in the control valve operates at the stroke end of each cylinder. The OCL value for the pump circuit is set at a higher level than the current at the relief valve set pressure. As relief occurs in the hydraulic circuit before the pump circuit current reaches the OCL valve, the OCL valve cannot be measured.
4-1
DISPLAY FUNCTION Page
DISPLAY ...........................................................................4-2 GENERAL........................................................................4-2
0
SCREEN ..........................................................................4-3
1
DETAIL DESCRIPTION ...................................................4-5
2
SETTING FUNCTION ......................................................4-9
3
SERVICE FUNCTIONS..................................................4-10 PASSWORD .................................................................. 4-11
4
ANALYZER .................................................................... 4-13
5
TUNING ......................................................................... 4-43
6
OPTION SET ................................................................. 4-55
7
MATCHING .................................................................... 4-57
8
MULTI-FUNCTION DISPLAY .....................................4-78
9
GENERAL...................................................................... 4-78 FEATURES LIST ........................................................... 4-79
10
ADMINISTRATOR FUNCTIONS ................................... 4-81
11
PASSWORD ................................................................ 4-100
12
ANALYZER .................................................................. 4-102
13
TUNING ....................................................................... 4-127
14
OPTION SET ............................................................... 4-136 MATCHING .................................................................. 4-141 OTHERS MENU........................................................... 4-158
4-2
DISPLAY GENERAL The display is placed on top of the right instrument panel to improve forward visibility from the operation seat. An LCD display that displays basic items, such as a battery capacity indicator, an hour meter and various warning lights, has been newly developed and provided as standard. As compared with previous LED indicators, the visibility and ease of recognition of various states have been substantially improved. In addition, a vehicle maintenance function, a feeling adjustment function and a specification setting function are provided as service functions.
Power select switch
Display area
Overheat warning indicator Spanner indicator OPS indicator Battery capacity indicator Power select indicator
Hour meter
Parking brake Battery fluid level warning indicator indicator Hour meter ON indicator Battery overheat warning indicator
4-3
SCREEN 1. Initial screen after Key-On Initial screen is displayed for two seconds after key-switch is turned on. Note: • The battery fluid level warning indicator is displayed only when a JIS battery is installed. • The battery overheat warning indicator is displayed only when a JIS battery is installed and the battery protection function is provided.
0 1 2 3 4 2. Status screen After the initial screen display, status screen is displayed.
5 6 7 8 9 10
3. Diagnostic code display If the diagnostic function is activated, the spanner indicator blinks and a warning sound is emitted to warn the operator of the occurrence of a failure in the vehicle. At that time, the key ON hour meter and error code indicating where the failure has occurred are displayed alternately in the hour meter area. 6 error codes are displayed at the maximum at intervals of 2 seconds. “E” is displayed in the meaning of the error.
Error code
11 12 13 14
4-4
4. Alphabetic characters and numbers in display area Numbers
Alphabet
Note: J,K,Q,X and Z are not displayed.
4-5
DETAIL DESCRIPTION 1.
Indicator (1) OPS indicator When the operator leaves the operation seat, this indicator lights up and the buzzer sounds for 1 second. (2) Parking brake indicator This indicator lights while the parking brake is engaged.
0
(3) Spanner indicator This indicator blinks and the buzzer sounds if any vehicle’s error are detected. At that time, an error code is displayed in the key ON hour meter area.
2
(4) Overheat warning indicator If the temperature of the controller, motor driver or traveling-load handling motor rises to an abnormal level, this indicator lights up, a warning sound is emitted and the output is limited. In the event of overheat, the buzzer sounds for 5 seconds. In the event of a failure due to overheat, the buzzer continues to sound until recovery from the failure. Also, when the motor driver is cold, the indicator lights up, a warning sound is emitted for 5 seconds and the output is limited in order to protect the devices in the motor driver. (5) Battery overheat warning indicator (When a JIS battery is installed and the battery protection function is provided) If the battery fluid temperature rises above the specified level, this indicator lights up, a warning sound is emitted and the output is limited. This indicator also helps prevent the reduction in the battery life due to a rise in the battery fluid temperature. If this function hinders the operation, it can be disabled using the service function. (6) Battery fluid level warning indicator (When a JIS battery is installed) If it is detected that there is not enough battery fluid left in the battery, this indicator lights up to warn the operator. If the key switch is turned on while there is not enough battery fluid left, the buzzer also sounds for several seconds. Moreover, even when the key switch is off, this indicator blinks to prompt the operator to add battery fluid. (When a JIS battery is installed and the battery protection function is provided) If the vehicle has been operated exceeding the specified hour without enough battery fluid, the vehicle performance is limited according to the operated hour. When the vehicle performance is limited, the indicator blinks to warn the operator.
1 3 4 5 6 7 8 9 10 11 12 13 14
4-6
This warning is to prevent the battery from being used for a long time with not enough battery fluid and to prompt the operator to add battery fluid.
4-7
2.
Battery capacity indicator This indicates amount of charge in the battery in 10 stages.
(1) Low battery level warning If the remaining amount of battery fluid decreases below the warning level, the battery capacity indicator blinks. Also, when the operator turns the key switch from the OFF to ON position, a warning sound is emitted for 5 seconds.
(2) Battery over-discharge warning If the traveling or load handling operation is performed while the remaining amount of battery is below the specified value, all the segments of the battery capacity indicator blink and a warning sound is emitted to warn the operator that the battery is over-discharged.
Note: The chart below shows relations of “Battery over-discharge warning”, “Low battery level warning” and “Tuning No.1”. Discharged amount [%]
Normal tuning setting level [No.1] 1
2
3
4 Initial value
5
6
7
8
50 Low battery level warning Battery capacity indicator blinks.
60 70 80 90 100
Over-discharge warning 10 segments of battery capacity indicator blink.
No warning
4-8
3.
Power select indicator This indicator indicates the selected power mode (S, P or H). When “H mode lock” is enabled, H mode cannot be selected. The H mode lock function can be enabled or disabled using a “OPTION SET” provided in the service function.
4.
Key switch on hour meter This meter counts up and displays the key switch ON time. The digit “1” at the right end represents one tenth of an hour (6 minutes). The hour meter ON indicator continues to blink as long as the hour meter is in operation.
Hour meter ON indicator
5. Warning buzzer (1) Parking brake ON warning If the vehicle is started or the opertor tries to drive while the parking brake is not released, the parking brake indicator lights up and a warning sound is emitted. (2) Parking brake OFF warning If the key switch is turned off while the parking brake is released, a warning sound is emitted. When the key switch is on, if the operator leaves the operation seat for 2 seconds or more with the parking brake released, a warning sound is emitted. This function does not work before the start of the hour meter. (3) Return to neutral warning for travel OPS A warning sound is emitted to inform that the operator should release the accelerator and return the direction switch to neutral in order to start the vehicle. (No warning is displayed on the display.) (4) Return to neutral warning for load handling OPS A warning sound is emitted to inform that the operator should return the load handling levers to neutral in order to start the load handling operation. (No warning is displayed on the display.) (5) Return to neutral warning at key ON A warning sound is emitted to inform that, the operator should release the accelerator and return the direction switch to neutral in order to start the vehicle, when the key switch is on.(No warning is displayed on the display.) (6) Traveling and load handling warning during charging (For models with an on-vehicle charger) If the accelerator is operated or load handling is performed with the AC plug inserted, a warning sound is emitted to warn the operator, and the traveling or load handling operation is restricted.
4-9
SETTING FUNCTION Power select function The power mode (S, P or H) and its indication on the display change each time the power select switch on the status screen is pressed. When “H mode lock” is enabled, H mode cannot be selected. The H mode lock function can be enabled or disabled using a “OPTION SET” provided in the service function.
Power mode
Power select switch
Note: Always use a finger to operate the switch. Pressing a switch with a pointed stick may cause damage to the switch.
4-10
SERVICE FUNCTIONS General In addition to the functions that are described in the Operator’s Manual and available to customers, the display has the following built-in functions intended to be used by service staff to perform maintenance of the vehicle or set its specifications. The service functions are password-protected to prevent customers from using them by mistake, causing important internal data to be corrupted.
Service Function List When used Function
Vehicle delivery
Controller replacement
Others
Displays the electrical system status and reads the error information detected by controllers.
–
–
Upon vehicle abnormality
Makes fine adjustment of traveling and load handling functions.
–
{ *2
As requested by customer
Specification setting
Sets each vehicle option and other specifications. *1
–
{ *2,*3
–
Each control function enable/ disable
Enables or disables each control function.
–
{ *2,*3
–
Traveling function Load handling lever
Updates voltage values of sensor signals under the standard vehicle condition.
–
{ *2,*3
–
OCV starting current level
Sets the oil control valve starting current level.
–
{ *2,*5
{ *5
Tire data
Sets the tire constant.
–
{ *2
{ *4
Auto power-off time setting
Sets the auto power-off time.
–
{ *2
As requested by customer
Maximum speed limit setting
Sets the maximum speed limit.
–
{ *2
As requested by customer
Meter start
Starts counting the hour meter.
{
{ *3
Demo mode
Enables simultaneous operation of traveling and load handling before starting the hour meter.
–
–
Analyzer
Tuning
Option set
Matching
Others menu
Description
Before starting the hour meter
*1: The option set function is used to fit the specifications of the controller and display for the options actually equipped on the vehicle. *2: Controller: Main controller *3: Controller: Display *4: When tire size is changed or tires are replaced. *5: When replacing oil control valve.
Before Starting Matching Before performing matching, you must set the vehicle to “standard vehicle condition”. For “standard vehicle condition”, refer to section 14.
4-11
PASSWORD Note: • Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be damaged. • If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the beginning. If the SERVICE MENU cannot be displayed after several attempts, the system may be faulty.
Password Entry Procedure Step
Display
Press switch (1) and switch (2) at the same time for more than 5 seconds.
MODE
1 Switch (1)
Operation
Switch (2)
Vehicle response When pressing the switches, a short beep sounds, and after 2 seconds another short beep sounds. Hold down the switches for 5 seconds or more.
Press switch (2) within 10 Note : No sound is emitted. seconds.
MODE
2 Switch (1)
Switch (2) Press switch (1) within 10 A short beep sounds. seconds.
MODE
3 Switch (1)
Switch (2) Within 10 seconds, press switch (1) and switch (2) at the same time for more than 2 seconds.
MODE
4 Switch (1)
When pressing the switches, a short beep sounds, and after 2 seconds repeated short beeps sound.
Switch (2) Service function initial screen is displayed for 5 seconds.
5
ANALYZER MENU screen is automatically displayed. 6
4-12
Service Function Display Initial Screen
1 Analyzer menu
2 Tuning menu MODE
MODE
1 DIAG MEMORY
1 OPTIONSET
MODE
MODE
2 L LIFT
MODE
3 I02
MODE
3 L TILT
MODE
4 I03
MODE
4 L ATT1
MODE
5 I04
MODE
5 L ATT2
MODE
6 I05
MODE
END
MODE
7 ACT
MODE
8 VERSION
MODE
MODE
1 GENERAL
MODE
2 I01
3 Option set menu 4 Matching menu
END
5 Others menu
MODE
1 DRIVE
MODE
1 METER
MODE
2 SAS
MODE
2 DEMO
MODE
3 LEVER
MODE
4 OCV
MODE
5 TIRE
MODE
6 PWR OFF
MODE
7 SPEED
MODE
END
6 End
MODE
END
4-13
ANALYZER General Analyzer function supports operations for inspection/investigating faulty section by displaying the condition of the control system, using communication between each controller and the display. By switching the display to analyzer mode, operative conditions of the sensors and actuators which are used for traveling, load handling and OPS functions, or the error information detected by the controller can be read. This is very useful for checking operative condition of each function and saving time for repairing when there is a detect. The analyzer has the following functions: 1. Diagnostic memory function (DIAG MEMORY) The controller stores up to 10 error codes (diagnostic codes) detected in the electrical system in the past. The diagnostic function reads these error codes and indicates them on the display. Each error code is displayed with its detection time as the key ON hour meter reading. 2. In/Out monitor function (I/O MONITOR) This function displays switch ON/OFF state and the analog input values from individual sensors and switches in the traveling, load handling, and OPS systems. The circuit or sensor quality can be judged by monitoring the displayed value. (1) I/O TEMP/VOLT Displays the temperature of each electrical functional part and the analog input voltage detected by each controller. (2) I/O TRAVELING Displays each switch ON/OFF state and analog input voltages from sensors for traveling control. (3) I/O MATERIAL HANDLING Displays the load handling control switch ON/OFF states and analog input voltages from load handling control sensors. (4) I/O STEERING Displays the ON/OFF states of knob position correction control and the analog input voltages from respective sensors. (5) I/O OTHERS Displays the analog input voltages from battery current sensor. 3. Active test (ACTIVE TEST) In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in order to permit operation check of that function. 4. Program version display (VERSION) Displays program version of each controller.
4-14
Analyzer Screen Item List Analyzer menu screen 1. DIAG MEMORY
SPH Screen Classification Display No. area 1 DIAG
1
2. I/O TEMP/VOLT I(Temperature/Voltage)
2 I01
2
3. I/O TRAVELING (Travel Control)
01 to 10 1. to 10.
Indications of errors occurred
TDM
Drive motor temperature: °C
02
TDMDH
Drive motor driver heat sink temperature: °C
03
TDMDB
Drive motor driver board temperature: °C
04
TMCB
Main controller board temperature: °C
05
TPM
Pump motor temperature: °C
06
TPMDH
Pump motor driver heat sink temperature: °C
07
TPMDB
Pump motor driver board temperature: °C
08
TSLLT
Battery temperature: °C
09
TDSP
Display board temperature: °C
10
B48V/80V
Battery voltage: V
11
VBKY
Voltage after key switch: V
12
VBMBSL
Solenoid power source voltage: V
13
VBMB
Voltage after MB contactor: V
14
VDMD
Drive motor driver main circuit voltage: V
15
VPMD
Pump motor driver main circuit voltage: V
01
SPEED
Traveling speed: km/h
03 04 05 06
3
Description
01
02
3 I02
Display item
07
08 09 10 11 12 13 14
VRA VRB
Accelerator sensor1 voltage: V Accelerator sensor2 voltage: V Brake sensor1 voltage: V Brake sensor2 voltage: V
SWBK
Brake switch
SDM
Seat switch
DSF
Forward switch
DSR
Reverse switch
SPB
Parking brake switch
SPEED
Traveling speed: km/h
SPDDM SSD CSDM
Drive motor rpm: rpm Target rpm: rpm Drive motor rotation sensor1 voltage: V Drive motor rotation sensor2 voltage: V Drive motor current sensor1 voltage: V Drive motor current sensor2 voltage: V
4-15
Analyzer menu screen
SPH Screen Classification Display No. area
4. I/O M.HANDLING (Load handling Control)
SLLL
Lift lowering lock solenoid
01(2)
SLTFL
Tilt control solenoid
SDM
Seat switch
03 04 05 06 07
4
CSPM
10 11
VRL
Tilt control solenoid
13
CST
Tilt proportional valve solenoid current: A
VRT CSA1 VRA1 CSA2 VRA2
8 VER
8
Tilt lever angle sensor2 voltage: V Attachment (1) proportional valve solenoid current: A Attachment (1) lever angle sensor1 voltage: V Attachment (1) lever angle sensor2 voltage: V Attachment (2) proportional valve solenoid current: A Attachment (2) lever angle sensor1 voltage: V Attachment (2) lever angle sensor2 voltage: V
VRTRA
Tire angle sensor voltage: V (OPT: W/ Synchronized steering)
02
SPEED
Traveling speed : km/h
K-POS
Steering angle knob position actual value (target value), Steering synchronizer solenoid (OPT: W/ Synchronized steering)
06
SSTR
Steering angle sensor signal
01
CSBAT
Battery current sensor voltage: V
02
DPOT
(Not used)
01
STEERING Steering synchronizer solenoid forced operation SOL (OPT: W/ Synchronized steering)
02
LIFT LOW SOL
Lift lowering lock solenoid forced operation
03
TILT SOL
Tilt control solenoid forced operation
04
FAN
Cooling fan for controller forced operation
05
ACC OUT1 (Not used)
06
ACC OUT2 (Not used)
d
DISPLAY
Display program version
c
MAIN C/R
Main controller program version
T
DM DRIVER
Drive motor driver program version
P
PM DRIVER
Pump motor driver program version
03 05
8. VERSION (Program version)
Tilt lever angle sensor1 voltage: V
01
04
7
Lift lever angle sensor2 voltage: V
SLTFL
21
7 ACT
Lift lever angle sensor1 voltage: V
12
20
7. ACTIVE TEST (Active test)
Pump motor driver current sensor2 voltage: V Lift proportional valve solenoid current: A
19
6
Pump motor driver current sensor1 voltage: V
CSL
18
6 I05
Pump motor driver rotation sensor voltage: V
09
17
6. I/O OTHERS (Others)
Target rpm: rpm
Lift lowering lock solenoid
16
5
SSP
Pump motor rpm: rpm
SLLL
15
5 I04
SPDPM
08
14
5. I/O STEERING (Steering control)
Description
01(1) 02
4 I03
Display item
4-16
ANALYZER MENU screen Operation Procedure
MODE
Switch (1)
Switch (2)
1.
Enter the password on the status screen to display the service function initial screen.
2.
The screen where “1-ANL” is displayed is the ANALYZER MENU screen. On this screen, press switch (2) to display the “1 DIAG” (DIAG MEMORY) screen.
4-17
“1 DIAG” (1 DIAG MEMORY) Switch (1): Switching selection to “2 I01” Switch (2): Switching to “1 DIAG” detail screen
“2 I01” (2 I/O monitor1 TEMP/VOLT) Switch (1): Switching selection to “3 I02” Switch (2): Switching to “2 I01” detail screen
“3 I02” (3 I/O monitor2 TRAVELING) Switch (1): Switching selection to “4 I03” Switch (2): Switching to “3 I02” detail screen
“4 I03” (4 I/O monitor3 M.HANDLING) Switch (1): Switching selection to “5 I04” Switch (2): Switching to “4 I03” detail screen
4-18
“5 I04” (5 I/O monitor4 STEERING) Switch (1): Switching selection to “6 I05” Switch (2): Switching to “5 I04” detail screen
“6 I05” (6 I/O monitor5 OTHERS) Switch (1): Switching selection to “7 ACT” Switch (2): Switching to “6 I05” detail screen
“7 ACT” (7 ACTIVE TEST) Switch (1): Switching selection to “8 VER” Switch (2): Switching to “7 ACT” detail screen
“8 VER” (8 VERSION) Switch (1): Switching selection to “E END” Switch (2): Switching to “8 VER” detail screen
4-19
“E END” Switch (1): Switching selection to “1 DIAG” (DIAG MEMORY) Switch (2): Returning to the “1-ANL” (ANALYZER MENU) screen
Diagnostic Memory Function (DIAG MEMORY) The controller stores up to 10 most recent errors. The “1 DIAG” (DIAG MEMORY) screen displays these diagnostic codes with their detection time information (in key ON hour meter reading). The most recent diagnostic code is displayed as 1, followed by 2, 3 and so on to 10.
Operation Procedure 1.
2.
MODE
Switch (1)
Switch (2)
Enter the password on the status screen to display the service function initial screen.
Press switch (2) once and make sure that “1 DIAG” (DIAG MEMORY) is displayed on the screen. Then, press switch (2) (to confirm) to display the “1 01” screen. Note: A diagnostic code and hour meter information are displayed alternately. 3. Press switch (1) to display the next diagnostic code. 4. Press switch (2) on the “1 E” screen to return to the ANALYZER MENU screen. Note: • When no diagnostic code is displayed on the screen and the hour meter time is 0.0h, it indicates that no errors occurred in the past after that row. • It is impossible to directly jump from the DIAG MEMORY screen to other function screen. Return to the ANALYZER MENU screen. • For details of diagnostic code, refer to Repair manual, Diagnostic Code List. (Refer to page 5-6)
4-20
“1 DIAG: 1 01 to 1 10” Displays diagnostic codes 1 to 10. Switch (1): Next screen Switch (2): Not used
Displayed alternately.
No. 01 to 10
Diagnostic code (Example: H 1-4)
Time of occurrence (Key-on hour meter)
“1 DIAG: 1 E” Switch (1): Switching selection to “1 DIAG: 1 01” Switch (2): Returning to the ANALYZER MENU screen
4-21
In/Out Monitor Function (I/O MONITOR) This function displays the analog input voltage and the switch state of each of traveling, material handling, synchronized steering and OPS switches, sensors and actuators. The circuit or their quality can be judged by monitoring the displayed value.
In/Out Monitor (1) (I01) Displays the temperature of each electrical functional part and the analog input voltage detected by each controller.
Operation Procedure 1.
2.
MODE
Switch (1)
Switch (2)
Enter the password on the status screen to display the service function initial screen.
Press switch (2) once and switch (1) once, and make sure that “2 I01” is displayed on the screen. Then, press switch (2) (to confirm) to display the “2 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “2 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen. Note: You cannot move directly from “2 I01” screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
4-22
“2 01” Drive motor temperature: °C Temperature of the drive motor is displayed.
“2 02” Drive motor driver heat sink temperature: °C Temperature of the drive motor driver heat sink is displayed.
“2 03” Drive motor driver board temperature: °C Temperature of the drive motor driver board is displayed.
“2 04” Main controller board temperature: °C Temperature of main controller board is displayed.
“2 05” Pump motor temperature: °C Temperature of pump motor is displayed.
“2 06” Pump motor driver heat sink temperature: °C Temperature of the pump motor driver heat sink is displayed.
“2 07” Pump motor driver board temperature: °C Temperature of the pump motor driver board is displayed.
“2 08” (W/ Fluid level and temperature unit) Battery temperature: °C Battery temperature is displayed. (W/O Fluid level and temperature unit) ---
“2 09” Display board temperature: °C Display board temperature is displayed.
“2 10” Battery voltage: V Battery voltage is displayed.
4-23
“2 11” Voltage after key switch: V Voltage after key switch is displayed.
“2 12” Solenoid power source voltage: V Voltage of solenoid power source is displayed.
“2 13” Voltage after MB contactor: V Voltage of after MB contactor is displayed.
“2 14” Drive motor driver main circuit voltage: V Voltage of drive motor driver main circuit is displayed.
“2 15” Pump motor driver main circuit voltage: V Voltage of pump motor driver main circuit is displayed. Switch (1): Next screen Switch (2): Not used
“2 I01: 2 E” Switch (1): Switching selection to “2 I01: 2 01” Switch (2): Returning to the ANALYZER MENU screen
4-24
In/Out Monitor (2) (I02) Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
2.
Press switch (2) once and switch (1) twice, and make sure that “3 I02” is displayed on the screen. Then, press switch (2) (to confirm) to display the “3 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “3 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen.
3. MODE
Switch (1)
Switch (2) Note: You cannot move directly from “3 I02” screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“3 01” Traveling speed: km/h Displays the traveling speed
4-25
“3 02” Accelerator sensor 1 voltage: V Displays input voltage from the accelerator sensor to the controller. Standard: When accelerator is not operated: 0.40 to 1.25 V When accelerator pedal is fully depressed: 2.25 to 4.80 V
“3 03” Accelerator sensor 2 voltage: V Displays input voltage from the accelerator sensor to the controller. Standard: When accelerator is not operated: 0.65 to 2.32 V When accelerator pedal is fully depressed: 2.70 to 4.80 V
“3 04” Brake sensor 1 voltage: V Displays input voltage from the brake sensor to the controller. (W/ Brake sensor) Standard: When brake is not operated: 0.50 to 1.50 V When brake pedal is fully depressed: 1.05 to 4.80 V (W/O Brake sensor) Standard: 0.00V
“3 05” Brake sensor 2 voltage: V Displays input voltage from the brake sensor to the controller. (W/ Brake sensor) Standard: When brake is not operated: 0.79 to 2.58 V When brake pedal is fully depressed: 1.50 to 4.80 V (W/O Brake sensor) Standard: 0.00V
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“3 06” Brake switch Displays the status of the brake switch. (W/ Brake sensor) SWBK: 0 (W/O Brake sensor) SWBK: 0=OFF (Brake is operated) SWBK: 1=ON (Brake is not operated)
“3 07 (1)” Seat switch Switch ON/OFF quality judgment by sitting on and leaving the operator’s seat 1 = ON when sitting on the seat 0 = OFF when leaving the seat
“3 07 (2)” Forward switch (DSF)
“3 07 (3)” Reverse switch (DSR) Switch ON/OFF quality judgment by operating the direction lever Direction lever
Display DSF :
DSR :
Forward
1 (= ON)
0 (= OFF)
Neutral
0 (= OFF)
0 (= OFF)
Reverse
0 (= OFF)
1 (= ON)
“3 07 (4)” Parking brake switch Switch ON/OFF quality judgment by operating the parking brake lever. 0 = OFF (in a state of parking brake being operated) 1 = ON (in a state of parking brake being released) Seat switch
Forward switch
Reverse switch
Parking brake switch
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“3 08” Traveling speed: km/h Displays the traveling speed
“3 09” Drive motor revolution: rpm This screen indicates the measured revolution of the drive motor. The rotation sensor is checked by actually running the vehicle. The number of revolution of the drive motor increases with an increase in the traveling speed.
“3 10” Drive motor target revolution: rpm This screen indicates the target number revolution of the drive motor.
“3 11” Drive motor rotation sensor 1 voltage: V
“3 12” Drive motor rotation sensor 2 voltage: V This screen indicates the voltages of the drive motor rotation sensors. Standard: When motor is stopped: Constant, either 0.30 to 0.90 V or 1.10 to 1.70 V When motor is rotating: Variable between approx. 0.30 to 1.70 V
“3 13” Drive motor current sensor 1 voltage: V
“3 14” Drive motor current sensor 2 voltage: V This screen indicates the voltages of the drive motor current sensors. Standard: When vehicle is stopped: Approx. 2.50 V When vehicle is running: 0.50 to 4.50 V Switch (1): Next screen Switch (2): Not used
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“3 I02: 3 E” Switch (1): Switching selection to “3 I02: 3 01” Switch (2): Returning to the ANALYZER MENU screen
In/Out Monitor (3) (I03) Displays the load handling control switch ON/OFF states and analog input voltages from load handling control sensors.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
2.
Press switch (2) once and switch (1) three times, and make sure that “4 I03” is displayed on the screen. Then, press switch (2) (to confirm) to display the “4 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “4 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen.
3. MODE
Switch (1)
Switch (2) Note: You cannot move directly from “4 I03” screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
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Tilt control solenoid
“4 01 (1)” Lift lowering lock solenoid Displays output signal to the lift lowering lock solenoid.
“4 01 (2)” Tilt control solenoid Displays output signal to the tilt control solenoid. Lever status
Lift lowering lock solenoid
No operation
Lift lever Up
Down
Tilt lever Forward
Backward
7 01(1) Lift lowering 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) 0 (=OFF) lock solenoid Item 7 01(2) Tilt control 0 (=OFF) 0 (=OFF) 0 (=OFF) 1 (=ON) 0 (=OFF) solenoid
“4 02” Seat switch Switch ON/OFF quality judgment by sitting on and leaving the operator’s seat 1 = ON when sitting on the seat 0 = OFF when leaving the seat
“4 03” Pump motor revolution: rpm This screen indicates the measured revolution of the pump motor. The rotation sensor is checked by actually running the vehicle. The number of revolution of the pump motor increases with an increase in the load handling speed.
“4 04” Pump motor target revolution: rpm This screen indicates the target number revolution of the pump motor.
“4 05” Pump motor driver rotation sensor voltage: V Displays the voltage from the pump motor driver rotation sensor. Standard: When motor is stopped: Constant, either 0.30 to 0.90 V or 1.10 to 1.70 V When motor is rotating: Variable between approx. 0.30 to 1.70 V
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“4 06” Pump motor current sensor 1 voltage: V
“4 07” Pump motor current sensor 2 voltage: V This screen indicates the voltages of the pump motor current sensors. Standard: Standard value when vehicle is stopped: Approx. 2.5 V (When load handling lever, steering wheel, and forward/backward switch are in neutral) Other than the above: 0.5 to 4.5 V
“4 08” See “4 01 (1)”
“4 09” Lift proportional valve solenoid current: A Displays the current from the lift proportional solenoid. Standard: During uppermost raising operation: 0.25 to 0.95 A During lowermost lowering operation: 0.25 to 0.95 A When lever is neutral: 0.00 A The current increases according to the amount of operation of the lift lever
“4 10” Lift lever angle sensor 1 voltage: V Displays input voltage from lift lever angle sensor 1 to the controller. Standard: (Conventional lever) During uppermost raising operation: 1.65 to 4.60 V During lowermost lowering operation: 0.30 to 2.88 V When lever is neutral: 1.65 to 2.88 V (Mini lever/ Joystick) During uppermost raising operation: 1.78 to 4.50 V During lowermost lowering operation: 0.30 to 2.76 V When lever is neutral: 1.78 to 2.76 V The voltage increases during lift-up operation, while it decreases during lift-down operation.
“4 11” Lift lever angle sensor 2 voltage: V Displays input voltage from lift lever angle sensor 2 to the controller. Standard: (Conventional lever) During uppermost raising operation: 0.30 to 3.20 V During lowermost lowering operation: 1.52 to 4.50 V When lever is neutral: 1.52 to 3.20 V (Mini lever/ Joystick) During uppermost raising operation: 0.30 to 2.76 V During lowermost lowering operation: 1.78 to 4.50 V When lever is neutral: 1.78 to 2.76 V The voltage decreases during lift-up operation, while it increases during lift-down operation.
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“4 12” Tilt control solenoid See “4 01 (2)”
“4 13” Tilt proportional valve solenoid current: A Displays the current from the tilt proportional solenoid. Standard: During uppermost forward operation: 0.25 to 0.95 A During lowermost backward operation: 0.25 to 0.95 A When lever is neutral: 0.00 A The voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 14” Tilt lever angle sensor 1 voltage: V Displays input voltage from lift lever angle sensor 1 to the controller. Standard: (Conventional lever) During uppermost forward operation: 1.65 to 4.50 V During lowermost backward operation: 0.30 to 2.88 V When lever is neutral: 1.65 to 2.88 V (Mini lever/ Joystick) During uppermost forward operation: 1.78 to 4.50 V During lowermost backward operation: 0.30 to 2.76 V When lever is neutral: 1.78 to 2.76 V The input voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 15” Tilt lever angle sensor 2 voltage: V Displays input voltage from lift lever angle sensor 2 to the controller. Standard: (Conventional lever) During uppermost forward operation: 0.30 to 3.20 V During lowermost backward operation: 1.52 to 4.50 V When lever is neutral: 1.52 to 3.20 V (Mini lever/ Joystick) During uppermost forward operation: 0.30 to 2.76 V During lowermost backward operation: 1.78 to 4.50 V When lever is neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation.
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“4 16” Attachment 1 proportional valve solenoid current: A Displays the current from the attachment 1 proportional solenoid. Standard: During uppermost raising operation: 0.25 to 0.95 A During lowermost lowering operation: 0.25 to 0.95 A When lever is neutral: 0.00 A The voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 17” Attachment 1 lever angle sensor 1 voltage: V Displays input voltage from attachment 1 lever angle sensor 1 to the controller. Standard: (Conventional lever) During uppermost raising operation: 1.65 to 4.50 V During lowermost lowering operation: 0.30 to 2.88 V When lever is neutral: 1.65 to 2.88 V (Mini lever/ Joystick) During uppermost raising operation: 1.78 to 4.50 V During lowermost lowering operation: 0.30 to 2.76 V When lever is neutral: 1.78 to 2.76 V The voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 18” Attachment 1 lever angle sensor 2 voltage: V Displays input voltage from attachment 1 lever angle sensor 2 to the controller. Standard: (Conventional lever) During uppermost raising operation: 0.30 to 3.20 V During lowermost lowering operation: 1.52 to 4.50 V When lever is neutral: 1.52 to 3.20 V (Mini lever/ Joystick) During uppermost raising operation: 0.30 to 2.76 V During lowermost lowering operation: 1.78 to 4.50 V When lever is neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation.
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“4 19” Attachment 2 proportional valve solenoid current: A Displays the current from the attachment 2 proportional solenoid. Standard: During uppermost raising operation: 0.25 to 0.95 A During lowermost lowering operation: 0.25 to 0.95 A When lever is neutral: 0.00 A The voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 20” Attachment 2 lever angle sensor 1 voltage: V Displays input voltage from attachment 2 lever angle sensor 1 to the controller. Standard: (Conventional lever) During uppermost raising operation: 1.65 to 4.50 V During lowermost lowering operation: 0.30 to 2.88 V When lever is neutral: 1.65 to 2.88 V (Mini lever/ Joystick) During uppermost raising operation: 1.78 to 4.50 V During lowermost lowering operation: 0.30 to 2.76 V When lever is neutral: 1.78 to 2.76 V The voltage increases during backward tilting operation, while it decreases during forward tilting operation.
“4 21” Attachment 2 lever angle sensor 2 voltage: V Displays input voltage from attachment 2 lever angle sensor 2 to the controller. Standard: (Conventional lever) During uppermost raising operation: 0.30 to 3.20 V During lowermost lowering operation: 1.52 to 4.50 V When lever is neutral: 1.52 to 3.20 V (Mini lever/ Joystick) During uppermost raising operation: 0.30 to 2.76 V During lowermost lowering operation: 1.78 to 4.50 V When lever is neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation. Switch (1): Switching selection to “4 I03: 4 01” Switch (2): Not used
“4 I03: 4 E” Switch (1): Switching selection to “4 I03: 4 01” Switch (2): Returning to the ANALYZER MENU screen
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In/Out Monitor (4) (I04) Displays the ON/OFF states of knob position and the analog input voltages from respective sensors.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
2.
Press switch (2) once and switch (1) four times, and make sure that “5 I04” is displayed on the screen. Then, press switch (2) (to confirm) to display the “5 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “5 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen.
3. MODE
Switch (1)
Switch (2) Note: You cannot move directly from “5 I04” screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“5 01” Tire angle sensor voltage: V Displays input voltage from the tire angle sensor to the controller. (W/ Tire angle sensor) Standard: Standard when tires are in straight ahead position: 1.80 to 2.40 V The input voltage increases when the steering wheel is turned clockwise to turn right. The input voltage decreases when the steering wheel is turned counterclockwise to turn left. (W/O Tire angle sensor) 0.00 V
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“5 02” Traveling speed: km/h Displays the traveling speed
“5 03” Steering angle knob position actual value The knob position calculated and recognized by the controller from the steering angle sensor signal.
“5 04” Steering angle knob position target value The knob position calculated and recognized by the controller from the tire angle sensor signal. (W/ Tire angle sensor) Standard: The value shall increases during right turn, and it shall decrease during left turn. Display range: 0 to 159 (W/O Tire angle sensor) Fixed at 80
“5 05” Switch ON/OFF quality judgment by operating the steering synchronizer solenoid. (W/ Tire angle sensor) 0 = OFF non-energized state (Position compensation disabled) 1 = ON energized state (Position compensation enabled) (W/O Tire angle sensor) ---
159 0 1 80
Standard Standard position position
One rotation (360°) of the steering wheel is divided by 160, and the value is set to “80” when the knob is in the position as indicated in the illustration. Clockwise turn of the steering wheel: Increase in value Counterclockwise turn of the steering wheel: Decrease in value Display range: 0 to 159
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“5 06” Steering angle sensor signal When the steering wheel is rotated once, SS1 and SS2 repeat ON and OFF. SSC only turns on when the knob is in the standard position. 1 = ON 0 = OFF SS1
SS2
Switch (1): Next screen Switch (2): Not used
SSC
“5 I04: 5 E” Switch (1): Switching selection to “5 I04: 5 01” Switch (2): Returning to the ANALYZER MENU screen
In/Out Monitor (5) (I05) Displays the analog input voltages from battery current sensor.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
2.
Press switch (2) once and switch (1) five times, and make sure that “6 I05” is displayed on the screen. Then, press switch (2) (to confirm) to display the “6 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “6 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen.
3. MODE
Switch (1)
Switch (2)
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Note: You cannot move directly from “6 I05” screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“6 01” Battery current sensor voltage: V Displays input voltage from the battery current sensor to the controller. Standard value when vehicle is stopped: Approx. 2.5 V (When load handling lever, steering wheel, and forward/backward switch are in neutral) Other than the above: 2.3 to 2.7 V Switch (1): Switching selection to “6 I05: 6 02” Switch (2): Not used
“6 02” Not used Switch (1): Switching selection to “6 I05: 6 E” Switch (2): Not used
“6 I05: 6 E” Switch (1): Switching selection to “6 I05: 6 01” Switch (2): Returning to the ANALYZER MENU screen
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ACTIVE TEST (Active Test) In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in order to permit operation check of that function.
Active Test Item List Selection Item Item
Description
7 01 Knob position correcting solencid (STEERING forced operation SOL)
Signal
Content of operation
Signal
Content of operation
OFF
By-pass close
ON
By-pass open
OFF
Lowering not possible
ON Lowering possible
7 02 (LIFT LWR SOL)
Lift lowering lock solencid forced operation forced operation
7 03 (TILT SOL)
Tilt control solencid forced operation OFF
7 04 (FAN)
Cooling fan for controller forced operation
OFF
Forward tilt not possible
ON
Forward tilt possible
Fan stops
ON
Fan rotates
7 05 Not used (ACC OUT1)
Not used
7 06 Not used (ACC OUT2)
Not used
• On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item. • If the selected item is forcibly turned off or on by pressing the switch (2) and it is switched over to another item by pressing the switch (1), forced operation is canceled (and switches over to normal operation). • The displayed character string indicates whether or not the selected item is forcibly operated. (Refer to below) Display off on (Blink)
Condition Selected item not forcibly operated Selected item forcibly turned ON
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
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2.
Press switch (2) once and switch (1) six times, and make sure that “7 ACT” (ACTIVE TEST) is displayed on the screen. Then, press switch (2) (to confirm) to display the “7 01” screen.
MODE
Switch (1)
Switch (2) 3.
From here on, the screen changes in sequence each time switch (1) is pressed. On the “7 E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen. Note: You cannot move directly from “7 ACT” (ACTIVE TEST) screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“7 01” Knob position correcting solenoid (W/O Knob position correcting solenoid) --(W/ Knob position correcting solenoid) Slowly turn the steering wheel, and check the difference of the rear tire movement. ON (By-pass open): Tires do not move match OFF (By-pass close): Tires move (normal operation)
“7 02” Lift lowering lock solenoid Check the quality of lowering action by lift lowering operation. ON (Solenoid ON): Lowering possible (normal operation) OFF (Solenoid OFF): Lowering not possible
“7 03” Tilt control solenoid Check the quality of mast forward tilt operation by forward tilt operation. ON (Solenoid ON): Forward tilt possible OFF (Solenoid OFF): Forward tilt not possible
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“7 04” Cooling fan Forcibly output the ON/OFF signal to check the fan operation ON: Fan rotates OFF: Fan stops * This function is inoperative in the 50-8FBN15 to 20, because no fan is provided in them.
“7 05” Not used
“7 06” Not used Switch (1): Moving to the next item Switch (2): Forcibly turning on or off the selected item
“7 ACT: 7 E” Switch (1): Switching selection to “7 ACT: 7 01” Switch (2): Returning to the ANALYZER MENU screen
VERSION (Program Version) Displays program version of each controller.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen.
2.
Press switch (2) once and switch (1) seven times, and make sure that “8 VER” (VERSION) is displayed on the screen. Then, press switch (2) (to confirm) to display the “8d” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “8E” screen, press switch (2) to return to the “1-ANL” (ANALYZER MENU) screen.
3. MODE
Switch (1)
Switch (2)
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Note: You cannot move directly from “8 VER” (VERSION) screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“8 d” Program version of the display
“8 c” Program version of the main controller
“8 T” Program version of the drive motor driver
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“8 P” Program version of the pump motor driver Switch (1): Switching selection to “8 VER: 8 d” Switch (2): Not used
“8 E” Switch (1): Switching selection to “8 VER: 8 d” Switch (2): Returning to the ANALYZER MENU screen
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TUNING General This feature performs fine adjustment of traveling and load handling controls. When receiving requests from the customer such as the request to weaken the accelerator-off regenerative braking force, various settings levels can be adjusted on the tuning screens. Tuning functions has 75 items. (included spare items)
Tuning Item List Display
Multifunction display/DX
Menu No. Menu No. Activation timing of low battery capacity warning and battery over-discharge warning.
1
2 3 4 5 6
Fast
*
7
8
1 01
No.1
1 02
No.2 Battery charge indicator calibration No.1
Slow decrease
1 03
No.3 Battery charge indicator calibration No.2
Sensitive
*
Insensitive
1 04
No.4 Motor torque when the battery discharge has proceeded
Power down
*
Power keep
1 05
No.5 Not used
1 06
No.6 Accelerator pedal sensitivity
1 07
Slow Disabled *
Fast decrease
* Insensitive
*
Sensitive
No.7 Acceleration torque
Weak
*
Strong
1 08
No.8 Acceleration soft-start
Slow
*
Quick
1 09
No.9 Regenerative braking torque at accelerator-off
Weak
*
Strong
1 10
No.10 Regenerative braking soft-start at accelerator-off
Slow
*
Quick
1 11
No.11 Acceleration torque at switch-back
Weak
*
Strong
1 12
No.12 Acceleration soft-start at switch-back
Slow
*
Quick
No.13 Regenerative braking torque at switch-back
Weak
*
Strong
No.14 Regenerative braking soft-start at switch-back
Slow
*
Quick
No.15 Regenerative braking soft-stop at switch-back
Slow
*
Quick
1 16
No.16 Accelerator traction torque
Weak
*
Strong
1 17
No.17 Accelerator and brake traction torque
Weak
Strong *
1 18
No.18
Rollback speed when the travelling direction is opposite to the direction lever
Slow *
Quick
1 19
No.19
Rollback speed when the travelling direction is the same as the direction lever
Slow *
Quick
1 20
No.20 Not used
*
1 21
No.21 Not used
*
1 22
No.22 Maximum speed limitation during backward travelling
Slow
Quick *
1 23
No.23 Low speed setting during backward travelling
Slow
Quick *
1 24
No.24
1 25
No.25 Regenerative braking torque at brake on
1 13 1 14 1 15
TUNE GEN.
GENERAL
Level (*: Initial setting value)
Item
Deceleration during accelerator-off when going up on a slope
Weak
*
Strong
Weak
*
Strong
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Display
Multifunction display/DX
3 4 5 6 7
8 Quick *
No.27 Pump motor output during tilt forward and backward operation
Slow
1 28
No.28
Pump motor output during the attachment (1) lever push and pull Slow operation
*
Quick
1 29
No.29
Pump motor output during the attachment (2) lever push and pull Slow operation
*
Quick
No.30
Pump motor output during the attachment (3) lever push and pull Slow operation
*
Quick
1 30
*
No.31 Inching speed during Height Selector operation
Slow
1 32
No.32 Load meter display time
None Short
1 33
No.33
1 34
No.34 Not used
*
1 35
No.35 Not used
*
2 01
START Play at the beginning of lift down operation
2 05
LIFT DOWN
1 31
TUNE GEN.
1 27
2 04 LIFT
2
Slow
2 03
2 08 2 09 2 10 3 02 3 03 3 04 3 05 3 07 3 08 3 09
TILT BWD
3 06
3 10 4 02 4 03 4 04
ATT1 PUSH
4 01
4 05
4 08 4 09 4 10
ATT1 PULL
4 07
Small
Quick Long High
*
Wide
Slow
*
Quick
MAX Maximum speed during lift down operation
Slow
*
Quick
ACC
Acceleration speed during lift down operation
Weak
*
Strong
DEC
Deceleration speed during lift down operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during lift up operation
Slow
*
Quick
MAX Maximum speed during lift up operation
Slow
*
Quick
ACC
Acceleration speed during lift up operation
Weak
*
Strong
DEC
Deceleration speed during lift up operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during tilt forward operation
Slow
*
Quick
MAX Maximum speed during tilt forward operation
Slow
*
Quick
ACC
Acceleration speed during tilt forward operation
Weak
*
Strong
DEC
Deceleration speed during tilt forward operation
Weak
*
Strong
START Play at the beginning of tilt backward operation
Small
*
Wide
Slow
*
Quick
INCH Inching speed during tilt backward operation MAX Maximum speed during tilt backward operation
Slow
*
Quick
ACC
Acceleration speed during tilt backward operation
Weak
*
Strong
DEC
Deceleration speed during tilt backward operation
Weak
*
Strong
START Play at the beginning of the attachment (1) lever push operation Small
*
Wide
INCH Inching speed during the attachment (1) lever push operation
Slow
*
Quick
MAX Maximum speed during the attachment (1) lever push operation Slow
*
Quick
ACC
Acceleration speed during the attachment (1) lever push operation
Weak
*
Strong
DEC
Deceleration speed during the attachment (1) lever push operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during the attachment (1) lever pull operation
Slow
*
Quick
MAX Maximum speed during the attachment (1) lever pull operation
START Play at the beginning of the attachment (1) lever pull operation
4 06
*
Quick
INCH Inching speed during lift down operation
START Play at the beginning of tilt forward operation TILT FWD
3 01
*
Temperature at which the battery temperature protection function Low limits the vehicle performance in the maximum *
START Play at the beginning of lift up operation
2 06 2 07
TILT
1
No.26 Pump motor output during lift up operation
2 02
ATT1
No.
Level (*: Initial setting value)
1 26
LIFT UP
GENERAL
Menu No. Menu
Item
Slow
*
Quick
ACC
Acceleration speed during the attachment (1) lever pull operation Weak
*
Strong
DEC
Deceleration speed during the attachment (1) lever pull operation Weak
*
Strong
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Display
Multifunction display/DX
Menu No. Menu
5 02 5 03
5 05 5 06 5 07 5 08 5 09 5 10
Level (*: Initial setting value) 1
2 3 4 5 6 7
8
Small
*
Wide
INCH Inching speed during the attachment (2) lever push operation
Slow
*
Quick
MAX Maximum speed during the attachment (2) lever push operation
Slow
*
Quick
ACC
Acceleration speed during the attachment (2) lever push operation Weak
*
Strong
DEC
Deceleration speed during the attachment (2) lever push operation Weak
*
Strong
Small
*
Wide
INCH Inching speed during the attachment (2) lever pull operation
Slow
*
Quick
MAX Maximum speed during the attachment (2) lever pull operation
Slow
*
Quick
ACC
Acceleration speed during the attachment (2) lever pull operation
Weak
*
Strong
DEC
Deceleration speed during the attachment (2) lever pull operation
Weak
*
Strong
START Play at the beginning of the attachment (2) lever pull operation ATT2 PULL
ATT2
5 04
No. START Play at the beginning of the attachment (2) lever push operation
ATT2 PUSH
5 01
Item
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TUNING MENU screen Operation Procedure
MODE
Switch (1)
1.
Enter the password on the status screen to display the service menu screen.
2.
“1-ANL” (ANALYZER MENU) is initially displayed on the SERVICE MENU screen. On this screen, press switch (1) once to move to the TUNING MENU screen where “2-TUN” is displayed. Press switch (1) to move to the OPTION MENU “3OPT” screen, or switch (2) to move to the “1 GENERA” (GENERAL) screen.
Switch (2) Note: The number of tuning menu items displayed varies according to the number of spools of the conventional handling lever.
“1 GENERA” (1 GENERAL) General Tuning Switch (1): Next screen Switch (2): To TUNING LEVEL setting screen
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“2 L LIFT” Lift Lever Tuning Switch (1): Next screen Switch (2): To TUNING LEVEL setting screen
“3 L TILT” Tilt Lever Tuning Switch (1): Next screen Switch (2): To TUNING LEVEL setting screen
“4 L ATT1” Attachment 1 Lever Tuning Switch (1): Next screen Switch (2): To TUNING LEVEL setting screen
“5 L ATT2” Attachment 2 Lever Tuning Switch (1): Next screen Switch (2): To TUNING LEVEL setting screen
4-48
“E END” Switch (1): Switching selection to “1 GENERA” (GENERAL) Switch (2): Returning to the “2 TUN” (TUNING MENU) screen
TUNING (GENERAL) Used to fine adjust settings related to traveling, load handling, and so on (except for settings related to the load handling levers).
Operation Procedure 1. 2.
MODE
Switch (1)
Switch (2)
Display the TUNING MENU screen. Check that “1. GENERA” (GENERAL) is selected, and press the switch (2) to display “1 01” setting screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “1E” screen, press switch (2) to return to the TUNING MENU screen. Note: You cannot move directly from “1 GENERA” (GENERAL) screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“1 01 to 1 35” General Tuning For correspondence between numbers and items, see the tuning item list. Switch (1): Switching selection to next screen Switch (2): Increasing the tuning level (After level 8, the tuning level returns to level 1.)
No.
Tuning level
4-49
“1 E” Switch (1): Switching selection to “1 01 Switch (2): Returning to the “1 GENERA” (GENERAL) screen
TUNING (2 L LIFT) Sets tuning levels for the lift lever.
Operation Procedure 1. 2.
MODE
Switch (1)
Switch (2)
Display the tuning menu screen. Press switch (2) once and switch (1) once, and make sure that “2 L LIFT” is displayed on the screen. Then, press switch (2) (to confirm) to display the “2 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “2 E” screen, press switch (2) to return to the TUNING MENU screen. Note: You cannot move directly from “2 L LIFT” screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
4-50
“2 01 to 2 10” Lift Lever Tuning For correspondence between numbers and items, see the tuning item list. Switch (1): Switching selection to next screen Switch (2): Increasing the tuning level (After level 8, the tuning level returns to level 1.)
No.
Tuning level
“2 E” Switch (1): Switching selection to “2 01” Switch (2): Returning to the “2 L LIFT” screen
TUNING (3 L TILT) Sets tuning levels for the tilt lever.
Operation Procedure 1. 2.
MODE
Switch (1)
Switch (2)
Display the tuning menu screen. Press switch (2) once and switch (1) twice, and make sure that “3 L TILT” is displayed on the screen. Then, press switch (2) (to confirm) to display the “3 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “3 E” screen, press switch (2) to return to the TUNING MENU screen. Note: You cannot move directly from “3 L TILT” screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
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“3 01 to 3 10” Tilt Lever Tuning For correspondence between numbers and items, see the tuning item list. Switch (1): Switching selection to next screen Switch (2): Increasing the tuning level (After level 8, the tuning level returns to level 1.)
No.
Tuning level
“3 E” Switch (1): Switching selection to “3 01” Switch (2): Returning to the “3 L TILT” screen
4-52
TUNING (4 L ATT1) Sets tuning levels for the attachment 1 lever.
Operation Procedure 1. 2.
MODE
Switch (1)
Switch (2)
Display the tuning menu screen. Press switch (2) once and switch (1) three times, and make sure that “4 L ATT1” is displayed on the screen. Then, press switch (2) (to confirm) to display the “4 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “4 E” screen, press switch (2) to return to the TUNING MENU screen. Note: You cannot move directly from “4 L ATT1” screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“4 01 to 4 10” Attachment 1 Lever Tuning For correspondence between numbers and items, see the tuning item list. Switch (1): Switching selection to next screen Switch (2): Increasing the tuning level (After level 8, the tuning level returns to level 1.)
No.
Tuning level
4-53
“4 E” Switch (1): Switching selection to “4 01” Switch (2): Returning to the “4 L ATT1” screen
TUNING (5 L ATT2) Sets tuning levels for the attachment 2.
Operation Procedure 1. 2.
MODE
Switch (1)
Switch (2)
Display the tuning menu screen. Press switch (2) once and switch (1) four times, and make sure that “5 L ATT2” is displayed on the screen. Then, press switch (2) (to confirm) to display the “5 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “5 E” screen, press switch (2) to return to the TUNING MENU screen. Note: You cannot move directly from “5 L ATT2” screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
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“5 01 to 5 10” Attachment 2 Lever Tuning For correspondence between numbers and items, see the tuning item list. Switch (1): Switching selection to next screen Switch (2): Increasing the tuning level (After level 8, the tuning level returns to level 1.)
No.
Tuning level
“5 E” Switch (1): Switching selection to “5 01” Switch (2): Returning to the “5 L ATT2” screen
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OPTION SET General 1. The option set function is used to fit the specifications of the controller and the multi-function display to the options actually equipped on the vehicle. The option set items are not functioning on the vehicle that doesn’t actually mount them even if the OPTION SET enables them. 2. When main controller or multi-function display is replaced, it is necessary to reset them according to the vehicle specifications.
Option Set Item List Switching settings Indication
Description
1 01
Adjust the battery capacity indicator calculation
1 02*
Battery fluid level and temperature unit
1 03*
Fluid level warning
YES
Enabled
NO
Disabled
1 04
Setting to enable/ disable H mode lock
YES
Enabled
NO*
Disabled
1 05
Setting of priority between accelerator and brake
A*
Accelerator priority
B
Brake priority
1 06*
Setting the number of ways for oil control valve
1 07*
Setting the load handling lever type
1 08*
Fishery industry model
1 09*
Attachment 1 lever clamp setting
A/B/C/D
1 10*
Attachment 2 lever clamp setting
A/B/C/D
1 11
Attachment 3 lever clamp setting
A* / B / C / D
1 12
Setting the mode of buzzer sound when OPS and return-to-neutral operate
1 13
Setting to enable/ disable buzzer sound when OPS operate
YES*
1 14
Setting to enable/disable parking brake off warning
1 15
Not used
Indication
Setting content
Setting content
Indication
A1 / A2 / B1* / B2 A: Not provided, B: Previous type (fluid level unit), C: Fluid and temperature unit
2/3/4/5 “5” is no used this model A
Conventional lever
B
Mini lever/ Joystick
YES
Enabled
NO
Disabled
Enabled
NO
Disabled
YES*
Enabled
NO
Disabled
YES
Not used
NO
Not used
A
Traction restrictions regardless of discharge level
B*
Traction restrictions according to discharge level
A*
Lift interrupt
B
Lift interrupt while traveling
A* / B / C
1 16
Setting the traction limitation mode at over-discharge warning
1 17
Setting the load handling limitation mode at over-discharge warning
1 18*
Battery fluid level protection
YES
Enabled
NO
Disabled
1 19*
Battery fluid temp protection
YES
Enabled
NO
Disabled
1 20
Power keep
YES*
Enabled
NO
Disabled
1 21
Not used
YES
Not used
NO
Not used
1 22*
Setting to enable/disable the steering knob synchronizer
YES
Enabled
NO
Disabled
1 23*
Model with on-vehicle charger
YES
Enabled
NO
Disabled
1 24
Not used
A
Not used
B
Not used
1 25
Not used
A
Not used
B
Not used
*: These items are set according to the type of each vehicle before shipment from the factory.
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OPTION SET MENU screen Operation Procedure 1.
Enter the password on the status screen to display the service menu screen.
2.
“1-ANL” (ANALYZER MENU) is initially displayed on the SERVICE MENU screen. On this screen, press switch (1) twice to move to the TUNING MENU screen where the “3-OPT” is displayed. Press switch (2) once and make sure that “1 OPT SET” is displayed. Then, press switch (2) again (to confirm) to display the OPTION SET screen. From here on, the screen changes in sequence each time switch (1) is pressed, and it returns to the OPTION SET screen.
MODE
3. Switch (1)
Switch (2)
Note: You cannot move directly from “1 OPT SET” screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“1 OPT SET” Switch (1): Next screen Switch (2): Switching the selected option set items
“E END” Switch (2): Returning to the “1 OPT SET” (option set menu) screen
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MATCHING General • Each function is controlled by using the sensors and each signal voltage at standard vehicle condition stored in the controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a sensor at standard vehicle condition) is required when performing maintenance on a section or replacing parts related to the sensor. • For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accelerator fully released, accelerator fully closed, brake fully released and brake operation starting positions are stored, respectively, in the controller to control based on these values. When servicing these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary. • For tire angle sensor used for synchronized steering, the signal voltage value at standard vehicle condition is stored, in the controller to control based on this value. When servicing or replacing tire angle sensor, matching (updating the sensor signal voltage value in the standard vehicle condition) is necessary. On the other hand, matching is needed for the tire angle sensor when the tire angle sensor or related part is replaced. • The oil control valve (OCV) starting current level is set at the factory for all the control valves together, and the settings are stored in the main controller memory. Therefore, the settings must be matched following maintenance or replacement of related parts. • Each lever angle sensor for load-handling lever function is controlled based on the memory of signal voltage values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary. • It is necessary to input the tire data to the controller according to the tire size, for maximum speed limiter. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire size or type is changed according to “TIRE DATA List”.
Matching Items and Prerequisite for Implementation 1. DRIVE No.
Indication
Description
Prerequisite for implementation
1
1 01
Accelerator sensor output value with fully opened accelerator position to the controller.
*1,*2
2
1 02
Accelerator sensor output value with fully stepped accelerator position to the controller.
*1,*2
3
1 03
Brake sensor output value with fully released brake position to the controller.
*1,*9
4
1 04
Brake sensor output value at the operation starting position of brake to the controller.
*1,*9
Description
Prerequisite for implementation
2. SAS No. 1
Indication 2 01
Tire angle sensor output value while the vehicle is traveling straight to the controller.
*1, *3
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3. LEVER No.
Indication
Description
Prerequisite for implementation
1
3 01
Lift lever angle sensor output value in the lift lever neutral position is stored in the controller.
*1, *4
2
3 02
Tilt lever angle sensor output value in the tilt lever neutral condition is stored in the controller.
*1, *5
3
3 03
Attachment (1) lever angle sensor output value in the attachment (1) lever neutral position is stored in the controller.
*1, *6
4
3 04
Attachment (2) lever angle sensor output value in the attachment (2) lever neutral position is stored in the controller.
*1, *7
Description
Prerequisite for implementation
4. OCV No.
1
2
Indication 4 A1
Control valve A01 starting current level
*1, *10
4 A2
Control valve A02 starting current level
*1, *10
4 A3
Control valve A03 starting current level
*1, *10
4 A4
Control valve A04 starting current level
*1, *10
4 B1
Control valve B01 starting current level
*1, *10
4 B2
Control valve B02 starting current level
*1, *10
4 B3
Control valve B03 starting current level
*1, *10
4 B4
Control valve B04 starting current level
*1, *10
5. TIRE DATA No. 1
Indication 5 01
Description The tire data according to the tire size is stored.
Prerequisite for implementation *1, *8
Prerequisite content for implementation *1: When main controller replacement *2: When removing/installing or replacing accelerator sensor *3: When removing/installing or replacing tire angle sensor or sensor cover *4: When replacing lift lever angle sensor *5: When replacing tilt lever angle sensor *6: When replacing attachment (1) lever angle sensor *7: When replacing attachment (2) lever angle sensor *8: When the tire size or type is changed. *9: When removing/installing or replacing brake sensor, or adjusting the brake pedal height *10: When replacing oil control valve.
Before Starting Matching Before performing matching, you must set the vehicle to “standard vehicle condition”. For “standard vehicle condition”, refer to section 14.
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MATCHING MENU screen Operation Procedure
MODE
Switch (1)
1.
Enter the password on the status screen to display the service menu screen.
2.
“1-ANL” (ANALYZER MENU) is initially displayed on the SERVICE MENU screen. On this screen, press switch (1) three times to move to the MATCHING MENU screen where “4-SET” is displayed. Press switch (1) once to move to the OTHER SERVICE FUNCTION MENU screen where “5-ETC” is displayed. Then, press switch (2) to move to the MATCHING MENU screen where “1 DRIVE” is displayed.
Switch (2)
“1 DRIVE” Switch (1): Switching selection to “2 SAS” Switch (2): Switching to “1 DRIVE” detail setting menu
“2 SAS” Switch (1): Switching selection to “3 LEVER” Switch (2): Switching to “2 SAS” detail setting menu
4-60
“3 LEVER” Switch (1): Switching selection to “4 OCV” Switch (2): Switching to “3 LEVER” detail setting menu
“4 OCV” Switch (1): Switching selection to “5 TIRE” Switch (2): Switching to “4 OCV” detail setting menu
“5 TIRE” Switch (1): Switching selection to “6 PWR OFF” Switch (2): Switching to “5 TIRE” detail setting menu
“6 PWR OFF” Switch (1): Switching selection to “7 SPEED” Switch (2): Switching to “6 PWR OFF” detail setting menu
4-61
“7 SPEED” Switch (1): Switching selection to “E END” Switch (2): Switching to “7 SPEED” detail setting menu
“E End” Switch (1): Switching selection to “1 DRIVE” Switch (2): Returning to the “4-SET” screen
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MATCHING (1 DRIVE) Matching is performed for drive function. 1. 2.
MODE
Switch (1)
Switch (2)
Display the MATCHING MENU screen. Press switch (2) once and make sure that “1 DRIVE” is displayed on the screen. Then, press switch (2) (to confirm) to display the “1 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “1 E” screen, press switch (2) to return to the MATCHING MENU screen Note: • The MATCHING SET screen displays a numeric value that represents the current state of the vehicle. During traveling matching operation, the spanner indicator blinks to indicate that the vehicle is in a state where it does not move even if the accelerator pedal is depressed. • On completion of the matching operation, an “O” is displayed on the display. • You cannot move directly from “MATCHING” screen to the screen of the other items. Return to MATCHING MENU screen once, then move to screen of each time.
4.
Make sure that the Spanner indicator on the display is blinking. Caution: During drive matching, the Spanner indicator blinks, informing that the vehicle does not run even if the accelerator pedal depressed.
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Matching completed
Item
Matching failed
Matching result
“1 01” Acceleration Sensor OFF Matching Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
“1 02” Acceleration Sensor ON Matching Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
“1 03” Brake Sensor OFF Matching Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
4-64
“1 04” Brake sensor actuation point matching Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
“1 E” Switch (1): Switching selection to “1 01” Switch (2): Returning to the “1 DRIVE” screen
MATCHING (2 SAS) Matching is performed for synchronized steering. 1. 2.
MODE
Switch (1)
Switch (2)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) once, and make sure that “2 SAS” is displayed on the screen. Then, press switch (2) (to confirm) to display the “2 01” screen 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “2 E” screen, press switch (2) to return to the MATCHING MENU screen. Note: • The MATCHING MENU screen displays a numeric value that represents the current state of the vehicle. • On completion of the matching operation, an “O” is displayed on the display.
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Matching completed
Item
Matching failed
Matching result
“2 01” Tire Angle Sensor Matching Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
“2 E” Switch (1): Switching selection to “2 01” Switch (2): Returning to the “2 SAS” screen
MATCHING (3 LEVER) Matching is performed for lever function. 1. 2.
MODE
Switch (1)
Switch (2)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) twice, and make sure that “3 LEVER” is displayed on the screen. Then, press switch (2) (to confirm) to display the “3 01” screen. 3. From here on, the screen changes in sequence each time switch (1) is pressed. On the “3 E” screen, press switch (2) to return to the MATCHING MENU screen. Note: • The number of the displayed lever matching items varies according to the number of levers. • After completion of the matching operation, fully tilt each lever to both the push and pull sides in order to learn the full-stroke voltage automatically. • On completion of the matching operation, an “O” is displayed on the display.
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Matching completed
Item
Matching failed
Matching result
“3 01 to 3 04” Switch (1): Switching selection to next screen Switch (2): Pressing this for more than 2 seconds will perform matching
4-67
“3 E” Switch (1): Switching selection to “3 01” Switch (2): Returning to the “3 LEVER” screen
MATCHING (4 OCV) Used to set the control valve starting current level. The starting current level is set according to the type of the mounted control valve before shipment from the factory. However, if the control valve or the main controller is changed, the starting current should be set again according to the value printed on or attached to the new control valve. 1. 2.
3. MODE
Switch (1)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) three times, and make sure that “4 OCV” is displayed on the screen. Then, press switch (2) (to confirm) to display the “4 A1” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “4 E” screen, press switch (2) to return to the MATCHING MENU screen.
Switch (2)
Reference: Plate of curent level.
4-68
“4 A1 to 4 B4” Control valve starting current level setting screen 4 A1: Control valve A01 starting current level 4 A2: Control valve A02 starting current level 4 A3: Control valve A03 starting current level 4 A4: Control valve A04 starting current level 4 B1: Control valve B01 starting current level 4 B2: Control valve B02 starting current level 4 B3: Control valve B03 starting current level 4 B4: Control valve B04 starting current level Switch (1): Switching selection to next screen Switch (2): Increasing the starting current level
“4 E” Switch (1): Switching selection to “4 A1” Switch (2): Returning to the “4 OCV” screen
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MATCHING (5 TIRE) Used to set the tire data. The tire data is set according to the type of the mounted tires before shipment from the factory. If the type or size of tire is changed, the tire data should be set again according to the “Tire Data List”. 1. 2.
3. MODE
Switch (1)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) four times, and make sure that “5 TIRE” is displayed on the screen. Then, press switch (2) (to confirm) to display the “5 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “5 E” screen, press switch (2) to return to the MATCHING MENU screen.
Switch (2)
“5 01” Tire Data Setting Switch (1): Switching selection to next screen Switch (2): Increasing the tire constant
“5 E” Switch (1): Switching selection to “5 01” Switch (2): Returning to the “5 TIRE” screen
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Tire Data List 1 ton models Tire size
Tire type
Applicable models 1.5 ton
1.6 ton
1.8 ton
STD (J-Lug) tire
271
-
-
Rib-Lug tire
271
-
-
STD (J-Lug) tire
-
299
299
Rib-Lug tire
-
299
299
J-Lug, Oversize tire
299
-
-
Rib-Lug, Oversize tire
299
-
-
21x8-9-14PR
Side-ring (J-Lug) tire
273
273
273
21x8-9-10PR
Rib-Lug, Side-ring tire
267
267
267
J-Lug, Non-Punc tire
276
276
-
U-Lug, Non-Punc tire
276
276
-
Non-marking tire
276
276
-
J-Lug, Non-Punc tire
-
-
306
U-Lug, Non-Punc tire
-
-
306
Non-marking tire
-
-
306
J-Lug, Non-Punc, Oversize tire
306
306
-
U-Lug, Non-Punc, Oversize tire
306
306
-
Non-marking, Oversize tire
306
306
-
J-Lug, Non-Punc, Side-ring tire
272
272
272
U-Lug, Non-Punc, Side-ring tire
272
272
272
Non-marking, Side-ring tire
272
272
272
6.00-9-10PR
6.50-10-10PR
6.00-9
6.50-10
21x8-9
2 ton models Tire size 21x8-9-14PR
21x8-9
23x9-10
Tire type
Applicable models 2.0 ton
2.5 ton
STD (J-Lug) tire
270
270
Rib-Lug tire
270
270
J-Lug, Non-Punc tire
272
272
U-Lug, Non-Punc tire
272
272
Non-marking tire
272
272
J-Lug, Non-Punc, Side-ring tire
309
309
U-Lug, Non-Punc, Side-ring tire
309
309
3 ton model Tire size 28x9-15-14PR
28x9-15
Tire type
Applicable models 3.0 ton
STD (J-Lug) tire
369
Rib-Lug tire
369
J-Lug, Non-Punc tire
368
U-Lug, Non-Punc tire
368
Non-marking tire
368
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POWER OFF (6 PWR OFF) Used to set the auto power off time. 1. 2.
3. MODE
Switch (1)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) five times, and make sure that “6 PWR OFF” is displayed on the screen. Then, press switch (2) (to confirm) to display the “6 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “6 E” screen, press switch (2) to return to the MATCHING MENU screen.
Switch (2)
“6 01” Auto power off time setting The auto power off time can be set in a range of 2 to 60 minutes in steps of 1 minute. It is displayed in the following sequence: 2 → 3 → 4 · · · 60 → OFF → 2. Switch (1): Switching selection to next screen Switch (2): Changing the auto power off time
“6 E” Switch (1): Switching selection to “6 01” Switch (2): Returning to the “6 PWR OFF” screen
4-72
SPEED (7 SPEED) Used to set the maximum speed limit. 1. 2.
3. MODE
Switch (1)
Display the MATCHING MENU screen. Press switch (2) once and switch (1) six times, and make sure that “7 SPEED” is displayed on the screen. Then, press switch (2) (to confirm) to display the “7 01” screen. From here on, the screen changes in sequence each time switch (1) is pressed. On the “7 E” screen, press switch (2) to return to the MATCHING MENU screen.
Switch (2)
“7 01” Maximum speed limit setting screen The maximum speed limit can be set in a range of 2 to 20 km/h in steps of 1 km/h. It is displayed in the following sequence: 2 → 3 → 4 · · · 20 → OFF → 2. Switch (1): Switching selection to next screen Switch (2): Changing the maximum speed limit
“7 E” Switch (1): Switching selection to “7 01” Switch (2): Returning to the “7 SPEED” screen
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OTHERS MENU OTHERS MENU screen Operation Procedure 1.
Enter the password on the status screen to display the service menu screen.
2.
“1-ANL” (ANALYZER MENU) is initially displayed on the SERVICE MENU screen. On this screen, press switch (1) four times to move to the OTHERS MENU screen where “5-ETC” is displayed. Note: After completion of the hour meter start operation, OTHERS MENU screen is not displayed any more.
MODE
Switch (1)
Switch (2)
“1 METER” Switch (1): Switching selection to next screen Switch (2): Switching to the meter start operation screen
“2 DEMO” Switch (1): Switching selection to next screen Switch (2): Switching to the demo mode operation screen
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“E END” Switch (1): Switching selection to “1 METER” Switch (2): Returning to the “5-ETC” screen
HOUR METER START Used to make the hour meter start to count up. This function also enables the following functions, regardless of whether the demo mode is enabled or disabled. • Enables the load handling operation during traveling. • Enables the parking brake OFF warning function. 1. 2.
Display the OTHERS MENU screen. Press switch (2) once and make sure that “1 METER” is displayed on the screen. Then, press (2) (to confirm) to display the “1 01” screen.
MODE
Switch (1)
Switch (2)
“1 01” 1. 2.
While holding down switch (2) for 2 seconds or more, press (1) (to switch to YES). Press switch (1) to move to the “1 E” screen. Switch (1): Switching selection to “1 E” Switch (2): Used only for the start operation
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“1 E” Switch (1): Switching selection to “1 01” Switch (2): Returning to the “1 METER” screen
Note: After completion of the hour meter start operation, the hourglass icon on the key ON hour meter blinks to indicate that the counting has started. Key ON hour meter before the start of counting
Key ON hour meter after the start of counting
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DEMO MODE This menu item is used to enable or disable the demo mode. Before starting the hour meter, you can enable the following functions temporarily in the demo mode. Demo mode
Yes (enabled)
No (disabled)
Load handling during traveling
Allowed
Not allowed
Parking brake OFF warning
Enabled
Disabled
Note: Even after the demo mode has been disabled, the data recorded and the settings made during the demo mode are all retained. 1. 2.
Display the OTHERS MENU screen. Press switch (2) once and switch (1) once, and make sure that “2 DEMO” is displayed on the screen. Then, press (2) (to confirm) to display the “2 01” screen. Note: After completion of the hour meter start operation, the other service function menu is not displayed any more.
MODE
Switch (1)
Switch (2)
“2 01” 1. 2. 3.
Press switch (2) to switch to YES. Press switch (1) to move to the “2 E” screen. Press switch (2) to move to the “2 DEMO” screen. Switch (1): Switching selection to “2 E” Switch (2): Switching between YES and NO Note: While demo mode is selected, “DEMO” is displayed on the key ON hour meter screen.
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“2 E” Switch (1): Switching selection to “2 01” Switch (2): Returning to the “2 DEMO” screen
Hour meter screen in demo mode
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MULTI-FUNCTION DISPLAY GENERAL The multi-function display consisting of a full-dot matrix LCD panel and LED indicators, and the multifunction display DX with a load meter function also have been made available as options. Dedicated LED indicators have been adopted for various warning indicators to improve color tone and visibility. A full-dot matrix LCD panel has been adopted for the main display to display various information in an easy-to-see way according to the vehicle state and operation state. The multi-function display is provided not only with the functions of displaying and providing vehicle information, such as vehicle speed and remaining battery capacity, but also with functions that allow the operator (or the administrator) to set the vehicle performance. In addition to these functions, it has also a maintenance function, a feeling adjustment function and a specification setting function. .
(5) (6)
(10)
(7) (8) (9)
(11) (12) (13)
(1)
(2)
(3)
No.
Description
(1)
Switch (1): Low speed setting switch/Down switch
(2)
Switch (2): Power select switch/Left switch
(3)
Switch (3): Time or date select switch/Right switch
(4)
Switch (4): Meter mode select switch/Enter switch
(5)
Multiple screen display area
(6)
OPS indicator
(7)
Parking brake indicator
(8)
Height limit indicator
(9)
Low speed setting indicator
(10)
Spanner indicator
(11)
Overheat warning indicator
(12)
Battery overheat warning indicator
(13)
Battery fluid level warning indicator
(4)
4-79
FEATURES LIST {: Operator available : Operator available when menu lock setting is “NO” : Administrator only (protected by the administrator password) New: New feature
–: NOT AVAILABLE STD: BUILT-IN OPT: OPTION
Features
Operation
Calendar Initial screen after key-on
Maximum speed limiter
New
Status indicator of function settings
–
STD
–
STD
–
STD
–
–
STD
Parking brake indicator
–
–
STD
Low speed setting (turtle) indicator
–
–
STD
New
–
OPT With Height selector
Spanner indicator
–
–
STD
Overheat warning indicator
–
–
STD
New
–
OPT When JIS batter is installed
New
–
OPT When JIS battery is installed and battery protection function is provided
–
–
OPT When charger is installed
Battery capacity indicator
–
–
STD
Digital speedometer
–
–
STD
Power select (ESPH/original) indicator
–
–
STD
Load meter
–
–
New
–
STD
New
–
OPT With SAS
New
–
STD
–
–
STD
Wheel indicator
New
–
Direction indicator
New
–
Key switch on hour meter
–
–
STD
Lap time meter
–
–
STD
Traveling hour meter
–
–
STD
Load handling hour meter
–
–
STD
Traveling/Load handling hour meter
–
–
STD
New
–
STD
Odometer
–
–
STD
Trip meter
–
–
STD
New
–
STD
Battery fluid level warning indicator Battery overheat indicator
Charging progress indicator
Maintenance indicator Auto speed control indicator Menu lock indicator Date/Time
Meter
Multi-function Display DX
OPS indicator
Height limit indicator
Status display
Multi-function display
Seat on hour meter
Maintenance hour meter
–
STD
OPT With SAS or Synchronized steering
4-80 Features
Operation –
–
STD
Low battery level warning
–
–
STD
Overheat warning
–
–
STD
New
–
STD
New
–
OPT When JIS battery is installed and battery protection function is provided
Parking brake ON warning
–
–
STD
Parking brake OFF warning
–
–
STD
OPS operation information
–
–
STD
Return to neutral warning for travel OPS
–
–
STD
Return to neutral warning for load handling OPS
–
–
STD
Return to neutral warning at key ON
–
–
STD
Diagnostic code display
–
–
STD
Overspeed alarm
–
–
STD
New
–
OPT With Shock sensor
Clock set
–
{
STD
Power select (ESPH) function
–
STD
Travel power control level setting
–
STD
Load handling power control level setting
–
STD
Low speed setting
–
STD
New
STD
–
STD
Maintenance hour meter setting
New
STD
Auto power off time setting
New
STD
Second password registration for administrator
New
STD
–
STD
Battery overheat warning
Shock detection alarm
Setting function
Maximum speed limitation setting Overspeed alarm setting
Menu lock setting Indication of target height memory Support function for Height selector
Support function for Shock sensor
Support function for PIN code entry
Multi-function Display DX
Battery over-discharge warning
Low temperature warning
Warning function
Multi-function display
{
Automatic height control setting
New
Lifting height limiter
Maximum height limitation
Display of shock detection histories
Cancellation of shock detection warning
New
Shock detection level setting
Measurement of shock
PIN code entry and setting
Profile setting
New
OPT With Height selector
OPT With Shock sensor
OPT With PIN code entry
4-81
ADMINISTRATOR FUNCTIONS Administrator can set the following items. Administrator functions are protected with password so that the general operators cannot change these settings.
Administrator menu list Except PIN code entry model Setting menu
Setting screen Power mode select*1
Power control functions
Setting of travel power control level*1 Setting of load handling power control level*1 Speed setting of low speed*1
Travel functions
Speed setting of maximum speed limiter Speed setting of overspeed alarm*1 Zero-point setting of load meter (DX only) Height position setting of height selector*1*2
Load handling functions
Height position clearing of height selector*1*2 Setting of lifting height limit*1*2 Height position setting of maximum height limiter*2 Setting of maintenance hour meter
Vehicle management functions
Setting of auto power off Setting of administrator’s second password Setting of menu-lock Checking shock memories
Shock sensor functions (With Shock sensor)
Reset of shock alarm Measurement and setting of shock Clearing shock memories
*1: When menu lock setting is released, the operator can set it. *2: With Height selector
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PIN code entry model Setting menu
Setting screen Registry of PINs Change of profile assignment
PIN code entry functions
Delete of PINs Profile data setting Change of initial PIN Zero-point setting of load meter (DX only) Height position setting of height selector*1*2
Load handling functions
Height position clearing of height selector*1*2 Setting of lifting height limit*1*2 Height position setting of maximum height limiter*2 Setting of maintenance hour meter Setting of auto power off
Vehicle management functions
Setting of auto log off Setting of administrator’s second password Setting of menu-lock Checking shock memories
Shock sensor functions (With Shock sensor)
Reset of shock alarm Measurement and setting of shock
*1: When menu lock setting is released, the operator can set it. *2: With Height selector
4-83
Password Entry Procedure Note: Always operate switches on the display with a fingertip. If a sharp pointed tool is used, the switch may be damaged. If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the begining. Administrator should prevent operators from knowing this password. Step
Display
Operation
1 Switch (2)
Switch (4)
Press switch (2) and switch (4) at the same time for more than 2 seconds.
Vehicle response When pressing the switches, a short beep sounds, and after 2 seconds another short beep sounds.
Press switch (3) within 10 A short beep sounds. seconds.
2 Switch (3)
3
Press switch (3) within 10 seconds.
A short beep sounds.
Within 10 seconds, press switch (2) and switch (4) at the same time for more than 2 seconds.
When pressing the switches, a short beep sounds, and after 2 seconds repeated short beeps sound.
Switch (3)
4 Switch (2)
Switch (4)
5
When the second password has been set: Password screen is displayed. Enter the password. Other: Skip this screen.
6
Administrator menu screen is displayed automatically.
4-84
ADMINISTRATOR MENU screen (Except PIN code entry) Power control setting menu
Traveling setting menu
Load handling setting menu
Vehicle management setting menu
Shock sensor function setting menu
Return to the status screen
4-85
Operation Procedure
Switch (1)
Switch (2)
Switch (3)
1.
Input the password on the status screen to display the administrator menu screen.
2.
Press switch (2) or switch (3) to select the desired menu tab. The selected tab is emphatically displayed and items that can be set are displayed below.
3.
Press switch (1) to select the item, and press switch (4) (enter) to display the menu or setting screen for each function.
Switch (4)
Note: Select the return tab on the Administrator Menu screen, and press switch (4) (enter) to display the status screen.
4-86
Setting Screen 1.
Power Control Setting Menu screen This menu screen can set the drive and lift power control function.
(1) Power select screen The power select mode (E,S, P, H or Original) can be selected by pressing switch (2) or switch (3) on the power select screen by shifting to the corresponding indicator position. This is the same as the one in the operator functions. Switch (2): S -> E ->ESPH -> H -> P Switch (3): S -> P -> H -> ESPH -> E Switch (4): Returning to power control setting menu screen Note: When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled or disabled using a set of options provided in the service function. (2) Drive power control level setting The drive power of the original mode can be set in five steps. Switch (2): Select the lower level Switch (3): Select the higher level Switch (4): Returning to power control setting menu screen This is the same as the one in the operator functions. Note: When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled or disabled using a set of options provided in the service function.
4-87
(3) Lift power control level setting The lift power of the original mode can be set in five steps. Switch (2): Select the lower level Switch (3): Select the higher level Switch (4): Returning to power control setting menu screen This is the same as the one in the operator functions. Note: When H mode lock is enabled, H mode cannot be selected. H mode lock can be enabled or disabled using a set of options provided in the service function. 2.
Travel Setting Menu Screen This menu screen can set the travel control function.
(1) Low speed setting screen The limit speed of the Low-speed setting function can be changed. Switch (2): Setting traveling speed down Switch (3): Setting traveling speed up Switch (4): Returning to setting menu screen This is the same as the one in the operator functions. It is adjustable from 2 to 20 km/h with a step of 1 km/h. If the operator set the speed to more than 20km/h, the low speed function is disabled. In that case “OFF” is displayed. (2) Maximum speed limit setting screen The limit speed of the Maximum speed limiter can be changed. Switch (2): Setting traveling speed down Switch (3): Setting traveling speed up Switch (4): Returning to setting menu screen It is adjustable from 2 to 20 km/h with a step of 1 km/h. If the operator set the speed to more than 20km/h, the maximum speed limit function is disabled. In that case “OFF” is displayed.
4-88
(3) Over speed alarm setting screen The speed to activate the over speed alarm function can be changed. Switch (2):Setting traveling speed down Switch (3):Setting traveling speed up Switch (4):Returning to setting menu screen It is adjustable from 5 to 20 km/h with a step of 1 km/h. If the operator set the speed to more than 20km/h, the over speed alarm function is disabled In that case “OFF” is displayed. 3.
Load Handling Setting Menu Screen This menu screen can set the Load Handling control function.
(1) Load meter zero point adjustment screen (Multifunction display DX only) Zero point of the load meter is adjusted. V mast At low lift height (ZERO SET): Set the mast approximately vertical, and raise forks at height of approximately 500 mm from the ground. Pressing switch (1) for more than 2 seconds will reset the indicated value to 0. In that case “OK” is displayed. Switch (4):Return to menu screen
4-89
FV and FSV mast At low lift height (ZERO SET1): Set the mast approximately vertical, and raise forks at height of approximately 500 mm from the ground. Pressing switch (1) for more than 2 seconds will reset the indicated value to 0. In that case “OK” is displayed. Switch (4): Next screen
FV and FSV mast At high lift height (ZERO SET2): Set the mast approximately vertical, and raise the rear lift cylinders to a height of approximately 100 mm. Pressing switch (1) for more than 2 seconds will reset the indicated value to 0. In that case “OK” is displayed. Switch (4): Return to menu screen
(2) Automatic height control setting screen (W/ Height Selector) (Refer to New Model Feature 8 section)
(3) Clear all memories screen (W/ Height Selector) (Refer to New Model Feature 8 section)
4-90
(4) Height limiter setting screen (W/ Height Selector) (Refer to New Model Feature 8 section)
(5) Maximum height limiter setting screen (W/ Height Selector) (Refer to New Model Feature 8 section)
4.
Vehicle Management Setting Menu Screen This menu screen can set the vehicle management function.
4-91
(1) Maintenance hour meter setting screen Time for planned maintenance hour meter can be set from 10 to 2000 hours by 10-hour increments between 10 and 200 hours, while 50-hour increments between 200 and 2000 hours. Switch (2): Decreasing set time Switch (3): Increasing set time Switch (4): Returning to menu screen Pressing switch (1) for more than 2 seconds will reset the current value to 0. Note: This reset operation does not cause the stored set value to change. The maintenance hour meter can be turned off by reducing the maintenance time below 10 hours with switch (2). If turned off, the maintenance hour meter will not make a notification with the maintenance indicator or a warning sound, although it will retain the elapsed time data. (2) Auto power off time setting The time to activate the auto power off function can be changed. Switch (2): Decreasing set time Switch (3): Increasing set time Switch (4): Returning to menu screen It is adjustable from 2 to 60 minutes with a step of 1 minute. Auto power off function is disabled by selecting “OFF” which is next to “60 min”.
4-92
(3) Administrator’s second password setting screen The administrator can register the second password. The second password can be registered by continuing to press switch (1) for 2 seconds after entering it by using switch (1) to (4). If press the switch (4) for 2 seconds or more, the screen returns to the menu screen without memorizing it. Administrator should manage the second password so that it doesn’t get unknown. Even if it has got unknown, the service staff can clear it on the service menu.
Switch (1) Switch (2) Switch (3) Switch (4)
(4) Clear of password Pressing switch (1) for more than 2 seconds can clear the password on the administrator’s second password setting screen. If press the switch (4) for more than 2 seconds, the screen returns to the menu screen.
Switch (1) Switch (2) Switch (3) Switch (4)
4-93
(5) Menu lock screen Setting change by an operator can be limited. If “YES” is selected, the following restrictions are activated. • Operator setting menu screen not available • Power select setting screen not available • Power mode not switchable Switch (2): Selecting “Yes” Switch (3): Selecting “No” Switch (4): Returning to menu screen Conditions required to release the menu lock differ depending on the setting of the option set item “menu lock spec.”. The menu lock spec. is set to B by factory default. If the menu lock spec. is set to A: The menu lock release setting (NO) is valid until the key switch is turned off. It changes to “YES” when the key switch is turned off. If the menu lock spec. is set to B: The menu lock release setting (NO) is valid until it is returned to “YES” on the menu lock screen. Note: No menus are locked before the start of the hour meter. 5.
Shock Sensor Setting Menu Screen (OPT) This menu screen can set the Shock Sensor function. (Refer to New Model Feature 8 section)
4-94
6.
End Menu Screen Switch (4): Returning to status screen
4-95
ADMINISTRATOR MENU screen (With PIN code entry) PIN code entry menu
Load handling setting menu
Vehicle management setting menu
Shock sensor function setting menu
Return to the status screen
4-96
1.
PIN Code Entry System Setting Menu Screen This menu screen can set the PIN code entry function. (Refer to New Model Feature 8 section)
2.
Load Handling Setting Menu Screen (W/ Height Selector or Multi-function display DX) This menu screen can set the Load Handling control function. For details, refer to “Load Handling Setting Menu Screen” (W/O PIN code entry).
4-97
3.
Vehicle Management Setting Menu Screen This menu screen can set the vehicle management function. For details, refer to “Vehicle Management Setting Menu Screen” (W/O PIN code entry). For the setting of the log-off time in models with a key switch, refer to New Model Feature 8 section.
4.
Shock Sensor Setting Menu Screen (W/ Shock Sensor) This menu screen can set the Shock Sensor function. For details, refer to New Model Feature 8 section.
5.
End Menu Screen Switch (4): Returning to status screen
4-98
SERVICE FUNCTIONS In the multi-function display, aside from the general functions that an operator or an administrator normally use, the following service functions for use by the service staff for vehicle maintenance and specification setting are also provided. The service functions are protected by the password so that the important internal data will not be damaged by the customer’s misuse. Note: Do not disclose the password to the operator.
Service Function List When used
Option set
Matching
Others menu
Function
Description
Analyzer
Vehicle delivery
Controller replacement
Others
Displays the electrical system status and reads the error information detected by controllers.
–
–
Upon vehicle abnormality
Tuning
Makes fine adjustment of traveling and load handling functions.
–
{ *2
As requested by customer
Specification setting
Sets each vehicle option and other specifications. *1
–
{ *2,*3
–
Each control function enable/disable
Enables or disables each control function.
–
{ *2,*3
–
Traveling function/SAS/ Load handling lever
Updates voltage values of sensor signals under the standard vehicle condition.
–
{ *2,*3
{ *6
OCV starting current level
Sets the oil control valve starting current level.
–
{ *2
{ *5
Tire data
Makes the speedometer reading appropriate.
–
{ *2
{ *4
Load meter
Sets the load meter.
{ *3
When it is necessary
Meter start
Starts counting the hour meter.
{
{ *3
–
Demo mode
Enables simultaneous operation of traveling and load handling before starting the hour meter.
–
–
Before starting the hour meter
To default set
Initialize a set value with the default value.
–
{ *2,*3
When it is necessary
Service second password setting
Sets the service second password.
–
{ *3
When it is necessary
Administrator’s second password clear
Delete the administrator’s second password.
–
{ *3
As requested by customer
Reset of charger counter
Resets the charger counter to 0.
–
{ *3
When it is necessary
Contrast
Adjusts the contrast of the display screen.
–
{ *3
As requested by customer
4-99
*1: The option set function is used to fit the specifications of the controller and the multi-function display for the options actually equipped on the vehicle. Functions are not available for the vehicle where they are not mounted, even if the OPTION SET enables them. *2: Controller: Main controller *3: Controller: Multi-function display *4: When tire size is changed or tire is replaced *5: When oil control valve is replaced. *6: When removing/installing or replacing the brake sensor, accelerator sensor, or adjusting the pedal height.
Before Starting Matching Before performing matching, you must set the vehicle to “standard vehicle condition”. For “standard vehicle condition”, refer to section 14.
4-100
PASSWORD Note: • Always operate the display switches with a finger-tip. If a sharp pointed tool is used, the switch may be damaged. • If an operation error occurs during entry operation, turn the key switch OFF and re-enter from the beginning. If the SERVICE MENU cannot be displayed after several attempts, the system may be faulty.
Password Entry Procedure Step
Display
Operation
1 Switch (2)
Switch (3) Switch (4)
2
Vehicle response
When pressing the Press switch (2), switch switches, a short beep (3) and switch (4) at the sounds, and after 2 same time for more than 2 seconds another short seconds. beep sounds.
Press switch (4) within 10 seconds.
A short beep sounds.
Press switch (1) within 10 seconds.
A short beep sounds.
Within 10 seconds, press switch (2) and switch (3) at the same time for more than 2 seconds.
When pressing the switches, a short beep sounds, and after 2 seconds repeated short beeps sound.
Switch (4)
3 Switch (1)
4 Switch (2)
Switch (3)
5
When the service second password has been set: Second password screen is displayed. Input the second password. Other: This screen is skipped.
6
Service function initial screen is displayed for 5 seconds.
7
ANALYZER MENU screen is automatically displayed.
4-101
SERVICE MENU Screen Operation Procedure 1. Enter the password on the status screen to display the SERVICE MENU screen.
2.
Switch (2)
Select a desired function using the switch (2) or (3). Then press the switch (4) to display the function screen or setting screen of the selected function.
Switch (3) Switch (4)
ANALYZER MENU screen
Reads out information about the error detected by a controller and indicates the operating state of the electric system of the vehicle.
TUNING MENU screen
Fine adjusts the settings for traveling control, load handling control, etc.
OPTION SET MENU screen
Adjusts the display and the controllers according to the specifications of each vehicle or the control conditions set for it.
MATCHING MENU screen
Updates the sensor output voltages and the set values stored in the memories of the display and each controller.
OTHERS MENU screen
This allows you to: • Start each meter*. • Switch demo mode*. • Initialize the settings. • Set a service second password. • Clear the administrator second password. • Adjust the contrast of the LCD display.
END of SERVICE MENU
From this screen, you can move to a status screen.
*: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not displayed on the OTHERS MENU screen.
4-102
ANALYZER General The analyzer functions are designed to make it easy to check and troubleshoot the control system by displaying its state through communications between the display and each controller. By switching the display to analyzer mode, it becomes possible to check the operation state of each sensor and actuator used for the traveling, load handling, SAS and OPS functions, and also to read information about errors detected by controllers, which helps check the operation state of each function and reduce the repair time in the event of a failure. Thus, the use of the analyzer function ensures fast and easy servicing.
Analyzer Screen Item List Analyzer menu screen 1. DIAG MEMORY
Screen No. 1/2 to 2/2
2. I/O TEMP/VOLT 1/5
2/5
3/5
4/5
5/5 3. I/O TRAVELING
Display item 1. to 10.
Indications of errors occurred
TDM
Drive motor temperature: °C
TDMDH
Drive motor driver heat sink temperature: °C
TDMDB
Drive motor driver board temperature: °C
TMCB
Main controller board temperature: °C
TPM
Pump motor temperature: °C
TPMDH
Pump motor driver heat sink temperature: °C
TPMDB
Pump motor driver board temperature: °C
TSLLT
Battery temperature: °C
TDSP
Display board temperature: °C
B48V/80V
Battery voltage: V
VBKY
Voltage after key switch: V
VBMBSL
Solenoid power source voltage: V
VBMB
Voltage after MB contactor: V
VDMD
Drive motor driver main circuit voltage: V
VPMD
Pump motor driver main circuit voltage: V
SPEED
Drive speed: km/h
VRA 1/5 VRB
2/5
3/5
Description
Accelerator sensor1 voltage: V Accelerator sensor2 voltage: V Brake sensor1 voltage: V Brake sensor2 voltage: V
SWBK
Brake switch
SDM
Seat switch
DSF
Forward switch
DSR
Reverse switch
SPB
Parking brake switch
SYR
(Not used)
SLSW
(Not used)
SH
Lifting height switch
SPLF
Load sensor voltage: V (MPa display)
SPEED
Traveling speed: km/h
4-103 Analyzer menu screen 3. I/O TRAVELING
Screen No. 4/5
Display item SPDDM SSD
5/5 CSDM 4. I/O M.HANDLING
1/8
2/8
3/8
5/8
1/1
Drive motor current sensor1 voltage: V Drive motor current sensor2 voltage: V
SHS
Height selector switch
STK
Tilt knob switch
SDM
Seat switch
SHL
Height limit switch
VRTA
Tilt angle sensor voltage: V
SPLF
Load sensor voltage: V (MPa display)
SH
Lifting height switch
VRH
Height reel sensor voltage: V
SPDPM
CSPM
Pump motor rpm: rpm [Target rpm]: rpm Pump motor driver rotation sensor voltage: V Pump motor driver current sensor1 voltage: V Pump motor driver current sensor2 voltage: V
SLLL
Lift lowering lock solenoid
CSL
Lift proportional valve solenoid current: A Lift lever angle sensor1 voltage: V Lift lever angle sensor2 voltage: V
SLTFL
Tilt control solenoid
CST
Tilt proportional valve solenoid current: A
VRA1 CSA2
5. I/O STEERING
Drive motor rotation sensor2 voltage: V
Tilt control solenoid
CSA1
8/8
Drive motor rotation sensor1 voltage: V
SLTFL
VRT
7/8
[Target rpm]: rpm
Lift lowering lock solenoid
VRL
6/8
Drive motor rpm: rpm
SLLL
SSP 4/8
Description
VRA2
Tilt lever angle sensor1 voltage: V Tilt lever angle sensor2 voltage: V Attachment (1) proportional valve solenoid current: A Attachment (1) lever angle sensor1 voltage: V Attachment (1) lever angle sensor2 voltage: V Attachment (2) proportional valve solenoid current: A Attachment (2) lever angle sensor1 voltage: V Attachment (2) lever angle sensor2 voltage: V
VRTRA
Tire angle sensor voltage: V
SPEED
Traveling speed : km/h
K-POS
Steering angle knob position actual value (target value), Steering synchronizer solenoid
SSTR
Steering angle sensor signal
4-104 Analyzer menu screen
Screen No.
6. I/O OTHERS
Display item CSBAT
1/1
7. ACTIVE TEST 1/2
IPL
Description Battery current sensor voltage: V Shock sensor1 voltage: V Shock sensor2 voltage: V
DPOT
(Not used)
SWING SOL
(Not used)
STEERINGSOL
Steering synchronizer solenoid forced operation
LIFT LWR SOL Lift lowering lock solenoid forced operation
2/2
8. VERSION
1/2 2/2
TILT SOL
Tilt control solenoid forced operation
FAN
Cooling fan for controller forced operation
ACC OUT1
(Not used)
ACC OUT2
(Not used)
SWG TEST LMP
(Not used)
DISPLAY
Display program version
MAIN C/R
Main controller program version
DM DRIVER
Drive motor driver program version
PM DRIVER
Pump motor driver program version
4-105
ANALYZER MENU screen Operation Procedure 1. 2.
3.
Display the ANALYZER MENU screen. By default, the ANALYZER MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (2) and select the [Return] tab, move to the END menu. Press switch (3) to select the [TUN] tab and move to the TUNING MENU screen.
“1. DIAG MEMORY” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To DIAG MEMORY screen
“2. I/O TEMP/VOLT” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To I/O TEMP/VOLT screen
“3. I/O TRAVELING” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To I/O TRAVELING screen
“4. I/O M.HANDLING” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To I/O M.HANDLING screen
“5. I/O STEERING” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To I/O STEERING screen
“6. I/O OTHERS” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To I/O OTHERS screen
“7. ACTIVE TEST” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To ACTIVE TEST screen
“8. VERSION” Switch (1): Switching selection to next item Switch (2): To END menu Switch (3): To TUNING menu Switch (4): To VERSION screen
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Diagnostic Memory Function (DIAG MEMORY) The controller stores up to 10 latest errors. The DIAG MEMORY screen displays these diagnostic codes with their detection hour information (in key ON hour meter reading). The most latest diagnostic code is displayed as 1, followed by 2, 3 and so on to 10.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “1. DIAG MEMORY” is selected on the screen, and press switch (4) to display “DIAG MEMORY 1/2” screen. 3. Press switch (4) on “DIAG MEMORY 2/2” screen to return to the ANALYZER MENU screen. Note: • When no diagnostic code is displayed on the screen and the hour meter time is 0.0h, it indicates that no errors occurred in the past after that row. • It is impossible to directly jump from the DIAG MEMORY screen to other function screen. Return to the ANALYZER MENU screen. • For details of diagnostic code, refer to section 5, Diagnostic Code List.
“DIAG MEMORY 1/2” Displays diagnostic codes 1 to 5. Switch (4): To “DIAG MEMORY 2/2” screen
“DIAG MEMORY 2/2” Displays diagnostic codes 6 to 10. Switch (4): Returning to the ANALYZER MENU screen
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In/Out Monitor Function (I/O MONITOR) This function displays the analog input voltage and the switch state of each of traveling, load handling, SAS and OPS switches, sensors and actuators. The circuit or their quality can be judged by monitoring the displayed value.
In/Out Monitor (1) (I/O TEMP/VOLT) Displays the temperature of each electrical functional part and the analog input voltage detected by each controller.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Press the switch (1) to select the “2. I/O TEMP/VOLT” and press the switch (4) to display “I/O TEMP/VOLT 1/ 5” screen. 3. From here on, the screen changes in sequence each time switch (4) is pressed. On the “I/O TEMP/VOLT 5/ 5”, press switch (4) to return to the ANALYZER MENU screen. Note: You cannot move directly from I/O TEMP/VOLT screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“I/O TEMP/VOLT 1/5” TDM: Drive motor temperature: °C Temperature of drive motor is displayed. TDMDH: Drive motor driver heat sink temperature: °C Temperature of the drive motor driver heat sink is displayed. TDMDB: Drive motor driver board temperature: °C Temperature of the drive motor driver board is displayed. Switch (4): To “I/O TEMP/VOLT 2/5” screen
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“I/O TEMP/VOLT 2/5” TMCB: Main controller board temperature: °C Temperature of main controller board is displayed. TPM: Pump motor temperature: °C Temperature of pump motor is displayed. TPMDH: Pump motor driver heat sink temperature: °C Temperature of the pump motor driver heat sink is displayed. TPMDB: Pump motor driver board temperature: °C Temperature of the pump motor driver board is displayed. Switch (4): To “I/O TEMP/VOLT 3/5” screen
“I/O TEMP/VOLT 3/5” (W/ Battery fluid level and temperature unit) TSLLT: Battery temperature: °C Temperature of battery is displayed. (W/O Battery fluid level and temperature unit) ---TDSP: Display board temperature: °C Temperature of display board is displayed. Switch (4): To “I/O TEMP/VOLT 4/5” screen
“I/O TEMP/VOLT 4/5” B48/80V: Battery voltage: V Battery voltage is displayed. VBKY: Voltage after key switch: V Voltage after key switch is displayed. VBMBSL: Solenoid power source voltage: V Voltage of solenoid power source is displayed. VBMB: Voltage after MB contactor: V Voltage of after MB contactor is displayed. Switch (4): To “I/O TEMP/VOLT 5/5” screen
“I/O TEMP/VOLT 5/5” VDMD: Drive motor driver main circuit voltage: V Voltage of drive motor driver main circuit is displayed. VPMD: Pump motor driver main circuit voltage: V Voltage of pump motor driver main circuit is displayed. Switch (4): Returning to the ANALYZER MENU screen
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In/Out Monitor (2) (I/O TRAVELING) Displays each switch ON/OFF state and analog input voltages from sensors for traveling and swing control.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “3. I/O TRAVELING” is selected on the screen, and press switch (4) to display “I/O TRAVELING 1/5” screen. 3. Press switch (4) on “I/O TRAVELING 5/5” screen to return to the ANALYZER MENU screen. Note: It is impossible to directly jump from the I/O TRAVELING screen to other function screen. Return to the ANALYZER MENU screen.
“I/O TRAVELING 1/5” SPEED: Traveling speed: km/h Displays the traveling speed. VRA: Accelerator sensor 1 / 2 voltage: V Displays input voltage from the accelerator sensor to the controller. Standard: Accelerator sensor 1 When accelerator is not operated: 0.40 to 1.25 V When accelerator pedal is fully depressed: 2.25 to 4.80 V Accelerator sensor 2 When accelerator is not operated: 0.65 to 2.32 V When accelerator pedal is fully depressed: 2.70 to 4.80 V VRB: Brake sensor 1 / 2 voltage: V Displays input voltage from the brake sensor to the controller. Standard: Brake sensor 1 (W/ Brake sensor) When brake is not operated: 0.50 to 1.50 V When brake is operated: 1.05 to 3.10 V (W/O Brake sensor) 0.00 V Brake sensor 2 (W/ Brake sensor) When brake is not operated: 0.79 to 2.58 V When brake is operated: 1.50 to 3.82 V (W/O Brake sensor) 0.00 V SWBK: Brake switch Displays the status of the brake switch. (W/ Brake sensor) SWBK: 0 (W/O Brake sensor) SWBK: 0=OFF (in a state of brake being operated) SWBK: 1=ON (in a state of brake being released) Switch (4): To “I/O TRAVELING 2/5” screen
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“I/O TRAVELING 2/5” SDM: Seat switch Switch ON/OFF quality judgment by sitting on and leaving the operator’s seat SDM: 1 = ON when sitting on the seat SDM: 0 = OFF when leaving the seat DSF: Forward switch DSR: Reverse switch Switch ON/OFF quality judgment by operating the direction lever Direction lever
Display DSF:
DSR:
Forward
1 (=ON)
0 (=OFF)
Neutral
0 (=OFF)
0 (=OFF)
Reverse
0 (=OFF)
1 (=ON)
SPB: Parking brake switch Switch ON/OFF quality judgment by operating the parking brake lever. SPB: 0 = OFF (in a state of parking brake being operated) SPB: 1 = ON (in a state of parking brake being released) Switch (4): To “I/O TRAVELING 3/5” screen
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“I/O TRAVELING 3/5” SYR: Not used 0.00 V SLSW: Not used SH: Lifting height switch Displays the statuses of the lifting height switches.
SH1
SH2-1
SH2-2
0 = OFF 1 = ON Judges the quality of the switch ON/OFF by raising and lowering the fork. For the combination between lifting height switches, see the table below. Height
Display
SH1 Switch
SH2-1 Switch
SH2-2 Switch
Low lifting height
100
1 (=ON)
0 0 (=OFF) (=OFF)
High lifting height
010
0 (=OFF)
1 (=ON)
0 (=OFF)
* The height at which the lifting height switch is turned on or off varies according to the lifting height set for the mast. (W/ SAS, W/ Height Selector: V mast) Always 000 SPLF: Load sensor voltage: V (MPa) Displays input voltage from the load sensor to the controller, and detected pressure. (W/ SAS) Standard at no load: 0.5 to 4.5 V Voltage increases as load increases. (W/O SAS) 0.00 V SPEED: Traveling speed: km/h or mph Displays the traveling speed. Switch (4): To “I/O TRAVELING 4/5” screen
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“I/O TRAVELING 4/5” SPDDM: Drive motor revolution: rpm This screen indicates the measured and target numbers of revolutions of the drive motor. The rotation sensor is checked by actually running the vehicle. The number of revolutions of the drive motor increases with an increase in the traveling speed. Switch (4): To “I/O TRAVELING 5/5” screen
“I/O TRAVELING 5/5” SSD: Drive motor rotation sensor 1 / 2 voltage: V This screen indicates the voltages of the drive motor rotation sensors. Standard: When motor is stopped: 0.30 to 0.90 V or 1.10 to 1.70 V When motor is rotating: Variable between approx. 0.30 V and 1.70 V CSDM: Drive motor current sensor 1/2 voltage: V This screen indicates the voltages of the drive motor current sensors. Standard: Standard value when vehicle is stopped: Approx. 2.50 V Standard value when vehicle is running: 0.50 to 4.50 V Switch (4): Returning to the ANALYZER MENU screen
In/Out Monitor (3) (I/O M.HANDLING) Displays the load handling and mast control switch ON/OFF states and analog input voltages from load handling and mast control sensors.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “4. I/O M.HANDLING” is selected on the screen, and press the switch (4) to display “I/O M.HANDLING 1/8” screen. 3. Press switch (4) on “I/O M.HANDLING 8/8” screen to return to the ANALYZER MENU screen. Note: You cannot move directly from I/O M.HANDLING screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
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“I/O M.HANDLING 1/8” SLLL: Lift lock solenoid Displays output signal to the lift lock solenoid. SLTFL: Tilt control solenoid Displays output signal to the tilt control solenoid. SHS: Height selector switch Switch ON/OFF quality judgment by operating the height selector switch. (W/ Height selector) 0= OFF 1= ON (W/O Height selector) 0 STK: Tilt knob switch Switch ON/OFF quality judgment by operating the tilt knob switch. (W/O SAS) 0 (W/ SAS) 0= OFF 1= ON SDM: Seat switch Switch ON/OFF quality judgment by operating the seat switch. 0= OFF 1= ON SHL: Height limiter switch Switch ON/OFF quality judgment by operating the height limit switch. (W/ Height selector) 0= OFF 1= ON (W/O Height selector) 0 Seat condition
Lift lever
Tilt lever
Leaving seat
Not operated
Raising
Lowering
Forward tilt
Backward tilt
SLLL
0 (=OFF)
0 (=OFF)
1 (=ON)
0 (=OFF)
0 (=OFF)
0 (=OFF)
SLTFL
0 (=OFF)
0 (=OFF)
0 (=OFF)
1 (=ON)
0 (=OFF)
0 (=OFF)
SDM
1 (=ON)
1 (=ON)
1 (=ON)
1 (=ON)
1 (=ON)
0 (=OFF)
Lever condition
Item
Sitting on seat
Switch (4): To “I/O M.HANDLING 2/8” screen
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“I/O M.HANDLING 2/8” VRTA: Tilt angle sensor voltage: V Displays input voltage from the tilt angle sensor to the controller. (W/ SAS) Standard with mast in the vertical position: 1.01 to 4.00 V Mast vertical → forward tilt: Input voltage decreases Mast vertical → backward tilt: Input voltage increases (W/O SAS) 0.00 V SPLF: Load sensor voltage: V (MPa) See “I/O TRAVELING 3/5” SH: Lifting height switch See “I/O TRAVELING 3/5” VRH: Height reel sensor voltage: V Displays input voltage from the height reel sensor to the controller. (W/ Height Selector) Standard: 0.20 to 4.80 V Mast raising → Input voltage increases Mast lowering → Input voltage decreases (W/O Height Selector) 0.00V Switch (4): To “I/O M.HANDLING 3/8” screen
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“I/O M.HANDLING 3/8” SPDPM: Pump motor revolution: rpm This screen indicates the measured and target numbers of revolutions of the pump motor. The number of revolutions of the pump motor increases with an increase in the load handling speed. Switch (4): To “I/O M.HANDLING 4/8” screen
“I/O M.HANDLING 4/8” SSP: Pump motor driver rotation sensor voltage: V Displays the voltage from the pump motor driver rotation sensor. Standard: When motor is stopped: Constant, either 0.30 to 0.90 V or 1.10 to 1.70 V When motor is rotating: Variable between approx. 0.30 V and 1.70 V CSPM: Pump motor driver current sensor 1 / 2 voltage: V Displays the voltage from the pump motor driver current sensor 1 / 2. Standard: Standard value when vehicle is stopped: Approx. 2.5 V (When load handling lever, steering wheel, and forward/backward switch are in neutral) Other than the above: 0.5 to 4.5 V Switch (4): To “I/O M.HANDLING 5/8” screen
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“I/O M.HANDLING 5/8” SLLL: Lift lowering lock solenoid See “I/O M.HANDLING 1/8” CSL: Lift proportional solenoid current: A Displays the current from the lift proportional solenoid Standard: During uppermost raising operation: 0.25 to 0.95 A During lowermost lowering operation: 0.25 to 0.95 A When lever is in neutral: 0.00 A The current increases according to the amount of operation of the lift lever VRL: Lift lever angle sensor 1 / 2 voltage: V Displays input voltage from lift lever angle sensor 1 / 2 to the controller. Standard: Lift lever angle sensor 1 (Conventional lever) During uppermost raising operation: 1.65 to 4.50 V During lowermost lowering operation: 0.30 to 2.88 V When lever is in neutral: 1.65 to 2.88 V (Mini lever/Joystick) During uppermost raising operation: 1.78 to 4.50 V During lowermost lowering operation: 0.30 to 2.76 V When lever is in neutral: 1.78 to 2.76 V The voltage increases during raising operation, while it decreases during lowering operation. Standard: Lift lever angle sensor 2 (Conventional lever) During uppermost raising operation: 0.30 to 3.20 V During lowermost lowering operation: 1.52 to 4.50 V When lever is in neutral: 1.52 to 3.20 V (Mini lever/Joystick) During uppermost raising operation: 0.30 to 2.76 V During lowermost lowering operation: 1.78 to 4.50 V When lever is in neutral: 1.78 to 2.76 V The voltage decreases during raising operation, while it increases during lowering operation. Switch (4): To “I/O M.HANDLING 6/8” screen
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“I/O M.HANDLING 6/8” SLTFL: Tilt control solenoid See “I/O M.HANDLING 1/8” CST: Tilt proportional valve solenoid current: A Displays the current from the tilt proportional solenoid. Standard: During backwardmost tilting operation: 0.25 to 0.95 A During forwardmost tilting operation: 0.25 to 0.95 A When motor is stopped: 0.00 A The current increases according to the amount of operation of the tilt lever. VRT: Tilt lever angle sensor 1 / 2 voltage: V Displays input voltage from tilt lever angle sensor 1/2 to the controller. Standard: Tilt lever angle sensor 1 (Conventional lever) During backwardmost tilting operation: 1.65 to 4.50 V During forwardmost tilting operation: 0.30 to 2.88 V When lever is in neutral: 1.65 to 2.88 V (Mini lever/Joystick) During backwardmost tilting operation: 1.78 to 4.50 V During forwardmost tilting operation: 0.30 to 2.76 V When lever is in neutral: 1.78 to 2.76 V The voltage increases during backward tilting operation, while it decreases during forward tilting operation. Standard: Tilt lever angle sensor 2 (Conventional lever) During backwardmost tilting operation: 0.30 to 3.20 V During forwardmost tilting operation: 1.52 to 4.50 V When lever is in neutral: 1.52 to 3.20 V (Mini lever/Joystick) During backwardmost tilting operation: 0.30 to 2.76 V During forwardmost tilting operation: 1.78 to 4.50 V When lever is in neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation. Switch (4): To “I/O M.HANDLING 7/8” screen
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“I/O M.HANDLING 7/8” CSA1: Attachment 1 proportional valve solenoid current: A Displays the current from the attachment 1 proportional solenoid. Standard: During backwardmost tilting operation: 0.25 to 0.95 A During forwardmost tilting operation: 0.25 to 0.95 A When motor is stopped: 0.00 A The current increases according to the amount of operation of the tilt lever. VRA1: Attachment 1 lever angle sensor 1 / 2 voltage: V Displays input voltage from the attachment 1 lever angle sensor 1 / 2 to the controller. Standard: Attachment 1 lever angle sensor 1 (Conventional lever) During backwardmost tilting operation: 1.65 to 4.50 V During forwardmost tilting operation: 0.30 to 2.88 V When lever is in neutral: 1.65 to 2.88 V (Mini lever/Joystick) During backwardmost tilting operation: 1.78 to 4.50 V During forwardmost tilting operation: 0.30 to 2.76 V When lever is in neutral: 1.78 to 2.76 V The voltage increases during backward tilting operation, while it decreases during forward tilting operation. Standard: Attachment 1 lever angle sensor 2 (Conventional lever) During backwardmost tilting operation: 0.30 to 3.20 V During forwardmost tilting operation: 1.52 to 4.50 V When lever is in neutral: 1.52 to 3.20 V (Mini lever/Joystick) During backwardmost tilting operation: 0.3 to 2.76 V During forwardmost tilting operation: 1.78 to 4.50 V When lever is in neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation. Switch (4): To “I/O M.HANDLING 8/8” screen
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“I/O M.HANDLING 8/8” CSA2: Attachment 2 proportional valve solenoid current: A Displays the current from the attachment 2 proportional solenoid. Standard: During backwardmost tilting operation: 0.25 to 0.95 A During forwardmost tilting operation: 0.25 to 0.95 A When motor is stopped: 0.00 A The current increases according to the amount of operation of the tilt lever. VRA2: Attachment 2 lever angle sensor 1 / 2 voltage: V Displays input voltage from the attachment 2 lever angle sensor 1 / 2 to the controller. Standard: Attachment 2 lever angle sensor 1 (Conventional lever) During backwardmost tilting operation: 1.65 to 4.50 V During forwardmost tilting operation: 0.30 to 2.88 V When lever is in neutral: 1.65 to 2.88 V (Mini lever/Joystick) During backwardmost tilting operation: 1.78 to 4.50 V During forwardmost tilting operation: 0.30 to 2.76 V When lever is in neutral: 1.78 to 2.76 V The voltage increases during backward tilting operation, while it decreases during forward tilting operation. Standard: Attachment 2 lever angle sensor 2 (Conventional lever) During backwardmost tilting operation: 0.30 to 3.20 V During forwardmost tilting operation: 1.52 to 4.50 V When lever is in neutral: 1.52 to 3.20 V (Mini lever/Joystick) During backwardmost tilting operation: 0.3 to 2.76 V During forwardmost tilting operation: 1.78 to 4.50 V When lever is in neutral: 1.78 to 2.76 V The input voltage decreases during backward tilting operation, while it increases during forward tilting operation. Switch (4): Returning to the ANALYZER MENU screen
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In/Out Monitor (4) (I/O STEERING) Displays the ON/OFF states of knob position and the analog input voltages from respective sensors.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “5. I/O STEERING” is selected on the screen, and press the switch (4) to display “I/O STEERING 1/1” screen. 3. Press switch (4) on “I/O STEERING 1/1” screen to return to the ANALYZER MENU screen. Note: You cannot move directly from I/O STEERING screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“I/O STEERING 1/1” VRTRA: Tire angle sensor voltage: V Displays input voltage from the tire angle sensor to the controller. (W/ Tire angle sensor) Standard when tires are in straight ahead position: 1.80 to 2.40 V The input voltage increases when the steering wheel is turned clockwise to turn right. The input voltage decreases when the steering wheel is turned counterclockwise to turn left. (W/O Tire angle sensor) 0.00 V SPEED: Traveling speed: km/h or mph Displays the traveling speed. K-POS: Steering angle knob position actual value This screen indicates the actual (target) position of the steering knob and the ON/OFF status of the knob position compensation solenoid Actual value: The knob position calculated and recognized by the controller from the steering angle sensor signal Target value: The knob position calculated and recognized by the controller from the tire angle sensor signal (W/ Tire angle sensor) The value shall increases during a right turn, and it shall decrease during a left turn. Display range: 0 to 159 (W/O Tire angle sensor) Fixed at 80
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Steering synchronizer solenoid: (W/ Tire angle sensor) 0 = OFF non-energized state (Position compensation disabled) 1 = ON energized state (Position compensation enabled) (W/O Tire angle sensor) -
159 0 1 80
One rotation (360°) of the steering wheel is divided by 160, and the value is set to “80” when the knob is in the position as indicated in the illustration. Clockwise turn of the steering wheel: Increase in value Counterclockwise turn of the steering wheel: Decrease in value SSTR: Steering angle sensor pulse
Standard Standard position position
SS1
SS2
SSC
1 = ON 0 = OFF When the steering wheel is rotated once, SS1 and SS2 repeat ON and OFF. SSC only turns on when the knob is in the standard position. Switch (4): Returning to the ANALYZER MENU screen
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In/Out Monitor (5) (I/O OTHERS) Displays the analog input voltages from battery current sensor and shock sensor.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “6. I/O OTHERS” is selected on the screen, and press the switch (4) to display “I/O OTHERS 1/1” screen. 3. Press switch (4) on “I/O OTHERS 1/1” screen to return to the ANALYZER MENU screen. Note: You cannot move directly from I/O OTHERS screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“I/O OTHERS 1/1” CSBAT: Battery current sensor voltage: V Displays input voltage from the battery current sensor to the controller. Standard value when vehicle is stopped: Approx. 2.50 V (When load handling lever, steering wheel, and forward/backward switch are in neutral) Other than the above: 2.30 to 2.70 V IPL: Shock sensor 1/2 voltage: V Displays input voltage from the shock sensor to the controller. (W/ Shock Sensor) Standard value when vehicle is stopped: Approx. 2.0 V (W/O Shock Sensor) 0.00 V DOPT: Not used Switch (4): Returning to the ANALYZER MENU screen
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Active Test (ACTIVE TEST) In the active test mode, the controller forcibly outputs an activation signal (ON or OFF signal) to the selected item in order to permit operation check of that function.
Active Test Item List Selection Item Item
Description
Signal
SWING SOL
Not used
STEERING SOL
Knob position correcting solenoid forced operation
Content of Content of Signal operation operation Not used
OFF
By-pass close
ON
By-pass open
LIFT LWR SOL Lift lock solenoid forced operation
OFF
Lowering not possible
ON
Lowering possible
TILT SOL
Tilt control solenoid forced operation
OFF
Forward tilt not possible
ON
Forward tilt possible
FAN
Cooling fan for controller forced operation
OFF
Fan stops
ON
Fan rotates
ACC OUT1
Accessory output 1 (brake auxiliary equipment output) forced operation
Not used
ACC OUT2
Accessory output 2 (back-up auxiliary equipment output) forced operation
Not used
SWG TEST LMP
Swing lock solenoid operation display
Not used
• On the ACTIVE TEST screen, an ON or an OFF is always displayed next to each item. • If the selected item is forcibly turned off or on by pressing the switch (2) or (3) and it is switched over to another item by pressing the switch (1), forced operation is canceled (and switches over to normal operation). • The operation guidance in connection with the switches (2) and (3) indicates whether an item is forcibly operated or not. (Refer to below) Operation guidance
Condition Selected item not forcibly operated Selected item forcibly turned ON Selected items forcibly turned OFF Applicable function not provided or its state signal not received
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Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “7. ACTIVE TEST” is selected on the screen, and press the switch (4) to display “ACTIVE TEST 1/2” screen. 3. Press switch (4) on “ACTIVE TEST 2/2” screen to return to the ANALYZER MENU screen. Note: You cannot move directly from ACTIVE TEST screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“ACTIVE TEST 1/2” SWING SOL: Not used ---/--STEERING SOL: Knob position correcting solenoid Slowly turn the steering wheel, and check the difference of the rear tire movement. (W/O Knob position correcting solenoid) ---/--(W/ Knob position correcting solenoid) ON (By-pass open): Tires do not move match OFF (By-pass close): Tires move (normal operation) LIFT LWR SOL: Lift lock solenoid Check the quality of lowering action by lift lowering operation. ON (Solenoid ON): Lowering possible (normal operation) OFF (Solenoid OFF): Lowering not possible TILT SOL: Tilt control solenoid Check the quality of mast forward tilt operation by forward tilt operation. ON (Solenoid ON): Forward tilt possible OFF (Solenoid OFF): Forward tilt not possible Switch (1): Selecting the next item on the “ACTIVE TEST 1/2” screen Switch (2): Forcibly turning off the selected item Switch (3): Forcibly turning on the selected item Switch (4): To “ACTIVE TEST 2/2” screen
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“ACTIVE TEST 2/2” FAN: Cooling fan for controller Used to check the operation state of the controller cooling fan visually and through the display. ON: Fan rotates OFF: Fan stops * This function is inoperative in the 50-8FBN15 to 20, because no fan is provided in them. ACC OUT1: Accessory output 1 Not used ACC OUT2: Accessory output 2 Not used SWG TEST LAMP: Not used Switch (1): Selecting the next item on the “ACTIVE TEST 2/2” screen Switch (2): Forcibly turning off the selected item Switch (3): Forcibly turning on the selected item Switch (4): Returning to the ANALYZER MENU screen
VERSION (Program Version) Displays program version of each controller.
Operation Procedure 1. 2.
Display the ANALYZER MENU screen. Check the “8. VERSION” is selected on the screen, and press the switch (4) to display “VERSION 1/2” screen. 3. Press switch (4) on “VERSION 2/2” screen to return to the ANALYZER MENU screen. Note: You cannot move directly from VERSION screen to the screen of the other items. Return to ANALYZER MENU screen once, then move to screen of each time.
“VERSION 1/2” DISPLAY: Program version of the multi-function display MAIN C/R: Program version of the main controller Switch (4): To “VERSION 2/2” screen
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“VERSION 2/2” DM DRIVER: Program version of the drive motor driver PM DRIVER: Program version of the pump motor driver Switch (4): Returning to the ANALYZER MENU screen
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TUNING General This feature performs fine adjustment of traveling and load handling controls. When receiving requests from users, such as the request to weaken the acceleration off regenerative braking force, various settings levels can be changed on the tuning screens. Tuning functions has 75 items (included spare items)
Tuning Item List Display
Multifunction display/DX
Menu No. Menu No. Activation timing of low battery capacity warning and battery over-discharge warning.
1
2 3 4 5 6
Fast
*
7
8
1 01
No.1
1 02
No.2 Battery charge indicator calibration No.1
Slow decrease
1 03
No.3 Battery charge indicator calibration No.2
Sensitive
*
Insensitive
1 04
No.4 Motor torque when the battery discharge has proceeded
Power down
*
Power keep
1 05
No.5 Not used
1 06
No.6 Accelerator pedal sensitivity
1 07
Slow Disabled *
Fast decrease
* Insensitive
*
Sensitive
No.7 Acceleration torque
Weak
*
Strong
1 08
No.8 Acceleration soft-start
Slow
*
Quick
1 09
No.9 Regenerative braking torque at accelerator-off
Weak
*
Strong
1 10
No.10 Regenerative braking soft-start at accelerator-off
Slow
*
Quick
1 11
No.11 Acceleration torque at switch-back
Weak
*
Strong
1 12
No.12 Acceleration soft-start at switch-back
Slow
*
Quick
No.13 Regenerative braking torque at switch-back
Weak
*
Strong
No.14 Regenerative braking soft-start at switch-back
Slow
*
Quick
No.15 Regenerative braking soft-stop at switch-back
Slow
*
Quick
1 16
No.16 Accelerator traction torque
Weak
*
Strong
1 17
No.17 Accelerator and brake traction torque
Weak
Strong *
1 18
No.18
Rollback speed when the travelling direction is opposite to the direction lever
Slow *
Quick
1 19
No.19
Rollback speed when the travelling direction is the same as the direction lever
Slow *
Quick
1 20
No.20 Not used
*
1 21
No.21 Not used
*
1 22
No.22 Maximum speed limitation during backward travelling
Slow
Quick *
1 23
No.23 Low speed setting during backward travelling
Slow
Quick *
1 24
No.24
1 25
No.25 Regenerative braking torque at brake on
1 13 1 14 1 15
TUNE GEN.
GENERAL
Level (*: Initial setting value)
Item
Deceleration during accelerator-off when going up on a slope
Weak
*
Strong
Weak
*
Strong
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Display
Multifunction display/DX
3 4 5 6 7
8 Quick *
No.27 Pump motor output during tilt forward and backward operation
Slow
1 28
No.28
Pump motor output during the attachment (1) lever push and pull Slow operation
*
Quick
1 29
No.29
Pump motor output during the attachment (2) lever push and pull Slow operation
*
Quick
No.30
Pump motor output during the attachment (3) lever push and pull Slow operation
*
Quick
1 30
*
No.31 Inching speed during Height Selector operation
Slow
1 32
No.32 Load meter display time
None Short
1 33
No.33
1 34
No.34 Not used
*
1 35
No.35 Not used
*
2 01
START Play at the beginning of lift down operation
2 05
LIFT DOWN
1 31
TUNE GEN.
1 27
2 04 LIFT
2
Slow
2 03
2 06 2 07 2 08 2 09
3 02 3 03 3 04 3 05 3 07 3 08 3 09
TILT BWD
3 06
3 10 4 02 4 03 4 04
ATT1 PUSH
4 01
4 05
4 07 4 08 4 09 4 10
Small
Quick Long High
*
Wide
Slow
*
Quick
MAX Maximum speed during lift down operation
Slow
*
Quick
ACC
Acceleration speed during lift down operation
Weak
*
Strong
DEC
Deceleration speed during lift down operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during lift up operation
Slow
*
Quick
MAX Maximum speed during lift up operation
Slow
*
Quick
ACC
Acceleration speed during lift up operation
Weak
*
Strong
DEC
Deceleration speed during lift up operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during tilt forward operation
Slow
*
Quick
MAX Maximum speed during tilt forward operation
Slow
*
Quick
ACC
Acceleration speed during tilt forward operation
Weak
*
Strong
DEC
Deceleration speed during tilt forward operation
Weak
*
Strong
START Play at the beginning of tilt backward operation
Small
*
Wide
Slow
*
Quick
INCH Inching speed during tilt backward operation MAX Maximum speed during tilt backward operation
Slow
*
Quick
ACC
Acceleration speed during tilt backward operation
Weak
*
Strong
DEC
Deceleration speed during tilt backward operation
Weak
*
Strong
START Play at the beginning of the attachment (1) lever push operation Small
*
Wide
INCH Inching speed during the attachment (1) lever push operation
Slow
*
Quick
MAX Maximum speed during the attachment (1) lever push operation Slow
*
Quick
ACC
Acceleration speed during the attachment (1) lever push operation
Weak
*
Strong
DEC
Deceleration speed during the attachment (1) lever push operation
Weak
*
Strong
Small
*
Wide
INCH Inching speed during the attachment (1) lever pull operation
Slow
*
Quick
MAX Maximum speed during the attachment (1) lever pull operation
START Play at the beginning of the attachment (1) lever pull operation ATT1 PULL
4 06
*
Quick
INCH Inching speed during lift down operation
START Play at the beginning of tilt forward operation TILT FWD
3 01
*
Temperature at which the battery temperature protection function Low limits the vehicle performance in the maximum *
START Play at the beginning of lift up operation
2 10
TILT
1
No.26 Pump motor output during lift up operation
2 02
ATT1
No.
Level (*: Initial setting value)
1 26
LIFT UP
GENERAL
Menu No. Menu
Item
Slow
*
Quick
ACC
Acceleration speed during the attachment (1) lever pull operation Weak
*
Strong
DEC
Deceleration speed during the attachment (1) lever pull operation Weak
*
Strong
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Display
Multifunction display/DX
Menu No. Menu
5 02 5 03
5 05 5 06 5 07 5 08 5 09 5 10
Level (*: Initial setting value) 1
2 3 4 5 6 7
8
Small
*
Wide
INCH Inching speed during the attachment (2) lever push operation
Slow
*
Quick
MAX Maximum speed during the attachment (2) lever push operation
Slow
*
Quick
ACC
Acceleration speed during the attachment (2) lever push operation Weak
*
Strong
DEC
Deceleration speed during the attachment (2) lever push operation Weak
*
Strong
Small
*
Wide
INCH Inching speed during the attachment (2) lever pull operation
Slow
*
Quick
MAX Maximum speed during the attachment (2) lever pull operation
Slow
*
Quick
ACC
Acceleration speed during the attachment (2) lever pull operation
Weak
*
Strong
DEC
Deceleration speed during the attachment (2) lever pull operation
Weak
*
Strong
START Play at the beginning of the attachment (2) lever pull operation ATT2 PULL
ATT2
5 04
No. START Play at the beginning of the attachment (2) lever push operation
ATT2 PUSH
5 01
Item
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TUNING MENU Screen Operation Procedure 1. 2.
Display the ANALYZER MENU screen. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [TUN] tab. 3. Press switch (2) to select the [ANL] tab and move to the ANALYZER MENU screen. Press switch (3) to select the [OPT] tab and move to the OPTION SET MENU screen. Note: The number of tuning menu items displayed varies according to the number of spools of the lever.
“1. GENERAL” Switch (1): Switching selection to next item Switch (2): To ANALYZER menu Switch (3): To OPTION SET menu Switch (4): To TUNING LEVEL setting screen
“2. LIFT LEVER” Switch (1): Switching selection to next item Switch (2): To ANALYZER menu Switch (3): To OPTION SET menu Switch (4): To TUNING LEVEL setting screen
“3. TILT LEVER” Switch (1): Switching selection to next item Switch (2): To ANALYZER menu Switch (3): To OPTION SET menu Switch (4): To TUNING LEVEL setting screen
“4. ATT1 LEVER” Switch (1): Switching selection to next item Switch (2): To ANALYZER menu Switch (3): To OPTION SET menu Switch (4): To TUNING LEVEL setting screen
“5. ATT2 LEVER” Switch (1): Switching selection to next item Switch (2): To ANALYZER menu Switch (3): To OPTION SET menu Switch (4): To TUNING LEVEL setting screen
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GENERAL Used to fine adjust settings related to traveling, load handling, and so on (except for settings related to load handling lever tuning).
Operation Procedure 1. 2.
Display the TUNING MENU screen. Check the “1. GENERAL” is selected on the screen, and press the switch (4) to display “TUNE GEN (01 to 05)” screen. 3. Press switch (4) on “TUNE GEN (31 to 35)” screen to return to the TUNING MENU screen. Note: You cannot move directly from GENERAL screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“TUNE GEN.” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Switching to next screen
Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Returning to TUNING MENU screen
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LIFT LEVER (TUNING LIFT LEVER) Sets tuning levels for the lift lever.
Operation Procedure 1. 2.
Display the TUNING MENU screen. Check the “2. LIFT LEVER” is selected on the screen, and press the switch (4) to display “LIFT DOWN” screen. 3. Press switch (4) on “LIFT DOWN” screen to switch to the “LIFT UP” screen. Note: You cannot move directly from LIFT LEVER screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“LIFT DOWN” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Switching to next screen
“LIFT UP” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Returning to TUNING MENU screen
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TILT LEVER (TUNING TILT LEVER) Sets tuning levels for the tilt lever.
Operation Procedure 1. 2.
Display the TUNING MENU screen. Check the “3. TILT LEVER” is selected on the screen, and press the switch (4) to display “TILT FWD” screen. 3. Press switch (4) on “TILT FWD” screen to switch to the “TILT BWD” screen. Note: You cannot move directly from TILT LEVER screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“TILT FWD” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Switching to next screen
“TILT BWD” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Returning to TUNING MENU screen
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ATTACHMENT 1 LEVER (TUNING ATT1 LEVER) Sets tuning levels for the attachment 1 lever.
Operation Procedure 1. 2.
Display the TUNING MENU screen. Check the “4. ATT1 LEVER” is selected on the screen, and press the switch (4) to display “ATT1 PUSH” screen. 3. Press switch (4) on “ATT1 PUSH” screen to switch to the “ATT1 PULL” screen. Note: You cannot move directly from ATT1 LEVER screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“ATT1 PUSH” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Switching to next screen
“ATT1 PULL” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Returning to TUNING MENU screen
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ATTACHMENT 2 LEVER (TUNING ATT2 LEVER) Sets tuning levels for the attachment 2 lever.
Operation Procedure 1. 2.
Display the TUNING MENU screen. Check the “5. ATT2 LEVER” is selected on the screen, and press the switch (4) to display “ATT2 PUSH” screen. 3. Press switch (4) on “ATT2 PUSH” screen to switch to the “ATT2 PULL” screen. Note: You cannot move directly from ATT2 LEVER screen to the screen of the other items. Return to TUNING MENU screen once, then move to screen of each time.
“ATT2 PUSH” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Switching to next screen
“ATT2 PULL” Switch (1): Switching selection to next item Switch (2): Tuning level down Switch (3): Tuning level up Switch (4): Returning to TUNING MENU screen
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OPTION SET General 1. The option set function is used to fit the specifications of the controller and the multi-function display to the options actually equipped on the vehicle. The option set items are not functioning on the vehicle that doesn’t actually mount them even if the OPTION SET enables them. 2. When main controller or multi-function display is replaced, it is necessary to reset them according to the vehicle specifications.
Option Set Item List Switching settings Indication
Description
Indication
Setting content
Indication
Setting content
DISP.MODE
Setting the display language
YES
Japanese
NO*
English
MPH
Setting the traveling speed display unit
YES
mph
NO*
Km/h
DATE TYPE
Setting the calendar format
B-TYPE
Adjust the battery capacity indicator calculation
B UNIT*
Battery fluid level and temperature unit
B LEVEL ALM*
Fluid level warning
YES
Enabled
NO
Disabled
H MODE LOCK
Setting to enable/ disable H mode lock
YES
Enabled
NO*
Disabled
A
Unlock (“NO”) effective till key- OFF
B*
Unlock (“NO”) effective till set “YES”
A*
Accelerator priority
B
Brake priority
MENULOCK SPEC Setting the mode of menu lock release
ACCEL & BRK
Setting the priority between accelerator and brake
OCV WAY*
Setting the number of ways for oil control valve
LEVER SPEC*
Setting the load handling lever type
CLOSED MOTOR* Setting for fishery industry models
D/M* /Y(E) / Y/M/D(J) / M/D/Y(U) A1 / A2 / B1* / B2 A: Not provided, B: Previous type (fluid level unit), C: Fluid level and temperature unit
2/3/4/5 “5” is no used this model A
Conventional lever
B
Mini lever/ Joystick
YES
Enabled
NO
Disabled
D ACT ATT1*
Attachment 1 lever clamp setting
A/B/C/D
D ACT ATT2*
Attachment 2 lever clamp setting
A/B/C/D
D ACT ATT3
Attachment 3 lever clamp setting
A* / B / C / D
BUZZER SPEC
Setting the mode of buzzer sound when OPS and return-to-neutral operate
SEAT BUZZER
Setting to enable/disable buzzer sound when OPS operate
YES*
Enabled
NO
Disabled
PKB BUZZER
Setting to enable/disable parking brake off warning
YES*
Enabled
NO
Disabled
WHEEL IND*
Setting to enable/disable wheel indicator
YES
Enabled
NO
Disabled
SPD ALM2
Setting to enable/disable overspeed alarm 2
YES
Enabled
NO*
Disabled
ASC W/LOAD
Setting to enable/disable lifting height and load weight sensing traveling control
YES*
Enabled
NO
Disabled
MODE
Setting to enable/disable the vehicle speed limitation by lifting height and load weight sensing traveling control
S*
Enabled
A
Disabled
CURVE CONT
Setting to disable turning control
YES*
Enabled
NO
Disabled
A* / B / C
4-137 Switching settings Indication
Description
Indication
Setting content
Indication
Setting content
A
Traction restrictions regardless of discharge level
B*
Traction restrictions according to discharge level
A*
Lift interrupt
B
Lift interrupt while traveling
D-LIM MODE
Setting the traction limitation mode at over-discharge warning
P-LIM MODE
Setting the load handling limitation mode at over-discharge warning
T FWD LIMIT
Setting to enable/disable active mast front tilt angle control
YES*
Enabled
NO
Disabled
T BWD LEVEL
Setting to enable/disable backward tilt automatic leveling control
YES*
Enabled
NO
Disabled
T F-SPD LIM
Setting to enable/disable forward tilt speed limit control
YES*
Enabled
NO
Disabled
B LEVEL LIMIT*
Battery fluid level protection
YES
Enabled
NO
Disabled
B TEMP LIMIT*
Battery fluid temp protection
YES
Enabled
NO
Disabled
POWER KEEP
Power keep
YES*
Enabled
NO
Disabled
SHOCK SENSOR* Setting to enable/disable shock-sensor
YES
Enabled
NO
Disabled
H- SELECTOR*
Setting to enable/disable height selector
YES
Enabled
NO
Disabled
SHOU- TOKU*
Not used
YES
Not used
NO
Not used
KNOB CONT*
Setting to enable/ disable the steering knob synchronizer
YES
Enabled
NO
Disabled
CHARGER UNIT*
For models with on-vehicle charger
YES
Enabled
NO
Disabled
BACK BUZZER
Not used
A*
Not used
B
Not used
STOP LAMP
Not used
A*
Not used
B
Not used
*: These items are set according to the type of each vehicle before shipment from the factory.
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OPTION SET MENU Screen Operation Procedure 1. 2.
Display the ANALYZER MENU screen. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [OPT] tab. 3. Check that “1. OPTION SET” is selected, and press switch (4) to display OPTION SET screen. Note: You cannot move directly from OPTIONSET screen to the screen of the other items. Return to OPTIONSET MENU screen once, then move to screen of each time.
“OPTION SET” Screen 1 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3):Switching the selected option set item to the option on the right Switch (4): Switching to next screen
“OPTION SET” Screen 2 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
“OPTION SET” Screen 3 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
4-139
“OPTION SET” Screen 4 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
“OPTION SET” Screen 5 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
“OPTION SET” Screen 6 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
“OPTION SET” Screen 7 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): Switching to next screen
4-140
“OPTION SET” Screen 8 Switch (1): Switching selection to next item Switch (2): Switching the selected option set item to the option on the left Switch (3): Switching the selected option set item to the option on the right Switch (4): To “OPTIONSET MENU” screen
4-141
MATCHING General • Each function is controlled by using the sensors and each signal voltage at standard vehicle condition stored in the controller at the time of shipment. Therefore, a matching (updating of the signal voltage of a sensor at standard vehicle condition) is required when performing maintenance on a section or replacing parts related to the sensor. • For the accelerator sensor and brake sensor used for drive functions, the signal voltage values at accelerator fully released, accelerator fully closed, brake fully released and brake operation starting position are stored, respectively, in the controller to control based on these values. When servicing these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary. • For tire angle sensor used for synchronized steering, the signal voltage value at standard vehicle condition is stored, in the controller to control based on this value. When servicing or replacing tire angle sensor, matching (updating the sensor signal voltage value in the standard vehicle condition) is necessary. On the other hand, matching is needed for the tire angle sensor when the tire angle sensor or related part is replaced. • For the tilt angle, load and tire angle sensors used for SAS functions, the signal voltage values at standard vehicle condition are stored respectively, in the controller to control based on these values. When servicing or replacing these sensors, matching (updating the sensor signal voltage value in the standard vehicle condition) is necessary. Also, matching is needed for the tilt angle sensor when the vehicle posture has changed excessively, and for the load sensor when the load under no load condition (no load on fork) is changed because of addition or removal of any attachment or fork, replacement of mast or change of fork length. On the other hand, matching is needed for the tire angle sensor when the tire angle sensor or related part is replaced. • Each lever angle sensor for load-handling lever function is controlled based on the memory of signal voltage values in the neutral position stored in the controller at the time of shipment. When servicing these sensors or replacing related parts, MATCHING (updating the sensor signal voltage value in the standard vehicle condition) is necessary. • The oil control valve (OCV) starting current level is set at the factory for all the control valves together, and the settings are stored in the main controller memory. Therefore, the settings must be matched following maintenance or replacement of related parts. • The load meter display is based on the mast specifications and unloaded load sensor signal voltage, which are stored in the multifunction display. Therefore, the settings must be matched following maintenance or replacement of the mast or load sensor. • It is necessary to input the tire data to the controller according to the tire size, for optimizing the speedometer reading. Although the tire data is set to the value of new tires at the time of shipment, adjust it whenever the tire size or type is changed according to “TIRE DATA List”.
4-142
Matching Items and Prerequisite for Implementation 1. DRIVE No.
Indication
Description
Prerequisite for implementation
1
ACCEL OFF
Accelerator sensor output value with fully opened accelerator position to the controller.
*1,*2
2
ACCEL ON
Accelerator sensor output value with fully stepped accelerator position to the controller.
*1,*2
3
BRAKE OFF
Brake sensor output value with fully released brake position to the controller.
*1,*16
4
BRAKE ACT
Brake sensor output value at the operation starting position of brake to the controller.
*1,*16
Description
Prerequisite for implementation
2. SAS No.
Indication
1
TILT LEVEL
Tilt angle sensor output value with fork in the horizontal position to the controller.
2
TILT FWD LIMIT
Tilt angle sensor output value at the forward tilt limit position and the load sensor output value without load to the controller.
3
TIRE POSITION
Tire angle sensor output value while the vehicle is traveling straight to the controller.
*1, *6
4
MAST TYPE
The mast type is stored.
*8, *14
HEIGHT SENSOR
With the forks at their lowest position, store the lift height sensor output value in the controller memory.
*1, *8, *18
Description
Prerequisite for implementation
5
*1, *3, *4 *7, *8, *9 *1, *3, *4, *5 *7, *8, *9
3. LEVER No.
Indication
1
LEVER1
Lift lever angle sensor output value in the lift lever neutral position is stored in the controller.
*1, *10
2
LEVER2
Tilt lever angle sensor output value in the tilt lever neutral condition is stored in the controller.
*1, *11
3
LEVER3
Attachment (1) lever angle sensor output value in the attachment (1) lever neutral position is stored in the controller.
*1, *12
4
LEVER4
Attachment (2) lever angle sensor output value in the attachment (2) lever neutral position is stored in the controller.
*1, *13
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4. OCV No.
1
2
Indication
Description
Prerequisite for implementation
A01
Control valve A01 starting current level
*1, *17
A02
Control valve A02 starting current level
*1, *17
A03
Control valve A03 starting current level
*1, *17
A04
Control valve A04 starting current level
*1, *17
B01
Control valve B01 starting current level
*1, *17
B02
Control valve B02 starting current level
*1, *17
B03
Control valve B03 starting current level
*1, *17
B04
Control valve B04 starting current level
*1, *17
5. LOAD METER (Multi-function display DX only) No.
1
2
3
4
Indication
Description
Prerequisite for implementation
MAST TYPE
The mast type is stored. V→SV→FSV→FV→FSW→FW→QFV→ ⎡ - ⎦ (N/A)
*8, *14
CYL. SIZE1
Diameter of the lift cylinder is stored.
*8, *14
CYL. SIZE2
Diameter of the lift cylinder is stored.
*8, *14
ZERO SET1
Zero point of the load meter is stored.
*5, *7, *8, *14
ZERO SET2
Zero point of the load meter is stored.
*5, *7, *8, *14
COMPENSATION
The value of load meter compensation data is stored.
As requested by customer to adjust the accuracy
6. LEVER No. 1
Indication TIRE DATA
Description The tire data according to the tire size is stored.
Prerequisite content for implementation *1: When main controller replacement *2: When removing/installing or replacing accelerator sensor *3: When removing/installing or replacing tilt angle sensor *4: When length change or replacing of tilt angle sensor rod *5: When removing/installing or replacing load sensor *6: When removing/installing or replacing tire angle sensor or sensor cover *7: When installing or changing attachment or fork *8: When removing/installing or replacing mast *9: When removing/installing or replacing tilt cylinder
Prerequisite for implementation *1, *15
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*10: *11: *12: *13: *14: *15: *16: *17: *18:
When replacing lift lever angle sensor When replacing tilt lever angle sensor When replacing attachment (1) lever angle sensor When replacing attachment (2) lever angle sensor When replacing multifunction display When the tire size or type is changed. When removing/installing or replacing brake sensor, or adjusting the brake pedal height When replacing oil control valve When removing/installing or replacing height reel sensor
Before Starting Matching Before performing matching, you must set the vehicle to “standard vehicle condition”. For “standard vehicle condition”, refer to section 14.
4-145
MATCHING MENU Screen Operation Procedure 1. 2. 3.
Enter the password on the status screen to display the service function initial screen. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [MAT] tab. Press switch (2) to select the [OPT] tab and move to the OPTION SET screen. Press switch (3) to select the [etc.] tab and move to the OTHER SERVICE FUNCTION MENU screen.
“1. DRIVE” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING DRIVE” screen
“2. SAS” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING SAS” screen
“3. LEVER” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING LEVER” screen
“4. OCV” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING OIL CONTROL VALVE” screen
“5. LOAD METER” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING LOAD METER” screen
“6. TIRE DATA” Switch (1): Switching selection to next item Switch (2): To OPTION SET menu Switch (3): To OTHERS menu Switch (4): To “MATCHING TIRE DATA” screen
4-146
DRIVE (MATCHING DRIVE) Matching is performed for drive function.
Operation Procedure 1. 2.
Display the MATCHING MENU screen. Check the “1. DRIVE” is selected on the screen, and press the switch (4) to display “ACCEL OFF” screen. 3. Press switch (4) on “BRAKE ACT” screen to return to the MATCHING MENU screen. 4. Press the switch (4) to display MATCHING screen. Values in bracket ( ) are currently stored value. Values outside bracket ( ) are current vehicle condition value. Note: • In standard vehicle condition, if the value in the bracket ( ) and the value outside the bracket ( ) are different, matching is required. • Make sure that the Diagnostic indicator on the display is blinking. • If matching is performed, “OK” is indicated on the display. • You cannot move directly from MATCHING screen to the screen of the other items. Return to MATCHING MENU screen once, then move to screen of each time. 5.
Make sure that the Spanner indicator on the display is blinking. Caution: During drive matching, the Spanner indicator blinks, informing that the vehicle does not run even if the accelerator pedal depressed.
“ACCEL OFF” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “ACCEL ON” screen
4-147
“ACCEL ON” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “BRAKE OFF” screen
“BRAKE OFF” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “BRAKE ACT” screen
“BRAKE ACT” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “MATCHING MENU” screen
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SAS (MATCHING SAS) Matching is performed for SAS function.
Operation Procedure 1. 2.
Display the MATCHING MENU screen. Check the “2. SAS” is selected on the screen, and press the switch (4) to display “TILT LEVEL” screen. 3. From here on, the screen changes in sequence each time switch (4) is pressed. On the TIRE POSITION (tire angle matching), MAST TYPE or HEIGHT SENSOR screen, press switch (4) to return to the MATCHING MENU screen. (The operation is determined by the settings of the option set, height sensor and mast type.) 4. Press the switch (4) to display MATCHING screen. Values in bracket ( ) are currently stored value. Values outside bracket ( ) are current vehicle condition value. Note: • In standard vehicle condition, if the value in the bracket ( ) and the value outside the bracket ( ) are different, matching is required. • If matching is performed, “OK” is indicated on the display. • You cannot move directly from MATCHING screen to the screen of the other items. Return to MATCHING MENU screen once, then move to screen of each time.
“TILT LEVEL” Screen (Models with SAS) Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “TILT FWD LIMIT” screen
“TILT FWD LIMIT” Screen (Models with SAS) Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “TIRE POSITION” screen
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“TIRE POSITION” Screen (Models with SAS or synchronized steering) Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “MATCHING MENU” screen
“MAST TYPE” Screen (W/ Height sensor) Used to select the type of the mounted mast. Select “-” if the mast type is not specified. Switch (2): Switching in the following sequence: “-” (unspecified) → QFV → FW → FSW → FV → FSV → SV → V Switch (3): Switching in the following sequence: V → SV → FSV → FV → FSW → FW → QFV → “-” (unspecified) Switch (4): MAST TYPE=V: To “HEIGHT SENSOR” screen MAST TYPE=Except V: To “MATCHING MENU” screen Note: The screen is the same as the mast type setting screen on the load meter matching menu.
“HEIGHT SENSOR” Screen This screen is displayed if “V mast” is selected (W/ Height selector) on the MAST TYPE screen. It is not displayed if any type of mast other than V mast is selected (W/O Height selector). Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “MATCHING MENU” screen
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LEVER (MATCHING LEVER) Matching is performed for load handling lever functions.
Operation Procedure 1. 2.
Display the MATCHING MENU screen. Check the “3. LEVER” is selected on the screen, and press the switch (4) to display “LEVER1” screen. 3. From here on, the screen changes in sequence each time switch (4) is pressed, and it returns to the MATCHING MENU screen. Note: • The number of tuning menu items displayed varies according to the number of spools of the lever. • Values in bracket ( ) are currently stored value. Values outside bracket ( ) are current vehicle condition value. • If matching is performed, “OK” is indicated on the display. • After completion of the matching operation, fully tilt each lever to both the push and pull sides in order to learn the full-stroke voltages automatically. • You cannot move directly from MATCHING screen to the screen of the other items. Return to MATCHING MENU screen once, then move to screen of each time.
“LEVER1” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): Switching selection to next item
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“LEVER2” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): Switching selection to next item
“LEVER3” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): Switching selection to next item
“LEVER4” Screen Switch (1): Pressing this for more than 2 seconds will perform matching Switch (4): To “MATCHING MENU” screen
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OCV (MATCHING OIL CONTROL VALVE) Used to set the control valve starting current level. The starting current level is set according to the type of the mounted control valve before shipment from the factory. However, if the control valve or the main controller is changed, the starting current should be set again according to the value specified on or attached to the new control valve.
Operation Procedure 1. 2. 3.
Display the MATCHING MENU screen. Check the “4. OCV” is selected on the screen, and press the switch (4) to display “MAT. OCV” screen. From here on, the screen changes in sequence each time switch (4) is pressed, and it returns to the MATCHING MENU screen.
Reference: Plate of curent level.
“OCV A01 to OCV A04” Screen Control valve starting current setting screen OCV A01: Control valve A01 starting current level OCV A02: Control valve A02 starting current level OCV A03: Control valve A03 starting current level OCV A04: Control valve A04 starting current level Switch (1): Switching selection to next item Switch (2): Reducing the starting current level Switch (3): Increasing the starting current level Switch (4): To “MAT.OCV B01” screen
“OCV B01 to OCV B04” Screen OCV B01: Control valve B01 starting current level OCV B02: Control valve B02 starting current level OCV B03: Control valve B03 starting current level OCV B04: Control valve B04 starting current level Switch (1): Switching selection to next screen Switch (2): Reducing the starting current level Switch (3): Increasing the starting current level Switch (4): To “MATCHING MENU” screen
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LOAD METER (MATCHING LOAD METER: DX ONLY) Matching is performed for load meter functions.
Operation Procedure 1. 2. 3.
Display the MATCHING MENU screen. Check the “5. LOAD METER” is selected on the screen, and press the switch (4) to display “LOAD METER” screen. From here on, the screen changes in sequence each time switch (4) is pressed. On the COMPENSATION screen, press switch (4) to return to the MATCHING MENU screen.
“MAST TYPE” Screen Mast type setting screen Used to select the type of the mounted mast. Select “-” if the mast type is not specified. If “Unspecified” is selected, the load meter function will be disabled. Switch (1): Not used Switch (2): Switching in the following sequence: “-” (unspecified) → QFV → FW → FSW → FV → FSV → SV → V Switch (3): Switching in the following sequence: V → SV → FSV → FV → FSW → FW → QFV → “-” (unspecified) Switch (4): Switching selection to next item
“CYL. SIZE” Screen (V mast only) Cylinder diameter setting screen (low lifting height) Switch (1): Not used Switch (2): Reducing the cylinder diameter Switch (3): Increasing the cylinder diameter Switch (4): Switching selection to next item
“CYL. SIZE 1” Screen (Except V mast) Cylinder diameter No.1 setting screen (low lifting height) Switch (1): Not used Switch (2): Reducing the cylinder diameter No.1 Switch (3): Increasing the cylinder diameter No.1 Switch (4): Switching selection to next item
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“CYL. SIZE 2” Screen (Except V mast) Cylinder diameter No.2 setting screen (high lifting height) Switch (1): Not used Switch (2): Reducing the cylinder diameter No.2 Switch (3): Increasing the cylinder diameter No.2 Switch (4): Switching selection to next item
Cylinder Diameter List Mast type
V
FSV
FV
Models
Cylinder diameter No.1
Cylinder diameter No.2
1.5 ton, 1.6 ton, 1.8 ton
45
-
2.0 ton, 2.5 ton
50
-
3.0 ton
55
-
1.5 ton, 1.6 ton, 1.8 ton
70
45
2.0 ton, 2.5 ton
75
50
3.0 ton
85
55
1.5 ton, 1.6 ton, 1.8 ton
70
32
2.0 ton, 2.5 ton
75
35
3.0 ton
85
40
• Lift cylinder bore(V),Front lift cylinder bore(FSV,FV). • Rear lift cylinder bore(FSV),Piston rod outside diameter of rear lift cylinder(FV).
“ZERO SET” Screen (V mast only) “ZERO SET 1” Screen (Except V mast) The result is displayed if the matching operation (holding down switch (1) for more than 2 seconds) is performed. OK: Matching completed NG: The signal voltage is outside the matching range or a load is lifted high on the mast. Note: If “NG” is displayed, check the states of the vehicle and mast, as well as the load meter for malfunction and its harness for break and short circuit. Switch (1): Pressing this for more than 2 seconds will perform matching Switch (2): Not used Switch (3): Not used Switch (4): Switching selection to next item
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“ZERO SET 2” Screen (Except V mast) The result is displayed if the matching operation (holding down switch (1) for more than 2 seconds) is performed. OK: Matching completed NG: The signal voltage is outside the matching range or a load is lifted high on the mast. Note: If “NG” is displayed, check the states of the vehicle and mast, as well as the load meter for malfunction and its harness for break and short circuit. Switch (1): Pressing this for more than 2 seconds will perform matching Switch (2): Not used Switch (3): Not used Switch (4): Switching selection to next item
“CONPENSATION” Screen Load meter compensation screen To correct the value, place the mast in an upright position, put a load (whose weight is determined correctly) on the fork, lift up the fork approximately 1 m and under these conditions, adjust the value displayed at the upper right part of the screen to the load weight. Switch (1): Not used Switch (2): Correcting the value to the negative side Switch (3): Correcting the value to the positive side Switch (4): To “MATCHING MENU” screen
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TIRE DATA (MATCHING TIRE DATA) Used to set the tire constant. The tire constant is set according to the type of the mounted tires before shipment from the factory. However, if the type or size of tire is changed, the tire constant should be set again according to the tire constant list.
Operation Procedure 1. 2. 3.
Display the MATCHING MENU screen. Check the “6. TIRE DATA” is selected on the screen, and press the switch (4) to display “TIRE DATA” screen. Press switch (4) again to return to the MATCHING MENU screen.
“TIRE DATA” Screen Switch (1): Not used Switch (2): Reducing the tire constant Switch (3): Increasing the tire constant Switch (4): To “MATCHING MENU” screen
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Tire Data List 1 ton models Tire size
Tire type
Applicable models 1.5 ton
1.6 ton
1.8 ton
STD (J-Lug) tire
271
-
-
Rib-Lug tire
271
-
-
STD (J-Lug) tire
-
299
299
Rib-Lug tire
-
299
299
J-Lug, Oversize tire
299
-
-
Rib-Lug, Oversize tire
299
-
-
21x8-9-14PR
Side-ring (J-Lug) tire
273
273
273
21x8-9-10PR
Rib-Lug, Side-ring tire
267
267
267
J-Lug, Non-Punc tire
276
276
-
U-Lug, Non-Punc tire
276
276
-
Non-marking tire
276
276
-
J-Lug, Non-Punc tire
-
-
306
U-Lug, Non-Punc tire
-
-
306
Non-marking tire
-
-
306
J-Lug, Non-Punc, Oversize tire
306
306
-
U-Lug, Non-Punc, Oversize tire
306
306
-
Non-marking, Oversize tire
306
306
-
J-Lug, Non-Punc, Side-ring tire
272
272
272
U-Lug, Non-Punc, Side-ring tire
272
272
272
Non-marking, Side-ring tire
272
272
272
6.00-9-10PR
6.50-10-10PR
6.00-9
6.50-10
21x8-9
2 ton models Tire size 21x8-9-14PR
21x8-9
23x9-10
Tire type
Applicable models 2.0 ton
2.5 ton
STD (J-Lug) tire
270
270
Rib-Lug tire
270
270
J-Lug, Non-Punc tire
272
272
U-Lug, Non-Punc tire
272
272
Non-marking tire
272
272
J-Lug, Non-Punc, Side-ring tire
309
309
U-Lug, Non-Punc, Side-ring tire
309
309
3 ton model Tire size 28x9-15-14PR
28x9-15
Tire type
Applicable models 3.0 ton
STD (J-Lug) tire
369
Rib-Lug tire
369
J-Lug, Non-Punc tire
368
U-Lug, Non-Punc tire
368
Non-marking tire
368
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OTHERS MENU Note: After completing the hour meter start setting, “METER START” and “DEMO MODE” will not be displayed on the “OTHERS MENU”. Before hour meter start
After hour meter start
Operation Procedure 1. 2. 3.
Enter the password on the status screen to display the service function initial screen. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Press switch (2) to select the [MAT] tab and move to the MATCHING menu screen. Press switch (3) to select the [Return] tab and return to the status screen.
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“1. METER START” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To METER START setting screen
“2. DEMO MODE” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To DEMO MODE setting screen
“3. TO DEFAULT SET” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To TO DEFAULT SET setting screen
“4. MASK PASSWORD” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To MASK PASSWORD setting screen
“5. MANAGER PASS CLR” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To MANAGER PASS CLR setting screen
“6. CHARGER CNT CLR” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To CHARGER CNT CLR setting screen
“7. CONTRAST” Switch (1): Switching selection to next screen Switch (2): To MATCHING menu Switch (3): To END menu Switch (4): To CONTRAST setting screen
METER START (HOUR METER START) This menu item is used to make the following meters start counting: hour meters, odometer, trip meter and maintenance hour meter. With this menu option, you can also enable the following functions or operations regardless of whether the demo mode is enabled or disabled. • Enables the load handling operation during traveling. • Enables the parking brake reminder function. • Enables the detection, warning and recording function, while clearing the data on shock detected by the simplified shock sensor (option). • Enables all functions of the PIN code entry system (option). Note: • This operation does not the clear the PIN code authentication data or the simplified shock detection level that was set when the demo mode was enabled. • Once the hour meter has started, it cannot be returned to the state where it was before it starts.
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Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. 3. Check the “1.METER START” is selected on the screen, and press the switch (4) to display “METER START” screen. Note: Keep in mind that H mode lock is kept as it was before the start of the hour meter. The status of H mode lock is displayed on the METER START screen so that it can be checked easily.
“METER START” Screen 1.
Press and hold down switch (2) for more than 2 seconds to additionally display a right arrow on the screen.
2.
Press switch (3) while holding down switch (2) to complete the setting. On completion of the setting, “YES” is highlighted instead of “NO.” Switch (4): To “OTHERS MENU” screen
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Key ON hour meter before the start
Key ON hour meter after the start
Note: On completion of the hour meter start operation, the hourglass icon on the key ON hour meter blinks to indicate that the hour meter has started to count up.
DEMO MODE This menu item is used to enable or disable the demo mode. Before starting the hour meter, you can enable the following functions temporarily in the demo mode. Demo mode
Yes (enabled)
No (disabled)
Load handling during traveling
Allowed
Not allowed
Parking brake OFF warning
Enabled
Disabled
Enabled
Disabled
Shock sensor (OPT)
PIN code entry system (OPT)
Detection, warning, recording
Authentication function
Registration, change or deletion of authentication number
Authentication Authentication possible only possible by simply for registered pressing the log-in authentication switch numbers Enabled
Disabled
Note: Even after the demo mode has been disabled, the data recorded and the settings made during the demo mode are all retained.
Operation Procedure 1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. 3. Check the “2.DEMO MODE” is selected on the screen, and press the switch (4) to display “DEMO MODE” screen. Note: • After the hour meter start operation completes, “METER START” and “DEMO MODE” items of other service function menus will not be displayed. • The demo mode screen always displays H mode lock condition.
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“DEMO MODE” Screen Switch (1): Not used Switch (2): Setting from YES Switch (3): Setting from NO Switch (4): Return to “OTHERS MENU” screen
Note: During demo mode, “DEMO” is displayed in the key on hour meter screen.
TO DEFAULT SET This menu item is used to initialize the tuning values or the settings of items with default values. Setting items applied: • Menu lock • Power select mode (ESPH) • Drive power control setting, load handling power control setting • Low speed setting • Maximum speed setting • Over speed alarm setting • Tuning level • Auto power OFF time Note: This does not apply to data dependent on each individual vehicle, such as option set data, various matching data, load meter setting data and tire constant data.
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Operation Procedure Before hour meter start
After hour meter start
1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Before hour meter start 3. Press the switch (1) to check if “3. TO DEFAULT SET” is selected. 4. Press the switch (4) to display TO DEFAULT SET screen. After hour meter start 3. Display the OTHERS MENU screen and press the switch (1), select the “1. TO DEFAULT SET”. 4. Press the switch (4) to display TO DEFAULT SET screen.
“TO DEFAULT SET” Screen 1.
2.
Press the switch (2) and select the “YES”.
To initialize the settings, press and hold down the switch (1) for more than 2 seconds. When the settings are reset to the default values, progress is displayed as a bar. When reset is complete, [OK] is displayed. Note: • When the Default Set operation is in progress, do not turn off the ignition key switch or disconnect the battery plug. • You can return to another service function menu by pressing the switch (4), except when the Default Set operation is in progress.
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SERVICE SECOND PASSWORD SETTING (MASK PASSWORD) This menu item is used to set or clear a service second password. You can enter any four-digit number as a service second password, using the 4 switches on the multifunction display. If you set a service second password, you will be prompted to enter the second password after you enter the ordinary password necessary to display the SERVICE FUNCTION screen, and you can move to the SERVICE FUNCTION screen only when the passwords you entered coincide with the registered ones. No service second password has been set by default. Note: Do not forget the password you set. In the event you forget it, replace the multi-function display.
Operation Procedure Before hour meter start
After hour meter start
1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Before hour meter start 3. Press the switch (1) to check if “4. MASK PASSWORD” is selected. 4. Press the switch (4) to display MASK PASSWORD screen. After hour meter start 3. Display the OTHERS MENU screen and press the switch (1), select the “2. MASK PASSWORD”. 4. Press the switch (4) to display MASK PASSWORD screen.
“Service second password clear” If you press and hold down the switch (1) for more than 2 seconds without entering any digit on the MASK PASSWORD screen, the registered password is deleted and “OK” appears on the completion of its deletion. Note: The service second password can be cleared only when no digit has been entered (when every box is [ ]).
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“Service second password set” 1.
When you enter a four-digit number, “SET” appears in the lower left corner of the screen, informing that you are ready to save it as a password. 2. Press and hold down the switch (1) for more than 2 seconds to save the password. After the password has been saved, “OK” appears. Note: • A 4-digit number needs to be entered in order for it to be accepted as a password. • If you press and hold down the switch (4) for more than 2 seconds, the number you entered becomes invalid and the screen switches over to another service function menu screen.
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ADMINISTRATOR’S SECOND PASSWORD CLEAR (MANAGER PASS CLR) This menu item is used to clear the administrator second password. If so requested by the customer, you can clear the administrator second password on the service function screen.
Operation Procedure Before hour meter start
After hour meter start
1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Before hour meter start 3. Press the switch (1) to check if “5. MANAGER PASS CLR” is selected. 4. Press the switch (4) to display MANAGER PASS CLR screen. After hour meter start 3. Display the OTHERS MENU screen and press the switch (1), select the “3. MANAGER PASS CLR”. 4. Press the switch (4) to display MANAGER PASS CLR screen.
“MANAGER PASS CLR” Screen If you press and hold down the switch (1) for more than 2 seconds, the administrator second password is deleted and “OK” appears on the completion of its deletion. Switch (1): Clears the password if pressed and held down for more than 2 seconds Switch (2): Not used Switch (3): Not used Switch (4): Returning to OTHERS MENU screen
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CHARGER COUNTER CLEAR (WITH ON-VEHICLE CHARGER ONLY) This menu item is used to clear the charger counter. You can clear the charger counter on the service function screen.
Operation Procedure Before hour meter start
After hour meter start
1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Before hour meter start 3. Press the switch (1) to check if “6. CHARGER CNT CLR” is selected. 4. Press the switch (4) to display CHARGER CNT CLR screen. After hour meter start 3. Display the OTHERS MENU screen and press the switch (1), select the “4. CHARGER CNT CLR”. 4. Press the switch (4) to display CHARGER CNT CLR screen.
“CHARGER CNT CLR” Screen If you press and hold down the switch (1) for more than 2 seconds, the charger counter is deleted. Switch (1): Clears the counter if pressed and held down for more than 2 seconds Switch (2): Not used Switch (3): Not used Switch (4): Returning to OTHERS MENU screen
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LCD CONTRAST ADJUSTMENT This menu item is used to adjust the contrast of the multi-function LCD display.
Operation Procedure Before hour meter start
After hour meter start
1.
Enter the password on the status screen to display the service function initial screen. 2. By default, the SERVICE MENU screen is displayed with the [ANL] tab selected. On this screen, press the switch (3) and select the [etc.] tab. Before hour meter start 3. Press the switch (1) to check if “7. CONTRAST” is selected. 4. Press the switch (4) to display CONTRAST screen. After hour meter start 3. Display the OTHERS MENU screen and press the switch (1), select the “5. CONTRAST”. 4. Press the switch (4) to display CONTRAST screen.
“CONTRAST” Screen Switch (1): Not used Switch (2): Contrast level down Switch (3): Contrast level up Switch (4): Returning to OTHERS MENU screen
5-1
TROUBLESHOOTING Page
BEFORE TROUBLESHOOTING ................................5-2 CONNECTOR HANDLING ..............................................5-2 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE ...............................................................5-2
TROUBLESHOOTING METHOD................................5-4 TO USE SST ....................................................................5-5 DIAGNOSIS CODE LIST ..............................................5-6
0 2 2 3 4
WHEN ERROR CODE IS DISPLAYED ...................5-22
5
WHEN NO ERROR CODE IS DISPLAYED ..........5-205
6 7 8 9 10 11 12 13 14
5-2
BEFORE TROUBLESHOOTING CONNECTOR HANDLING 1.
Disconnect the battery plug before connecting or disconnecting each connector or terminal.
2.
When disconnecting a connector, do not pull it at the harness but hold the connector itself and pull it after unlocking it. To connect, push the connector fully until it is locked in position.
3.
Bring a tester probe into contact with a connector terminal from the rear side of the coupler (harness side).
4.
If insertion from the rear side is impossible, as in the case of a waterproof connector, bring the tester probe carefully into contact with the terminal so as not to cause deformation of the connector terminal.
5.
Do not touch connector terminals directly with your hand.
6.
When bringing tester probes into contact with live terminals, prevent two tester probes from coming into contact with each other.
WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the following procedure: Continuity check 1.
Disconnect the connectors at both ends of the corresponding harness.
2.
Measure the resistance between corresponding terminals of the connectors at both ends.
Note: Measure while lightly shaking the wire harness up and down and sideways. Open circuit at the wire harness occurs rarely partway through a vehicle wiring but mostly at connectors. Inspect especially the sensor connectors with sufficient care.
5-3
Short circuit check 1.
Disconnect the connectors at both ends of the corresponding harness.
2.
Measure the resistance between the corresponding connector terminal and N1. Always inspect the connectors at both ends. Standard: 1 MΩ or above
Measure while lightly shaking the wire harness up and down and sideways.
ǡ
0 2 2
3.
Measure the resistance between a terminal corresponding to the connector terminal and N1. Always inspect the connectors at both ends. Standard: 1 MΩ or above
The wiring may short-circuit due to pinching by the body or defective clamping.
3 4 5 6
ǡ
7
ǡ
8 Visual and contact pressure checks • Disconnect the connectors at both ends of the corresponding harness. • Visually inspect that there is neither rust nor foreign matter trapped at connector terminals. • Inspect that there is no loosening or damage at the locked portion. Also, lightly pull the wire harness from the connector to check that it does not come off.
9 10 11 12 13 14
• Insert a male terminal same as that of the terminal to a female connector and check the extracting force. Defective contact may exist at a terminal where the extracting force is less than that of other terminals. Note: Even if there is rust or foreign matter trapped at the terminal, or the contact pressure between male and female terminals is low, abnormal contact condition may be changed to normal by disconnecting and reconnecting the connector. In that case, repeat connector connection and disconnection several times. If defect is perceived even once, terminal contact may be defective.
5-4
TROUBLESHOOTING METHOD Inspection: Check of seat switch condition 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN43 connector, connect the battery plug, and turn on the key switch. 3. Check the value of SDM, using the Analyzer menu. [ANL] I/O TRAVELING 2/5
SDM: 0
Defective portion Repair or replacement Seat switch defect
SDM: 1
To the next step depending on the result.
Inspection 1: 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN103, CN0104 and CN43 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Explanation of Frames 1. Disconnect the battery plug, disconnect the CN43 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN43 connector, connect the battery plug, and then turn on the key switch without sitting in the seat.
A single frame indicates measurement with a tester or an ordinary step.
Inspection: Check of seat switch condition Check the value of SDM, using the Analyzer menu. [ANL] I/O TRAVELING 2/5
A double frame indicates inspection by an analyzer function.
Test item.
5-5
TO USE SST Use SSTs for quick, accurate electrical troubleshooting on the 8FBN series. Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect connection, careful operation is necessary. SST No.
SST name
remarks
09230-13240-71
Main controller check harness
(for power source check)
0
09230-13700-71
CN76 short harness
61-1, 2
2
C2-2 C4-1 to 6 C5-1 to 6 C8-1, 2 09232-13130-71
CN7 IC check pin Check harness Each short harness
E2-2 E8-1, 2 FB-1, 2 62-1, 2 71-1 to 3 72-1 to 4 G5-1 to 6
09238-13130-71
CN97 harness CN90 check harness
68-1 to 3
09240-13241-71
For AC driver
E8-1, 2
Caution: Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept connected, various boards may be damaged.
2 3 4 5 6 7 8 9 10 11 12 13 14
Memory
A0-1
A0-2
A1-1
A1-2
A1-4
A2-1
A3-1
A3-2
A5-1
A8-1
Indication
DCR
PCR
A1-1
A1-2
A1-4
C/R
A3-1
A3-2
A5-1
A8-1
Traveling and load handling stop. Steering becomes stiff. Traveling and load handling stop. Steering becomes stiff. OPSS function invalid. Parking brake reminder alarm partially invalid. Traveling and load handling stop. Steering becomes stiff.
Diagnostic Battery connection incorrect (Different voltage) mode blinking
Diagnostic mode Seat switch GND abnormality (Short) blinking
Diagnostic F1 fuse abnormality (Open) mode blinking
Drive motor output restricted.
Diagnostic Battery connection incorrect mode blinking
Main controller circuit board overheating abnormality
Load handling stop. Steering becomes stiff.
Diagnostic Pump motor drive circuit high voltage mode blinking
O/H lighting
Traveling stop.
Diagnostic Drive motor drive circuit high voltage mode blinking
Load handling stop. Steering becomes stiff. Traveling and load handling stop. Steering becomes stiff.
Pump motor drive power circuit overheating abnormality
O/H lighting
Traveling stop.
Phenomenon on vehicle
Diagnostic mode Main controller high voltage blinking
Drive motor drive power circuit overheating abnormality
Error mode
O/H lighting
Lamp
Battery overheat warning (BT O/ H)
Overheat warning (O/ H)
Indicator : Diagnostic mode
Indication : Diagnosis code will be indicated on the display when vehicle trouble occurs. Memory : Use this indicated diagnosis code that can be checked on the display when using the mask function DIAG MEMORY.
DIAGNOSIS CODE LIST
Indication “C/R” appears only for Multifunction Display
Indication “PCR” appears only for Multifunction Display
Indication “DCR” appears only for Multifunction Display
Remarks
5-6
Memory
A8-2
A9-2
AA-1
AB-1
AB-2
AC-1
AD-1
AD-2
AD-5
AD-6
Indication
A8-2
A9-2
AA-1
AB-1
AB-2
AC-1
AD-1
AD-2
AD-5
AD-6
Cooling fan stops working. Drive motor output restricted. Cooling fan stops working. Drive motor output restricted. Traveling and load handling stop. Steering becomes stiff.
Diagnostic mode Cooling fan drive circuit abnormality blinking
Diagnostic Cooling fan abnormality (Open/ Short) mode blinking
Diagnostic Semiconductor switch abnormality mode blinking
Diagnostic Pump motor driver → Main controller communication abnormality mode (on start up) blinking
Diagnostic mode Pump motor driver → Main controller communication abnormality blinking
Diagnostic Drive motor driver → Main controller communication abnormality (on start mode up) blinking
Load handling stop. Steering becomes stiff.
Traveling stop.
Drive motor output restricted.
Diagnostic Main controller temperature sensor open/ VCC short abnormality mode blinking
Diagnostic mode Drive motor driver → Main controller communication abnormality blinking
Load handling stop.
Diagnostic F7 fuse abnormality (Open) mode blinking
Phenomenon on vehicle Traveling and load handling stop.
Error mode
Diagnostic F6 fuse abnormality (Open) mode blinking
Lamp
Remarks
5-7
Memory
AF-1
AF-2
AF-3
AF-4
AF-5
AF-6
AF-7
AF-8
C0-2
C1-1
C1-2
Indication
AF-1
AF-2
AF-3
AF-4
AF-5
AF-6
AF-7
AF-8
C0-2
C1-1
C1-2
Error mode
Diagnostic Drive motor current sensor over current. mode blinking
Diagnostic mode Drive motor current sensor neutral voltage error. blinking
Diagnostic Drive motor power circuit short mode blinking
Diagnostic Main controller CPU error mode blinking
Diagnostic mode Main controller CPU error blinking
Diagnostic Main controller CPU error mode blinking
Diagnostic Main controller CPU error mode blinking
Diagnostic mode Main controller CPU error blinking
Diagnostic Main controller CPU error mode blinking
Diagnostic Main controller CPU error mode blinking
Diagnostic mode Main controller CPU error blinking
Lamp
Traveling stop.
Some control operation unstable.
Traveling and load handling stop Steering becomes stiff.
Phenomenon on vehicle
Remarks
5-8
Memory
C2-1
C2-2
C3-1
C4-1
C4-2
C4-3
C4-4
C4-5
C4-6
C5-1
C5-2
C5-3
C5-4
Indication
DM
C2-2
C3-1
C4-1
C4-2
C4-3
C4-4
C4-5
C4-6
C5-1
C5-2
C5-3
C5-4
Drive motor overheating abnormality.
Error mode
Diagnostic mode Brake sensor POT2 VCC short. blinking
Diagnostic Brake sensor POT1 VCC short. mode blinking
Diagnostic Brake sensor POT2 open. mode blinking
Diagnosis code display only. Every function remain operable.
Drive motor output restricted.
Diagnostic Accelerator sensor matching value error. mode blinking
Diagnostic mode Brake sensor POT1 open. blinking
Traveling stop.
Diagnosis code display only. Every function remain operable.
Top speed decreases. Drive motor output restricted.
Phenomenon on vehicle
Diagnostic Accelerator sensor offset abnormality. mode blinking
Diagnostic mode Accelerator sensor POT2 VCC short. blinking
Diagnostic Accelerator sensor POT1 VCC short. mode blinking
Diagnostic Accelerator sensor POT2 open. mode blinking
Diagnostic mode Accelerator sensor POT1 open. blinking
Diagnostic Drive motor power circuit temperature sensor abnormality(Open/ Short). mode blinking
Diagnostic Drive motor temperature sensor abnormality (Open/ Short). mode blinking
O/H lighting
Lamp Indication “DM” appears only for Multifunction Display
Remarks
5-9
Memory
C5-5
C5-6
C8-1
C8-2
CB-1
CB-2
CB-3
CB-4
CB-5
CC-1
CC-4
CC-6
Indication
C5-5
C5-6
C8-1
C8-2
CB-1
CB-2
CB-3
CB-4
CB-5
CC-1
CC-4
CC-6
Diagnostic Drive motor drive CPU error. mode blinking
Diagnostic Drive motor drive CPU error. mode blinking
Diagnostic mode Drive motor drive CPU error. blinking
Diagnostic MB contactor drive circuit short. mode blinking
Diagnostic MB contactor drive circuit abnormality. mode blinking
Diagnosis code display only. Every function remain operable.
Traveling stop.
Traveling stop. Load handling stop. Steering becomes stiff.
Diagnosis code display only. Every function remain operable.
Diagnostic MB contactor short. mode blinking
Diagnostic mode MB contactor drive circuit open. blinking
Traveling and load handling stop. Steering becomes stiff.
Traveling stop.
Diagnostic MB contactor open. mode blinking
Diagnostic mode Drive motor speed (rotation) sensor short. blinking
Diagnostic Drive motor speed (rotation) sensor open. mode blinking
Traveling stop.
Diagnostic Brake sensor matching value error. mode blinking
Phenomenon on vehicle Top speed decreases. Drive motor output restricted.
Error mode
Diagnostic mode Brake sensor offset abnormality. blinking
Lamp
Remarks
5-10
Memory
E0-2
E1-1
E1-2
E2-1
E2-2
E3-1
E8-1
E8-2
EC-1
EC-4
EC-6
EE-1
EE-2
Indication
E0-2
E1-1
E1-2
PM
E2-2
E3-1
E8-1
E8-2
EC-1
EC-4
EC-6
EE-1
EE-2
Error mode
Pump motor overheating abnormality.
Diagnosis code display only. Every function remain operable. Settings cannot be changed by display operation.
Display operation inoperable.
Diagnostic mode Display → Main controller communication error. blinking
Diagnostic mode Display → Main controller communication error. (on start up) blinking
Load handling stop. Steering becomes stiff.
Pump motor output restricted.
Load handling stop. Steering becomes stiff.
Phenomenon on vehicle
Diagnostic Pump motor drive CPU error. mode blinking
Diagnostic mode Pump motor drive CPU error. blinking
Diagnostic Pump motor drive CPU error. mode blinking
Diagnostic Pump motor speed (rotation)sensor short. mode blinking
Diagnostic mode Pump motor speed (rotation) sensor open. blinking
Diagnostic Pump motor drive power circuit temperature sensor abnormality (Open/ mode Short). blinking
Diagnostic Pump motor temperature sensor abnormality (Open/ Short). mode blinking
O/H lighting
Diagnostic Pump motor current sensor over current. mode blinking
Diagnostic Pump motor current sensor neutral voltage error. mode blinking
Diagnostic Pump motor drive power circuit abnormality. mode blinking
Lamp
Indication “PM” appears only for Multifunction Display
Remarks
5-11
Memory
F1-1
F1-2
F4-1
F4-2
F4-3
F4-4
F4-5
F4-6
F4-7
F4-8
Indication
F1-1
F1-2
F4-1
F4-2
F4-3
F4-4
F4-5
F4-6
F4-7
F4-8
Error mode
Diagnostic mode Display CPU error. blinking
Diagnostic Display CPU error. mode blinking
Some control operations unstable.
Display function unstable.
Diagnostic mode Display CPU error. blinking
Diagnostic Display CPU error. mode blinking
Diagnosis code display only. Every function remain operable
Traveling and load handling cannot be performed simultaneously. W/ PIN Code Entry System: PIN code entry system invalid.
Vehicle settings cannot be changed by display operation.
Phenomenon on vehicle
Diagnostic Display CPU error. mode blinking
Diagnostic Display CPU error. mode blinking
Diagnostic mode Display CPU error. blinking
Diagnostic Display CPU error. mode blinking
Diagnostic mode Main controller → Display communication error. (on start up) blinking
Diagnostic mode Main controller → Display communication error. blinking
Lamp
Remarks
5-12
Memory
F5-1
F5-2
F5-3
F5-4
F6-1
F6-2
F7-1
F8-1
FB-1
FB-2
FC-1
FF-1
FF-2
Indication
F5-1
F5-2
F5-3
F5-4
F6-1
F6-2
F7-1
F8-1
FB-1
FB-2
-
FF-1
FF-2
Error mode
Charger does not start charging.
Charger does not complete charging.
Diagnostic mode Charging abnormality. blinking
Diagnostic Charging completion abnormality. mode blinking
Knob position correcting function does not work. Steering becomes stiff.
Diagnostic SSTR+ power supply circuit over current. mode blinking
Traveling performance degradation. Drive motor output restricted. Display turns OFF.
Battery electrolyte overheating abnormality.
Diagnostic mode D7V power supply circuit over current. blinking
BT O/H lighting
Diagnostic mode Battery current sensor over current. blinking
Battery capacity indication error occurs after charging completed.
Charging stops.
Diagnostic Charger transformer overheating abnormality. mode blinking
Diagnostic Battery current sensor neutral voltage error. mode blinking
Charging stops.
Diagnosis code display only. Every function remain operable
Phenomenon on vehicle
Diagnostic Safety timer activation mode blinking
Diagnostic mode Battery electrolyte level/ temperature sensor overheating abnormality. blinking
Diagnostic Battery electrolyte level/ temperature sensor open. mode blinking
Diagnostic Battery electrolyte level/ temperature sensor harness short. mode blinking
Diagnostic Battery electrolyte level/ temperature sensor harness open. mode blinking
Lamp
Remarks
5-13
Memory
-
-
31-1
31-3
32-1
32-3
33-1
33-3
61-1
61-2
62-1
62-2
Indication
COLD DCR
COLD PCR
31-1
31-3
32-1
32-3
33-1
33-3
61-1
61-2
62-1
62-2
Diagnostic mode Tilt angle sensor short. blinking
Diagnostic Tilt angle sensor open. mode blinking
Diagnostic Load sensor short. mode blinking
Partial limitation of mast control function.
Partial limitation of mast control function. Partial limitation of traveling control function. Partial limitation of turning speed control function.
Load handling stop. Steering becomes stiff.
Diagnostic mode Main controller → Pump motor driver CAN communication abnormality. blinking
Diagnostic mode Load sensor open. blinking
Travelling stop.
Diagnosis code display only. Every function remain operable
Diagnostic mode Main controller → Drive motor driver CAN communication abnormality. blinking
Diagnostic mode Pump motor driver ID abnormality. blinking
Diagnostic Drive motor driver ID abnormality. mode blinking
Load handling stop. Steering becomes stiff.
Diagnostic Declining of activating voltage for Pump motor drive circuit. mode blinking
Lifting speed restricted.
Top speed decrease. Drive motor output restricted.
Phenomenon on vehicle
Travelling stop.
Drive motor drive low temperature abnormality
Drive motor drive low temperature abnormality
Error mode
Diagnostic mode Declining of activating voltage for Drive motor drive circuit. blinking
O/H lighting
O/H lighting
Lamp
Indication: Only for Multifunction Display O/H lamp: Only for STD display
Indication: Only for Multifunction Display O/H lamp: Only for STD display
Remarks
5-14
Memory
64-1
64-2
64-3
64-4
65-1
65-2
65-3
65-4
66-1
67-1
Indication
64-1
64-2
64-3
64-4
65-1
65-2
65-3
65-4
66-1
67-1
Lift may not lower.
Mast does not tilt forward.
Mast does not tilt forward.
Diagnostic mode Lift lock solenoid abnormality (Short/ Open). blinking
Diagnostic Tilt control solenoid open. mode blinking
Diagnostic Tilt control solenoid short. mode blinking
Partial limitation of mast control function. Partial limitation of mast control function. Partial limitation of traveling control function. Height selector invalid. Partial limitation of turning speed control function.
Diagnostic Abnormal matching value of tilt angle sensor. mode blinking
Diagnostic Lifting height switch abnormality (Open/ Short). mode blinking
Diagnostic Tilt control solenoid abnormality (Open/ Short). mode blinking
Mast may not tilt forward.
Lift may not lower.
Diagnostic Lift lock solenoid drive circuit abnormality. mode blinking
Diagnostic mode Tilt control solenoid drive circuit abnormality. blinking
Lift does not lower.
Diagnostic Lift lock solenoid short. mode blinking
Phenomenon on vehicle Lift does not lower.
Error mode
Diagnostic Lift lock solenoid open. mode blinking
Lamp
Remarks
5-15
Memory
68-1
68-2
68-3
68-4
68-5
71-1
71-2
71-3
72-1
72-2
72-3
72-4
Indication
68-1
68-2
68-3
68-4
68-5
71-1
71-2
71-3
72-1
72-2
72-3
72-4
Error mode
Knob position correcting function stops working. Knob position correcting function stops working. Steering becomes stiff.
Diagnostic Steering angle sensor power circuit open. mode blinking
Knob position correcting function stops working. Steering becomes stiff.
Knob position correcting function stops working. Partial limitation of turning speed control function.
Misalignment of height selector stop position. Partial limitation of mast control function. Partial limitation of traveling control function. Partial limitation of turning speed control function.
(For V mast only) Partial limitation of mast control function. Partial limitation of traveling control function. Partial limitation of turning speed control function.
Lift speed is limited when maximum height limiter is in active setting. Height selector is disabled when maximum height limiter is invalid.
Phenomenon on vehicle
Diagnostic Steering angle sensor SSC open. mode blinking
Diagnostic mode Steering angle sensor SS2 open. blinking
Diagnostic Steering angle sensor SS1 open. mode blinking
Diagnostic Tire angle sensor fixation. mode blinking
Diagnostic mode Tire angle sensor short. blinking
Diagnostic Tire angle sensor open. mode blinking
Diagnostic Lifting height sensor matching abnormality. mode blinking
Diagnostic mode Lifting height sensor lowermost position abnormality. blinking
Diagnostic Lifting height sensor abnormality. mode blinking
Diagnostic Lifting height sensor short. mode blinking
Diagnostic mode Lifting height sensor open. blinking
Lamp
Remarks
5-16
Memory
73-1
73-2
73-3
73-4
74-1
H1-1
H1-2
H1-3
H1-4
H1-5
H2-1
H2-2
H2-3
Indication
73-1
73-2
73-3
73-4
74-1
H1-1
H1-2
H1-3
H1-4
H1-5
H2-1
H2-2
H2-3
Error mode
Diagnostic mode Tilt lever potentiometer output abnormality. blinking
Diagnostic Tilt lever potentiometer short. mode blinking
Tilting forward and backward stop.
Lifting and lowering stop.
Diagnostic mode Lift lever potentiometer matching value error. blinking
Diagnostic Tilt lever potentiometer open. mode blinking
Load handling stop.
Lifting and lowering stop.
Knob position correcting function stops working. Partial limitation of turning speed control function.
Knob position correcting function stops working.
Phenomenon on vehicle
Diagnostic Lift lever potentiometer neutral error. mode blinking
Diagnostic Lift lever potentiometer output abnormality. mode blinking
Diagnostic mode Lift lever potentiometer short. blinking
Diagnostic Lift lever potentiometer open. mode blinking
Diagnostic Abnormal matching value for tire angle. mode blinking
Diagnostic mode Knob position correcting solenoid abnormality (Open/ Short). blinking
Diagnostic Knob position correcting solenoid power circuit abnormality. mode blinking
Diagnostic Knob position correcting solenoid short. mode blinking
Diagnostic Knob position correcting solenoid open. mode blinking
Lamp
Remarks
5-17
Memory
H2-4
H2-5
H3-1
H3-2
H3-3
H3-4
H3-5
H4-1
H4-2
H4-3
H4-4
H4-5
Indication
H2-4
H2-5
H3-1
H3-2
H3-3
H3-4
H3-5
H4-1
H4-2
H4-3
H4-4
H4-5
Load handling stop.
Attachment 2 function stops working.
Diagnostic Attachment 2 lever potentiometer neutral error. mode blinking
Diagnostic Attachment 2 lever potentiometer matching value error. mode blinking
Diagnostic mode Attachment 2 lever potentiometer output abnormality. blinking
Diagnostic Attachment 2 lever potentiometer short. mode blinking
Attachment 2 function stops working.
Attachment 1 function stops working.
Diagnostic mode Attachment 1 lever potentiometer matching value error. blinking
Diagnostic Attachment 2 lever potentiometer open. mode blinking
Load handling stop.
Attachment 1 function stops working.
Diagnostic Attachment 1 lever potentiometer neutral error. mode blinking
Diagnostic Attachment 1 lever potentiometer output abnormality. mode blinking
Diagnostic mode Attachment 1 lever potentiometer short. blinking
Diagnostic Attachment 1 lever potentiometer open. mode blinking
Tilting forward and backward stop.
Diagnostic Tilt lever potentiometer matching value error. mode blinking
Phenomenon on vehicle Load handling stop.
Error mode
Diagnostic mode Tilt lever potentiometer neutral error. blinking
Lamp
Remarks
5-18
Memory
H5-1
H5-2
H5-3
H5-4
H5-5
H5-6
H6-1
H6-2
H6-3
H6-4
H6-5
H6-6
Indication
H5-1
H5-2
H5-3
H5-4
H5-5
H5-6
H6-1
H6-2
H6-3
H6-4
H6-5
H6-6
Error mode
Diagnostic Tilt forward/backward solenoid abnormality (Open/ Short). mode blinking
Diagnostic Tilt solenoid power circuit abnormality. mode blinking
Diagnostic mode Tilt forward solenoid short. blinking
Diagnostic Tilt forward solenoid open. mode blinking
Diagnostic Tilt backward solenoid short. mode blinking
Diagnostic mode Tilt backward solenoid open. blinking
Diagnostic Lift proportional solenoid (PULL/PUSH) abnormality (Open/ Short). mode blinking
Diagnostic Lift proportional solenoid power circuit abnormality. mode blinking
Diagnostic mode Lift proportional solenoid short. (PUSH) blinking
Diagnostic Lift proportional solenoid open. (PUSH) mode blinking
Diagnostic Lift proportional solenoid short. (PULL) mode blinking
Diagnostic Lift proportional solenoid open. (PULL) mode blinking
Lamp
Load handling stop.
Forward tilting stop.
Backward tilting stop.
Load handling stops.
Lowering stop.
Lifting stop.
Phenomenon on vehicle
Remarks
5-19
Memory
H7-1
H7-2
H7-3
H7-4
H7-5
H7-6
H8-1
H8-2
H8-3
H8-4
Indication
H7-1
H7-2
H7-3
H7-4
H7-5
H7-6
H8-1
H8-2
H8-3
H8-4
Error mode
Diagnostic mode Attachment 2 PUSH solenoid short. blinking
Diagnostic Attachment 2 PUSH solenoid open. mode blinking
Diagnostic Attachment 2 PULL solenoid short. mode blinking
Diagnostic mode Attachment 2 PULL solenoid open. blinking
Diagnostic Attachment 1 (PULL/PUSH) solenoid abnormality (Open/ Short). mode blinking
Diagnostic Attachment 1 (PULL/PUSH) solenoid power circuit abnormality. mode blinking
Diagnostic mode Attachment 1 PUSH solenoid short. blinking
Diagnostic Attachment 1 PUSH solenoid open. mode blinking
Diagnostic Attachment 1 PULL solenoid short. mode blinking
Diagnostic mode Attachment 1 PULL solenoid open. blinking
Lamp
Attachment 2 function stops working.
Load handling stop.
Attachment 1 function stops working.
Phenomenon on vehicle
Remarks
5-20
Memory
H8-5
H8-6
HB-1
HB-2
HB-3
G5-1
G5-2
G5-3
G5-4
G5-5
G5-6
Indication
H8-5
H8-6
HB-1
HB-2
HB-3
G5-1
G5-2
G5-3
G5-4
G5-5
G5-6
Error mode
Diagnostic Shock sensor 2 neutral voltage error. mode blinking
Diagnostic mode Shock sensor 2 short. blinking
Diagnostic Shock sensor 2 open. mode blinking
Diagnostic Shock sensor 1 neutral voltage error. mode blinking
Diagnostic mode Shock sensor 1 short. blinking
Diagnostic Shock sensor 1 open. mode blinking
Diagnostic Proportional solenoid power supply circuit (RY1) over current. mode blinking
Diagnostic mode Proportional solenoid power supply circuit short. blinking
Diagnostic Proportional solenoid power supply circuit (RY1) open. mode blinking
Diagnostic Attachment 2 (PULL/PUSH) solenoid abnormality (Open/ Short). mode blinking
Diagnostic Attachment 2 (PULL/PUSH) solenoid power circuit abnormality. mode blinking
Lamp
Shock sensor disabled.
Load handling stop.
Phenomenon on vehicle
Remarks
5-21
5-22
WHEN ERROR CODE IS DISPLAYED z Error Code A0-1 (Drive motor drive power-circuit overheating abnormality) Related portion
1·2 ton series (Model without 50-)
Main controller
CN104-8(98,FNDC1)
CN113-2
CN104-3 (1, CBAT+)
CN113-1
Cooling fan 1
Drive motor drive circuit Temperature-sensor 3 ton series
Main controller
CN104-8(98,FNDC1)
CN128-2
CN104-3 (1, CBAT+)
CN128-5
CN101-18 (99, VFAN)
CN128-9
1·2 ton series (Model with 50-)
CN128-10 Cooling fan power
CN128-3
CN113-2 CN113-1
Drive motor drive circuit Temperature-sensor
Cooling fan 1
Drive motor drive circuit Temperature-sensor
Probable cause: (1) The power cable and motor cable tightening is defective. (2) Connector contact defect (3) Harness defect (4) Cooling fan clogging
(5) Cooling fan defect (6) Overheating(continuous overload operation) (7) Drive motor drive circuit defect (8) Main controller defect
Disconnect the battery plug, and confirm whether there is looseness in the conclusion part of the power cable motor cable. Do not leave the vehicle standing in a hot place.
5-23 Error code A0-1
*If AB-1, AB-2 is also displayed, perform troubleshooting with priority given to AB-1. Forcibly turn on the cooling fans, using Active Test in the Analyzer menu, and check the rotation of the cooling fan 1 . Model without 50- and the fans do not rotate.
STD: [ANL] 7 ACT 7-04 (FAN) Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN FAN OFF → ON
1
Model with 50-, or model without 50- and the fans rotate. Inspection: Temperature check Turn on the key switch and check the value of TDMDH using the Analyzer menu. STD: [ANL] 2 IO1 2-02 (TDMDH) Multifunction/ DX: [ANL] I/O TEMP/VOLT 1/5 Record the value of TDMDH. Turn off the key switch and leave the vehicle standing for a while (about 15 minutes). The TDMDH temperature is 74°C or more and it has lowered by 5°C or more compared to the TDMDH temperature previously checked. Inspection: Temperature check Turn on the key switch and check the value of TDMDH using the Analyzer menu. STD: [ANL] 2 IO1 2-02 (TDMDH) Multifunction/ DX: [ANL] I/O TEMP/VOLT 1/5 The TDMDH temperature is less than74°C
The TDMDH temperature is 74°C or more and it has not lowered by 5°C or more compared to the TDMDH temperature previously checked. Drive motor drive circuit defect
Check the following and take necessary action, and use the device as it is. * Whether exhaust vent is blocked by paper etc. * Whether operation was performed under overload conditions
5-24 Jp
1 With the battery plug and the CN113 connector disconnected, visually check inside the connector and the caulked portion of its wire for defects. (refer to Before Troubleshooting) 1. Connect the CN113 connector and the battery plug. 2. Turn on the key switch and forcibly turn on the cooling fans. And check the rotation of the cooling fan 1 , using Active Test in the Analyzer menu .
The cooling fan 1 rotates.
Connector contact defect
OK Inspection 1: Fan power supply check (3 ton series only) 1. Turn off the key switch, and disconnect the battery plug. 2. Disconnect the CN128 connector and measure the resistance of the power supply of the cooling fan.
NG
Power supply of the cooling fan defect
OK Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN101, CN104, CN113, CN114 and CN128 connectors, check the harnesses for their continuities (CN101 and CN128 connectors are only for 3 ton series ).
Harness defect
OK. Inspection: Cooling fan 1 check. 1. Disconnect the battery plug and disconnect the CN101, CN104, CN113 and CN128 connectors (CN101 and CN128 connectors are only for 3 ton series ). Connect the battery plug and turn on the key switch. 2. Forcibly turn on the cooling fans, using Active Test in the Analyzer menu, and check the rotation of the cooling fan 1 . STD: [ANL] 7 ACT 7-04 (FAN) Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN The fan does not rotate. The cooling fan 1 defect.
The fan rotates. Connector contact defect
* If the fan does not rotate using the Active Test in the Analyzer menu after replacing the fan, there might be other defects, so replace the main controller.
Inspection 1: Fan power supply check (3 ton series only) Disconnect the battery plug and the CN128 connector, and measure the resistance of the power supply of the cooling fan. Portions to be checked
Standard
CN128-2 to CN128-5
approx. 4.7kΩ
CN128-5 to CN128-9
approx. 4.7kΩ
CN128-5 to CN128-3
0Ω
CN128-3 to CN128-10
approx. 4.7kΩ
5-25
Inspection 2: Harness check Check each harness for its continuity. Disconnect the battery plug and the CN101, CN104, CN113 and CN114 connectors, and visually check inside the connector and the caulked portion of its wire for defects. Perform the check with the SST disconnected. (Refer to BEFORE TROUBLESHOOTING.) Note:Perform this check with SST disconnected. 1·2 ton series Portions to be checked
Standard
CN104-3 to CN113-1
Continuity
CN104-8 to CN113-2
Continuity
CN104-3 to CN104-8
No continuity
3 ton series Portions to be checked
Standard
CN101-18 to CN128-9
Continuity
CN104-3 to CN128-5
Continuity
CN104-8 to CN128-2
Continuity
CN101-18 to CN104-3
No continuity
CN101-18 to CN104-8
No continuity
CN104-3 to CN104-8
No continuity
CN128-3 to CN113-1
Continuity
CN128-10 to CN113-2
Continuity
CN113-1 to CN113-2
No continuity
5-26
z Error Code A0-2 (Pump motor drive power-circuit overheating abnormality) Related portion
Pump motor drive circuit Temperature-sensor
Probable cause: (1) The power cable and motor cable tightening is defective. (2) Overheating (continuous overload operation) (3) Pump motor drive circuit defect Disconnect the battery plug, and confirm whether there is looseness in the conclusion part of the power cable motor cable. Do not leave the vehicle standing in a hot place. Error code A0-2 Inspection: Temperature check Turn on the key switch and check the value of TPMDH using the Analyzer menu. STD: [ANL] 2 IO1 2-06 (TPMDH) Multifunction/ DX: [ANL] I/O TEMP/VOLT 2/5 (TPMDH) Record the value of TPMDH. Turn off the key switch and leave the vehicle standing for a while (about 15 minutes). The TPMDH temperature is 74°C or more it has lowered by 5°C or more compared to the TPMDH temperature previously checked. Inspection: Temperature check Turn on the key switch and check the value of TPMDH using the Analyzer menu. STD: [ANL] 2 IO1 2-06 (TPMDH) Multifunction/ DX [ANL] I/O TEMP/VOLT 2/5 (TPMDH) The TPMDH temperature is less than 74°C
The TPMDH temperature is 74°C or more and it has not lowered by 5°C or more compared to the TPMDH temperature previously checked. Pump motor drive circuit defect
Check the following and take necessary action, and use the device as it is. * Whether operation was performed under overload conditions
5-27
z Error Code A1-1 (Main controller high voltage) Related portion
F7
CN102-3 (19, VBMBSL)
P3
Main controller CN102-4 (19, VBMBSL)
Probable cause: (1) Battery defect (2) MB contactor defect (3) F7 fuse open (After the key switch is turned on and off, A9-2 will be displayed.)
(4) Battery plug defect (5) Battery overvoltage (6) The battery plug was disconnected during traveling. (7) Out of the battery electrolyte.
Error code A1-1
* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
Turn off and back on the key switch. A1-1 error does not occurs
A1-1 error occurs.
Inspection: Check of VBMBSL voltage Check the VBMBSL voltage, using the Analyzer menu. STD: [ANL] 2 IO1 2-12 (VBMBSL) Multifunction/ DX: [ANL] I/O TEMP/VOLT 4/5 VBMBSL: [48V] Less than 65 V [80V] Less than 110 V
VBMBSL: [48V] 65V or more [80V] 110V or more
Inspection: Check of battery voltage 1. Turn off the key switch and disconnect the battery plug. 2. Measure the voltage between both ends of the battery plug with a circuit tester. Inspection: Check of F7 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F7 fuse and measure the resistance between its both ends with a circuit tester.
[48V] Approx. 48 V [80V] Approx. 80 V Main controller defect NG (∞ Ω)
[48V] 65 V or more [80V] 110 V or more Replace the battery.
F7 fuse open
OK (0 Ω) Was the battery plug disconnected during traveling? NO Check the battery plug. Check the battery electrolyte.
YES
Do not disconnect the battery plug during traveling except in case of an emergency.
5-28
z Error Code A1-2 (Drive motor drive circuit high voltage) Related portion
MB P1
F1
P4 Drive motor drive circuit
Probable cause: (1) Battery defect (2) MB contactor defect (3) F1 fuse open
(4) Battery plug defect (5) Drive motor drive circuit defect
If CB-1 is also displayed, perform troubleshooting with priority given to CB-1. If CB-3 is also displayed, perform troubleshooting with priority given to CB-3. If A1-1 is also displayed, perform troubleshooting with priority given to A1-1. Error code A1-2 Turn the key switch from OFF to ON to check for A1-2 errors. error A1-2 error does not occurs occur
Inspection: Check of voltage of drive motor drive circuit Check the value of VDMD, using the Analyzer menu. STD: [ANL] 2 IO1 2-14 (VDMD) Multifunction/ DX: [ANL] I/O TEMP/VOLT 5/5 (VDMD) VDMD: [48V] Less than 65 V [80V] Less than 108 V
VDMD: [48V] 65 V or more [80V] 108 V or more
Inspection 1: Check the battery voltage 1. Turn off the key switch and disconnect the battery plug. 2. Measure the voltage between both ends of the battery plug with a circuit tester. Inspection 2: Check of F1 fuse [48V] Less than 65 V 1. Turn off the key switch and disconnect the [80V] Less than 108V battery plug. Drive motor drive circuit defect NG 2. Remove the F1 fuse and measure the resistance between its both ends with a circuit (∞ Ω) F1 fuse open tester.
[48V] 65 V or more [80V] 108V or more Battery defect
OK (0 Ω) Was the battery plug disconnected during traveling? NO * Check the battery plug. * Check the battery electrolyte.
YES
Do not disconnect the battery plug during traveling except in case of an emergency.
5-29
z Error Code A1-4 (Pump motor drive circuit high voltage) Related portion
MB P1
F1
P4 Pump motor drive circuit
Probable cause: (1) Battery defect (2) MB contactor defect (3) F1 fuse open
(4) Battery plug defect (5) Pump motor drive circuit defect
If CB-1 is also displayed, perform troubleshooting with priority given to CB-1. If CB-3 is also displayed, perform troubleshooting with priority given to CB-3. If A1-1 is also displayed, perform troubleshooting with priority given to A1-1. Error code A1-4 Turn the key switch from OFF to ON to check for A1-4 errors. error A1-4 error does not occurs occur
Inspection: Check of voltage of pump motor drive circuit Check the value of VPMD, using the Analyzer menu. STD: [ANL] 2 IO1 2-15 (VPMD) Multifunction/DX: [ANL] I/O TEMP/VOLT 5/5 (VPMD) VPMD: [48V] Less than 65 V [80V] Less than 108 V
VPMD: [48V] 65 V or more [80V] 108V or more
Inspection 1: (Check the battery voltage.) 1. Turn off the key switch and disconnect the battery plug. 2. Measure the voltage between both ends of the battery plug with a circuit tester. Inspection 2: (Check of F1 fuse) [48V] Less than 65 V 1. Turn off the key switch and disconnect the [80V] Less than 108V battery plug. Pump motor drive circuit defect 2. Remove the F1 fuse and measure the NG resistance between its both ends with a circuit (∞ Ω) F1 fuse open tester.
[48V] 65 V or more [80V] 108V or more Battery defect
OK (0 Ω) Was the battery plug disconnected during traveling? NO * Check the battery plug. * Check the battery electrolyte.
YES
Do not disconnect the battery plug during traveling except in case of an emergency.
5-30
z Error Code A2-1 (Main controller overheating abnormality) Related portion
Main controller Temperature sensor
TH101
Probable cause: (1) The ambient temperature around the Main controller is high.(3) Temperature sensor defect (Main controller (2) Overheating (continuous overload operation) defect) Do not leave the vehicle standing in a hot place. Error code A2-1 Inspection: Temperature check Turn on the key switch and check the value of TMCB using the Analyzer menu. STD: [ANL] 2 IO1 2-04 (TMCB) Multifunction/ DX: [ANL] I/O TEMP/VOLT 2/5 (TMCB) Record the value of TMCB. Turn off the key switch and leave the vehicle standing for a while (about 30 minutes). The TMCB temperature is 79°C or more and it has lowered by 5°C or more compared to the TMCB temperature previously checked. Inspection: Temperature check Turn on the key switch and check the value of TMCB using the Analyzer menu. STD: [ANL] 2 IO1 2-04 (TMCB) Multifunction/ DX: [ANL] I/O TEMP/VOLT 2/5 (TMCB) The TMCB temperature is less than 79°C
The TMCB temperature is 79°C or more and it has not lowered by 5°C or more compared to the TMCB temperature previously checked. Main controller defect
Check the following and take necessary action, and use the device as it is. (The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
5-31
z Error Code A3-1 (Battery connection incorrect ) Related portion 48 V F5
P1
CN104-1(41, B48V) Main controller
Battery
N1
80V F6
P1
CN104-1(18, B80V) Main controller
Battery
N1
Probable cause: (1) Charger contact defect. (2) Set voltage defect. (3) The voltage in the B48V line after the F5 fuse is above the set voltage.(48V) The voltage in the B80V line after the F6 fuse is above the set voltage.(80V) (4) Main controller defect. Error code A3-1 Turn off the key switch and disconnect the battery plug. A3-1 error does not occur. Then, connect the battery plug correctly, turn back on the key switch to check for errors.
Plug contact defect or incorrect connection of battery
A3-1 error occurs. Inspection: Check of battery voltage STD: [ANL] 2 IO1 2-10 Multifunction/ DX: [ANL] I/O TEMP/VOLT 4/5
[48V] B48: Less than 65V [80V] B80: Less than 110V
Main controller defect
[48V] 65V or more [80V] 110 V or more [48V] Less than 65 V [80V] Less than 110 V
Check of battery voltage P1[+]←→N1[-] [48V] 65V or more [80V] 110 V or more
Check the battery, and replace it with a regular battery if necessary.
Main controller defect
5-32
z Error Code A3-2 (Battery connection incorrect ) Related portion 48 V F5
P1
CN104-1(41, B48V)
CN101-4(41, VBBT)
Main controller
Battery
N1
80V F6
P1
P0
F5
CN104-1(18, B80V)
CN101-4(41, VBBT)
Main controller
Battery N1
Probable cause: (1) Main controller incorrectly installed. (2) Main controller defect. Error code A3-2 Turn off the key switch and disconnect the battery plug. Wrong part number. Then, check if the part number of the main controller is correct. Correct part number or The controller has not been replaced. Main controller defect
Wrong main controller installed.
5-33
z Error Code A5-1 (Seat switch GND short abnormality) Related portion
CN103-6 (51, LS-)
CN44-1
Main controller
Seat switch CN104-18 (67, SDM)
CN44-2
Probable cause: (1) Connector contact defect (2) Seat switch defect
(3) Harness defect (4) Main controller defect
Error code A5-1 1. Disconnect the battery plug, disconnect the CN44 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN44 connector, connect the battery plug, and then turn on the key switch without sitting in the seat.
Inspection: Check of seat switch condition Check the value of SDM, using the Analyzer menu.
SDM: 0
Connector contact defect
STD: 3 IO2 3-07 (SDM) Multifunction/ DX: [ANL] I/O TRAVELING 2/5 (SDM) SDM: 1 Inspection: Check of seat switch condition 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN44 connector, connect the battery plug, and turn on the key switch. 3. Check the value of SDM, using the Analyzer menu.
SDM: 0
Seat switch defect
STD: 3 IO2 3-07 (SDM) Multifunction/ DX: [ANL] I/O TRAVELING 2/5 (SDM) SDM: 1 Inspection 1:Harness check 1. Turn off the key switch and disconnect the battery NG plug. 2. Disconnect the CN103, CN104 and CN44 connectors and check the harnesses for their continuities. OK Main controller defect
Harness defect
5-34 Inspection 1: Check each harness for its continuity. Before this check, turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and CN92 connectors, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
CN103-6 to CN44-1
Continuity
CN104-18 to CN44-2
Continuity
CN44-1 to CN44-2
No continuity
5-35
z Error Code A8-1, -2 (F1 and F6 fuse abnormality (Open)) Related portion 48 V MB
F1
P4
P3 CN104-2 (44, VBMB)
Battery F6
CN136-5 Main controller
N1
Drive motor drive circuit Pump motor drive circuit
80V MB
F1
P4
P2 CN104-1 (18,B80V)
Battery F6
CN136-5 Main controller
N1 Drive motor drive circuit Pump motor drive circuit
Probable cause: (1) Cable or connector contact defect (2) Improper installation of F1 or F6 fuse (3) F1 or F6 fuse open (4) F6 fuse holder defect (48V only) (5) Harness or cable defect (6) Main controller defect
5-36 Error code A8-1
* If CB-1, CB-3, CB-5, A8-2 or A9-2 occurs, perform troubleshooting with priority given to CB-1, CB-3, CB-5, A8-2 or A9-2. 1. Turn off the key switch and disconnect the battery plug. Visually check the following terminals for loose bolts: drive motor drive circuit positive terminal, pump motor drive circuit positive terminal, contactor panel P4 terminal, drive motor drive circuit negative terminal, pump motor drive circuit negative terminal A8-1 error does not and N1 terminal. occur. Caution: Before starting the job, measure the voltage between positive terminal and GND; if there is any voltage, insert a resistor at approx. 100Ω between + and GND to discharge the capacitor. 2. Connect the battery plug and turn on the key switch to check for errors.
Improper fastening of terminals
A8-1 error occurs.
Inspection: Check of supply voltages to drive motor drive circuit and pump motor drive circuit. 1. Measure the voltage between the positive and negative terminals of each drive circuit.
[48V] All motor drive circuits Approx. 48 V [80V] All motor drive circuits Approx. 80 V
Drive motor drive circuit defect Pump motor drive circuit defect
0V Inspection: Check of installation of F1 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Visually check if the F1 fuse is installed properly. 3. Connect the power cable, connect the battery plug, and then turn on the key switch.
A8-1 error does not occur.
F1 fuse installation defect
A8-1 error occurs. Inspection: Check of F1 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F1 fuse and measure the resistance between its both ends with a circuit tester.
NG (∞ Ω)
F1 fuse open or Motor drive circuit defect (*) or Cable between P4-N1 short
OK (0 Ω) Motor drive circuit defect (*) or Cable between P4-motor drive circuit positive terminal breakage Cable between N1-motor drive circuit negative terminal breakage
Motor drive circuit defect (*) Turn off the key switch and disconnect the battery plug, remove the copper bar for connection to the motor drive circuit positive terminal. Measure the resistance between the positive and negative terminals of the motor drive circuit. When using an analog tester: Positive terminal: [-] probe Negative terminal: [+] probe
} Motor drivers are defective if their resistance measured is 10
Ω or less.
5-37 Error code A8-2
* If CB-1, CB-3 or CB-5 occurs, Perform troubleshooting with priority given to CB-1, CB-3 or CB-5. 1. Before this check, disconnect the battery plug, disconnect the CN136 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN136 connector, connect the battery plug, and then turn on the key switch to check for errors.
A8-2 error does not occur.
Connector contact defect
A8-2 error occurs. Inspection: Check of installation of F6 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Visually check if the F6 fuse is installed properly. 3. Connect the F6 fuse and turn on the key switch to check for errors.
A8-2 error does not occur.
F6 fuse installation defect
A8-2 error occurs. Inspection: Check of VBMBSL voltage (48V only) 1. Check the value of VBMBSL, using the Analyzer menu. STD: [ANL] 2 IO 2-12 (VBMBSL) Multifunction/ DX: [ANL] I/O TEMP/ VOLT 4/5 (VBMBSL))
VBMBSL: Less than 25 V
Identify the causes of CB1 to CB5.
VBMBSL: More than 25 V Inspection: Check of F6 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F6 fuse and measure the resistance between its both ends with a circuit tester.
NG (∞ Ω)
F6 fuse open
OK (0 Ω) Inspection: Check of F6 fuse holder (48V only) 1. Connect the F6 fuse, disconnect the connector of the NG (∞ Ω) F6 fuse holder. 2. Measure the resistance of the connector of the F6 fuse holder between its both ends with a circuit tester.
F6 fuse holder defect
OK (0 Ω) Inspection 1: Harness check 1. (48V) Connect the connector of the F6 fuse holder. (80V) Install the F6 fuse. 2. Disconnect the CN104, CN136 connector. OK Main controller defect
NG
Harness defect
5-38 Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN136, CN104 connectors, P2 terminal (80V) or P3 teminal (48V) disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked CN104-2 to CN136-5 48V
80V
Standard Continuity
CN136-5 (fuse side) to P3 terminal
Continuity
CN104-2 to N1
No continuity
CN136-5 (fuse side) to N1
No continuity
CN104-1 to CN136-5
Continuity
CN136-5 (fuse side) to P2 terminal
Continuity
CN104-1 to N1
No continuity
CN136-5 (fuse side) to N1
No continuity
5-39
z Error Code A9-2 (F7 fuse abnormality (Open)) Related portion 48 V
CN102-3 (19, VBMBSL)
CN136-6
F7
P3
F7
P3
Main controller CN102-4 (19, VBMBSL)
80V
CN102-3 (19, VBMBSL) Main controller
CN136-6
CN102-4 (19, VBMBSL) CN104-2 (19, VBMB)
Probable cause: (1) Connector contact defect (2) MB contactor defect (3) F7 fuse installation defect (4) F7 fuse open
(5) F7 fuse holder defect (48V only) (6) Harness defect (7) Main controller defect
5-40 Error code A9-2
* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5. 1. Before this check, disconnect the battery plug, disconnect the CN136 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN136 connector, connect the battery plug, and then turn on the key switch to check for errors.
A9-2 error does not occur.
Connector contact defect
A9-2 error occurs. Inspection: Check of installation of F7 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Visually check if the F7 fuse is installed properly. 3. Connect the F7 fuse and turn on the key switch to check for errors.
A9-2 error does not occur.
F7 fuse installation defect
A9-2 error occurs. Inspection: Check of VBMB voltage (48V only) Check the value of VBMB, using the Analyzer menu. STD: [ANL] 2 IO1 2-13 (VBMB) Multifunction/ DX: [ANL] I/O TEMP/VOLT 4/5 (VBMB)) (48V only) VBMB: 25 V or more A
(48V only) VBMB: Less than 25 V
Identify the causes of CB1 to CB5.
5-41 A
Inspection: Check of VDMD and VPMD voltage (80V only) STD: [ANL] 2 IO1 2-14 (VDMD) Multifunction/ DX: [ANL] I/O TEMP/ VOLT 5/5 (VDMD))
(80V only) Both less than 25 V
Identify the causes of CB1 to CB5.
STD: [ANL] 2IO 2-15 (VPMD) Multifunction/ DX: [ANL] I/O TEMP/ VOLT 5/5 (VPMD)) (80V only) Either one is 25 V or more Inspection: Check of F7 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F7 fuse and measure the resistance between its both ends with a circuit tester.
NG (∞ Ω)
F7 fuse defect
OK (0 Ω) Inspection: Check of F7 fuse holder (48V only) 1. Connect the F7 fuse and disconnect the connector of NG (∞ Ω) the F7 fuse holder. 2. Measure the resistance between its both ends of the connector of the F7 fuse holder with a circuit tester.
F7 fuse holder defect
OK (0 Ω) Inspection 1: Harness check 1. (48V) Connect the connector of the F7 fuse holder. (80V) Install the F7 fuse. 2. Disconnect the CN102, CN136 and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN102, CN136 connectors and P3 terminal disconnected. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Note:Tighten the P3 terminal surely. Portions to be checked
Standard
CN136-6 to CN102-3
Continuity
CN136-6 to CN 102-4
Continuity
CN136-6 to CN 104-2 (80V only)
Continuity
CN136-6 to P3 terminal
Continuity
CN102-3 to N1
No continuity
CN102-4 to N1
No continuity
CN104-2 to N1 (80V only)
No continuity
CN136-6 to N1
No continuity
5-42
z Error Code AA-1 (Main controller temperature sensor abnormality) Related portion
Main controller
Temperature sensor
TH101
Probable cause: Main controller defect Error code AA-1
* If AA-1 is displayed, the Main controller is defective, so replace it.
5-43
z Error Code AB-1 (Cooling fan drive circuit abnormality) Related portion 1·2 ton series CN113-2
CN104-8(98,FNDC1)
Cooling fan 1 Main controller
CN113-1
CN104-3 (1,CBAT+)
CN114-2
Cooling fan 2
CN114-1
3 ton series CN104-8(98,FNDC1)
CN128-2 CN128-10
Main controller
CN104-3 (1,CBAT+)
CN101-18 (99, VFAN)
CN128-5
CN128-9
Fan power supply
CN128-3 CN128-8 CN128-4
CN113-2 CN113-1
Cooling fan 1
CN114-2 CN114-1
Probable cause: (1) Connector contact defect (2) Cooling fan defect (3) Harness defect (4) Fan power supply defect (3 ton series only) (5) Main controller defect
Cooling fan 2
5-44 Error code AB-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN113 and CN114 connectors, and visually check inside the connector and the caulked portion of its wire for defects. AB-1 error does not (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN113 and CN114 connectors, connect occur. the battery plug, turn on the key switch, forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if the cooling fans rotate. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN
Connector contact defect
AB-1 error occurs. Inspection: Check of cooling fan drive circuit 1. Turn off the key switch and disconnect the battery plug, disconnect the CN113 and CN114 connectors, and then connect the battery plug and turn on the key AB-1 error occurs. switch. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if any error occurs. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN
A
AB-1 error does not occur. Inspection 1: Check of cooling fan 1 1. Turn off the key switch and disconnect the battery plug, connect the CN113 connector, disconnect the CN114 connector, and then connect the battery plug and turn on the key switch. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if any error occurs. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN Cooling fan 1 rotates. Inspection 2: Check of cooling fan 2 1. Turn off the key switch and disconnect the battery plug, connect the CN114 connector, disconnect the CN113 connector, and then connect the battery plug and turn on the key switch. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if cooling fan 2 rotates. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN Inspection 1: AB-1 error occurs. Inspection 2: AB-1 error does not occur. Cooling fan 1 defect
Inspection 1: AB-1 error does not occur. Inspection 2: AB-1 error occurs. Cooling fan 2 defect
AB-1 error occurs for both inspection 1 and 2 AB-1 error does not occur for both inspection 1 and 2
Cooling fan 1 defect Cooling fan 2 defect
5-45 A
Inspection: Check of fan power supply (3 ton only) 1. Turn off the key switch and disconnect the battery plug, disconnect the CN128 connector, and then connect the battery plug and turn on the key switch. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if any error occurs. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN
AB-1 error does not occur.
Fan power supply defect
AB-1 error occurs. Inspection 3: Harness check 1. Turn off the key switch and disconnect the battery NG plug. 2. Disconnect the CN101, CN104, CN113, CN114 and CN128 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Inspection 3:Check each harness for its continuity. Perform this check with the battery plug and the CN101, CN104, CN113, CN114 and CN128 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 1·2 ton series Portions to be checked
Standard
CN104-3 to CN113-1
Continuity
CN104-3 to CN114-1
Continuity
CN104-8 to CN113-2
Continuity
CN104-8 to CN114-2
Continuity
CN104-3 to CN104-8
No continuity
3 ton series Portions to be checked
Standard
CN101-18 to CN128-9
Continuity
CN104-3 to CN128-5
Continuity
CN104-8 to CN128-2
Continuity
CN101-18 to CN104-3
No continuity
CN101-18 to CN104-8
No continuity
CN104-3 to CN104-8
No continuity
CN128-3 to CN113-1
Continuity
CN128-4 to CN114-1
Continuity
CN128-10 to CN113-2
Continuity
CN128-8 to CN114-2
Continuity
CN113-1 to CN113-2
No continuity
CN114-1 to CN114-2
No continuity
5-46
z Error Code AB-2 (Cooling fan abnormality) Related portion 3 ton series
Main controller
CN104-8(98,FNDC1)
CN128-2
CN104-3 (1,CBAT+)
CN128-5
CN101-18 (99, VFAN)
CN128-9
CN104-4 (N2, N2) CN104-5 (N2, N2)
CN128-10 Fan power supply
CN128-3 CN128-8 CN128-4
CN104-6 (N2, N2) CN103-5 (N2, N2)
CN113-2 CN113-1
Cooling fan 1
CN114-2 CN114-1
Probable cause: (1) Connector contact defect (2) Fan power supply defect (3) Harness defect (4) Main controller defect
Cooling fan 2
5-47 Error code AB-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN113 and CN114 connectors, and visually check inside the connector and the caulked portion of its wire for defects. AB-2 error does not (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN113 and CN114 connectors, connect occur. the battery plug, turn on the key switch, forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check if the cooling fans rotate. STD: 7 ACT 7-04 FAN Multifunction/ DX: [ANL]ACTIVE TEST 2/2 FAN
Connector contact defect
AB-2 error occurs. Inspection: Check of fan power supply 1. Turn off the key switch and disconnect the battery plug 2. Disconnect the CN128 connector, and measure the resistance of the fan power supply. (CN128-2 to CN128-5, CN128-5 to CN128-9) Standard: approx. 4.7 KΩ
NG
Power supply defect
OK Inspection 1: Harness check (Between main controller and power supply) 1. Turn off the key switch and disconnect the battery NG plug. 2. Disconnect the CN101, CN104, CN113, CN114 and CN128 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN101, CN104, CN113, CN114 and CN128 connectors disconnected. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING. Portions to be checked
Standard
CN101-18 to CN128-9
Continuity
CN104-3 to CN128-5
Continuity
CN104-8 to CN128-2
Continuity
CN101-18 to CN104-4
No continuity
CN128-2 to CN104-4
No continuity
CN128-8 to 104-4
No continuity
CN128-10 to CN104-4
No continuity
CN128-9 to CN104-4
No continuity
CN128-5 to CN104-4
No continuity
CN128-3 to CN104-4
No continuity
CN128-4 to CN104-4
No continuity
5-48
z Error Code AC-1 (Semiconductor switch abnormality) Related portion 48 V MB P2
F1
P3
P4
+ CN110-8
CN142-1 RCP
+
CN142-2
CN111-8
Drive motor drive circuit Pump motor drive circuit
CN143-2 Pre-charge unit
CN143-5
CN103-4 (42,KYSAT) CN143-1
Main controller
CN104-1 (41, B48V)
F5
CN101-4 (41, VBBT)
80V MB P2
F1
P3
P4
+ CN110-8
CN142-1 RCP
+
CN142-2
CN111-8
Drive motor drive circuit Pump motor drive circuit
CN143-2 CN143-5
F6
Probable cause: (1) Drive motor drive circuit harness defect (2) Pump motor drive circuit harness defect (3) Drive motor drive circuit defect (4) Pump motor drive circuit defect (5) Main controller defect (6) Pre-charge unit defect
Pre-charge unit
CN103-4 (42,KYSAT) CN143-1 CN104-1 (18, B80V)
Main controller
5-49 Error code AC-1 Inspection1: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN103, CN104, CN110, CN111 connectors and positive terminals of the drive motor drive circuit and the pump motor drive circuit. Check the harnesses for their continuities.
A
OK Remove the F1 fuse.
Inspection: Check of Main controller Disconnect the CN143 connector, connect the CN103 and CN104 connectors, connect the battery plug, and then turn on the key switch to check for errors.
AC-1 error occurs.
Main controller defect
AC-1 error does not occur. Inspection: Check of pump motor drive circuit 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN143 and CN111 connectors, connect the battery plug, and then turn on the key switch to check for errors.
Inspection: Check of drive motor drive circuit 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect CN111, connect CN110, connect the battery plug, and then turn on the key switch to check for errors.
Defect in sections where AC-1 error occurs during drive motor drive circuit check and pump motor drive circuit check. A Inspection2: Harness check 1. Disconnect the CN142 and CN143 connectors and check the harnesses for their continuities. OK RCP defect Pre-charge unit defect
NG
Harness defect
5-50 Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN103, CN104, CN111, CN110 connectors and the positive terminals of the drive motor drive circuit and the pump motor drive circuit disconnected, visually check inside each connector and the caulked portion of each wire for defects. Then, check the continuities between the CN103 connector and the positive terminal of the motor drive circuit. Also, check the continuities between the harnesses and N1. (Refer to BEFORE TROUBLESHOOTING.) Note:Tighten the positive terminals of the motor drive circuit surely. Portions to be checked
Standard
CN103-4 [+] to positive terminals of the motor drive circuit [-]
∞Ω
CN103-4 [-] to positive terminals of the motor drive circuit [+]
approx. 70 Ω (in range of 10 Ω)
CN103-4[-] to N1[+]
∞Ω
N1 [+] to positive terminals of the motor drive circuit [-]
∞Ω
※ [+], [-]: In case of analogue tester
Inspection 2: Check each harness for its continuity. Perform this check with the battery plug and the CN103, CN104, CN111, CN110, CN142 and CN143 connectors and the positive terminals of the drive motor drive circuit and the pump motor drive circuit disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
CN143-1 to CN143-5
∞Ω
CN143-1 to CN143-2
∞Ω
CN143-1 to CN142-2
∞Ω
CN142-1 to N1
∞Ω
CN142-2 to N1
∞Ω
CN143-1 to N1
∞Ω
CN143-2 to N1
∞Ω
5-51
z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication abnormality) Related portion
CN143-1 CN103-4 (42, KYSAT) CN103-11 (145, CAN1H)
CN143-2
Pre-charge unit
CN103-12 (146, CAN1L) Main controller
CN103-3 (14, DGND)
CN110-8 CN110-17 CN110-10 CN110-2
CN103-5 (N2,N2)
Drive motor drive circuit
CN104-4 (N2,N2) CN104-5 (N2,N2) CN104-6 (N2,N2)
CN111-8 CN111-17 CN111-10 CN111-2
CN111-12 CN111-11
Probable cause: (1) Wrong motor driver type (2) Connector contact defect (3) Harness defect (4) Motor drive circuit defect (5) Pre-charge unit defect * If AC-1 occurs, perform troubleshooting with priority given to AC-1.
Pump motor drive circuit
5-52 Error code AD-1, -2, -5, -6 Disconnect the battery plug and check if the part number of the motor driver is correct. Especially if the motor drive circuit has just been replaced, check that a different model motor driver hasn’t been installed.
Wrong part number
Wrong motor driver type
Correct part number 1. Turn off the key switch and disconnect the battery plug and visually check inside the CN110 and CN111 connectors and the caulked portions of their wires for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect all connectors and the battery plug, and then turn on the key switch to check for errors. Especially if a motor drive circuit has just been replaced before the error occurred, check if the connector is connected correctly.
AD-1, AD-2, AD-5, AD-6 None of the error codes above are displayed.
Connector contact defect
Either AD-2 or AD-6 is displayed. (*1: Record the error code that has been displayed.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN103, CN104, CN110, CN111 and CN143 connectors and check the harnesses for their continuities.
Harness defect
OK Inspection 2: Pre-charge unit check 1. Make sure that the battery plug is disconnected. 2. Check the continuities between the CN143-1 and CN143-2 of the pre-charge unit.
No contituities
Pre-charge unit defect
Continuities Inspection: Battery voltage check 1. Turn off the key switch, and then connect the CN103, CN104 and CN143 connectors. At the same time, Less than 15 V leave the CN110 and CN111 connectors disconnected. 2. Turn on the key switch and measure the voltage between CN110-8 and N2. 15 V or more Motor drive circuit defect Error that was recorded in *1 AD-2: Drive motor drive circuit defect AD-6: Pump motor drive circuit defect
Main controller defect
5-53 Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN103, CN104, CN110, CN111 and CN143 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
Point
CN103-4 to CN143-1
Continuity
AD-1, 2, 5, 6
CN143-2 to CN110-8
Continuity
AD-1, 2
CN103-11 to CN110-17
Continuity
AD-1, 2
CN103-12 to CN110-10
Continuity
AD-1, 2
CN103-3 to CN110-2
Continuity
AD-1, 2
CN110-8 to CN110-17
No continuity
AD-1, 2
CN110-8 to CN110-10
No continuity
AD-1, 2
CN110-8 to CN110-2
No continuity
AD-1, 2
CN110-17 to CN110-10
No continuity
AD-1, 2
CN110-17 to CN110-2
No continuity
AD-1, 2
CN110-10 to CN110-2
No continuity
AD-1, 2
CN111-12 to CN111-11
Continuity
AD-5, 6
CN143-2 to CN111-8
Continuity
AD-5, 6
CN103-11 to CN111-17
Continuity
AD-5, 6
CN103-12 to CN111-10
Continuity
AD-5, 6
CN103-3 to CN111-2
Continuity
AD-5, 6
CN111-8 to CN111-17
No continuity
AD-5, 6
CN111-8 to CN111-10
No continuity
AD-5, 6
CN111-8 to CN111-2
No continuity
AD-1, 2
CN111-17 to CN111-10
No continuity
AD-5, 6
CN111-17 to CN111-2
No continuity
AD-1, 2
CN111-10 to CN111-2
No continuity
AD-1, 2
CN103-4 to CN103-5
No continuity
AD-2, 6
CN103-11 to CN103-5
No continuity
AD-2, 6
CN103-12 to CN103-5
No continuity
AD-2, 6
Inspection 2: Check the pre-charge unit. Perform this chech with the battery plug and the CN143 connector disconnected. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
Point
CN143-1 to CN143-2
Continuity
AD-2, 6
5-54
z Error Code AF-1, -2, -3, -4, -5, -6, -7, -8 (CPU error) Related portion
Main controller
Probable cause: Main controller defect Error code AF-1, -2, -3, -4, -5, -6, -7, -8
* If AF is displayed, the Main controller is defective, so replace it.
5-55
z Error Code C0-2 (Drive motor power-circuit short) Related portion P7
U Drive motor drive circuit
P8
V
Drive motor
P9
W
Probable cause: (1) Drive motor defect (2) Motor cable defect
(3) Drive motor drive circuit defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3. * Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. 1. Turn off the key switch and disconnect the battery plug and visually C0-2 error check the fastened or caulked portions of the motor cables for does not occur. defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the cables, connect the battery plug, and then turn on the key switch to check for errors.
Improper fastening of motor cable
C0-2 error occurs. Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the three motor cables from the drive circuit and insulate the terminals of the cables disconnected. 3. Connect the battery plug and turn on the key switch. 4. Check if the C0-2 error occurs.
C0-2 error occurs.
Drive motor drive circuit defect
C0-2 error does not occur. Inspection 1: (Check of motor cables) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the motors cables from both the motor and the motor drive circuit. 3. Check the motor cables for its continuity.
NG
Motor cable defect
OK Inspection: (Check of motor drive circuit) *1 1. Replace the drive motor drive circuit with the pump motor drive C0-2 error circuit. occurs. 2. Connect the battery plug and turn on the key switch. 3. Check the error code that is displayed. (Ignore the error codes 32-1, 32-3.) E0-2 error occurs. Drive motor drive circuit defect (Note: Drive circuit that is originally the drive motor drive circuit before replacement)
Drive motor defect
5-56 *1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the motor drive circuits. Inspection: (Motor check) 1. Turn off the key switch and disconnect the battery plug. 2. Check the Drive motor. (See page 5-5)
NG
Drive motor defect
OK Drive motor drive circuit defect
Inspection 1: Continuity check of motor cables Check the cables for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked portion of each cable for defects, and then check the P7, P8 and P9 cables. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
Both ends of P7 cable
Continuity
Both ends of P8 cable
Continuity
Both ends of P9 cable
Continuity
P7 cable and P8 cable
No continuity
P8 cable and P9 cable
No continuity
P9 cable and P7 cable
No continuity
5-57
z Error Code C1-1 (Drive motor current sensor neutral voltage error) Related portion
Drive motor drive circuit
Current sensor
Probable cause: Drive motor drive circuit defect Error code C1-1
* If C1-1 is displayed, the drive motor drive circuit is defective, so replace it.
5-58
z Error Code C1-2 (Drive motor current sensor over current) Related portion P7
U Drive motor drive circuit
P8
V
Drive motor
P9
W
Probable cause: (1) Drive motor defect (2) Motor cable defect (3) Drive motor drive circuit defect (4) Drive motor speed (rotation) sensor defect * If C8-1, 2 is also displayed, perform troubleshooting with priority given to C8-1, 2. * Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. Turn the key switch from OFF to ON, to check for errors.
C0-2 error occurs.
Proceed to identify the cause of C0-2.
C0-2 error does not occur. 1. Turn off the key switch and disconnect the battery plug and visually check the fastened or caulked portions of the motor cables for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the cables and the battery plug, turn on the key switch and check for errors while seated in the operator’s seat, direction switch in forward position and accelerator operated.
C1-2 error does not occur.
Improper fastening of motor cable
C1-2 error occurs. Inspection 1: (Check of motor cables) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the motors cables from both the motor and the motor drive circuit. 3. Check the motor cables for its continuity.
NG
Drive motor cable defect
OK Inspection: (Check motor drive circuit)*1 1. Turn off the key switch and disconnect the battery plug. C1-2 error occurs. 2. Replace the drive motor drive circuit with the pump motor drive circuit. 3. Connect the battery plug, and turn on the key switch. 4. Check the error code. (Disregard 32-1 & 32-3)
Drive motor defect
E1-2 error occurs. Drive motor drive circuit defect (Note: Drive circuit that is originally the drive motor drive circuit before replacement)
5-59 *1If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the motor drive circuits. Inspection: (Motor check) 1. Turn off the key switch and disconnect the battery plug. 2. Check the drive motor.
NG
Drive motor defect
OK Drive motor drive circuit defect
Inspection 1: Continuity check of motor cables Check the cables for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked portion of each cable for defects, and then check the P7, P8 and P9 cables. Refer to BEFORE TROUBLESHOOTING. Portions to be checked
Standard
Both ends of P7 cable
Continuity
Both ends of P8 cable
Continuity
Both ends of P9 cable
Continuity
P7 cable and P8 cable
No continuity
P8 cable and P9 cable
No continuity
P9 cable and P7 cable
No continuity
5-60
z Error Code C2-1 (Drive motor overheating abnormality) Related portion
CN110-23 (86, STDMR+) Drive motor drive circuit
CN110-22 (87, STDMR)
CN52-2 Drive motor Temperature sensor
CN52-1
Probable cause: (1) Overheating (continuous overload operation) Do not leave the vehicle standing in a hot place. Error code C2-1 Inspection: Temperature check Turn on the key switch. STD: [ANL] 2 IO1 2-01 (TDM) Multifunction/ DX: [ANL] I/O TEMP/VOLT 1/5 (TDM) Record the value of TDM. Turn off the key switch and leave the vehicle standing for a while (about 30 minutes).
Inspection: Temperature check Turn on the key switch. STD: [ANL] 2 IO1 2-01 (TDM) Multifunction/ DX: [ANL] I/O TEMP/VOLT 1/5 (TDM) TDM: less than A° C
The TDM temperature is A° C or more and it has not lowered by 5° C or more compared to the TDM temperature previously checked.
The TDM temperature is A° C or more for both the drive motor temperature sensor and it has lowered by 5° C or more compared to the TDM temperature previously checked.
Table: Temperature A (° C) Model
STD
Fisherman spec.
1ton series (with 50-)
116
-
1 ton series
116
126
2 ton series (with 50-)
116
-
2 ton series
96
121
3 ton series
106
121
Proceed to identify the cause of C2-2. Check the following and take necessary action, and use the device as it is. (The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
5-61
z Error Code C2-2 (Drive motor temperature sensor abnormality) Related portion
CN110-23 (86, STDMR+) Drive motor drive circuit
CN52-2
CN110-22 (87, STDMR)
CN52-1
Drive motor Temperature sensor
Probable cause: (1) Connector contact defect (2) Drive motor temperature sensor defect
(3) Drive motor temperature sensor harness defect (4) Drive motor drive circuit defect
Error code C2-2 1. Turn off the key switch and disconnect the battery plug and visually check inside the CN52 connector and the caulked portions of their wires for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN50 connector, connect the battery plug, and then turn on the key switch to check for errors.
C2-2 error does not occur.
Connector contact defect
C2-2 error occurs. Inspection 1: (Check of temperature sensor unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN52 connector and check the temperature sensor as a single unit.
NG
Temperature sensor defect
OK Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN110 and CN52 connectors and check the harnesses for their continuities. OK Drive motor drive circuit defect
NG
Harness defect
5-62 Inspection 1: Check of temperature sensor as a single unit Check item Temperature sensor resistance (on sensor side: CN52-2 and CN52-1) Standard value: Approx. 245 Ω to 600 kΩ Resistance value varies depending on temperature (Use the following values as a standard). Temperature
Resistance (CN52-2⇔CN52-1)
20° C
Approx. 13 kΩ
80° C
Approx. 1.75 kΩ
100° C
Approx. 1 kΩ
Inspection 2: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN110 and CN52 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Note:Perform this check with SST disconnected. Portions to be checked
Standard
CN110-23 to CN52-2
Continuity
*1
CN110-22 to CN52-1
Continuity
*1
CN52-1 to CN52-2
No continuity
*1:Connect CN52-1 and CN52-2 on the harness side through 09232-13130-71 and check if there is continuity between CN110-23 and CN110-22.
5-63
z Error Code C3-1 (Drive motor power circuit temperature sensor abnormality) Related portion
Drive motor drive circuit
Temperature sensor
TH101
Probable cause: Drive motor drive circuit defect Error code C3-1
* If C3-1 is displayed, the drive motor is defective, so replace it.
5-64
z Error Code C4-1, -2, -3, -4, -5, -6 (Accelerator sensor abnormality) Related portion
Main controller
CN101-27 (53, VRA1+)
CN26-5
CN102-30 (52, VRA1)
CN26-4
CN101-22 (50, VRA-)
CN26-6
CN101-26 (55, VRA2+)
CN26-1
CN102-32 (54, VRA2)
CN26-3
CN101-32 (51, POT-)
CN26-2
Accelerator sensor
Probable cause: (1) Connector contact defect (2) Accelerator sensor defect (3) Accelerator sensor harness defect
(4) Main controller defect (5) Accelerator fully open/fully closed matching error
Error code C4-1, -2, -3, -4, -5 1. Turn off the key switch and disconnect the battery plug, and visually check if the accelerator senor is installed correctly, and also check inside the CN26 connector and the caulked portion of its wire for C4-1, -2, -3, -4, -5 defects. (Refer to BEFORE TROUBLESHOOTING.) errors do not occur. Improper installation of acceleration sensor 2. Connect the CN26 connector, connect the battery Connector contact defect plug, turn on the key switch, and depress and release the accelerator pedal to check if an error occurs. (No error code must be displayed when the accelerator is operated.) C4-1, -2, -3, -4 or -5 error occurs. Inspection 1: Check of accelerator sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN26 connector and measure the resistance of the accelerator sensor.
NG
Accelerator sensor defect
OK Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities.
NG
OK Main controller defect * No error code must be displayed when the accelerator is operated.
Harness defect
5-65 Error code C4-6 Inspection 3: Matching Perform matching between the fully closed and fully open states of the accelerator.
After the completion of matching, C4-6 error does not occur.
Use the device as it is.
After the completion of matching, C4-6 error occurs. Main controller defect
Inspection 1: Check the accelerator sensor as a single unit. Perform this check with the battery plug and CN26 disconnected and CN101 and CN102 connected. (1)Measuring the resistance of the accelerator sensor Standard (on sensor side): CN26-5 to CN26-6 CN26-1 to CN26-2
1.8 to 3.5 kΩ (Open state)
(2)Measuring the resistance of the accelerator sensor output circuit Standard (on sensor side): CN26-4 to CN26-6 CN26-3 to CN26-2
The resistance must increase as the potentiometer is rotated.
Inspection 2: Check each harness for its continuity. Perform this check with the battery plug, CN26, CN101 and CN102 disconnected. visually check inside each connector and the caulked portion of each wire for defects. Refer to BEFORE TROUBLESHOOTING. { : Items to be checked Portions to be checked
Standard
CN101-27 to CN26-5 CN102-30 to CN26-4
C4 1
2
3
4
5
6
Continuity
{
−
−
−
{
−
*1
Continuity
{
−
−
−
−
−
*1
CN101-22 to CN26-6
Continuity
−
−
{
−
{
−
*3
CN101-26 to CN26-1
Continuity
−
{
−
−
{
−
*2
CN102-32 to CN26-3
Continuity
−
{
−
−
−
−
*2
CN101-32 to CN26-2
Continuity
−
−
−
{
{
−
*4
CN26-5 to CN26-6
No continuity
{
−
−
−
−
−
CN26-5 to CN26-2
No continuity
{
−
−
−
−
−
CN26-4 to CN26-6
No continuity
{
−
−
−
{
−
CN26-4 to CN26-2
No continuity
{
−
−
−
{
−
CN26-4 to CN26-5
No continuity
−
−
{
−
{
−
CN26-4 to CN26-1
No continuity
−
−
{
−
{
−
CN26-1 to CN26-6
No continuity
−
{
−
−
−
−
CN26-1 to CN26-2
No continuity
−
{
−
−
−
−
CN26-3 to CN26-6
No continuity
−
{
−
−
{
−
CN26-3 to CN26-2
No continuity
−
{
−
−
{
−
CN26-3 to CN26-5
No continuity
−
−
−
{
{
−
CN26-3 to CN26-1
No continuity
−
−
−
{
{
−
CN102-30 to CN102-32
No continuity
−
−
−
−
{
−
5-66 *1:Connect CN26-5 and CN26-4 on the harness side through 09232-13130-71 and check if there is continuity between CN101-27 and CN102-30. *2:Connect CN26-1 and CN26-3 on the harness side through 09232-13130-71 and check if there is continuity between CN101-26 and CN102-32. *3:Connect CN26-6 and CN26-4 on the harness side through 09232-13130-71 and check if there is continuity between CN101-22 and CN102-30. *4:Connect CN26-2 and CN26-3 on the harness side through 09232-13130-71 and check if there is continuity between CN101-32 and CN102-32. Inspection 3: Perform matching. (See section 13)
5-67
z Error Code C5-1, -2, -3, -4, -5, -6 (Brake sensor abnormality) Related portion
Main controller
CN101-34 (72, VRB1+)
CN6-1
CN102-33 (71, VRB1)
CN6-4
CN101-22 (50, VRA-)
CN6-6
CN101-33 (74, VRB2+)
CN6-5
CN102-25 (73, VRB2)
CN6-3
CN101-32 (51, POT-)
CN6-2
Brake sensor
Probable cause: (1) Connector contact defect (2) Brake sensor defect (3) Brake sensor harness defect
(4) Main controller defect (5) Brake fully closed/fully open matching error
Error code C5-1, -2, -3, -4, -5 1. Disconnect the battery plug, and visually check if the brake senor is installed correctly, and also check inside the CN6 connector and the caulked portion of its wire C5-1, -2, -3, -4, -5 for defects. (Refer to BEFORE TROUBLESHOOTING.) errors do not occur. Improper installation of brake sensor 2. Connect the CN6 connector, connect the battery plug, Connector contact defect turn on the key switch, and depress and release the brake pedal to check if an error occurs. (No error code must be displayed when the brake is operated.)* C5-1, -2, -3, -4 or -5 error One of these errors occurs. Inspection 1: Check of brake sensor 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN6 connector and measure the resistance of the brake sensor.
Brake sensor defect
OK Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities. OK Main controller defect * No error code must be displayed when the brake is operated.
Harness defect
5-68 Error code C5-6 Inspection 3: Matching Perform matching between the fully closed and fully open states of the brake.
After the completion of matching, C5-6 error does not occur.
Use the device as it is.
After the completion of matching, C5-6 error occurs. Main controller defect
Inspection 1: Check the brake sensor as a single unit. Perform this check with the battery plug and CN6 disconnected and CN101 and CN102 connected. (1)Measuring the resistance of the brake sensor Standard (on sensor side): CN6-5 to CN6-6 CN6-5 to CN6-2
1.8 to 3.5 kΩ (Open state)
(2)Measuring the resistance of the brake sensor output circuit Standard (on sensor side): CN6-5 to CN6-6 CN6-5 to CN6-2
The resistance must increase as the potentiometer is rotated.
Inspection 2: Check each harness for its continuity. Perform this check with the battery plug, CN6, CN101 and CN102 disconnected. visually check inside each connector and the caulked portion of each wire for defects. Refer to BEFORE TROUBLESHOOTING. {: Items to be checked Portions to be checked
Standard
CN101-34 to CN6-5 CN102-33 to CN6-4
C5 1
2
3
4
5
6
Continuity
{
−
−
−
{
−
*1
Continuity
{
−
−
−
−
−
*1
CN101-22 to CN6-6
Continuity
−
−
{
−
{
−
*3
CN101-33 to CN6-1
Continuity
−
{
−
−
{
−
*2
CN102-25 to CN6-3
Continuity
−
{
−
−
−
−
*2
CN101-32 to CN6-2
Continuity
−
−
−
{
{
−
*4
CN6-5 to CN6-6
No continuity
{
−
−
−
−
−
CN6-5 to CN6-2
No continuity
{
−
−
−
−
−
CN6-4 to CN6-6
No continuity
{
−
−
−
{
−
CN6-4 to CN6-2
No continuity
{
−
−
−
{
−
CN6-4 to CN6-5
No continuity
−
−
{
−
{
−
CN6-4 to CN6-1
No continuity
−
−
{
−
{
−
CN6-1 to CN6-6
No continuity
−
{
−
−
−
−
CN6-1 to CN6-2
No continuity
−
{
−
−
−
−
CN6-3 to CN6-6
No continuity
−
{
−
−
{
−
CN6-3 to CN6-2
No continuity
−
{
−
−
{
−
CN6-3 to CN6-5
No continuity
−
−
−
{
{
−
CN6-3 to CN6-1
No continuity
−
−
−
{
{
−
CN102-33 to CN102-25
No continuity
−
−
−
−
{
−
5-69 *1:Connect CN6-5 and CN6-4 on the harness side through 09232-13130-71 and check if there is continuity between CN101-34 and CN102-33. *2:Connect CN6-1 and CN6-3 on the harness side through 09232-13130-71 and check if there is continuity between CN101-33 and CN102-25. *3:Connect CN6-6 and CN6-4 on the harness side through 09232-13130-71 and check if there is continuity between CN101-22 and CN102-33. *4:Connect CN6-2 and CN6-3 on the harness side through 09232-13130-71 and check if there is continuity between CN101-32 and CN102-25. Inspection 3: Perform matching. (See section 13)
5-70
z Error Code C8-1 (Drive motor speed (rotation) sensor open) Related portion CN110-3 (78, SSDL+) P41
CN53-2
+ Drive motor drive circuit
CN110-5 (79, SSD1)
CN53-1
Speed sensor 1
CN54-2
N1
Speed sensor 2
CN110-6 (80, SSD2)
CN54-1
Probable cause: (1) Connector contact defect (2) Speed sensor harness defect (3) Speed sensor 1 defect
(4) Speed sensor 2 defect (5) Drive motor drive circuit defect
* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN110, CN53 and CN54 connectors and check the harnesses for their continuities.
CN110 and CN53 or between CN110 and CN54 Harness defect
NG
OK Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN53 and CN54 connectors and connect the CN110 connector. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between CN53-2 and N1.
Other than 9 to 13 V
9 to 13 V Inspection: (Check of error code) 1. Turn off the key switch and disconnect the battery plug. C8-1 error 2. Disconnect the CN53 and CN54 connectors. occurs. 3. Short-circuit the CN53-2 and CN53-1 connectors and the CN54-2 and CN541 connectors on the wire harness side. 4. Connect the battery plug and turn on the key switch. 5. Check the error code that appears. C8-2 error occurs. 1
Drive motor drive circuit defect
5-71
1
Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Measure the resistance between CN53-1 and N1 and that between CN54-1 and N1.
At least one of the resistances is not approx. 100 Ω.
Drive motor drive circuit defect
Both the resistances are approx. 100 Ω. Inspection: (Check of speed sensor) 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN110, CN53 and CN54 connectors. 3. Connect the battery plug and turn on the key switch to display the error code C8-1. 4. Check the value of SSD, using the Analyzer menu. STD: [ANL] I/O 2 3-11/ 3-12 Multifunction display/ DX: [ANL] I/O TRAVELING 5/5 SSD: 0.3 or less/0.4 to 1.9(*) Speed sensor 1 defect
SSD: 0.4 to 1.9/0.3 or less
Speed sensor 2 defect
SSD: 0.3 or less/0.3 or less Speed sensor 1 and 2 defect
* On the STD display, the first SSD value can be checked on I/O 2 3-11 screen and second on I/O 2 3-12 screen. On the multifunction display, both value can be checked on I/O TRAVELING 5/5 screen.
Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN110 CN53 and CN54, visually check inside each connector and the caulked portion of each wire for defects and then check the CN110, CN53 and CN54 harnesses. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
CN110-6 to CN53-2
Continuity
*1
CN110-6 to CN54-2
Continuity
*2
CN110-4 to CN53-1
Continuity
*1
CN110-3 to CN54-1
Continuity
*2
CN110-6 to CN110-3
No continuity
CN110-6 to CN110-4
No continuity
CN110-3 to CN110-4
No continuity
*1:Connect CN53-1 to CN53-2 through SST and check if there is continuity between CN110-6 to CN110-4. *2:Connect CN54-1 to CN54-2 through SST and check if there is continuity between CN110-6 to CN110-3.
5-72
z Error Code C8-2 (Drive motor speed (rotation) sensor short) Related portion CN53-2
CN110-3 (78, SSD+) P41 + Drive motor drive circuit N1
CN110-5 (79, SSD1)
CN53-1
Speed sensor 1
CN54-2 Speed sensor 2
CN110-6 (80, SSD2)
CN54-1
Probable cause: (1) Connector contact defect (2) Speed sensor harness defect (3) Speed sensor 1 defect
(4) Speed sensor 2 defect (5) Drive motor drive circuit defect
* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. Between CN110 and CN53 or between CN110 and CN54 Harness defect
Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN110, CN53 and CN54 connectors and check the harnesses for their continuities. OK Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN53 and CN54 connectors and connect the CN110 connector. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between CN53-2 and N1.
9 to 13 V Other than
9 to 13 V Inspection: (Check of error code) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN53 and CN54 connector. 3. Connect the battery plug and turn on the key switch. 4. Check the error code that appears. C8-1 error occurs. 1
C8-2 error occurs.
Drive motor drive circuit defect
5-73
1
Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Measure the resistance between CN53-1 and N1 and that between CN54-1 and N1.
At least one of the resistances is not approx. 100 Ω.
Drive motor drive circuit defect
Both the resistances are approx. 100 Ω. Inspection: (Check of speed sensor) 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN110, CN53 and CN54 connectors. 3. Connect the battery plug and turn on the key switch to display the error code C8-2. 4. Check the value of SSD, using the Analyzer menu. STD: [ANL] I/O 2 3-11/ 3-12 Multifunction display/ DX: [ANL] I/O TRAVELING 5/5 SSD: 2.0 or more/0.4 to 1.9(*) Speed sensor 1 defect
SSD: 0.4 to 1.9/2.0 or more
Speed sensor 2 defect
SSD: 2.0 or more/2.0 or more
Speed sensor 1 and 2 defect
* On the STD display, the first SSD value can be checked on I/O 2 3-11 screen and second on I/O 2 3-12 screen. On the multifunction display, both value can be checked on I/O TRAVELING 5/5 screen.
Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN110, CN53 and CN54, visually check inside each connector and the caulked portion of each wire for defects and then check the CN110, CN53 and CN54. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
CN110-6 to CN53-2
Continuity
*1
CN110-6 to CN54-2
Continuity
*2
CN110-4 to CN53-1
Continuity
*1 *2
CN110-3 to CN54-1
Continuity
CN110-6 to CN110-3
No continuity
CN110-6 to CN110-4
No continuity
CN110-3 to CN110-4
No continuity
*1:Connect CN53-1 to CN53-2 through SST and check if there is continuity between CN110-6 to CN110-4. *2:Connect CN54-1 to CN54-2 through SST and check if there is continuity between CN110-6 to CN110-3.
5-74
z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality) Related portion 48V
MB P2
F1
P3
F7
P4 CN136-6
CN102-3 (19, VBMBSL)
N1 CN102-4 (19, VBMBSL) F6 F5
CN136-5
CN104-2 (44, VBMB)
CN136-2
CN104-1 (41, B48V)
Main controller
CN101-4 (41, VBBT) CN136-3 MB contactor CN136-4
80V
MB P2
CN104-9 (2, CBAT-) CN104-3 (1, CBAT+)
F1
P3
F7
P4 CN136-6
CN102-3 (19, VBMBSL) CN102-4 (19, VBMBSL) CN104-2 (19, VBMB)
F6
F5
N1
CN136-5
CN104-1 (18, B80V)
CN136-2
CN101-4 (41, VBBT)
CN136-3
CN104-9 (2, CBAT-)
MB contactor CN136-4
CN104-3 (1, CBAT+)
Probable cause: (1) Connector contact defect (2) MB contactor defect (3) Harness defect
(4) Fuse defect (5) Fuse holder defect (6) Main controller defect
Main controller
5-75 Error code CB-1 * If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.
Disconnect and then connect the battery plug again, and turn on the key switch and turn the steering to see if an error occurs.
CB-1error does not occur.
Check the state of the battery.
CB-1 error occurs. Check if the MB contactor actuation sound is heard when the key switch is turned on.
No actuation sound
Identify the cause of CB-3.
Actuation sound Inspection: Check of the F6 (48V), F7 (48V, 80V) fuse 1. Turn off the key switch and disconnect the battery plug. ∞Ω 2. Remove the F6 and F7 fuses and measure the resistance between their both ends with a circuit tester.
F6 fuse defect (48V) F7 fuse defect (48V, 80V)
0Ω Inspection: Check of the F6 (48V), F7 (48V, 80V) fuse holders 1. Install the F6 and F7 fuses and disconnect the connector from the fuse holder. ∞Ω 2. Measure the resistance between both end of the connector side of the F6 fuse holder. Measure the resistance between both end of the connector side of the F7 fuse holder.
F6 fuse holder defect F7 fuse holder defect
0Ω Inspection 1: Harness check Disconnect the CN136, CN102, CN104 connectors and P3 terminal.
NG
Harness defect
OK Inspection: Voltage check 1. Connect all the connectors, connect the battery plug, and then turn on the key switch. 2. Measure the voltage between both ends on the contact side of the contactor. (Refer to the figure)
2
30 V or more
2
Less than 30 V Main controller defect
MB contactor defect
5-76 Error code CB-2 * If the error codes AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, EC-1and -4 are displayed all at once, perform troubleshooting with priority given to AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, and EC-1and -4. If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.
Disconnect and then connect the battery plug again, turn on the key switch and wait for 5 seconds. After that, turn off the key switch and then back on the key switch to see if an error occurs.
Use the device as it is. CB-2 error does not (There are cases where the occur. residual charge cannot be discharged for reasons of another error.)
CB-2 error occurs.
Check if the MB contactor opens when the key switch is turned off.
The contactor opens.
A
The contactor does not open. Inspection: Check of MB contactor 1. Turn off the key switch and disconnect the battery plug. 2. Measure the voltage between P4 and N1 of the contactor to see that it is 3 V or less. 3. Visually check the conditions of the contacts of the MB contactor.
The contactor does not open.
MB contactor defect
The contactor opens. Identify the cause of CB-3.
A
Inspection: Check of voltage 1. Disconnect and then connect the battery plug again, turn on the key switch. 2. Turn off the key switch and 5 seconds or more after that, measure the voltage between P4 and N1 of the contactor. 15 V or more Pump motor drive circuit defect
Less than 15 V
Main controller defect
5-77 Error code CB-3, -5 1. Disconnect the battery plug and visually check inside the CN136 CB-3, -5 error does connector and the caulked portions of their wires for defects. (Refer not occur. to BEFORE TROUBLESHOOTING.) Connector contact defect 2. Connect the CN136 connector, connect the battery plug, and then turn on the key switch to check for errors. CB-3 or CB-5 Error occurs. Inspection: Check of MB contactor coil 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN136 connector and measure the resistance of the MB contactor coil (resistance between CN136-3 and CN136-4). Standard value: 15 to 30 Ω (Approx. 20 Ω: 20°C)
MB contactor defect
OK Inspection 2: Harness check Disconnect the CN104 and the CN136 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Error code CB-4 Disconnect the battery plug and visually check inside the CN136 connector and the caulked portions of their wires for defects. (Refer to BEFORE TROUBLESHOOTING.) Inspection: Check of MB contactor coil 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN136 connector and measure the resistance of the MB contactor coil (resistance between CN136-3 and CN136-4). Standard value: 15 to 30 Ω (Approx. 20 Ω: 20°C) Inspection 2: Harness check Disconnect the CN104 and CN136 connectors and check the harnesses for their continuities. Defective portion: Portion where a problem was found during a check of the MB contactor coil or harness. Main controller defect
5-78 Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN136, CN102, CN104 connectors and disconnected, visually check inside each connector and the caulked portion of each wire for defects. Refer to BEFORE TROUBLESHOOTING.
48V
80V
Portions to be checked
Standard
Point
CN136-5 to P3
Continuity
CB-1
CN136-6 to P3
Continuity
CB-1
CN136-5 to CN104-2
Continuity
CB-1
CN136-6 to CN102-3
Continuity
CB-1
CN136-6 to CN102-4
Continuity
CB-1
CN136-5 to N1
No continuity
CB-1
CN136-6 to N1
No continuity
CB-1
CN136-6 to P3
Continuity
CB-1
CN136-6 to CN102-3
Continuity
CB-1
CN136-6 to CN102-4
Continuity
CB-1
CN136-6 to CN104-2
Continuity
CB-1
CN136-6 to N1
No continuity
CB-1
Inspection 2: Check each harness for its continuity. Before this check, disconnect the battery plug, disconnect the CN104 and CN136 connectors, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.)
Portions to be checked
Standard
Point
CN136-3 to CN104-9
Continuity
CB-3
CN136-4 to CN104-3
Continuity
CB-3
CN136-3 to CN136-4
No continuity
CB-4, 5
CN136-3 to N1
No continuity
CB-3
CN136-4 to N1
No continuity
CB-3
CN136-3 to P1
No continuity
CB-4
CN136-3 to P4
No continuity
CB-4
5-79
z Error Code CC-1, -4, -6 (CPU error) Related portion
MB P2
P4
P3
Drive motor drive circuit
U
P7
V
P8
W
P9
CN110-23 CN52-2 (86, STDMR+) CN110-22 CN52-1 87, STDMR)
Probable cause: (1) Drive motor drive circuit defect (2) Drive motor temperature sensor defect (3) Drive motor temperature sensor harness defect Error code CC -4, -6
* If CC-4, -6 is displayed, the drive motor drive circuit is defective, so replace it. Error code CC -1 Inspection 1: (Check of temperature sensor unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN52 connector and check the temperature sensor.
NG
Temperature sensor defect
OK Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN110 and CN52 connectors and check the harnesses for their continuities. OK Drive motor drive circuit defect
NG
Harness defect
Drive motor
Drive motor temperature sensor
5-80 Inspection 1: Check of temperature sensor Check each harness of sensor side for its continuity.
Portions to be checked
Standard
P7 to CN52-1 (on sensor side)
No continuity
P7 to CN52-2 (on sensor side)
No continuity
Inspection 2: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN110 and CN52 connectors, and visually check inside each connector and the caulked portion of each wire for defect. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
P2 to CN110-22
No continuity
P2 to CN110-23
No continuity
P4 to CN110-22
No continuity
P4 to CN110-23
No continuity
5-81
z Error Code E0-2 (Pump motor drive power circuit short) Related portion P4
N2
+
-
P14
U Pump motor drive circuit
P15
V
Pump motor
P16
W
Probable cause: (1) Pump motor drive circuit defect (2) Motor cable defect
(3) Pump motor drive circuit defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3. * Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. * If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below 3 V. 1. Disconnect the battery plug and visually check the fastened or E0-2 error caulked portions of the motor cables for defects. (Refer to does not occur. BEFORE TROUBLESHOOTING.) 2. Connect the cables, connect the battery plug, and then turn on the key switch to check for errors.
Improper fastening of motor cable
E0-2 error occurs. Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the three motor cables from the drive circuit and insulate the terminals of the cables disconnected. 3. Connect the battery plug and turn on the key switch. 4. Check if the E0-2 error occurs.
E0-2 error occurs.
Pump motor drive circuit defect
E0-2 error does not occur. Inspection 1: (Check of motor cables) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the motors cables from both the motor and the motor drive circuit. 3. Check the motor cables for its continuity.
NG
Motor cable defect
OK Inspection: (Check of motor drive circuit) *1 1. Turn off the key switch and disconnect the battery plug. E0-2 error 2. Replace the pump motor drive circuit with the drive motor drive occurs. circuit. 3. Connect the battery plug and turn on the key switch. 4. Check the error code that is displayed. (Ignore the error codes 321 and 32-3.) C0-2 error occurs. Pump motor drive circuit defect (Note: Drive circuit that is originally the drive motor drive circuit before replacement)
Pump motor defect
5-82 *1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the motor drive circuits. Inspection: (Motor check) 1. Turn off the key switch and disconnect the battery plug. 2. Check the pump motor. (See page 5-14)
NG
Pump motor drive circuit defect
OK Pump motor drive circuit defect
Inspection 1: Continuity check of motor cables Check the cables for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked portion of each cable for defects, and then check the P14, P15 and P16 cables. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
Both ends of P14 cable
Continuity
Both ends of P15 cable
Continuity
Both ends of P16 cable
Continuity
P14 cable and P15 cable
No continuity
P15 cable and P16 cable
No continuity
P16 cable and P14 cable
No continuity
5-83
z Error Code E1-1 (Pump motor current sensor neutral voltage error) Related portion
Pump motor drive circuit
Current sensor
Probable cause: Pump motor drive circuit defect Error code E1-1
* If E1-1 is displayed, the pump motor drive circuit is defective, so replace it.
5-84
z Error Code E1-2 (Pump motor current sensor over current) Related portion
P4 + N2
Pump motor drive circuit
-
P14
U
P15
V
P16
W
Pump motor
Probable cause: (1) Pump motor defect (2) Pump motor cable defect (3) Pump motor drive circuit defect * Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or the like under the vehicle to support the vehicle. * If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below 3V. Error code E1-2 Turn the key switch from OFF to ON to check for E0-2 error.
E0-2 error occur
Proceed to identify the cause of E0-2
E0-2 error does not occur Turn off the key switch and disconnect the battery plug and visually check the fastened or caulked portions of E1-2 error the motor cables for defects. (Refer to BEFORE does not occur TROUBLESHOOTING) After installing the cables, connect the battery plug and turn the key switch ON. Sit in the seat and perform a load handling operation (lift or tilt), checking for errors.
Improper fastening of motor cable
E1-2 error occur Inspection 1: (Check of motor cables) 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the motor cables from both the motor and motor drive circuit. 3. Check motor cables for its continuity. OK 1
Motor cable defect
5-85
1 Inspection: (Check of motor drive circuit)*1 1. Replace the pump motor drive circuit with the drive motor drive circuit. 2. Connect the battery plug and turn on the key switch. 3. Check the error code that is displayed. (Ignore the error codes 32-1 and 32-3)
E1-2 error occur
Pump motor defect
C1-2 error occur Pump motor drive circuit defect (Note: Drive circuit that is originally the drive motor drive circuit before replacement)
*1If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the motor drive circuit. Inspection: (Motor check) 1. Turn off the key switch and disconnect the battery plug. 2. Check the pump motor. (See page 5-14)
NG
Pump motor defect
OK Pump motor drive circuit defect
Inspection 1: Continuity check of motor cables Check the cables for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each terminal and the caulked portion of each cable for defects, and then check the P14, P15 and P16 cables. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Both ends of P14 cable
Continuity
Both ends of P15 cable
Continuity
Both ends of P16 cable
Continuity
P14 cable and P15 cable
No continuity
P15 cable and P16 cable
No continuity
P16 cable and P14 cable
No continuity
5-86
z Error Code E2-1 (Pump motor temperature overheating abnormality) Related portion
CN111-23 (88, STPM+) Pump motor drive circuit
CN111-4 (89, STPM)
CN55-2 Pump motor Temperature sensor
CN55-1
Probable cause: Overheating (continuous overload operation) Do not leave the vehicle standing in a hot place. Error code E2-1 Inspection: Temperature check Turn on the key switch and check the value of TPM using the Analyzer menu. STD: [ANL] 2 IO1 2-05 (TPM) Multifunction/ DX: [ANL] I/O TEMP/VOLT 2/5 (TPM) Record the value of TPM. Turn off the key switch and leave the vehicle standing for a while (about 30 minutes).
Inspection: Temperature check Turn on the key switch and check the value of TPM using the Analyzer menu. STD: [ANL] 2 IO1 2-05 (TPM) Multifunction/ DX: [ANL] I/O TEMP/VOLT 2/5 (TPM) TPM: Less than A°C
The temperature of TPM is A°C or more and it has not lowered by 5°C or more compared to the TPM temperature previously checked.
Proceed to identify the cause of E2-2.
The temperature of TPM is A°C or more and it has lowered by 5°C or more compared to the temperature of TPM previously checked.
Table: Temperature A (° C) Model
STD
Fisherman spec.
1ton series (with 50-)
116
-
1 ton series
111
121
2 ton series (with 50-)
111
-
2 ton series
121
121
3 ton series
121
121
Check the following and take necessary action, and use the device as it is. (The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
5-87
z Error Code E2-2 (Pump motor temperature sensor abnormality) Related portion
CN111-23 (88, STPM+) Pump motor drive circuit
CN55-2
CN111-22 (89, STPM)
CN55-1
Pump motor Temperature sensor
Probable cause: (1) Connector contact defect (2) Pump motor temperature sensor defect (3) Pump motor temperature sensor harness defect (4) Pump motor drive circuit defect Error code E2-2 1. Turn off the key switch and disconnect the battery plug and visually check inside the CN55 connector and the caulked portions of their wires for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN55 connector, connect the battery plug, and then turn on the key switch to check for errors.
E2-2 error does not occurs.
Connector contact defect
E2-2 error occurs. Inspection 1: (Check of temperature sensor unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN55 connector and check the temperature sensor as a single unit.
NG
Temperature sensor defect
OK Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN111 and CN55 connectors and check the harnesses for their continuities. OK Pump motor drive circuit defect
NG
Harness defect
5-88 Inspection 1: Check of temperature sensor as a single unit Check item Temperature sensor resistance (on sensor side: CN55-2 and CN55-1) Standard value Approx. 245 Ω and 600 kΩ * Resistance changes (It is a standard as for the following value). Temperature
Resistance (CN55-2⇔CN55-1)
20°C
Approx. 13 kΩ
80°C
Approx. 1.75 kΩ
100°C
Approx. 1 kΩ
Inspection 2: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug and the CN111 and CN55 connectors and with SST disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN111-23 to CN55-2
Continuity
*1
CN111-22 to CN55-1
Continuity
*1
CN55-1 to CN55-2
No continuity
*1:Connect CN55-1 and CN55-2 on the harness side through 09232-13130-71 and check if there is continuity between CN111-4 and CN111-5.
5-89
z Error Code E3-1 (Pump motor drive power circuit temperature sensor abnormality) Related portion
Pump motor drive circuit Temperature sensor
Probable cause: Pump motor drive circuit defect Error code E3-1
* If E3-1 is displayed, the pump motor drive circuit is defective, so replace it.
5-90
z Error Code E8-1 (Pump motor speed (rotation) sensor open) Related portion P4
N2
CN111-6 (81, SSP+)
+ Pump motor drive circuit -
CN56-2
CN111-4 (82, SSP1)
Speed sensor
CN56-1
Probable cause: (1) Connector contact defect (2) Speed sensor harness defect
(3) Speed sensor defect (4) Pump motor drive circuit defect
* If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below 3 V. Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN111 and CN56 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN56 connector and connect the CN111 connector. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between CN56-2 and N2.
Other than 9 to 13 V
Pump motor drive circuit defect
9 to 13 V Inspection: (Check of error code) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN56 connector. 3. Using SST 09232-13240-71, connect the CN56-1 and CN56-2. 4. Connect the battery plug and turn on the key switch. 5. Check the error code that appears.
E8-1 error occur.
Pump motor drive circuit defect
E8-2 error occurs. Inspection: (Check of motor drive circuits) Other than 1. Turn off the key switch and disconnect the battery plug. Approx. 2. Disconnect 09232-13130-71 from the CN56 connector (on the wire harness 100 Ω side). 3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor drive circuit. 4. Measure the resistance between CN56-1 and N2 on the SST side. Approx. 100 Ω Speed sensor defect
Pump motor drive circuit defect
5-91 Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN56, and visually check inside each connector and the caulked portion of each wire for defects and then check each harness. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN111-6 to CN56-2
Continuity
*1
CN111-4 to CN56-1
Continuity
*1
CN111-6 to CN111-4
No continuity
*1:Connect CN56-1 and CN56-2 on the harness side through 09232-13130-71 and check if there is continuity between CN111-6 and CN111-4.
5-92
z Error Code E8-2 (Pump motor speed (rotation) sensor short) Related portion P4
N2
CN111-6 (81, SSP+)
+ Pump motor drive circuit -
CN56-2
CN111-4 (82, SSP1)
Speed sensor
CN56-1
Probable cause: (1) Connector contact defect (2) Speed sensor harness defect
(3) Speed sensor defect (4) Pump motor drive circuit defect
* If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below 3 V. Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN111 and CN56 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Inspection: (Check of motor drive circuits) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN56 connector and connect the CN111 connector. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between CN56-2 and N2.
Other than 9 to 13 V
Pump motor drive circuit defect
9 to 13 V Inspection: (Check of error code) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN56 connector. 3. Using SST 09232-13240-71, connect the CN56-1 and CN56-2. 4. Connect the battery plug and turn on the key switch. 5. Check the error code that appears.
E8-2 error occurs.
Pump motor drive circuit defect
E8-1 error occurs. Inspection: (Check of motor drive circuits) Approx. 1. Turn off the key switch and disconnect the battery plug. 100 Ω 2. Disconnect 09232-13130-71 from the CN56 connector (on the wire harness Other than side). 3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor drive circuit. 4. Measure the resistance between CN56-1 and N2 on the SST side. Approx. 100 Ω Speed sensor defect
Pump motor drive circuit defect
5-93
Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN56, and visually check inside each connector and the caulked portion of each wire for defects and then check each harness. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN111-6 to CN56-2
Continuity
*1
CN111-4 to CN56-1
Continuity
*1
CN111-6 to CN111-4
No continuity
*1:Connect CN56-1 and CN56-2 on the harness side through 09232-13130-71 and check if there is continuity between CN111-6 and CN111-4.
5-94
z Error Code EC-1, -4, -6 (CPU error) Related portion
MB P2
P3
P4 Pump motor drive circuit
U
P14
V
P15
W
P16
CN111-23 (88, STPM+) CN111-22 (89, STPM)
CN55-2 CN55-1
Probable cause: (1) Pump motor drive circuit defect (2) Pump motor temperature sensor defect (3) Pump motor temperature sensor harness defect Error code EC -4, -6
* If EC is displayed, the pump motor drive circuit is defective, so replace it. Error code EC -1 Inspection 1: (Check of temperature sensor unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN55 connector and check the temperature sensor.
NG
Temperature sensor defect
OK Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN111 and CN55 connectors and check the harnesses for their continuities. OK Pump motor drive circuit defect
NG
Harness defect
Pump motor
Pump motor temperature sensor
5-95 Inspection 1: Check of temperature sensor Check each harness of sensor side for its continuity.
Portions to be checked
Standard
P14 to CN55-1 (on sensor side)
No continuity
P14 to CN55-2 (on sensor side)
No continuity
Inspection 2: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN111 and CN55 connectors, and visually check inside each connector and the caulked portion of each wire for defect. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
P2 to CN111-22
No continuity
P2 to CN111-23
No continuity
P4 to CN111-22
No continuity
P4 to CN111-23
No continuity
5-96
z Error Code EE-1, -2 (Display → Main controller communication error) Related portion
Main controller
CN103-3 (14, DGND)
CN70-4
CN103-14 (16, D7V)
CN70-5
CN103-11 (145, CAN1H)
CN70-16
CN103-12 (146, CAN1L)
CN70-15
Probable cause: (1) Connector contact defect (2) Harness defect (3) Display defect (4) Main controller defect Error code EE-1, 2
* Identify the cause of F1-1 or F1-2.
Display
5-97
z Error Code F1-1, -2 (Main controller → Display communication error) Related portion CN103-11 (145,CAN1H)
CN70-16 (145, CAN1H)
Main controller
Display CN103-12 (146,CAN1L)
CN70-15 (146, CAN1L)
Probable cause: (1) Connector contact defect (2) Harness defect
(3) Main controller defect (4) Display defect
Error code F1-1, F1-2 Turn off the key switch and disconnect the battery plug and visually check inside CN103 to CN70 connectors and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
No error occurs. Connector contact defect
Connect the connector, connect the battery plug and turn on the key switch, and check if any error occurs. Error occurs.
If the version of at least one motor drive circuit is displayed
Inspection 1: Check the version information on the I/O monitor.
Main controller defect
If the version of a motor drive circuit is not displayed: Inspection 2: Disconnect the CN103 and CN70 connectors and check the harnesses for their continuities.
NG
Harness (between CN103 and CN70) defect
OK Display defect (*1) *1 If the symptom persists after replacement of the display, there should be any other problems, so replace the Main controller.
Inspection 2: Check harnesses for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN70 and CN103 connectors and check the harnesses for their continuities. Portions to be checked
Standard
CN103-11 to CN70-16
Continuity (Approx. 0 Ω)
CN103-12 to CN70-15
Continuity (Approx. 0 Ω)
CN70-15 to CN70-16
No continuity (Not 0 Ω)
5-98
z Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error) Related portion
Multi-display
Probable cause: Display defect Error code F4-1, -2, -3, -4, -5, -6, -7, -8
* If F4 is displayed, the display is defective, so replace it.
5-99
z Error Code F5-1 (Battery electrolyte level/ temperature sensor harness open) Related portion P1 electrolyte level connector
sensor power supply R Electrolyte level/ temp. sensor unit electrolyte temp. sensor
CN70-26 (140, SLLT)
sensor output Y
electrolyte level detection G
electrolyte temp. B electrolyte temp. W
electrolyte temp. connector N1
Probable cause: (1) Connector contact defect (2) Wrong unit connected (3) Harness defect (4) Electrolyte level/ temperature sensor defect (5) Display defect
Battery
CN35
Display
5-100 Error code F5-1 1. Turn off the key switch and disconnect the battery plug, and visually check if the CN35 harness connector on the vehicle side and the electrolyte level/ temperature sensor unit are connected. 2. Connect the connector, connect the battery plug, and then turn on the key switch to see if any error occurs.
F5-1 error does not occur. Connector contact defect
F5-1 error occurs
Check that the unit connected to the CN35 harness connector is the electrolyte level/ temperature sensor unit.
Not electrolyte level/ temp. sensor unit
Wrong unit connected • Connect the correct electrolyte level/ temperature sensor unit. • If using the conventional unit (unit with LED screen), change the setting of the battery unit.
electrolyte level/ temp. sensor unit is connected Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN35 and CN70 connector and check the harnesses for their continuities.
NG
Harness defect
OK Inspection 2: Output current of the the electrolyte level/ temperature sensor unit check 1. Disconncect the CN35 connector. 2. Connect the battery plug, turn off the key switch and then check the output current of the the electrolyte level/ temperature sensor unit .
NG
Electrolyte level/ temperature sensor unit defect
OK Display defect
Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN35 and CN70 connectors, and visually check inside each connector and the caulked portion of each wire for defects and then check each harness. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN35 to CN70-26
Continuity
Inspection 2: Output current of the the electrolyte level/ temperature sensor unit Check the the electrolyte level/ temperature sensor unit for its output current. Disconnect the CN35 connector and connect the battery plug. Turn off the key switch and check the output current of the electrolyte level/ temperature sensor between the CN35 connector (the electrolyte level/ temperature sensor side) and N1. Portions to be checked
Standard
CN35[+] to N1[-]
Current H, Current L: approx. 2mA to 15mA ※ [+], [-]: In case of analogue tester
5-101
z Error Code F5-2 (Battery electrolyte level/ temperature sensor harness short) Related portion P1 electrolyte level connector sensor output Y
electrolyte level detection G sensor power supply R Electrolyte level/ temp. sensor unit electrolyte temp. sensor
electrolyte temp. B electrolyte temp. W
electrolyte temp. connector N1 Battery
Probable cause: (1) Connector contact defect (2) Harness defect (3) Electrolyte level/ temperature sensor defect (4) Display defect
CN35
CN70-26 (140, SLLT)
CN70-1 (128, CH7V) CN70-5 (16, D7V) CN70-6 (162, ITKY3) CN70-8 (160, ITKY1) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY) CN70-20 (161, ITKY2) CN70-21 (163, IPSTKY1) CN70-22 (123, SW1) CN70-23 (122, SW2) CN70-24 (121, SW3) CN70-25 (129, CHAC) CN70-33 (132, CHMS)
Display
5-102 Error code F5-2 1.Turn off the key switch and disconnect the battery plug, and visually F5-2 error does check inside the CN35 and CN70 connectors and the caulked portion not occur. of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the connector, connect the battery plug, and then turn on the key switch to see if any error occurs.
Connector contact defect
F5-2 error occurs Inspection 1: Display voltage check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN35, connect the battery plug, turn on the key switch and then check the voltage of the display.
OK (0V)
Electrolyte level/ temperature sensor unit defect
NG (without 0V) Inspection 2: Harness voltage check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN35 and CN70 connector, connect the battery plug, turn on the key switch and then check the voltage of harness
NG (without 0V)
Harness defect
OK (0V) Inspection 3: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN35 and CN70 connector and check the harness for their continuities. OK Display defect
NG Harness defect
5-103
Inspection 1: Display voltage check Check each harness for its continuity. Disconnect the CN35 connector, connect the battery plug and then turn on the key switch to check the voltage between CN35 to N1. Portions to be checked
Standard
CN35 (main harness side) to N1
0V
Inspection 2: Harness voltage check Disconnect the CN35 and CN70 connector and connect the battery plug. Turn on the key switch and check the voltage between CN35 to N1. Portions to be checked
Standard
CN35 (main harness side) to N1
0V
Inspection 3: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN35 and CN70, and with no SST attached visually check inside each connector and the caulked portion of each wire for defects and then check each harness. (Refer to BEFORE TROUBLESHOOTING) Note: Perform this check with SST disconnected. Portions to be checked
Standard
CN70-26 to CN70-1
No continuity
CN70-26 to CN70-5
No continuity
CN70-26 to CN70-6
No continuity
CN70-26 to CN70-8
No continuity
CN70-26 to CN70-15
No continuity
CN70-26 to CN70-16
No continuity
CN70-26 to CN70-18
No continuity
CN70-26 to CN70-20
No continuity
CN70-26 to CN70-21
No continuity
CN70-26 to CN70-22
No continuity
CN70-26 to CN70-23
No continuity
CN70-26 to CN70-24
No continuity
CN70-26 to CN70-25
No continuity
CN70-26 to CN70-33
No continuity
5-104
z Error Code F5-3 (Battery electrolyte level/ temperature sensor open) Related portion P1 electrolyte level connector
sensor power supply R Electrolyte level/ temp. sensor unit electrolyte temp. sensor
CN70-26 (140, SLLT)
sensor output Y
electrolyte level detection G
electrolyte temp. B electrolyte temp. W
electrolyte temp. connector N1 Battery
Probable cause: (1) Connector contact defect (2) Usage of the battery electrolyte under low temperature (below -20°C) (3) Electrolyte temperature sensor defect (4) Electrolyte level/ temperature sensor unit defect
CN35
Display
5-105 Error code F5-3
* If F5-2 error is also displayed, perform troubleshooting with priority given to F5-2. 1.Turn off the key switch and disconnect the battery plug, and visually F5-3 error does check inside the connector of the electrolyte level/ temperature not occur. sensor and the caulked portion of each wire for defects. Connector contact defect (Refer to BEFORE TROUBLESHOOTING) 2. Connect the connector, connect the battery plug, and then turn on the key switch to see if any error occurs. F5-3 error occurs Check the following and take F5-3 error does necessary action, and use the 1. Turn off the key switch and leave the vehicle at normal temperature not occur. device as it is. for a while. • Whether the vehicle is used after 2. Turn on the key switch and check if any error occurs . standing under low temperature (below -20°C) F5-3 error occurs Inspection 1: Check the electrolyte temperature sensor as a single unit 1.Turn off the key switch and disconnect the battery plug. 2. Disconnect the electrolyte temperature sensor connector and check the sensor as a single unit.
NG
Electrolyte temperature sensor defect
OK Electrolyte level/ temperature sensor unit defect
Inspection 1: Check the electrolyte temperature sensor as a single unit Check item Resistance of the electrolyte temperature sensor (Electrolyte temperature sensor side: electrolyte temperature B to W) Standard: Approx. 330 kΩ to 35kΩ (When temperature of electrolyte is 0°C to 50 °C) *Resistance value varies according to the temperature of electrolyte. Temperature of electrolyte
Resistance value of the electrolyte temperature sensor
0°C
approx. 330 kΩ
20°C
approx. 124 kΩ
50°C
approx. 35 kΩ
5-106
z Error Code F5-4 (Battery electrolyte level/ temperature sensor overheating abnormality) Related portion P1 electrolyte level connector
sensor power supply R
CN35
Electrolyte level/ temp. sensor unit electrolyte temp. sensor
CN70-26 (140, SLLT)
sensor output Y
electrolyte level detection G
DISPLAY
electrolyte temp. B electrolyte temp. W
electrolyte temp. connector N1
Battery
Probable cause: (1) Connector contact defect (2) Incorrect connection of unit (3) Electrolyte temperature sensor defect (4) Electrolyte level/ temperature sensor unit defect Error code F5-4
* If F5-1 error is also displayed, perform troubleshooting with priority given to F5-1. *
1.Turn off the key switch and disconnect the battery plug, and visually F5-4 error does check inside the connector of the electrolyte temperature sensor and not occur. the caulked portion of each wire for defects. Connector contact defect (Refer to BEFORE TROUBLESHOOTING) 2. Connect the connector and the battery plug, and then turn on the key switch to see if any error occurs. F5-4 error occurs
Check that the unit connected to the CN35 harness connector is the electrolyte level/ temperature sensor unit.
Not electrolyte level/ temp. sensor unit
Wrong unit connected • Connect the correct electrolyte level/ temperature sensor unit. • If using the conventional unit (unit with LED), change the setting of the battery unit.
electrolyte level/ temp. sensor unit is connected Inspection 1: Check the electrolyte temperature sensor as a single unit 1.Turn off the key switch and disconnect the battery plug. 2. Disconnect the electrolyte temperature sensor connector and check the sensor as a single unit. OK Electrolyte level/ temperature sensor unit defect
NG
Electrolyte temperature sensor defect
5-107
Inspection 1: Check the electrolyte temperature sensor as a single unit Check item Resistance of the electrolyte temperature sensor (Electrolyte temperature sensor side: electrolyte temperature B to W) Standard: Abnormality when the resistance value is below approx. 6kΩ.
5-108
z Error Code F6-1 (Saftey timer activation) Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
FCH
P2
Transformer Thermo switch Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N2, GND)
N2
AC Power supply
AC Power plug Power cable
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CHGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
(95, MSCH)
Probable cause: (1) AC power supply voltage defect (5) Harness defect (2) Power cable defect (6) Operation panel defect (3) Magnet switch defect (7) Display defect (4) FCH fuse blown *For causes other than listed above, refer to “Although the charging is complete, the battery is not fully charged” or “ The magnet switch is not closed when a START button is pressed”.
5-109 Error code F6-1
* F6-1 error indication will disappear after disconnecting the AC power plug. Error code can be checked on DIAG MEMORY of the mask function. * Before performing troubleshooting of F6-1 error, turn on the key switch and check if any other error code will be indicated. If displayed, perform troubleshooting with priority given to that error. *
Inspection 1: Voltage check on the AC power supply side 1.Turn off the key switch and disconnect the AC power plug. 2. Check voltage of each AC power supply terminal.
NG (0V or abnormal voltage reduction, phase interruption) AC power supply defect defect
OK (AC191 to 220V)
Inspection 2: AC power plug terminal voltage check 1.Turn off the key switch and disconnect the AC power plug. 2. Check voltage of each AC power plug terminal.
NG (0V or abnormal voltage reduction, phase interruption)
Power cable defect
OK (AC191 to 220V) Not all 10 charging progress indicator come on in 10 seconds after starting the test
Inspection : Charger timer test (Refer to REPAIR MANUAL)
Display defect
*If it is impossible to perform timer test, perform inspection 4 first, and then try timer test of charger again.
Test complete
F7-1 error
Inspection : Magnet switch check 1.Turn off the key switch and connect the AC power plug. 2.Press “START” button. 3.Check if the magnet switch is closed and held in that position. OK (Closed and held)
NG
To “ The magnet switch is not closed when a START button is pressed” Inspection : Magnet switch check 1.Press “STOP” button. 2. Check magnet switch for its continuity. OK (Open)
NG( Not open) Magnet switch defect
Inspection 3 : FCH fuse check 1.Turn off the key switch and disconnect the AC power plug and the battery plug. 2. Remove the FCH fuse and check for its continuity. OK (Continuity) To “ Although the charging is complete,
the battery is not fully charged”
NG (No continuity) FCH fuse blown
5-110 Inspection 4: Operation button check 1.Disconnect the AC power plug and the battery plug. 2. Disconnect the CN69 connector and check for its continuity.
NG
Operation panel defect
OK Inspection 5: Harness check 1. Disconnect the CN69 and 70 connectors and check for their continuities.
NG
Harness defect
OK Display defect Inspection 1: Check AC power supply voltage Portions to be checked
Standard
Each AC power supply terminal
191 to 220 V
Inspection 2: Check AC power plug Portions to be checked
Standard
Each power plug terminal
191 to 220 V
Inspection 3: Check FCH fuse Remove the FCH fuse and check for its continuity. Portions to be checked
Standard
Both end of the FCH fuse
Continuity
Inspection 4: Check operation button Disconnect the CN69 connector, and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Operation
Portions to be checked
Standard
Hold down the “STOP” button
CN69-5 to CN69-3 (operation panel side)
Continuity
Hold down the “START” button
CN69-7 to CN69-3 (operation panel side)
Continuity
Release the “ STOP” button
CN69-5 to CN69-3 (operation panel side)
No continuity
Release the “ START” button
CN69-7 to CN69-3 (operation panel side)
No continuity
Inspection 5: Check harness Disconnect the CN69 and CN70 connectors, and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-7 to CN70-22
Continuity
CN69-5 to CN70-24
Continuity
CN70-22 to CN70-24
No continuity
CN70-24 to CN70-2
No continuity
CN70-24 to CN70-3
No continuity
CN70-24 to CN70-4
No continuity
CN70-24 to CN70-36
No continuity
5-111
z Error Code F6-2 (Charger transformer overheating abnormality) Related portion
Transformer thermo switch CN68-1
CN70-28(139, SWTT) Display
CN68-2
CN70-4 (14, DGND)
Transformer
1·2 ton series CN113-2
CN104-8(98,FNDC1)
Cooling fan 1 (controller) Main controller
CN113-1
CN104-3 (1,CBAT+)
CN114-2
Cooling fan 2 (transformer)
CN114-1
3 ton series CN104-8(98,FNDC1)
CN128-2 CN128-10
Main controller
CN104-3 (1,CBAT+)
CN101-18 (99, VFAN)
CN128-5
CN128-9
Fan power supply
CN128-3 CN128-8 CN128-4
CN113-2 CN113-1
CN114-2 CN114-1
Cooling fan 1 (controller)
Cooling fan 2 (transformer)
5-112
Probable cause: (1) Transformer defect (2) Tap adjustment defect (3) Transformer thermo switch defect (4) Harness defect (5) Fan defect (6) Display defect (7) Connector contact defect (8) Fan power supply defect Error code F6-2
* If AB-1, AB-2 errors are also displayed, perform troubleshooting with priority given to AB-1, AB-2. Inspection : Transformer check as a single unit ( Refer to REPAIR MANUAL)
NG
Transformer defect
OK If there is defect in the transformer, it may be caused by other factors, so follow the check procedure below after replacing the transformer. Inspection : Tap voltage check ( Refer to REPAIR MANUAL)
NG
Tap adjustment defect
OK NG (F6-2 error occurs immediately)
Connect the AC power plug. OK
Inspection 1 : Overheating detect function check 1.Turn off the key switch and disconnect the battery plug and the AC power plug. 2.Disconnect the CN68 connector and check if any error occurs. NG (F6-2 error is detected)
OK (F6-2 error is not detected) Transformer thermo switch defect
Inspection 2 : Harness check Disconnect the CN68 and CN70 connectors and check harness. NG
OK
Harness defect A Display defect
5-113 A
1. Disconnect the AC power plug. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check the rotation of the cooling fan 2. OK (Cooling fan 2 rotates) STD Display: [ANL]7 ACT 7-04 Multifunction Display: [ANL]ACTIVE TEST 2/2 FAN OFF → ON
Normal Use the devise as it is
NG (Cooling fan 2 does not rotate) 1. Disconnect the battery plug, and visually check inside the CN114 connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the connector and the battery plug, and then OK turn on the key switch. Forcibly turn on the cooling (Cooling fan 2 rotates) fans, using Active Test in the Analyzer menu, and check the rotation of the cooling fan 2.
Connector contact defect
STD Display: [ANL]7 ACT 7-04 Multifunction Display: [ANL]ACTIVE TEST 2/2 FAN OFF → ON NG (Cooling fan 2 does not rotate) Inspection 3: Fan power supply check (3 ton model only) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN128 connector and check the resistance of the fan power supply.
NG
Fan power supply defect
OK Inspection 4: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN101, CN104, CN113, CN114 and CN128 connectors and check the harnesses for their continuities. (The CN101 and CN128 connectors are only for 3 ton model) OK B
Harness defect
5-114 B
Inspection: Cooling fan 2 check 1. Disconnect the battery plug and connect the CN101, CN104, CN114 and CN128 connectors (the CN101 and CN128 connectors are only for 3 ton model), connect the battery plug and turn on the key switch. 2. Forcibly turn on the power to the cooling fans, using Active Test in the Analyzer menu, and check the rotation of the Cooling fan 2. STD Display: [ANL]7 ACT 7-04 Multifunction Display: [ANL]ACTIVE TEST 2/2 FAN OFF→ ON NG (Cooling fan 2 does not rotate) Cooling fan 2 defect
OK (Cooling fan 2 rotates) Connector contact defetct
* If the replaced fan does not rotate in the ACTIVE TEST mode, there might be other defected part, so replace the main controller.
Inspection 1: Check overheating detect function Perform this check with the CN68 connector disconnected and short-circuit the CN68-1 and CN68-2 connectors on the main harness side. Connect the battery plug and the AC power plug, and check if the F6-2 does not occur. Inspection 2: Check harness Check each harness for its continuity. Perform this check with the battery plug and the CN68 and CN70 connectors disconnected. (Refer to BEFORE TROUBLESHOOTING.) Portions to be checked
Standard
CN68-1 to CN70-28 (main harness side)
Continuity
*1
CN68-2 to CN70-4 (main harness side)
Continuity
*1
CN68-1 to CN68-2 (main harness side)
No continuity
*1 Short-circuit the CN68-1 to CN68-2 connectors (harness side), and check for the continuities between the CN70-28 and CN70-4.
Inspection 3: Check fan power supply (3 ton model only) Check the resistance of the fan power supply. Perform this check with the battery plug and the CN128 connector disconnected. Portions to be checked
Standard
CN128-2 to CN128-5
Approx. 4.7 kΩ
CN128-5 to CN128-9
Approx. 4.7 kΩ
CN128-5 to CN128-4
0Ω
CN128-4 to CN128-8
Approx. 4.7 kΩ
5-115
Inspection 4: Harness check Check the resistance of the fan power supply. Disconnect the battery plug and the CN101, CN104, CN114 and CN128 connectors, visually check the caulked portion of each wire for defects and perform the check. (Refer to BEFORE TROUBLESHOOTING.) 1·2 ton series Portions to be checked
Standard
CN104-3 to CN114-1
Continuity
CN104-8 to CN114-2
Continuity
CN104-3 to CN104-8
No continuity
3 ton series Portions to be checked
Standard
CN101-18 to CN128-9
Continuity
CN104-3 to CN128-5
Continuity
CN104-8 to CN128-2
Continuity
CN101-18 to CN104-3
No continuity
CN101-18 to CN104-8
No continuity
CN104-3 to CN104-8
No continuity
CN128-4 to CN114-1
Continuity
CN128-8 to CN114-2
Continuity
CN114-1 to CN114-2
No continuity
5-116
z Error Code F7-1 (Charger START abnormality) Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermo switch P2
FCH Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N1,N1)
N2
AC Power supply
AC Power plug Power cable
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CHGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
(95, MSCH)
Probable cause: (1) Wire connection defect (2) Capacity unsuitable (3) Tap adjustment defect (4) FCH fuse blown (5) Transformer defect
(6) Magnet switch defect (7) Harness defect (8) Main controller defect (9) Operation panel defect (10) Display defect
DISPLAY
5-117 Error code F7-1
* If F6-1errors are also displayed, perform troubleshooting with priority given to F6-1. *
Inspection: Voltage check of the battery power supply Compare the indicated value on the display and the actual measured value (P2 ←→ N2).
NG (Displayed value is outside the range of ± 10% of actual measured value)
STD Display: [ANL]2 IO1 2-10 Multifunction Display: [ANL]I/O TEMP/ VOLT 4/5
Main controller defect
OK (Displayed value is in the range of ± 10% of actual measured value) Inspection 1: Wire connection check 1. Turn off the key switch and disconnect the AC power plug and the NG battery plug. 2. Check the wire connection.
Wire connection defect
OK Inspection: Check the power distribution of the transformer 1. Connect the battery plug and the AC power plug. 2. Press “START” button of the charger. 3. Check the transformer operating sound. * After the check, press “STOP” button to stop charging.
NG (Not heard)
B
OK (Heard) Inspection: Check the compatibility of the capacity of the battery and NG the transformer. (Refer to REPAIR MANUAL)
Capacity unsuitable
OK Inspection: Tap adjustment check (Refer to the REPAIR MANUAL)
NG OK
Transformer defect
Tap adjustment defect
5-118
B
Inspection : Transformer fuse check (Refer to the REPAIR MANUAL)
NG( ∞ Ω)
FCH fuse defect
OK(0Ω) Inspection 2: Primary voltage of transformer check 1. Disconnect the CN61 connector. 2. Connect the AC power plug and press “START” button of the charger.
OK
Transformer defect
NG Inspection 3: Magnet switch voltage check 1. Disconnect the CN61 connector and perform the check.
OK
Magnet switch defect
NG Inspection 4: Harness check 1. Turn off the key switch and disconnect the AC power plug and the battery plug. 2. Disconnect the CN69 and CN70 connectors.
NG
Harness defect
OK Operation panel defect (*1) *1 If there is no improvement in symptom after replacing the operation panel, there might be other defected part, so replace the display.
Inspection 1: Check wire connection Check if the P2 and N2 terminals of the transformer and the main controller are correctly connected and there is no looseness. Check if the CN61, CN69 and CN70 connectors are correctly connected. Check if there is no loose connection at the battery plug and the AC power plug. (Also check if terminal is in good condition and there is no heat generation at the time of power distribution) Check if there is no damage on the power cable. Inspection 2: Check primary voltage of transformer
Disconnect the CN61 connector, connect the AC power plug and press “START” button. Portions to be checked
Standard
CN61-1 (U) to CN61-2 (V) (REC side)
191 to 220 V
CN61-2 (V) to CN61-4 (W) (REC side)
191 to 220 V
CN61-4 (W) to CN61-1 (U) (REC side)
191 to 220 V
5-119
Inspection 3: Check voltage of magnet switch
Disconnect the CN61 connector, connect the AC power plug and press “START” button. Portions to be checked
Standard
A1 to 96
191 to 220 V
Press “STOP” button. Portions to be checked
Standard
A1 to 96
0V A1
CLK-50JT
FW-1S 96
Inspection 4: Check harness Disconnect the CN69 and CN70 connectors, and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-1 to CN70-33
Continuity
CN69-3 to CN70-2
Continuity
5-120
z Error Code F8-1 (Charging completion abnormality) Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermoswitch P2
FCH Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N1,N1)
N2
Power supply
Power plug
Power cable
Operation panel
Magnet switch (95, MSCH)
Probable cause: (1) Magnet switch defect (2) Harness defect (3) Operation panel defect (4) Main controller defect (5) Display defect
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CHGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
5-121 Error code F8-1 *
Turn off the breaker of the power distribution panel and stop power supply of AC200V to the AC power plug, and then perform the check.
Inspection: Voltage check of the battery power supply Compare the indicated value on the display and the actual measured value (between P2 ←→ N2).
NG (Displayed value is outside the range of ± 10% of actual measured value)
STD Display: [ANL]2 IO1 2-10 Multifunction Display: [ANL]I/O TEMP/ VOLT 4/5
Main controller defect
OK (Displayed value is in the range of ± 10% of actual measured value) Inspection 1: Magnet switch check 1.Turn off the key switch and disconnect the AC power plug and the NG (Continuity) battery plug. 2. Disconnect the CN61 connector and check for its continuity.
Magnet switch defect
OK (No continuity) Inspection 2: Operation panel check 1. Disconnect the CN69 connector and perform the check.
NG
Operation panel defect
OK Inspection 3: Harness check 1.Disconnect the CN69 and CN70 connectors and perform the check.
NG
Harness defect
OK Inspection 4: Magnet switch signal check 1. Disconnect the CN70 connector and perform the check. OK (No continuity) Operation panel defect
NG (Continuity)
Display defect
5-122
Inspection 1: Check magnet switch
Disconnect the CN61 connector and make sure that the magnet switch is turned off. Portions to be checked
Standard
Main input terminal (R) to main output terminal (R)
No continuity
Main input terminal (S) to main output terminal (S)
No continuity
Main input terminal (T) to main output terminal (T)
No continuity
FW-1S Main input terminal (R)
Main input terminal (S)
Main output terminal (R) Main output terminal (S)
CLK-50JT Main input terminal (T)
Main output terminal (T)
Main input Main input terminal (S) terminal (R)
Main output terminal (R)
Main output terminal (S)
Main input terminal (T)
Main output terminal (T)
Inspection 2: Check operation panel Disconnect the CN69 connector, and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-1 to CN69-3 (Operation panel side)
No continuity
Inspection 3: Check harness Disconnect the CN69 and the CN70 connectors, and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-1 to CN69-3 (Main harness side)
No continuity
CN69-3 to CN70-33
No continuity
CN70-33 to CN70-2
No continuity
CN70-33 to CN70-3
No continuity
CN70-33 to CN70-4
No continuity
CN70-33 to CN70-36
No continuity
Inspection 4: Check magnet switch signal Disconnect the CN70 connector and perform the check Portions to be checked
Standard
CN70-33 to CN70-2 (Display side)
No continuity
5-123
z Error Code FB-1, -2 (Battery current sensor neutral voltage error) Related portion
Main controller
CN104-10 (303, CSBAT+)
CN137-1
CN102-24 (304, CSBAT)
CN137-3
CN102-35 (305, CSBAT-)
CN137-2
Battery current sensor
Probable cause: (1) Connector contact defect (2) Harness defect
(3) Battery current sensor defect (4) Main controller defect
Error code FB-1, -2 Disconnect the battery plug, disconnect the CN137 connector, and FB-1, FB-2 visually check inside each connector and the caulked portion of each error does not occur. wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect Connect the connector, connect the battery plug, and then turn on the key switch to check for errors. FB-1 or FB-2 error occurs. Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN102 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Inspection: Check of battery current sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN137. 3. Connect the battery plug and turn on the key switch. 4. Check the value of CSBAT using the Analyzer menu. STD: [ANL] 6 IO5 6-01 (CSBAT) Multifunction/ DX: [ANL] I/O OTHERS 1/1 CSBAT
CSBAT: Other than 0.00 Main controller defect
01(CSBAT): Approx. 0.00 Inspection: Check of battery current sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect CN137 and connect CN137-1 to CN137-3 on the harness side through 09232-13130-71. 3. Connect the battery plug and turn on the key switch. 4. Check the value of CSBAT using the Analyzer menu. STD: [ANL] 6 IO5 6-01 (CSBAT) Multifunction/ DX: [ANL] I/O OTHERS 1/1 CSBAT
CSBAT: Approx. 5.00 Battery current sensor defect
01(CSBAT): Other than 5.00 Main controller defect *1 If the symptom persists after replacement of the Current sensor, there should be any other problems, so replace the Main controller.
5-124 Inspection 1: Check each harness for its continuity. Disconnect the battery plug, disconnect the CN137, CN102 and CN104, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING.) Note: Perform this check with SST disconnected.
Portions to be checked
Standard
CN104-10 to CN137-1
Continuity
*1
CN102-24 to CN137-3
Continuity
*1
CN102-35 to CN137-2
Continuity
*2
CN137-1 to CN137-2
No continuity
CN137-3 to CN137-1
No continuity
CN137-3 to CN137-2
No continuity
*1:Connect CN137-1 and CN137-3 on the harness side through 09232-13130-71 and check if there is continuity between CN104-10 and CN102-24. *2:Connect CN137-2 and CN137-3 on the harness side through 09232-13130-71 and check if there is continuity between CN102-24 and CN102-35.
5-125
z Error Code FC-1 (Battery electrolyte overheating abnormality) Related portion
DISPLAY
CN70-26 (140, SLLT)
CN35
Electrolyte level/ temp. sensor unit
Probable cause: (1) Overheating (continuous overload operation, immediate use after charging the battery) Do not leave the vehicle standing in a hot place. Error code FC-1
* If F5-1, F5-2, F5-3 and F5-4 errors are also displayed, perform troubleshooting with priority given to F5-1, F5-2, F5-3 and F5-4. Inspection: Check of TSLLT temperature value (temperature of electrolyte) 1. Turn on the key switch. STD: [ANL] 2 IO1 2-08 (TSLLT) Multifunction display/ DX: [ANL] I/O TEMP/ VOLT 3/5 (TSLLT) Record the value of 08(TSLLT). 1. Turn off the key switch and disconnect the battery plug. 2. Remove the electrolyte temperature sensor from the battery.
Inspection: Check of TSLLT temperature value (ambient temperature) 1.Connect the battery plug and turn on the key switch. STD: [ANL] 2 IO1 2-08(TSLLT) Multifunction display/ DX: [ANL] I/O TEMP/ VOLT 3/5 (TSLLT)
08 (TSLLT): Same value as temperature of electrolyte Perform troubleshooting of F5-3 and F5-4.
08 (TSLLT): Below temperature of electrolyte • Install the electrolyte temperature sensor on the battery. • Leave the vehicle for over 12 hours until 08(TSLLT) gets below 57°C. (The possible cause might be the continuous overload operation or the immediate use after charging the battery. So check how the vehicle was operated.)
5-126
z Error Code FF-1, -2 (Power supply circuit over current) Related portion
CN103-14 (16,D7V)
CN70-5 Display
Main controller
CN103-3 (14, DGND)
CN70-4
CN103-13 (311, SSTR+)
CN19-1
CN103-6 (51, LS-)
CN19-2
Steering-wheel angle sensor
Probable cause: (1) Connector contact defect (2) Display or steering angle sensor defect (3) Harness defect (4) Main controller defect Error code FF-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN70 connector and visually check inside the connector and Screen is displayed. the caulked portion of its wire for defects. (Refer to BEFORE Connector contact defect TROUBLESHOOTING) 2. Connect the connector, connect the battery plug, and then turn on the key switch to see if a screen is displayed. No screen is displayed. Inspection: Check of display 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN70. Approx. 7 V 3. Connect the battery plug and turn on the key switch. 4. Measurement of voltage Measure the voltage between the CN70-5 and CN70-4 connectors on the harness side.
Display defect
0V Inspection 1: Harness check NG 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN103 connector and check the harnesses for their continuities. OK Main controller defect
Harness defect
5-127 Inspection 1: Check each harness for its continuity. Disconnect the battery plug, disconnect the CN70 and CN103 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN103-14 to CN70-5
Continuity
CN103-3 to CN70-4
Continuity
CN70-5 to CN70-4
No continuity
Error code FF-2 1. Disconnect the battery plug, disconnect the CN19 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN19 connector, connect the battery plug, and then turn on the key switch to check for errors.
FF-2 error does not occur. Connector contact defect
FF-2 error occurs. Inspection: Check of steering angle sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN19. Approx. 15 V 3. Connect the battery plug and turn on the key switch. 4. Measurement of voltage Measure the voltage between the CN19-1 and CN19-2 connectors on the harness side.
Steering angle sensor defect
0V Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN103 connector and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Inspection 2: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN19 and CN103 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN103-13 to CN19-1
Continuity
CN103-6 to CN19-2
Continuity
CN19-1 to CN19-2
No continuity
5-128
z Error code 31-1 Declining of activating voltage for Drive motor drive circuit Related portion 1·2 ton series MB
F1
P3
P2
P4
+
Drive motor CN110-8 drive circuit RCP
N1
CN143-2 Pre-charge unit
CN143-5
CN103-4 (42, KYSAT) CN143-1 CN104-1 (41, B48V)
Main controller
CN101-4 (41, VBBT)
F5 3 ton series MB P2
F1
P3
P4
+
Drive motor CN110-8 drive circuit RCP
N1
CN143-5
CN143-2 Pre-charge CN103-4 (42, KYSAT) unit CN143-1 CN104-1 (18, B80V)
F6
Probable cause: (1) Battery defect (2) RCP resistance defect (3) F1 fuse defect (4) F5 fuse defect (1·2 ton series) (5) F6 fuse defect (3 ton series) (6) Pre-charge unit defect (7) Main controller defect (8) Drive motor drive circuit defect (9) Wire-harness defect
Main controller
5-129 Error code 31-1 1. Disconnect the battery plug and visually check inside the CN143, CN103 and CN110 connectors and the caulked portion of its wire for defect (Refer to BEFORE TROUBLESHOOTING). No error occurs 2.Visually check the Drive motor drive circuit plus, P1, P3 and P4 terminal whether they are loosened or not. 3. Connect the connectors and battery plug, then turn on the key switch to check for error.
Connector contact defect Improper fastening of terminals
Error occurs Inspection 1: (Harness check) 1.Turn off the key switch and disconnect the battery NG plug. 2. Disconnect the CN103, CN104 and the plus terminal of Drive motor drive circuit and check the harness.
1
OK Inspection: (Check of Input voltage for Motor drive circuit) 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN103, CN104 and the plus terminal of Drive motor drive circuit. 3. Connect battery plug and turn on the key switch. 4. Measure the voltage between the plus terminal of Drive motor drive and N1.
[48V] More than 20 V Drive motor driver circuit defect [80V] More than 35 V
[48V] [80V] Less than 20 V Less than 35 V Inspection: Voltage check of B48 V (1·2 ton series)/ B80V (3 ton series) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between the CN104-1and N1.
[48V] More than 20 V Main controller defect [80V] More than 35 V
[48V] [80V] Less than 20 V Less than 35 V Inspection: F5 fuse (1·2 ton series)/ F6 fuse (3 ton) 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F5 fuse and the F6 fuse and measure the resistance between its both ends with a circuit tester.
∞Ω
F5 fuse defect (1·2 ton series) F6 fuse defect (3 ton series)
0Ω Inspection: Check battery voltage P1[+] ← → N1[-] [48V] [80V] Less than 20 V Less than 35 V Battery defect
[48V] More than 20 V [80V] More than 35 V
Harness defect between the P1 and CN104-1
5-130
1 Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnnect the CN103, CN143 and check the harness.
NG
Harness defect between CN103 and CN143
OK Inspection: F1 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F1 fuse and measure the resistance between its both ends with a circuit tester.
∞Ω
F1 fuse defect
0Ω Inspection: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN103, CN104 and install the F1 fuse. 3. Check the continuity between the Plus terminal of Drive motor driver and P3.
No continuity
Harness defect between P3 and plus terminal of the Motor driver
Continuity Inspection 3: (Pre-charge unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN143 and check the Pre-charge unit. OK RCP defect, Harness defect between CN143-5 and P3.
NG
Pre-charge unit defect
5-131 Inspection 1: Harness continuity/shorts Check each harness for its continuity Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of Drive motor driver, and visually check inside each connector and caulked portion. Then check the continuity between the CN103 and plus terminal of Drive motor driver. (Refer to BEFORE TROUBLESHOOTING) After inspection, plus terminal of Drive motor driver should be surely tightened. Portions to be checked
Standard
CN103-4[+] to Plus terminal of motor driver[-]
∞Ω
CN103-4[-] to Plus terminal of motor driver [+]
Approx. 70 Ω (10 Ω range) ※ [+], [-]: In case of analogue tester
Inspection 2: Harness continuity/shorts Check each harness for its continuity Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside each connector and caulked portion. Then check the harness between CN103 and CN143. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN103-4 to CN143-1
Continuity
Inspection 3: Pre-charge unit check Check the Pre-charge unit Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity. Portions to be checked
Standard
CN143-1[+] to CN143-5[-]
∞Ω
CN143-1[-] to CN143-5[+]
Approx. 50 Ω (10 Ω range) ※ [+], [-]: In case of analogue tester
5-132
z Error code 31-3 Declining of activating voltage for Pump motor drive circuit Related portion 1·2 ton series P2
MB
F1
P3
P4
+ CN111-8
Pump motor drive circuit
RCP
N1
CN143-2 CN143-5
Pre-charge unit
CN103-4 (42, KYSAT) CN143-1 CN104-1 (41, B48V)
F5
Main controller
CN101-4 (41, VBBT )
3 ton series MB P2
F1
P3
P4
+ CN111-8
RCP
N1
CN143-2 CN143-5
Pre-charge unit
CN103-4 (42, KYSAT) CN143-1 CN104-1 (18, B80V)
F6
Probable cause: (1) Battery defect (2) RCP resistance defect (3) F1 fuse defect (4) F5 fuse defect (1·2 ton series) (5) F6 fuse defect (3 ton series) (6) Pre-charge unit defect (7) Main controller defect (8) Pump motor drive circuit defect (9) Wire-harness defect
Pump motor drive circuit
Main controller
5-133 Error code 31-3 1. Disconnect the battery plug, connector CN143, CN103 and CN111 and visually check inside the connector and the caulked portion of its wire for No error occurs defect (Refer to BEFORE TROUBLESHOOTING). 2. Visually check the Pump motor drive circuit plus, P1, P3, P4 whether the terminal is loosened or not. 3. Connect the connectors and battery plug, then turn on the key switch to check for error.
Improper fastening of terminals
error occurs Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery NG plug. 2. Disconnect the CN103, CN104 and the plus terminal of Pump motor drive circuit and check the harness.
1
OK Inspection: (Check of Input voltage for Motor drive circuit) 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN103, CN104 and the plus terminal of Pump motor drive circuit. 3. Connect battery plug and turn on the key switch. 4. Measure the voltage between the plus terminal of Pump motor driver and N1.
[48V] More than 20 V Pump motor driver circuit defect [80V] More than 35 V
[48V] [80V] Less than 20 V Less than 35 V Inspection: Voltage check of B48 V (1·2 ton series)/ B80V (3 ton series) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104. 3. Connect the battery plug and turn on the key switch. 4. Measure the voltage between the CN104-1and N1.
[48V] More than 20 V Main controller defect [80V] More than 35 V
[48V] [80V] Less than 20 V Less than 35 V Inspection: F5 fuse (1·2 ton series)/ F6 fuse (3 ton) 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F5 fuse and the F6 fuseand measure the resistance between its both ends with a circuit tester.
∞Ω
F5 fuse defect (1·2 ton series) F6 fuse defect (3 ton series)
0Ω Inspection: Check battery voltage P1[+] ← → N1[-] [48V] [80V] Less than 20 V Less than 35 V Battery defect
[48V] More than 20 V [80V] More than 35 V
Harness defect between the P1 and CN104-1
5-134
1 Inspection 2: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnnect the CN103, CN143 and check the harness.
NG
Harness defect between CN103 and CN143
OK Inspection: F1 fuse 1. Turn off the key switch and disconnect the battery plug. 2. Remove the F1 fuse and measure the resistance between its both ends with a circuit tester.
∞Ω
F1 fuse defect
0Ω Inspection: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Connect the CN103, CN104 and install the F1 fuse. 3. Check the continuity between the plus terminal of Pump motor driver and P3.
No continuity
Harness defect between P3 and plus terminal of the motor driver
Continuity Inspection 3: (Pre-charge unit) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN143 and check the Pre-charge unit. OK RCP defect, harness defect between CN143-5 and P3.
NG
Pre-charge unit defect
5-135 Inspection 1: Harness continuity/shorts Check each harness for its continuity Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of Pump motor driver, and visually check inside each connector and caulked portion. Then check the continuity between the CN103 and plus terminal of Pump motor driver. (Refer to BEFORE TROUBLESHOOTING) After inspection, plus terminal of Pump motor driver should be surely tightened. Portions to be checked
Standard
CN103-4[+] to Plus terminal of motor driver[-]
∞Ω
CN103-4[-] to Plus terminal of motor driver [+]
Approx. 70 Ω (10 Ω range) ※ [+], [-]: In case of analogue tester
Inspection 2: Harness continuity/shorts Check each harness for its continuity Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside each connector and caulked portion. Then check the harness between CN103 and CN143. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN103-4 to CN143-1
Continuity
Inspection 3: Pre-charge unit check Check the Pre-charge unit Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity. Portions to be checked
Standard
CN143-1[+] to CN143-5[-]
∞Ω
CN143-1[-] to CN143-5[+]
Approx. 50 Ω (10 Ω range) ※ [+], [-]: In case of analogue tester
5-136
z Error Code 32-1 (Drive motor driver ID abnormality) Related portion
Drive motor drive circuit
Probable cause: (1) Connector contact defect (2) Drive motor drive circuit harness defect (3) Drive motor drive circuit defect * When a pump motor drive circuit is installed as a drive motor drive circuit, the 32-1 error always occurs (which does not mean that the new drive circuit is defective). Turn off and then back on the key switch. If AD-5 or 6 is also displayed, perform troubleshooting with priority given to AD-5 or 6. Error code 32-1 1. Disconnect the battery plug, disconnect the CN110 connector, and 32-1 visually check inside the connector and the caulked portion of its error does not occur. wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN110 connector, connect the battery plug, and then turn on the key switch to check for errors. 32-1 error occurs. Drive motor drive circuit defect
Drive motor drive circuit connector contact defect
5-137
z Error Code 32-3 (Pump motor driver ID abnormality) Related portion
CN111-12 (152, STEP)
Pump motor drive circuit
CN111-11 (152, STEP1)
Probable cause: (1) Connector contact defect (2) Pump motor drive circuit harness defect (3) Pump motor drive circuit defect * When a new motor drive circuit is installed on the vehicle, the 32-3 error always occurs (which does not mean that the new drive motor drive circuit is defective). Turn off and then back on the key switch. If AD-1 or 2 is also displayed, perform troubleshooting with priority given to AD-1 or 2. Error code 32-3 1. Disconnect the battery plug, disconnect the CN111 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN111 connector, connect the battery plug, and then turn on the key switch to check for errors. 32-3 error occurs. Pump motor drive circuit defect
32-3 error does not occur.
Pump motor drive circuit connector contact defect
5-138
z Error code 33-1 Main controller → Drive motor driver CAN communication abnormality Related portion CN143-2
CN143-1 CN103-4 (42, KYSAT) CN103-11 (145, CAN1H)
Pre-charge unit
CN103-12 (146, CAN1L) CN103-3 (14, DGND) Main controller
CN103-5 (N2,N2) CN104-4 (N2,N2) CN104-5 (N2,N2) CN104-6 (N2,N2)
Probable cause (1) Connector contact defect (2) Harness defect (3) Motor driver circuit defect (4) Main controller defect *If AD-1, 2 occurs, perform troubleshooting with priority given to AD-1, 2.
CN110-8 CN110-17 CN110-10 CN110-2
Drive motor driver circuit
5-139 Error code 33-1 Disconnect the battery plug, connector CN110, CN143 and visually check inside the connector and the caulked portion of its wire for 33-1 error does not defect (Refer to BEFORE TROUBLESHOOTING). occur Connect the connectors and battery plug, then turn on the key switch to check for error. Especially, after replacing the motor driver circuit, should be confirmed the connection of each connector.
Connector contact defect
33-1 error occurs Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN103, CN104, CN143, CN110 and check the harness.
NG
Harness defect
OK 33-1 error does not Turn the key off and connect the CN103, CN143, CN104, CN110 then occur turn the key on.
Connector contact defect
33-1 error occurs Inspection: (Motor driver circuit) ∗1 1. Replacing the Drive motor driver and Pump motor driver. 2. Connect the battery plug and turn on the key switch. 3. Check the error code (The 32-1 and 32-3 can be ignored even if displayed). 33-3 error occurs Drive motor driver circuit defect (note: this is drive motor driver before replacing)
33-1error does not occur
Main controller defect
5-140 Inspection 1: Harness continuity/shorts Check each harness for its continuity and short Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104, CN143, CN110 and visually check inside each connector and caulked portion. Then check the continuity and short of each harness (Refer to BEFORE TROUBLESHOOTING). Portion to be checked
Standard
CN103-4 to CN143-1
Continuity
CN143-2 to CN110-8
Continuity
CN103-11 to CN110-17
Continuity
CN103-12 to CN110-10
Continuity
CN103-3 to CN110-2
Continuity
CN110-8 to CN110-17
No continuity
CN110-8 to CN110-10
No continuity
CN110-8 to CN110-2
No continuity
CN110-17 to CN110-10
No continuity
CN110-17 to CN110-2
No continuity
CN110-10 to CN110-2
No continuity
CN103-4 to CN103-5
No continuity
CN103-11 to CN103-5
No continuity
CN103-12 to CN103-5
No continuity
5-141
z Error code 33-3 Main controller → Pump motor driver CAN communication abnormality Related portion CN143-2
CN143-1 CN103-4 (42, KYSAT) CN103-11 (145, CAN1H)
Pre-charge unit
CN103-12 (146, CAN1L) CN103-3 (14, DGND) Main controller
CN103-5 (N2, N2) CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause (1) Connector contact defect (2) Harness defect (3) Motor driver circuit defect (4) Main controller defect *If AD-5, 6 occurs, perform troubleshooting with priority given to AD-5, 6.
CN111-8 CN111-17 CN111-10 CN111-2
Pump motor driver circuit
5-142 Error code 33-3 Disconnect the battery plug, connector CN111, CN143 and visually check inside the connector and the caulked portion of its wire for 33-3 defect (Refer to BEFORE TROUBLESHOOTING). No error occurs Connect the connectors and battery plug, then turn on the key switch to check for error. Especially, after replacing the motor driver circuit, should be confirmed the connection of each connector.
Connector contact defect
33-3 error occurs Inspection 1: (Harness check) 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN103, CN104, CN143, CN110, CN111 and check the harness.
NG
Harness defect
OK Turn the key off and connect the CN103, CN143, CN104, CN110, CN111 then turn the key on.
33-3 No error occurs
Connector contact defect
33-3 error occurs Inspection: (Motor driver circuit) ∗1 1. Replacing the Drive motor driver and Pump motor driver. 2. Connect the battery plug and turn on the key switch. 3. Check the error code (The 32-1 and 32-3 can be ignored even if displayed). 33-1 error occurs Pump motor driver circuit defect (Note: this is pump motor driver before replacing)
33-3 No error occurs
Main controller defect
5-143 Inspection 1: Harness continuity/shorts Check each harness for its continuity and short Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104, CN143, CN111 and visually check inside each connector and caulked portion. Then check the continuity and short of each harness (Refer to BEFORE TROUBLESHOOTING). Portion to be checked
Standard
CN103-4 to CN143-1
Continuity
CN143-2 to CN111-8
Continuity
CN103-11 to CN111-17
Continuity
CN103-12 to CN111-10
Continuity
CN103-3 to CN111-2
Continuity
CN111-8 to CN111-17
No continuity
CN111-8 to CN111-10
No continuity
CN111-8 to CN111-2
No continuity
CN111-17 to CN111-10
No continuity
CN111-17 to CN111-2
No continuity
CN111-10 to CN111-2
No continuity
CN103-4 to CN103-5
No continuity
CN103-11 to CN103-5
No continuity
CN103-12 to CN103-5
No continuity
5-144
z Error Code 61-1,-2 (Load sensor abnormality) Related portion
Main controller
CN104-12 (58, SPLF+)
CN91-1
CN103-29 (59, SPLF)
CN91-2 Load sensor
CN101-32 (51, POT-)
CN91-3
Probable cause: (1) Connector contact defect (2) Load sensor defect (3) Load sensor harness defect (4) Main controller defect Error code 61-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN91 connector, and visually check inside the connector and 61-1 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN91 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
61-1 error occurs. Inspection: Check of load sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN91 connector and connect CN91-1 to CN91-2 on the harness side through 09230-13700-71. 3. Connect the battery plug and turn on the key switch. Check the error code.
61-2 error occurs.
Load sensor defect
61-1 error occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for its continuities. OK Main controller defect
NG
Harness defect
5-145 Error code 61-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN91 connector, and visually check inside the connector and 61-2 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN91 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
61-2 error occurs. Inspection: Check of load sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN91 connector. 3. Connect the battery plug and turn on the key switch. Check the error code.
61-1 error occurs.
Load sensor defect
61-2 error occurs. Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1, 2: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN7, CN101, CN103 and CN104 connectors, and with SST disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN104-12 to CN7-1
Continuity
61-1
*1
CN103-29 to CN7-2
Continuity
61-1
*1
CN101-32 to CN7-3
Continuity
61-2
*2
CN7-3 to CN7-2
No continuity
61-1
CN7-3 to CN7-1
No continuity
61-1
CN7-2 to CN7-1
No continuity
61-2
*1:Connect CN7-1 and CN7-2 on the harness side through 09230-13700-71 and check if there is continuity between CN104-12 and CN103-29. *2:Connect CN7-2 and CN7-3 on the harness side through 09230-13700-71 and check if there is continuity between CN103-29 and CN101-32.
5-146
z Error Code 62-1,-2 (Tilt angle sensor abnormality) Related portion
Main controller
CN101-20 (57, VRTA+)
CN86-1
CN103-17 (56, VRTA)
CN86-2
CN101-32 (51, POT-)
CN86-3
Tilt angle sensor
Probable cause: (1) Connector contact defect (2) Tilt angle sensor defect (3) Tilt angle sensor harness defect (4) Main controller defect Error code 62-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN86 connector, and visually check inside the connector and 62-1 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN86 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
62-1 error occurs. Inspection: Check of tilt angle sensor 1. Turn off the key switch and disconnect the battery plug. 62-2 2. Disconnect the CN86 connector and connect CN86-1 and CN86-2 error occurs. on the harness side through 09232-13130-71. 3. Connect the battery plug and turn on the key switch. Check the error code.
Tilt angle sensor defect
62-1 error occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-147 Error code 62-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN86 connector, and visually check inside the connector and 62-2 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN86 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
62-2 error occurs. Inspection: Check of tilt angle sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN86 connector. 3. Connect the battery plug and turn on the key switch. Check the error code.
62-1 error occurs.
Tilt angle sensor defect
62-2 error occurs. Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1, 2: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN86, CN101, and CN103 connectors, and with SST disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN101-20 to CN86-1
Continuity
62-1
*1
CN103-17 to CN86-2
Continuity
62-1
*1
CN101-32 to CN86-3
Continuity
62-2
*2
CN86-3 to CN86-2
No continuity
62-1
CN86-3 to CN86-1
No continuity
62-1
CN86-2 to CN86-1
No continuity
62-2
*1:Connect CN86-1 and CN86-2 on the harness side through 09232-13130-71 and check if there is continuity between CN101-20 and CN103-17 *2:Connect CN86-2 and CN86-3 on the harness side through 09232-13130-71 and check if there is continuity between CN103-17 and CN101-32
5-148
z Error Code 64-1,-2,-3,-4 (Lift lower lock solenoid abnormality) Related portion
CN101-1 (3, SOLLU+)
CN88-2
CN102-16 (4, SLLL-)
CN88-1
CN103-5 (N2, N2) Main controller
Lift lock solenoid
CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Lift lock solenoid harness defect (3) Lift lock solenoid defect (4) Main controller defect If the 64-3 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code 64-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN88 connector, and visually check inside the connector and 64-4 error occurs. the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN88 connector, connect the battery plug, and then turn on the key switch to check for errors. No error occurs. Lower the lift to see if an error occurs.
64-1 error does not occur.
Track down the cause of the 64-4 error.
Connector contact defect
64-1 error occurs. Inspection: Check of lift lock solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN88 and measure the resistance of the lift lock solenoid (Resistance between CN88-1 and CN88-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the lift lock solenoid or its harness. Main controller defect
5-149 Error code 64-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN88 connector, and visually check inside the connector and 64-3 the caulked portion of its wire for defects. (Refer to BEFORE error occurs. TROUBLESHOOTING) 2. Connect the CN88 connector, connect the battery plug, and then turn on the key switch to check for errors. No error occurs. Lower the lift to see if an error occurs.
64-2 error does not occur.
Track down the cause of the 64-3 error.
Connector contact defect
64-2 error occurs. Inspection: Check of lift lock solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN88 and measure the resistance of the NG lift lock solenoid (Resistance between CN88-1 and CN88-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
Lift lock solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect Error code 64-3 Turn off the key switch and disconnect the battery plug, disconnect the CN88 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) Inspection: Check of lift lock solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN88 and measure the resistance of the lift lock solenoid (Resistance between CN88-1 and CN88-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the lift lock solenoid or its harness. Main controller defect
5-150 Error code 64-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN88 connector, and visually check inside the connector and 64-4 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN88 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
64-4 error occurs. Inspection: Check of lift lock solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN88 and measure the resistance of the NG lift lock solenoid (Resistance between CN88-1 and CN88-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
Lift lock solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN88, CN101, CN102, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN101-1 to CN88-1
Continuity
64-4
* *
CN102-16 to CN88-2
Continuity
64-4
CN101-1 to CN104-4
No continuity
64-4
CN102-16 to CN104-4
No continuity
64-4
CN88-2 to CN88-1
No continuity
64-1,2,3,4
CN88-2 to P1
No continuity
64-1,2,3,4
CN88-2 to P4
No continuity
64-1,2,3,4
*Connect the CN88 connector and measure the resistance between CN101-1 and CN102-16 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C)
5-151
z Error Code 65-1,-2,-3,-4 (Tilt control solenoid abnormality) Related portion
CN101-2 (6, SLTFB+)
CN89-2
CN102-19 (7, SLTFL-)
CN89-1
CN103-5 (N2, N2) Main controller
Tilt solenoid
CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Tilt control solenoid defect (3) Tilt control solenoid harness defect (4) Main controller defect If the 65-3 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code 65-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN89 connector, and visually check inside the connector and 65-4 the caulked portion of its wire for defects. (Refer to BEFORE error occurs. TROUBLESHOOTING) 2. Connect the CN89 connector, connect the battery plug, and then turn on the key switch to check for errors. No error occurs. Tilt the mast forward to check again if an error occurs.
65-1 error does not occur.
Track down the cause of the 65-4 error.
Connector contact defect
65-1 error occurs. Inspection: Check of tilt control solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN89 and measure the resistance of the tilt control solenoid (Resistance between CN89-1 and CN89-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the tilt control solenoid or its harness. Main controller defect
5-152 Error code 65-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN89 connector, and visually check inside the connector and 65-3 the caulked portion of its wire for defects. (Refer to BEFORE error occurs. TROUBLESHOOTING) 2. Connect the CN89 connector, connect the battery plug, and then turn on the key switch to check for errors. No error occurs. Tilt the mast forward to check again if an error occurs.
65-2 error does not occur.
Track down the cause of the 65-3
Connector contact defect
65-2 error occurs. Inspection: Check of tilt control solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN89 and measure the resistance of the NG tilt control solenoid (Resistance between CN89-1 and CN89-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
Tilt control solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Error code 65-3 Turn off the key switch and disconnect the battery plug, disconnect the CN89 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) Inspection: Check of tilt control solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN89 and measure the resistance of the tilt control solenoid (Resistance between CN89-1 and CN89-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the tilt control solenoid or its harness. Main controller defect
5-153 Error code 65-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN89 connector, and visually check inside the connector and 65-4 the caulked portion of its wire for defects. (Refer to BEFORE error not occur. TROUBLESHOOTING) 2. Connect the CN89 connector, connect the battery plug, and then turn on the key switch to check for errors.
Connector contact defect
65-4 error occurs. Inspection: Check of tilt control solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN89 and measure the resistance of the NG tilt control solenoid (Resistance between CN89-1 and CN89-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
Tilt control solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN89, CN101, CN102, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN101-2 to CN89-1
Continuity
65-4
* *
CN102-19 to CN89-2
Continuity
65-4
CN101-2 to CN104-4
No continuity
65-4
CN102-19 to CN104-4
No continuity
65-4
CN89-2 to CN89-1
No continuity
65-1,2,3,4
CN89-2 to P1
No continuity
65-1,2,3,4
CN89-2 to P4
No continuity
65-1,2,3,4
*Connect the CN89 connector and measure the resistance between CN101-2 and CN102-19 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C)
5-154
z Error Code 66-1 (outside the range of matching value for tilt angle error) Related portion
Main controller
Probable cause: (1) The tilt horizontal angle matching value is outside the specified matching range. (2) The forward tilt angle matching value is outside the specified matching range. (3) The load sensor matching value is outside the specified matching range. Matching Perform matching of the tilt horizontal angle, the forward tilt angle, and the load sensor. Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, 66-1 error occurs. Main controller defect
After the completion of matching, 66-1 error does not occur. Use the device as it is.
5-155
z Error Code 67-1 (Lifting height switch open) Related portion
Main controller
CN102-10 (51, LS-)
CN92-1
CN104-22 (90, SH1)
CN92-2
CN103-24 (91, SH2-1)
CN92-3
Lifting height switch
Probable cause: (1) Connector contact defect (2) Harness defect
(3) Lifting height switch defect (4) Main controller defect
Error code 67-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN92 connector, and visually check inside the connector and 67-1 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN92 connector and the battery plug, turn on the key switch, and then raise the lift from its lowermost to uppermost position to see if an error occurs.
Connector contact defect
67-1 error occurs. Inspection: Check of lifting switch input value Turn on the key switch and check the value of SH using the Analyzer SH: 000 menu. [ANL] I/O M.HANDLING 2/8 (SH)
1
SH: Other than 000 Inspection: Check of lifting switch input value 1. Lower the lift to its lowermost position. 2. Turn off the key switch and disconnect the battery plug. 3. Disconnect the CN92 connector. 4. Turn on the key switch and check the value of SH using the Analyzer menu. [ANL] I/O M.HANDLING 2/8 (SH)
SH: 000
Lifting height switch defect
SH: Other than 000 A
A
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-156 1
Is the lifting height switch equipped?
NO
2
YES Inspection: Check of mast lifting height 1. Visually check the state of the lifting switch when an error is detected.
Lifting height switch arm is released. (High lifting height) 3
Lifting height switch arm is held. (Low lifting height) Inspection: Check of the lifting height switch as a single unit. 1. Keep the conditions under which the error occurs. 2. Turn off the key switch and disconnect the battery plug. 3. Disconnect the CN92. 4. Check for continuity on the switch side. CN92-1 to CN92-2 Continuity CN92-1 to CN92-3 Continuity
NG
Lifting height switch defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
2 Inspection 2: Harness check Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-157 3 Inspection: Check of the lifting height switch as a single unit. 1. Keep the conditions under which the error occurs. 2. Turn off the key switch and disconnect the battery plug. 3. Disconnect the CN92 connector. 4. Check for continuity on the switch side. CN92-1 to CN92-2 No continuity CN92-1 to CN92-3 Continuity
NG
Lifting height switch defect
OK Inspection 1: Harness check Disconnect the CN102,103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN92, CN102, CN103 and CN104 connectors disconnected. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN102-10 to CN92-1
Continuity
CN104-22 to CN92-2
Continuity
CN103-24 to CN92-3
Continuity
CN92-1 to CN92-2
No continuity
CN92-1 to CN92-3
No continuity
CN92-2 to CN92-3
No continuity
Inspection 2: Check each harness for its continuity. Perform this check with the CN102, CN103 and CN104 connectors disconnected. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN102-10 to CN104-22
Continuity
CN104-22 to CN103-24
No continuity
CN103-24 to CN102-10
No continuity
5-158
z Error Code 68-1,-2,-3,-4,-5 (Lifting height sensor abnormality) Related portion
Main controller
CN101-32 (51, POT-)
CN90-1
CN101-24 (219, VRH+)
CN90-2
CN103-28 (220, VRH)
CN90-3
Lifting height sensor
Probable cause: (1) Lifting height sensor defect (2) Connector contact defect (3) Lifting height sensor harness defect (4) Main controller defect (5) Lowermost lift position matching value is outside the specified matching range. Error code 68-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN90 connector, and visually check inside the connector and 68-1 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN90 connector, connect the battery plug, and then turn on the key switch to check how the vehicle operates and if an error occurs.
Connector contact defect
68-1 error occurs. Inspection: Check of lifting height sensor as a single unit 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect CN90 and connect CN90-2 to CN90-3 on the harness side through 09238-13130-71. 3. Connect the battery plug and turn on the key switch. Check the error code.
68-2 error occurs.
Lifting height sensor defect
68-1 error occurs. Inspection 1: Continuity and short check of harness 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-159 Error code 68-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN90 connector, and visually check inside the connector and 68-2 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN90 connector, connect the battery plug, and then turn on the key switch to check how the vehicle operates and if an error occurs.
Connector contact defect
68-2 error occurs. Inspection: Check of lifting height sensor as a single unit 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN90 connector. 3. Connect the battery plug and turn on the key switch. Check the error code.
68-1 error occurs.
Lifting height sensor defect
68-2 error occurs. Inspection 1: Continuity and short check of harness 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect Error code 68-3 Visual check of lifting height sensor • Is the wire broken? • Is the wire wound around or pulled out of the reel correctly when the lift is raised to or lowered from an elevated position? (V mast: all mast height, FSV mast: high lifting height only)
NG
Lifting height sensor defect
OK 1. Turn off the key switch and disconnect the battery plug, disconnect the CN90 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN90 connector, connect the battery plug, and then turn on the key switch. Inspection: Check of lifting height sensor input value Raise the lift to an elevated position. Then, further raise the lift by 1 m from this position and check the change in the value of VRH at that time. Check the value of VRH using the Analyzer menu. Multifunction/ DX: [ANL] I/O M.HANDLING 2/8
Change in VRH value: 0.5 or more
Normal (Connector contact defect)
Change in VRH value: Less than 0.5 Inspection 1: Continuity and short check of harness 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN90, CN101 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-160 Error code 68-4 Check Iowermost lift position matching value • Has the lowermost lift position value been changed before error code appears?
Changed
Perform lowermost lift position matching. (Refer to section 13 MATCHING) 68-4 error does not occur after matching
Not changed.
Normal Visual check of lifting height sensor • Is the wire broken? • Is the wire wound around or pulled out of the reel correctly when the lift is raised to or lowered from an elevated position?
NG
Lifting height sensor defect
OK 1. Turn off the key switch and disconnect the battery plug, disconnect 68-4 error the CN90 connector, and visually check inside the connector and does not the caulked portion of its wire for defects. (Refer to BEFORE occur TROUBLESHOOTING) 2. Connect the CN90 connector, connect the battery plug, and then turn on the key switch.
Connector contact defect
68-4 error occurs. Inspection 1: Continuity and short check of harness 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN90, CN101 and CN103 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Error code 68-5
Perform lowermost lift position matching. Refer to DISPLAY / MASK FUNCTION / MATCHING 68-5 error occurs after matching Main controller defect
68-5 error does not occur after matching Normal
5-161
Inspection 1: Harness continuity/shorts Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN90, CN101 and CN103 and perform the check without connecting SST.
Portions to be checked
Standard
Point
CN101-24 to CN90-2
Continuity
68-1, 3, 4
*1
CN103-28 to CN90-3
Continuity
68-1, 3, 4
*1
CN101-32 to CN90-1
Continuity
68-2, 3, 4
*2
CN90-1 to CN90-3
No continuity
68-1, 3, 4
CN90-2 to CN90-1
No continuity
68-1, 3, 4
CN90-3 to CN90-2
No continuity
68-2, 3, 4
*1:Connect CN90-2 and CN90-3 on the harness side through 09238-13130-71 and check if there is continuity between CN101-24 and CN103-28. *2:Connect CN90-3 and CN90-1 on the harness side through 09238-13130-71 and check if there is continuity between CN103-28 and CN101-32.
5-162
z Error Code 71-1,-2,-3 (Tire angle sensor abnormality) Related portion
Main controller
CN101-23 (316, VRTRA+)
CN97-3
CN102-31 (317, VRTRA)
CN97-2
CN102-26 (51, POT-)
CN97-1
Tire angle sensor
Probable cause: (1) Connector contact defect (2) Tire angle sensor harness defect (3) Tire angle sensor defect (4) Tire angle sensor joint, rear axle link system defect (5) Main controller defect Error code 71-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN97 connector, and visually check inside the connector and 71-1 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN97 connector, connect the battery plug, and then turn on the key switch to check how the steering operates and if an error occurs.
71-1 error occurs.
71-1 error occurs. Inspection: Check of tire angle sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN97connector and connect CN97-3 and CN97-2 on the harness side. 3. Connect the battery plug and turn on the key switch to check the error code.
71-2 error occurs.
Tire angle sensor defect
71-1 error occurs. Inspection: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the battery plug and the CN101 and CN102 connectors and check the harness for their continuities. OK Main controller defect
Harness defect
5-163 Error code 71-2, -3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN97 connector, and visually check inside the connector and 71-2, 71-3 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN97 connector, connect the battery plug, and then turn on the key switch to check how the steering operates and if an error occurs.
Connector contact defect
71-2 or 71-3 error occurs. Inspection: Check of tire angle sensor 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN97 connector. 3. Connect the battery plug and turn on the key switch to check the error code.
71-3 error occurs.
Tire angle sensor defect Tire angle sensor installation portion defect.
71-2 error occurs or no error occurs. Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1, 2: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug and the CN97, CN101 and CN102 connectors and with SST disconnected visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN101-23 to CN97-3
Continuity
71-1
*1
CN102-31 to CN97-2
Continuity
71-1
*1
CN102-26 to CN97-1
Continuity
71-2
*2
CN97-1 to CN97-2
Continuity
71-1
CN97-1 to CN97-3
Continuity
71-1
CN97-2 to CN97-3
Continuity
71-2
*1:Connect CN97-3 and CN97-2 on the harness side through 09232-13130-71 and check if there is continuity between CN101-23 and CN102-31. *2:Connect CN97-1 and CN97-2 on the harness side through 09232-13130-71 and check if there is continuity between CN110-26 and CN110-31.
5-164
z Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality) Related portion
Main controller
CN103-13 (311, SSTR+)
CN19-1
CN104-30 (312, SSTR1)
CN19-3
CN104-31 (313, SSTR2)
CN19-4
CN104-24 (314, SSTRC)
CN19-5
CN102-10 (51, LS-)
CN19-2
Steering angle sensor
Probable cause: (1) Connector contact defect (2) Steering angle sensor harness defect (3) Steering angle sensor defect (4) Main controller defect The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is rotated. Error code 72-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN19 connector, and visually check inside the connector and 72-1 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN19 connector, connect the battery plug, turn on the key switch, and turn the steering wheel to see if an error occurs.
Connector contact defect
72-1 error occurs. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR) SSTR: 0** (* represents either 0 or 1.) Turn off the key switch, disconnect the battery plug and disconnect the CN19 connector. After that, connect CN19-2 to CN19-3 (on the main harness side) through 09232-13130-71 to short them, and then connect the battery plug and turn on the key switch.
B
SSTR: 1** (* represents either 0 or 1.)
A
5-165
B Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: 1** (* represents either 0 or 1.)
Steering angle sensor defect
SSTR: 0** (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities.
NG
Main harness defect
OK Main controller defect
A Turn off the key switch and disconnect the battery plug and the CN19 connector. Connect the battery plug and turn on the key switch. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: 0** (* represents either 0 or 1.)
Steering angle sensor defect
SSTR: 1** (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Main harness defect
5-166 Error code 72-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN19 connector, and visually check inside the connector and 72-2 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING.) 2. Connect the CN19 connector, connect the battery plug, turn on the key switch, and turn the steering wheel to see if an error occurs.
Connector contact defect
72-2 error occurs Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: *1* (* represents either 0 or 1.)
C
SSTR: *0* (* represents either 0 or 1.) Turn off the key switch, disconnect the battery plug and disconnect the CN19 connector. After that, connect CN19-2 to CN19-4 (on the main harness side) through 09232-13130-71 to short them, and then connect the battery plug and turn on the key switch. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR
SSTR: *1* (* represents either 0 or 1.)
Steering angle sensor defect
SSTR: *0* (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities.
NG
Main harness defect
OK Main controller defect
C Disconnect the CN104 connector and disconnect the CN19 connector. Connect the battery plug and turn on the key switch. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: *0* (* represents either 0 or 1.)
Steering angle sensor defect
SSTR: *1* (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Main harness defect
5-167 Error code 72-3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN19 connector, and visually check inside the connector and 72-3 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN19 connector, connect the battery plug, turn on the key switch, and turn the steering wheel to see if an error occurs.
Connector contact defect
72-3 error occurs. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: **1 (* represents either 0 or 1.)
E
SSTR: **0 (* represents either 0 or 1.) Turn off the key switch, disconnect the battery plug and disconnect the CN19 connector. After that, connect CN19-2 to CN19-5 (on the main harness side) through 09232-13130-71 to short them, and then connect the battery plug and turn on the key switch. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: **1 (* represents either 0 or 1.)
Steering angle sensor defect
SSTR: **0 (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities.
NG
Main harness defect
OK Main controller defect
E Turn off the key switch and disconnect the CN104 connector and disconnect the CN19 connector. Connect the battery plug and turn on the key switch. Inspection: Checking the state, turning the steering wheel Turn on the key switch and check the value of SSTR using the Analyzer menu. STD: [ANL] 5 IO4 4-06 (SSTR) Multifunction/ DX: [ANL] I/O STEERING 1/1 (SSTR)
SSTR: **0 (* represents either 0 or 1.) Steering angle sensor defect
SSTR: **1 (* represents either 0 or 1.) Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Main harness defect
5-168 Error code 72-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN19 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE 72-4 TROUBLESHOOTING) error does not occur. 2. Connect the CN19 connector, connect the battery plug, turn on the key switch, and turn the steering wheel to see if an error occurs. (If the steering wheel cannot be turned easily, perform this check with the direction switch in the Forward or Reverse position.)
Connector contact defect
72-4 error occurs. Inspection: Check of sensor supply voltage 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN19 connector. 3. Connect the battery plug and turn on the key switch. 4. Check the supply voltage to the sensor. CN19-1 ⇔ CN19-2
Approx. 15 V
Approx. 0 V Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN104 connectors and check the harnesses for their continuities. OK
NG
Main harness defect
Main controller defect Turn off the key switch, disconnect the battery plug, and then connect CN19. Connect the battery plug and turn on the key switch. Track down the cause of 72-1 (SSTR1). Proceed to identify the cause of 72-2 (SSTR2).
5-169 Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN19, CN102, CN103 and CN104 and perform the check without connecting SST. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Point
CN104-30 to CN19-3
Continuity
72-1
*1
CN104-31 to CN19-4
Continuity
72-2
*2
CN104-24 to CN19-5
Continuity
72-3
*3
CN103-13 to CN19-1
Continuity
72-4
*4
CN102-10 to CN19-2
Continuity
72-4
*4
CN19-1 to CN19-3
No continuity
72-1
CN19-1 to CN19-4
No continuity
72-2
CN19-1 to CN19-5
No continuity
72-3
CN19-2 to CN19-3
No continuity
72-1
CN19-2 to CN19-4
No continuity
72-2
CN19-2 to CN19-5
No continuity
72-3
CN19-1 to CN19-2
No continuity
72-1,2,3,4
*1:Connect CN19-1 and CN19-3 on the harness side through 09232-13130-71 and check if there is continuity between CN103-13 and CN104-30. *2:Connect CN19-1 and CN19-4 on the harness side through 09232-13130-71 and check if there is continuity between CN103-13 and CN104-31. *3:Connect CN19-1 and CN19-5 on the harness side through 09232-13130-71 and check if there is continuity between CN103-13 and CN104-24. *4:Connect CN19-1 and CN19-2 on the harness side through 09232-13130-71 and check if there is continuity between CN103-13 and CN102-10.
5-170
z Error Code 73-1,-2,-3,-4 (Steering knob correcting solenoid abnormality) Related portion
CN102-7 (329, SLS+)
CN98-2
CN102-14 (330, SLS-)
CN98-1
CN103-5 (N2, N2) Main controller
Steering knob correcting solenoid
CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Knob position correcting solenoid harness defect
(3) Knob position correcting solenoid defect (4) Main controller defect
If the 73-3 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code 73-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN98 connector, and visually check inside the 73-4 connector and the caulked portion of its wire for defects. (Refer to error occurs. BEFORE TROUBLESHOOTING) Connect the CN98 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the 73-4 error.
No error occurs. Using Active Test, forcibly turn on the output of the knob position correcting solenoid to see if an error occurs. STD: [ANL]7 ACT 7-01 STEERING SOL Multifunction/ DX: [ANL] ACTIVE TEST 1/2 STEERING SOL
73-1 error does not occur.
Connector contact defect
73-1 error occurs. Inspection: Check of knob position correcting solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN98 and measure the resistance of the knob position correcting solenoid (Resistance between CN98-1 and CN98-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the knob position correcting solenoid or its harness. Main controller defect
5-171 Error code 73-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN98 connector, and visually check inside the connector and 73-3 the caulked portion of its wire for defects. (Refer to BEFORE error occurs. TROUBLESHOOTING) Connect the CN98 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the 73-3 error.
No error occurs. Using Active Test, forcibly turn on the output of the knob position correcting solenoid to see if an error occurs.
73-2 error does not occur.
STD: [ANL]7 ACT 7-01 STEERING SOL Multifunction/ DX: [ANL] ACTIVE TEST 1/2 STEERING SOL
Connector contact defect
73-2 error occurs. Inspection: Check of knob position correcting solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect CN98 and measure the resistance of the knob position correcting solenoid (Resistance between CN98-1 and CN98-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
NG
Knob position correcting solenoid defect
OK Inspection 1: Harness check NG Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Error code 73-3 Turn off the key switch and disconnect the battery plug, disconnect the CN98 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) Inspection: Check of knob position correcting solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect CN98 and measure the resistance of the knob position correcting solenoid (Resistance between CN98-1 and CN98-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C) Inspection 1: Harness check Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities. Portion where a problem was found during a check of the knob position correcting solenoid or its harness. Main controller defect
5-172 Error code 73-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN98 connector, and visually check inside the connector and 73-4 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) Connect the CN98 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
73-4 error occurs. Inspection: Check of knob position correcting solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the connector CN98 and measure the resistance of the NG knob position correcting solenoid (Resistance between CN98-1 and CN98-2). Standard value: 7 to 17 Ω (approx. 10 Ω at 20°C)
Knob position correcting solenoid defect
OK Inspection 1: Harness check NG Disconnect the CN102, CN103 and CN104 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN98, CN102, CN103 and CN104 connectors, Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN102-7 to CN98-2
Continuity
73-4
* *
CN102-14 to CN98-1
Continuity
73-4
CN102-7 to CN104-4
No continuity
73-4
CN102-14 to CN104-4
No continuity
73-4
CN98-1 to CN98-2
No continuity
73-1,2,3,4
CN98-2 to P1
No continuity
73-1,2,3,4
CN98-2 to P4
No continuity
73-1,2,3,4
*Connect the CN98 connector and measure the resistance between CN102-7 and CN102-14 to see if it falls
between 7 and 17 Ω (approx. 10 Ω at 20°C).
5-173
z Error Code 74-1 (Outside the range of matching value for tire angle error) Related portion
Main controller
Probable cause: Tire straight running matching value is outside the specified matching range. If the 71-1, 71-2 or 71-3 error occurs, identify the cause of it first, and then perform the following.
Perform tire straight running matching. Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, 74-1 error occurs. Main controller defect
After the completion of matching, 74-1 error Matching has been made does not occur. correctly. Use the device as it is.
5-174
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer abnormality) Related portion
Main controller
CN101-25 (28, VRL+)
CN115-4
CN103-26 (20, VRL1)
CN115-2
CN103-18 (21, VRL2)
CN115-3
CN102-26 (51, POT-)
CN115-1
Lift lever potentiometer
If the lever was removed for a check, be sure to perform matching after installing it. The H1-4 error may occur if the key switch is turned on while the lift lever is being operated. * For the mini lever specification, CN115 is changed into CN162 and CN116 is changed into CN163.
Probable cause: (1) Connector contact defect (2) Lift lever potentiometer harness defect (3) Lift lever potentiometer defect (4) Main controller defect Error code H1-1, -2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN115 connector, and visually check inside the connector and H1-1, -2 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. Connector contact defect TROUBLESHOOTING) 2. Connect the CN115 connector, connect the battery plug, and turn on the key switch to see if an error occurs. H1-1, -2 error One of these errors occurs. Inspection: Check of lift lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the lift lever potentiometer connector (CN115) with the tilt lever potentiometer connector (CN116). 3. Connect the battery plug and turn on the key switch. Check the error code.
H2-1, -2 error One of these errors occurs. H1-4, H2-4 can be ignored.
Lift lever potentiometer defect
H1-1, -2 error One of these errors occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101,CN102 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-175 Error code H1-3 1. Turn off the key switch and disconnect the battery plug, and visually check inside the CN115 connector and the caulked portion H1-3 error does not of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) occur after matching 2. Connect the CN115 connector, connect the battery plug, and turn on the key switch. 3. Perform matching of the lift lever potentiometer and see if any error occurs.
Connector contact defect
Lift lever matching does not complete Inspection: Check of lift lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the lift lever potentiometer connector (CN115) with the tilt lever potentiometer connector (CN116). 3. Connect the battery plug and turn on the key switch. Perform matching of the tilt lever potentiometer.
Tilt lever matching does not complete
Lift lever potentiometer defect
H1-4, H2-4 can be ignored.
Tilt lever matching complete Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101,CN102 and CN103 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect (*Perform matching after troubleshooting.)
Error code H1-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN115 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN115 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
H1-4 error does not occur.
Connector contact defect
H1-4 error occurs. Inspection: Check of lift lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Check if the lift lever potentiometer is installed correctly. 3. Connect the battery plug and turn on the key switch. 4. Perform matching of the lift lever potentiometer. Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION / MATCHING
OK
Incorrect installation
NG Lift lever potentiometer defect Error code H1-5
Matching of the lift lever potentiometer Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, H1-5 error occurs. Main controller defect
After the completion of matching, H1-5 error does not occur.
Matching has been made correctly. Use the device as it is.
5-176 Inspection 1: Check each harness for its continuity. With the battery plug and the CN115, CN101, CN102 and CN103 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) { : Items to be checked Portions to be checked
Standard
CN101-25 to CN115-4 CN103-26 to CN115-2
H1 1
2
3
4
5
Continuity
{
−
−
−
−
Continuity
{
−
−
−
−
CN103-18 to CN115-3
Continuity
{
−
−
−
−
CN102-26 to CN115-1
Continuity
−
{
−
−
−
CN115-2 to CN115-1
No continuity
{
−
{
−
−
CN115-3 to CN115-1
No continuity
{
−
{
−
−
CN115-2 to CN115-4
No continuity
−
{
{
−
−
CN115-3 to CN115-4
No continuity
−
{
{
−
−
CN115-4 to CN115-1
No continuity
{
−
{
−
−
CN115-2 to CN115-3
No continuity
−
−
{
−
−
5-177
z Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality) Related portion
Main controller
CN101-28 (29, VRT+)
CN116-4
CN102-23 (22, VRT1)
CN116-2
CN102-22 (23, VRT2)
CN116-3
CN102-26 (51, POT-)
CN116-1
Tilt lever potentiometer
If the lever was removed for a check, be sure to perform matching after installing it. The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated. * For the mini lever specification CN116 is changed into CN163 and CN115 is changed into CN162.
Probable cause: (1) Connector contact defect (2) Tilt lever potentiometer harness defect (3) Tilt lever potentiometer defect (4) Main controller defect Error code H2-1, -2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN116 connector, and visually check inside the connector and H2-1, -2 the caulked portion of its wire for defects. (Refer to BEFORE error does not occur. TROUBLESHOOTING) 2. Connect the CN116 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H2-1, -2 error One of these errors occurs. Inspection: Check of tilt lever potentiometer H1-1, -2 error 1. Turn off the key switch and disconnect the battery plug. One of these errors 2. Replace the tilt lever potentiometer connector (CN116) with the lift occurs. lever potentiometer connector (CN115). H1-4, H2-4 3. Connect the battery plug and turn on the key switch. can be ignored. Check the error code.
Tilt lever potentiometer defect
H2-1, -2 error One of these errors occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-178 Error code H2-3 1. Turn off the key switch and disconnect the battery plug, and visually check inside the CN116 connector and the caulked portion H2-3 error does not of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) occur after matching 2. Connect the CN116 connector, connect the battery plug, and turn on the key switch. 3. Perform matching of the tilt lever potentiometer and see if any error occurs.
Connector contact defect
Tilt lever matching does not complete Inspection: Check of tilt lever potentiometer 1. Turn off the key switch and disconnect the battery plug. Tilt lever matching 2. Replace the tilt lever potentiometer connector (CN116) with the lift does not complete lever potentiometer connector (CN115). H1-4, H2-4 3. Connect the battery plug and turn on the key switch. Perform can be ignored. matching of the lift lever potentiometer.
Tilt lever potentiometer defect
Lift lever matching complete Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect (*Perform matching after troubleshooting.) Error code H2-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN116 connector, and visually check inside the connector and H2-4 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN116 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H2-4 error occurs. Inspection: Check of tilt lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Check if the tilt lever potentiometer is installed correctly. 3. Connect the battery plug and turn on the key switch. 4. Perform matching of the tilt lever potentiometer. Refer to MULTI-FUNCTION DISPLAY /MASK FUNCTION / MATCHING
OK
Incorrect installation
NG Tilt lever potentiometer defect Error code H2-5
Matching of the tilt lever potentiometer Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, H2-5 error occurs. Main controller defect
After the completion of matching, Matching has been made H2-5 error does not occur. correctly. Use the device as it is.
5-179
Inspection 1: Check each harness for its continuity. With the battery plug and the CN116, CN101, CN102 and CN103 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
CN101-28 to CN116-4 CN102-23 to CN116-2
H2 1
2
3
4
5
Continuity
{
−
−
−
−
Continuity
{
−
−
−
−
CN102-22 to CN116-3
Continuity
{
−
−
−
−
CN102-26 to CN116-1
Continuity
−
{
−
−
−
CN116-2 to CN116-1
No continuity
{
−
{
−
−
CN116-3 to CN116-1
No continuity
{
−
{
−
−
CN116-2 to CN116-4
No continuity
−
{
{
−
−
CN116-3 to CN116-4
No continuity
−
{
{
−
−
CN116-4 to CN116-1
No continuity
{
−
{
−
−
CN116-2 to CN116-3
No continuity
−
−
{
−
−
5-180
z Error Code H3-1, -2, -3, -4, -5 (Attachment 1 lever potentiometer abnormality) Related portion
Main controller
CN101-29 (30, VRAT1+)
CN119-4
CN102-21 (24, VRA11)
CN119-2
CN102-20 (25, VRA12)
CN119-3
CN102-26 (51, POT-)
CN119-1
Attachment 1 lever potentiometer
If the lever was removed for a check, be sure to perform matching after installing it. The H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being operated. * For the mini lever specification CN119 is changed into CN164 and CN115 is changed into CN162.
Probable cause: (1) Connector contact defect (3) Attachment 1 lever potentiometer defect (2) Attachment 1 lever potentiometer harness defect (4) Main controller defect Error code H3-1, -2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN119 connector, and visually check inside the connector and H3-1, -2 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. Connector contact defect TROUBLESHOOTING) 2. Connect the CN119 connector, connect the battery plug, and turn on the key switch to see if an error occurs. H3-1, -2 error One of these errors occurs. Inspection: Check of attachment 1 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the attachment 1 lever potentiometer connector (CN119) with the lift lever potentiometer connector (CN115). 3. Connect the battery plug and turn on the key switch. Check the error code.
H1-1, -2 error One of these errors occurs. H1-4, H3-4 can be ignored.
Attachment 1 lever potentiometer defect
H3-1, -2 error One of these errors occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-181 Error code H3-3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN119 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE H3-3 error does not TROUBLESHOOTING) occur after matching. 2. Connect the CN119 connector, connect the battery plug, and turn on the key switch. 3. Perform matching of the attachment 1 lever potentiometer and see if any error occurs.
Connector contact defect
Attachment 1 lever matching does not compete. Inspection: Check of attachment 1 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the attachment 1 lever potentiometer connector (CN119) with the lift lever potentiometer connector (CN115). 3. Connect the battery plug and turn on the key switch. Perform the matching of the lift lever potentiometer.
Lift lever matching does not complete H1-4, H3-4 can be ignored.
Attachment 1 lever potentiometer defect
Lift lever matching complete Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect (*Perform matching after troubleshooting.) Error code H3-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN119 connector, and visually check inside the connector and H3-4 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN119 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H3-4 error occurs. Inspection: Check of attachment 1 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Check if the attachment 1 lever potentiometer is installed correctly. 3. Connect the battery plug and turn on the key switch. 4. Perform matching of the attachment 1 lever potentiometer. Refer to DISPLAY / MASK FUNCTION / MATCHING
OK
Incorrect installation
NG Attachment 1 lever potentiometer defect
Error code H3-5
Matching of the attachment 1 lever potentiometer. Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, H3-5 error occurs. Main controller defect
After the completion of matching, Matching has been made H3-5 error does not occur. correctly. Use the device as it is.
5-182
Inspection 1: Check each harness for its continuity. Perform this check with the battery plug and the CN119, CN101 and CN102 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) { : Items to be checked H3
Portions to be checked
Standard
1
2
3
4
5
CN101-29 to CN119-4
Continuity
{
−
−
−
−
CN102-21 to CN119-2
Continuity
{
−
−
−
−
CN102-20 to CN119-3
Continuity
{
−
−
−
−
CN102-26 to CN119-1
Continuity
−
{
−
−
−
CN119-2 to CN119-1
No continuity
{
−
{
−
−
CN119-3 to CN119-1
No continuity
{
−
{
−
−
CN119-2 to CN119-4
No continuity
−
{
{
−
−
CN119-3 to CN119-4
No continuity
−
{
{
−
−
CN119-4 to CN119-1
No continuity
{
−
{
−
−
CN119-2 to CN119-3
No continuity
−
−
{
−
−
5-183
z Error Code H4-1, -2, -3, -4, -5 (Attachment 2 lever potentiometer abnormality) Related portion
Main controller
CN101-30 (31, VRAT2+)
CN120-4
CN102-29 (26, VRA21)
CN120-2
CN102-28 (27, VRA22)
CN120-3
CN102-26 (51, POT-)
CN120-1
Attachment 2 lever potentiometer
If the lever was removed for a check, be sure to perform matching after installing it. The H4-4 error may occur if the key switch is turned on while the attachment 2 lever is being operated. * For the mini lever specification CN120 is changed into CN165 and CN115 is changed into CN162.
Probable cause: (1) Connector contact defect (3) Attachment 2 lever potentiometer defect (2) Attachment 2 lever potentiometer harness defect (4) Main controller defect Error code H4-1, -2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN120 connector, and visually check inside the connector and H4-1, -2 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. Connector contact defect TROUBLESHOOTING) 2. Connect the CN120 connector, connect the battery plug, and turn on the key switch to see if an error occurs. H4-1, -2 error One of these errors occurs. Inspection: Check of attachment 2 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the attachment 2 lever potentiometer connector (CN120) with the lift lever potentiometer connector (CN115). 3. Connect the battery plug and turn on the key switch. Check the error code.
H1-1, -2 error One of these errors occurs. H1-4, H4-4 can be ignored.
Attachment 2 lever potentiometer defect
H4-1, -2 error One of these errors occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-184 Error code H4-3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN120 connector, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE H4-3 error does not TROUBLESHOOTING) occur after matching. 2. Connect the CN120 connector, connect the battery plug, and turn on the key switch. 3. Perform matching of the attachment 2 lever potentiometer and see if any error occurs.
Connector contact defect
Attachment 2 lever matching does not complete Inspection: Check of attachment 2 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Replace the attachment 2 lever potentiometer connector (CN120) with the lift lever potentiometer connector (CN115). 3. Connect the battery plug and turn on the key switch. Perform matching of the lift lever potentiometer.
Lift lever matching does not complete H1-4, H4-4 can be ignored.
Attachment 2 lever potentiometer defect
Lift lever matching complete Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN102 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect (*Perform matching after troubleshooting.) Error code H4-4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN120 connector, and visually check inside the connector and H4-4 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN120 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H4-4 error occurs. Inspection: Check of attachment 2 lever potentiometer 1. Turn off the key switch and disconnect the battery plug. 2. Check if the attachment 2 lever potentiometer is installed correctly. 3. Connect the battery plug and turn on the key switch. 4. Perform matching of the attachment 2 lever potentiometer. Refer to DISPLAY / MASK FUNCTION / MATCHING
OK
Incorrect installation
NG Attachment 2 lever potentiometer defect Error code H4-5
Matching of the attachment 2 lever potentiometer. Refer to DISPLAY / MASK FUNCTION / MATCHING After the completion of matching, H4-5 error occurs. Main controller defect
After the completion of matching, Matching has been made H4-5 error does not occur. correctly. Use the device as it is.
5-185
Inspection 1: Check each harness for its continuity. With the battery plug and the CN120, CN101 and CN102 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) { : Items to be checked H4
Portions to be checked
Standard
1
2
3
4
5
CN101-30 to CN120-4
Continuity
{
−
−
−
−
CN102-29 to CN120-2
Continuity
{
−
−
−
−
CN102-28 to CN120-3
Continuity
{
−
−
−
−
CN102-26 to CN120-1
Continuity
−
{
−
−
−
CN120-2 to CN120-1
No continuity
{
−
{
−
−
CN120-3 to CN120-1
No continuity
{
−
{
−
−
CN120-2 to CN120-4
No continuity
−
{
{
−
−
CN120-3 to CN120-4
No continuity
−
{
{
−
−
CN120-4 to CN120-1
No continuity
{
−
{
−
−
CN120-2 to CN120-3
No continuity
−
−
{
−
−
5-186
z Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality) Related portion CN101-5 (9, SLLA2+)
CN87-5
CN101-16 (11, SLPS-)
CN87-1 CN78-5
Main controller
CN101-17 (10, SLPL-)
CN78-1
Lift push solenoid Lift pull solenoid
CN103-5 (N2, N2) CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Lift push solenoid harness defect (3) Lift push solenoid defect
(4) Lift pull solenoid harness defect (5) Lift pull solenoid defect (6) Main controller defect
If the H5-5 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code H5-1, -3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H5-6 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H5-6 error.
No error occurs
H5-1, H5-3 error does Push and hold down the lift lever and pull and hold it up for more than not occur. 1 second each to check if an error occurs. H5-1 or H5-3 error occurs. Inspection: Check of lift solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the lift solenoid. (CN78-5 to CN78-1, CN87-5 to CN87-1). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the lift solenoid or its harness. Main controller defect
Connector contact defect
5-187 Error code H5-2, -4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H5-5 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H5-5 error.
No error occurs.
H5-2, H5-4 error does Push and hold up the lift lever and pull and hold it down for more than not occur. 1 second each to check if an error occurs.
Connector contact defect
H5-2 or H5-4 error occurs. Inspection: Check of lift solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the lift solenoid. (CN78-5 to CN78-1, CN87-5 to CN87-1). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Lift solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
OK Main controller defect Error code H5-5 Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Inspection: Check of lift solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the lift solenoid. (CN78-5 to CN78-1, CN87-5 to CN87-1). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the lift solenoid or its harness. Main controller defect
Harness defect
5-188 Error code H5-6 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
H5-6 error does not occur.
Connector contact defect
H5-6 error occurs. HB-2 error occurs.
Check if the HB-2 error has also occurred.
Track down the cause of the HB-2 error.
HB-2 error does not occur. Inspection: Check of lift solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the lift solenoid. (CN78-5 to CN78-1, CN87-5 to CN87-1). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Lift solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. NG 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN78, CN11, CN101, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Point
CN101-5 to CN78-5
Continuity
H5-6
*1
CN101-17 to CN78-1
Continuity
H5-6
*1
CN101-5 to CN11-5
Continuity
H5-6
*2
CN101-16 to CN11-1
Continuity
H5-6
*2
CN101-5 to CN104-4
No continuity
H5-6
CN101-17 to CN104-4
No continuity
H5-6
CN101-16 to CN104-4
No continuity
H5-6
CN78-5 to CN78-1
No continuity
H5-1, 2, 3, 4, 5, 6
CN11-5 to CN11-1
No continuity
H5-1, 2, 3, 4, 5, 6
CN78-1 to P1
No continuity
H5-1, 2, 3, 4, 5, 6
CN78-1 to P4
No continuity
H5-1, 2, 3, 4, 5, 6
CN11-1 to P1
No continuity
H5-1, 2, 3, 4, 5, 6
CN11-1 to P4
No continuity
H5-1, 2, 3, 4, 5, 6
*1:Connect CN78 to the solenoid and measure the resistance between CN101-5 and CN101-17 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C). *2:Connect CN11 to the solenoid and measure the resistance between CN101-5 and CN101-16 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
5-189
z Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality) Related portion CN101-6 (32, SLTA1+)
CN87-6
CN101-13 (34, STPS-)
CN87-2
Tilt push solenoid
CN78-6 CN78-2
CN101-12 (33, STPL-) Main controller
Tilt pull solenoid
CN103-5 (N2, N2) CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Tilt push solenoid harness defect (3) Tilt push solenoid defect
(4) Tilt pull solenoid harness defect (5) Tilt pull solenoid defect (6) Main controller defect
If the H6-5 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code H6-1, -3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H6-6 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if any error occurs.
Track down the cause of the H6-6 error.
No error occurs.
H6-1, H6-3 error does Push and hold down the tilt lever and pull and hold it up for more than not occur. 1 second each to check if an error occurs. H6-1 or H6-3 error occurs. Inspection: Check of tilt proportional solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the tilt solenoid. (CN78-6 to CN78-2, CN87-6 to CN87-2). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the tilt solenoid or its harness. Main controller defect
Connector contact defect
5-190 Error code H6-2, -4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H6-5 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H6-5 error.
No error occurs.
H6-2, H6-4 error does Push and hold up the tilt lever and pull and hold it down for more than not occur. 1 second each to check if an error occurs.
Connector contact defect
H6-2 or H6-4 error occurs. Inspection: Check of tilt proportional solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the tilt solenoid. (CN78-6 to CN78-2, CN87-6 to CN87-2). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Tilt solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
OK Main controller defect
Error code H6-5 Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Inspection: Check of tilt proportional solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the tilt solenoid. (CN78-6 to CN78-2, CN87-6 to CN87-2). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the tilt solenoid or its harness. Main controller defect
Harness defect
5-191 Error code H6-6 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the H6-6 error does not connector and the caulked portion of its wire for defects. (Refer to occur. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H6-6 error occurs. HB-2 error occurs.
Check if the HB-2 error has also occurred.
Track down the cause of the HB-2 error.
HB-2 error does not occur. Inspection: Check of tilt proportional solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors and measure the resistance of the tilt solenoid. (CN78-6 to CN78-2, CN87-6 to CN87-2). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Tilt solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN78, CN11, CN101, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Point
CN101-6 to CN78-6
Continuity
H6-6
*1
CN101-12 to CN78-2
Continuity
H6-6
*1
CN101-6 to CN11-6
Continuity
H6-6
*2
CN101-13 to CN11-2
Continuity
H6-6
*2
CN101-6 to CN104-4
No continuity
H6-6
CN101-12 to CN104-4
No continuity
H6-6
CN101-13 to CN104-4
No continuity
H6-6
CN78-6 to CN78-2
No continuity
H6-1, 2, 3, 4, 5, 6
CN11-6 to CN11-2
No continuity
H6-1, 2, 3, 4, 5, 6
CN78-2 to P1
No continuity
H6-1, 2, 3, 4, 5, 6
CN78-2 to P4
No continuity
H6-1, 2, 3, 4, 5, 6
CN11-2 to P1
No continuity
H6-1, 2, 3, 4, 5, 6
CN11-2 to P4
No continuity
H6-1, 2, 3, 4, 5, 6
*1:Connect CN78 to the solenoid and measure the resistance between CN101-6 and CN101-12 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C). *2:Connect CN11 to the solenoid and measure the resistance between CN101-6 and CN101-13 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
5-192
z Error Code H7-1, -2, -3, -4, -5, -6 (Attachment 1 PUSH/PULL solenoid abnormality) Related portion CN101-6 (32, SLTA1+)
CN87-7
Attachment 1 CN87-3 push solenoid
CN101-11 (37, SA1PS-)
CN78-7 Main controller
Attachment 1 CN78-3 push solenoid
CN101-10 (36, SA1PL-) CN103-5 (N2, N2) CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Attachment 1 push solenoid harness defect (3) Attachment 1 push solenoid defect
(4) Attachment 1 pull solenoid harness defect (5) Attachment 1 pull solenoid defect (6) Main controller defect
If the H7-5 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code H7-1, -3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H7-6 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H7-6 error.
No error occurs.
H7-1, H7-3 error does Push and hold down the attachment 1 lever and pull and hold it up for not occur. more than 1 second each to check if an error occurs. H7-1 or H7-3 error occurs. Inspection: Check of attachment 1 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 1 solenoid (CN78-7 to CN78-3, CN87-7 to CN87-3). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the attachment 1 solenoid or its harness. Main controller defect
Connector contact defect
5-193 Error code H7-2, -4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H7-5 error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H7-5 error.
No error occurs.
H7-2, H7-4 error does Push and hold up the attachment 1 lever and pull and hold it down for not occur. more than 1 second each to check if an error occurs.
Connector contact defect
H7-2 or H7-4 error occurs. Inspection: Check of attachment 1 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 1 solenoid (CN78-7 to CN78-3, CN87-7 to CN87-3). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Attachment 1 solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
OK Main controller defect Error code H7-5 Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Inspection: Check of attachment 1 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 1 solenoid (CN78-7 to CN78-3, CN87-7 to CN87-3). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the attachment 1 solenoid or its harness. Main controller defect
Harness defect
5-194 Error code H7-6 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the H7-6 error does not connector and the caulked portion of its wire for defects. (Refer to occur. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
H7-6 error occurs. Check if the HB-2 error has also occurred.
HB-2 error occurs.
Track down the cause of the HB-2 error.
NG
Attachment 1 solenoid defect
HB-2 error does not occur. Inspection: Check of attachment 1 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 1 solenoid (CN78-7 to CN78-3, CN87-7 to CN87-3). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C) OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN78, CN11, CN101, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Point
CN101-6 to CN78-7
Continuity
H7-6
*1
CN101-10 to CN78-3
Continuity
H7-6
*1
CN101-6 to CN11-7
Continuity
H7-6
*2
CN101-11 to CN11-3
Continuity
H7-6
*2
CN101-6 to CN104-4
No continuity
H7-6
CN101-10 to CN104-4
No continuity
H7-6
CN101-11 to CN104-4
No continuity
H7-6
CN78-7 to CN78-3
No continuity
H7-1, 2, 3, 4, 5, 6
CN11-7 to CN11-3
No continuity
H7-1, 2, 3, 4, 5, 6
CN78-3 to P1
No continuity
H7-1, 2, 3, 4, 5, 6
CN78-3 to P4
No continuity
H7-1, 2, 3, 4, 5, 6
CN11-3 to P1
No continuity
H7-1, 2, 3, 4, 5, 6
CN11-3 to P4
No continuity
H7-1, 2, 3, 4, 5, 6
*1:Connect CN78 to the solenoid and measure the resistance between CN101-6 and CN101-10 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C). *2:Connect CN11 to the solenoid and measure the resistance between CN101-6 and CN101-11 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
5-195
z Error Code H8-1, -2, -3, -4, -5, -6 (Attachment 2 PUSH/PULL solenoid abnormality) Related portion CN101-5 (9, SLLA2+)
CN87-8
Attachment 2 CN87-4 push solenoid
CN101-15 (40, SA2PS-)
CN78-8 Main controller
CN101-14 (39, SA2PL-)
CN78-4
Attachment 2 pull solenoid
CN103-5 (N2, N2) CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
Probable cause: (1) Connector contact defect (2) Attachment 2 push solenoid harness defect (3) Attachment 2 push solenoid defect
(4) Attachment 2 pull solenoid harness defect (5) Attachment 2 pull solenoid defect (6) Main controller defect
If the H8-5 error occurs, disconnect the battery plug immediately and track down the cause of it. Error code H8-1, -3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to H8-6 error occurs. BEFORE TROUBLESHOOTING.) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H8-6 error.
No error occurs. H8-1, H8-3 Push and hold down the attachment 2 lever and pull and hold it up for No error occurs more than 1 second each to check if an error occurs. H8-1 or H8-3 error occurs. Inspection: Check of attachment 2 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 2 solenoid (CN78-8 to CN78-4, CN87-8 to CN87-4). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the attachment 2 solenoid or its harness. Main controller defect
Connector contact defect
5-196 Error code H8-2, -4 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the H8-5 connector and the caulked portion of its wire for defects. (Refer to error occurs. BEFORE TROUBLESHOOTING) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Track down the cause of the H8-5 error.
No error occurs. H8-2, H8-4 Push and hold up the attachment 2 lever and pull and hold it down for error occurs more than 1 second each to check if an error occurs.
Connector contact defect
H8-2 or H8-4 error occurs. Inspection: Check of attachment 2 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 2 solenoid (CN78-8 to CN78-4, CN87-8 to CN87-4). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
NG
Attachment 2 solenoid defect
OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect Error code H8-5 Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Inspection: Check of attachment 2 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 2 solenoid (CN78-8 to CN78-4, CN87-8 to CN87-4). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C)
Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
Portion where a problem was found during a check of the attachment 2 solenoid or its harness. Main controller defect
5-197 Error code H8-6 1. Turn off the key switch and disconnect the battery plug, disconnect the CN78 and CN87 connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING.) 2. Connect the CN78 and CN87 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
H8-6 No error occurs
Connector contact defect
H8-6 error occurs. Check if the HB-2 error has also occurred.
HB-2 error occurs.
Track down the cause of the HB-2 error.
NG
Attachment 2 solenoid defect
HB-2 error does not occur. Inspection: Check of attachment 2 solenoid 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN78 and CN87 connectors. Measure the resistance of attachment 2 solenoid (CN78-8 to CN78-4, CN87-8 to CN87-4). Standard value: 6 to 12 Ω (approx. 7 Ω at 20°C) OK Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN103 and CN104 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN78, CN11, CN101, CN103 and CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
Point
CN101-5 to CN78-8
Continuity
H8-6
*1
CN101-14 to CN78-4
Continuity
H8-6
*1
CN101-5 to CN11-8
Continuity
H8-6
*2 *2
CN101-15 to CN11-4
Continuity
H8-6
CN101-5 to CN104-4
No continuity
H8-6
CN101-14 to CN104-4
No continuity
H8-6
CN101-15 to CN104-4
No continuity
H8-6
CN78-8 to CN78-4
No continuity
H8-1, 2, 3, 4, 5, 6
CN11-8 to CN11-4
No continuity
H8-1, 2, 3, 4, 5, 6
CN78-4 to P1
No continuity
H8-1, 2, 3, 4, 5, 6
CN78-4 to P4
No continuity
H8-1, 2, 3, 4, 5, 6
CN11-4 to P1
No continuity
H8-1, 2, 3, 4, 5, 6
CN11-4 to P4
No continuity
H8-1, 2, 3, 4, 5, 6
*1:Connect CN78 to the solenoid and measure the resistance between CN101-5 and CN101-14 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C). *2:Connect CN11 to the solenoid and measure the resistance between CN101-5 and CN101-15 to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
5-198
z Error Code HB-1, -2, -3, (Solenoid power supply circuit over current) Related portion F7 CN102-5 (17, SOLCOM)
CN127-8 (17, SOLCOM) CN127-6 (19, VBMBSL)
CN102-6 (17, SOLCOM) CN102-13 (335, RY1)
CN136-6 (19, F7)
CN127-4 (335, RY1)
RY1
CN127-2 (97, FAN+)
CN101-3 (97, FAN+) CN101-5 (9, SLLA2+)
CN87-5
CN101-16 (11, SLPS-)
CN87-1
CN101-17 (10, SLPL-)
CN78-1 CN78-5
CN101-6 (32, SLTA1+)
CN87-6
CN101-13 (34, STPS-)
CN87-2
CN101-12 (33, STPL-)
CN78-2
Main controller
CN78-6
Lift PUSH solenoid Lift PULL solenoid Tilt PUSH solenoid Tilt PULL solenoid
CN87-7 CN101-11 (37, SA1PS-)
CN87-3
CN101-10 (36, SA1PL-)
CN78-3 CN78-7
ATT1 PUSH solenoid ATT1 PULL solenoid
CN87-8 CN101-15 (40, SA2PS-)
CN87-4
CN101-14 (39, SA2PL-)
CN78-4
CN103-5 (N2, N2)
CN78-8
CN104-4 (N2, N2) CN104-5 (N2, N2) CN104-6 (N2, N2)
ATT2 PUSH solenoid ATT2 PULL solenoid
5-199
Probable cause: (1) Connector contact defect (2) Harness defect (3) RY1 defect (4) Main controller defect Error code HB-1 1. Turn off the key switch and disconnect the battery plug, disconnect the CN127 connector, and visually check inside the connector and HB-1 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN127connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
HB-1 error occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102 and CN127 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Relay defect (*1) *1 If the symptom persists after replacement of the relay, there should be any other problems, so replace the Main controller. Error code HB-2 1. Turn off the key switch and disconnect the battery plug, disconnect the CN127, CN87 and CN78 connectors, and visually check inside HB-2 error does not the connector and the caulked portion of its wire for defects. occur. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN127, CN87 and CN78 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
HB-2 error occurs. Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101, CN102, CN103, CN104, CN87 and CN78 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-200 Error code HB-3 1. Turn off the key switch and disconnect the battery plug, disconnect the CN127 connector, and visually check inside the connector and HB-3 error does not the caulked portion of its wire for defects. (Refer to BEFORE occur. TROUBLESHOOTING) 2. Connect the CN127 connector, connect the battery plug, and turn on the key switch to see if an error occurs.
Connector contact defect
HB-3 error occurs. Inspection 3: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN102 and CN127 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Relay defect (*1) *1 If the symptom persists after replacement of the relay, there should be any other problems, so replace the Main controller.
Inspection 1: Check each harness for its continuity. With the battery plug and the CN101, CN102, and CN127 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN102-13 to CN127-4
Continuity
HB-1
CN101-3 to CN127-2
Continuity
HB-1
CN102-5 to CN127-8
Continuity
HB-1
CN102-6 to CN127-8
Continuity
HB-1
CN127-6 to CN136-6
Continuity
HB-1
5-201 Inspection 2: Check each harness for its continuity. With the battery plug and the CN101, CN102, CN103, CN104, CN87 and CN78 connectors disconnected, visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN102-5 to CN104-4
No continuity
HB-2
CN102-6 to CN104-4
No continuity
HB-2
CN101-5 to CN104-4
No continuity
HB-2
CN101-6 to CN104-4
No continuity
HB-2
CN101-16 to CN104-4
No continuity
HB-2
CN101-17 to CN104-4
No continuity
HB-2
CN101-13 to CN104-4
No continuity
HB-2
CN101-12 to CN104-4
No continuity
HB-2
CN101-11 to CN104-4
No continuity
HB-2
CN101-10 to CN104-4
No continuity
HB-2
CN101-15 to CN104-4
No continuity
HB-2
CN101-14 to CN104-4
No continuity
HB-2
Inspection 3: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect the CN102 and CN127 connectors, and visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN127-4 to P1
No continuity
HB-3
CN127-4 to P4
No continuity
HB-3
CN127-4 to CN127-2
No continuity
HB-3
5-202
z Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality) Related portion
Main controller
CN103-8 (300, IPL+)
CN130-3
CN103-30 (301, IPL1)
CN130-2
CN101-32 (51, POT-)
CN130-1
Shock sensor 1
CN129-3 CN103-19 (302, IPL2)
CN129-2
Shock sensor 2
CN129-1
Probable cause: (1) Connector contact defect (2) Shock sensor harness defect (3) Shock sensor defect (4) Main controller defect Error code G5-1 or G5-4 (For G-5-4, read the numbers in brackets, which refer to the corresponding error code, connector number, etc.) 1. Turn off the key switch and disconnect the battery plug, disconnect the CN130 [CN129] connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN130 [CN129] connector, connect the battery plug, and turn on the key switch to see if an error occurs.
G5-1 [G5-4] error does not occur.
Connector contact defect
G5-1 [G5-4] error occurs. Inspection: Check of shock sensor 1 [shock sensor 2] 1. Turn off the key switch and disconnect the battery plug. G5-2 [G5-5] 2. Disconnect the CN130 [CN129] connector and connect the CN130- error occurs. 3 to CN130-2 [CN129-3 to CN129-2] on the harness side through 09232-13130-71. 3. Connect the battery plug and turn on the key switch. Check the error code.
Shock sensor 1 [shock sensor 2] defect
G5-1 [G5-4] error occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG Harness defect
5-203 Error code G5-2 or G5-5 (For G-5-5, read the numbers in brackets, which refer to the corresponding error code, connector number, etc.) 1. Turn off the key switch and disconnect the battery plug, disconnect the CN130 [CN129] connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN130 [CN129] connector, connect the battery plug, and turn on the key switch to see if an error occurs.
G5-2 [G5-5] error does not occur.
Connector contact defect
G5-2 [G5-5] error occurs. Inspection: Check of shock sensor 1 [shock sensor 2] 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN130 [CN129] connector. 3. Connect the battery plug and turn on the key switch. Check the error code.
G5-1 [G5-4] error occurs.
Shock sensor 1 [shock sensor 2] defect
G5-2 [G5-5] error occurs. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities.
NG
Harness defect
OK Main controller defect
Error code G5-3 or G5-6 (For G-5-6, read the numbers in brackets, which refer to the corresponding error code, connector number, etc.) 1. Turn off the key switch and disconnect the battery plug, disconnect the CN130 [CN129] connectors, and visually check inside the connector and the caulked portion of its wire for defects. (Refer to BEFORE TROUBLESHOOTING) 2. Connect the CN130 [CN129] connector, connect the battery plug, and turn on the key switch to see if an error occurs. (after one minute)
G5-3 [G5-6] error does not occur.
Connector contact defect
G5-3 [G5-6] error occurs. Inspection: Check of shock sensor 1 [shock sensor 2] 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN130 [CN129] connector. 3. Connect the battery plug and turn on the key switch. Check the error code.
G5-1 [G5-4] error occurs.
Shock sensor 1 [shock sensor 2] defect
G5-1 [G5-4] error does not occur. Inspection 1: Harness check 1. Turn off the key switch and disconnect the battery plug. 2. Disconnect the CN101 and CN103 connectors and check the harnesses for their continuities. OK Main controller defect
NG
Harness defect
5-204 Inspection 1: Check each harness for its continuity. Turn off the key switch and disconnect the battery plug, disconnect CN130 [CN129], CN101 and CN103 and perform the check without connecting SST. Visually check inside each connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Portions to be checked
Standard
Point
CN103-8 to CN130-3
Continuity
G5-1
*1
CN103-30 to CN130-2
Continuity
G5-1
*1
CN101-32 to CN130-1
Continuity
G5-2, -3
*2
CN130-2 to CN130-1
No continuity
G5-1
CN130-3 to CN130-1
No continuity
G5-1
CN130-3 to CN130-2
No continuity
G5-2, -3
CN103-8 to CN129-3
Continuity
G5-4
*3
CN103-19 to CN129-2
Continuity
G5-4
*3
CN101-32 to CN129-1
Continuity
G5-5, -6
*4
CN129-2 to CN129-1
No continuity
G5-4
CN129-3 to CN129-1
No continuity
G5-4
CN129-3 to CN129-2
No continuity
G5-5, -6
*1:Connect CN130-2 and CN130-3 on the harness side through 09232-13130-71 and check if there is continuity between CN103-30 and CN103-8. *2:Connect CN130-1 and CN130-2 on the harness side through 09232-13130-71 and check if there is continuity between CN103-32 and CN103-30 *3:Connect CN129-2 and CN129-3 on the harness side through 09232-13130-71 and check if there is continuity between CN103-8 and CN103-19. *4:Connect CN129-2 and CN129-1 on the harness side through 09232-13130-71 and check if there is continuity between CN101-32 and CN103-19.
Power-supply related control
Control systems Failed portions and failure modes
–
Using the Administrator menu, check if PIN has been registered.
Display (with PIN code entry) : PIN not registered Display power supply and ground harness (with PIN code entry) : Wire breakage, short circuit, leakage (harness or connector) Display (with PIN code entry) : Internal failure Main controller : Internal failure (D7V, DGND)
Check the operation of each switch. : Check if a response (lighting of LED or sounding of buzzer) is given only to a particular switch. If there are two types of switches: switch to which a response is given and switch to which no response is given in the combination of (1, 2 and 3), (4, 5 and 6), (7, 8 and 9) or (OFF, 0 and ON), it is certain that there is a defective switch.
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–
Check the battery voltage. : Battery plug is disconnected. Check the battery voltage.
How to check
Numeric keypad main body (with PIN code entry) : Switch failure
Numeric keypad harness (with PIN code entry) : Open failure
Although the key switch or tenBattery key operation is turned on, power : Low voltage is not supplied. (The display screen does not Key switch main body appear, and the vehicle does not : Open failure move.) Key switch harness : Wire breakage, short circuit or leakage (harness, connector or F5 and F6 fuses)
Phenomena on the vehicle
Probable causes of problems for which no error code is displayed If an error code is displayed or the spanner indicator blinks , be sure to perform checks with priority given to it.
WHEN NO ERROR CODE IS DISPLAYED
• Check the harness and repair or replace it if necessary. • Replace the display. • Replace the main controller.
• Register PIN using the Administrator menu.
• Replace the numeric keypad.
• Check the harness and repair or replace it if necessary.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary. • Replace the F5 and F6 fuses.
• Charge the Battery
Action and remedies
5-205
Brake sensor main body (model without 50-) Check the brake sensor voltage, using : Internal failure Analyzer. : Direction switch in neutral Brake sensor installation portion Fully open and close the brake pedal to : The link or the installation portion is broken or damaged. check the change in voltage. Brake sensor harness : Wire breakage, short circuit, leakage (harness or connector)
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
Accelerator fully closed/fully open matching value : No agreement with the vehicle state
Check the matching value on the Matching screen.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Accelerator sensor main body Check the accelerator sensor voltage, using : Internal failure Analyzer. Accelerator sensor installation portion : Direction switch is in neutral. : The link or the installation portion is broken Fully open and close the drive to check the or damaged. change in voltage at that time. Accelerator sensor harness : Wire breakage, short circuit, leakage (harness or connector)
• Operate them correctly.
• Check the harness and repair or replace it if necessary. • Replace the display. • Replace the main controller.
Action and remedies
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
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–
How to check
Check the direction switch, using Analyzer. : Accelerator is fully closed. Operate the direction switch to see if it turns on and off normally. (The vehicle does not run if the forward and reverse switches are turned on simultaneously.)
Direction switch main body : Open failure Direction switch harness : Wire breakage, short circuit (harness or connector)
The vehicle does not run. After the key switch was turned on, the (The drive motor does not rotate.) accelerator was not released or the direction switch was not returned to neutral.
Traveling
Display power supply or ground harness : Wire breakage, short circuit, leakage (harness or connector) Display : Internal failure Main controller : Internal failure
Failed portions and failure modes
The display screen does not appear. (The vehicle runs normally.)
Phenomena on the vehicle
Power-supply related control
Control systems
5-206
Traveling
Control systems Failed portions and failure modes
The vehicle does not run uphill
• Perform matching again.
: Check the matching value on the Matching screen.
Accelerator sensor fully closed/ opened matching value : no agreement with the vehicle state
• Replace the main controller. • Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
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Accelerator sensor main body Check the accelerator sensor voltage, using Analyzer. : Internal failure : Direction switch in neutral Accelerator sensor installation portion : The link or the installation portion is broken Fully open and close the accelerator pedal or damaged. to check the change in voltage. Accelerator sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Main controller : Internal failure
Check the voltage of the drive motor current sensor, using Analyzer. : Seated in seat, direction switch in forward position, brake released Operate the accelerator and check the change in the current sensor voltage.
Drive motor drive circuit : Internal failure Motor cables : Wire breakage, short circuit or leakage (cable or terminal board)
• Check the cable, and repair or replace it if necessary. • Replace the drive motor drive circuit.
• Check the drive motor speed sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the voltage of the drive motor speed sensor, using Analyzer. : Seated in seat, direction switch in forward position, brake released Operate the accelerator and check the change in the speed sensor voltage.
Main body of drive motor speed sensor : Internal failure Drive motor speed sensor installation portion : Gap improperly adjusted Drive motor harness : Wire breakage, short circuit, leakage (harness or connector)
• Check the seat and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
Action and remedies
• Check the brake, and repair or replace it if necessary. • Check the drive motor, and repair or replace it if necessary.
Check the seat switch, using Analyzer. : Direction switch in neutral, drive fully closed Check if the switch turns on and off normally, sitting in the seat or standing beside it.
: Check the matching value on the Matching screen.
How to check
Brake Check the brake and the drive motor. : Dragging (internal failure) : With the battery plug disconnected, the Drive motor parking brake released and the front : Seizure or dragging of drive motor (internal wheels off the ground, rotate each tire to failure) see if it rotates smoothly.
Seat switch main body : Open failure Seat switch harness : Wire breakage (harness, connector)
The vehicle does not run. Brake sensor fully closed/ operating point (The drive motor does not rotate.) matching value (model without 50-) : no agreement with the vehicle state
Phenomena on the vehicle
5-207
Traveling
Control systems
The vehicle does not run uphill
Phenomena on the vehicle
• Perform matching again.
Brake sensor fully closed/ operating point matching value (models without 50-) : no agreement with the vehicle state
• Replace the main controller.
• Check the cable, and repair or replace it if necessary. • Replace the drive motor drive circuit. Check the voltage of the drive motor current sensor, using Analyzer. : Seated in seat, direction switch in forward position, brake released Operate the accelerator and check the change in the current sensor voltage.
Drive motor drive circuit : Internal failure Motor cables : Wire breakage, short circuit or leakage (cable or terminal board)
–
• Check the drive motor speed sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the voltage of the drive motor speed sensor, using Analyzer. : Seated in seat, direction switch in forward position, brake released Operate the accelerator and check the change in the speed sensor voltage.
Main body of drive motor speed sensor : Internal failure Drive motor speed sensor installation portion : Gap improperly adjusted Drive motor harness : Wire breakage, short circuit, leakage (harness or connector)
Main controller : Internal failure
• Check the brake, and repair or replace it if necessary. • Check the drive motor, and repair or replace it if necessary.
Brake Check the brake and the drive motor. : Dragging (internal failure) : With the battery plug disconnected, the Drive motor parking brake released and the front : Seizure or dragging of drive motor (internal wheels off the ground, rotate each tire to failure) see if it rotates smoothly.
Check the matching value on the Matching screen.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Brake sensor main body (models without 50-) Check the brake sensor voltage, using : Internal failure Analyzer. Brake sensor installation portion : Direction switch in neutral : The link or the installation portion is broken Fully open and close the brake pedal to or damaged. check the change in voltage. Brake sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Action and remedies • Check the switch and replace it if necessary. • Check the harness and repair or replace it if necessary.
How to check
Brake switch main body (models with 50-) Check the brake switch, using Analyzer. : Internal failure : Direction switch in neutral Brake switch installation portion Operate the brake pedal to see if the brake : The link or the installation portion is broken switch turns on and off normally. or damaged. Brake switch harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
5-208
Load handling and power steering
Control systems
Only load handling cannot be performed. (The pump motor operates normally during steering operation and direction switch operation.)
Load handling cannot be performed and the steering is heavy. (The pump motor does not work for load handling operation, steering operation and direction switch operation.)
Phenomena on the vehicle
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–
Main controller : Internal failure
Check the seat switch, using Analyzer. : Load handling lever in neutral Check if the switch turns on and off normally, sitting in the seat or standing beside it.
Seat switch main body : Open failure Seat switch harness : Wire breakage (harness, connector) Pump : Leak Priority valve : Leak, seizure
Measure the voltage of the load handling lever potentiometer, using Analyzer. : Leave the seat Tilt the load handling lever forward and backward to check the change in voltage.
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Main controller : Internal failure Main body of load handling lever potentiometer : Internal failure Installation of load handling lever potentiometer : Installation portion is broken or damaged. Load handling lever potentiometer harness : Wire breakage, short circuit, leakage (harness or connector)
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Measure the voltage of the pump motor current sensor, using Analyzer. : Seated in the seat Operate the direction switch and check the change in the current sensor voltage.
Pump motor drive circuit : Internal failure Motor cables : Wire breakage, short circuit or leakage (cable or terminal board) Pump : Seizure Pump motor : Seizure
Check the voltage of the pump motor speed sensor, using Analyzer. : Seated in the seat Operate the direction switch and check the change in the speed sensor voltage.
How to check
Pump motor speed sensor main body : Internal failure Pump motor speed sensor installation portion : Gap improperly adjusted Pump motor harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
• Replace the main controller.
• Check the pump, and repair or replace it if necessary. • Check the priority valve, and repair or replace it if necessary.
• Check the seat and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the Main controller.
• Check the pump, and repair or replace it if necessary. • Check the pump motor, and repair or replace it if necessary.
• Check the motor cables, and repair or replace them if necessary. • Replace the pump motor drive circuit.
• Check the pump motor speed sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
5-209
Check the steering angle sensor, using Analyzer. : Turn the steering wheel to check the input signal.
Direction switch : Open failure Direction switch harness : Wire breakage (harness, connector) Main body of steering angle sensor : Internal damage Installation of steering angle sensor : Cam or steering wheel is defective. Steering angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
The initial material handling speed is slow, or the free play of the lever is too big.
The steering is heavy. (The pump motor operates normally during load handling.)
Although ATT1 (ATT2) is operated, no operation is performed.
Display setting Check the setting value of OCV activating : The setting value of OCV activating current current on the screen by matching menu. is different from the specified value. Check the direction switch, using Analyzer. : Accelerator is fully closed. Operate the direction switch to see if it turns on and off normally.
Tilt control valve : Seizure (internal damage)
Only forward tilting is impossible. (Other load handling operations, including backward tilting, are possible.)
• Replace the Main controller.
• Check the pump, and repair or replace it if necessary. • Check the priority valve, and repair or replace it if necessary. • Check the PS valve, and repair or replace it if necessary.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Correct the setting value. Adjust the tuning activating current after setting the OCV activating current if fine tuning is needed.
• Check the tilt control valve, and repair or replace it if necessary.
• Check the lowering lock valve, and repair or replace it if necessary.
Action and remedies
Check the set value on the Option Set screen. • Change the setting
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Main controller : Internal failure Display setting : The serial number setting is not in agreement with that of the vehicle. (Option Set 1 06/ OCV WAY)
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Pump : Leak Priority valve : Leak, seizure PS valve : Leak, seizure
If a current flows, turn on the tilt control solenoid using Active Test to tilt the fork forward.
If a current flows, turn on the lowering lock solenoid using Active Test to lower the fork.
Lowering lock valve : Seizure (internal damage)
Only lowering is impossible. (Other load handling operations, including raising, are possible.)
How to check
Load handling and power steering
Failed portions and failure modes
Phenomena on the vehicle
Control systems
5-210
Buzzer-related control
OPS
Control systems
–
Main controller : Internal failure
The traveling OPS return-toneutral warning does not sound.
OPS operation warning does not sound.
• Check the oil control valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• Replace the drive motor drive circuit.
• Replace the main controller.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
Check that the built-in buzzer sounds a short beep when the MODE switch (microswitch) is pressed.
Display : Built-in buzzer is broken.
• If the buzzer does not sound, replace the display.
Check the set value on the Option Set screen. • Change the setting
Display setting : Return-to-neutral warning buzzer disabled (Option Set 1 12/ BUZZER SPEC)
• If the buzzer does not sound, replace the display.
Check that the built-in buzzer sounds a short beep when the MODE switch (microswitch) is pressed.
Display : Built-in buzzer is broken.
• Replace the main controller.
Check the set value on the Option Set screen. • Change the setting
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Display setting : OPS operation notification buzzer disabled (Option Set 1 12/ BUZZER SPEC) (Option Set 1 13/ SEAT BUZZER)
Main controller : Internal failure
Oil control valve Check the lift lowering lock valve, using Active • Check the oil control valve, and repair : Seizure of or leakage from lift lowering lock Test. or replace it if necessary. valve : Lift lock solenoid forcibly turned off (lift lock) • Check the solenoid and replace it if Lift lock solenoid harness Lower the lift to check the operation. necessary. : Short circuit, leakage (harness or • Check the harness and repair or connector) replace it if necessary.
Check the tilt control valve, using Active Test. : Tilt solenoid forcibly turned off (forward tilting stopped) Tilt the fork forward to check the operation.
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Check the seat switch, using Analyzer. : Direction switch in neutral, drive fully closed Check if the switch turns on and off normally, sitting in the seat or standing beside it.
How to check
Drive motor drive circuit : Internal failure
Main controller : Internal failure
Seat switch main body : Short circuit Seat switch harness : Short circuit (harness or connector)
Failed portions and failure modes
Only load handling OPS does not Oil control valve operate. : Seizure of or leakage from tilt control valve Tilt solenoid harness : Short circuit, leakage (harness or connector)
Only traveling OPS does not operate.
Neither traveling OPS nor load handling OPS operates.
Phenomena on the vehicle
5-211
Buzzer-related control
Control systems Failed portions and failure modes
Main controller : Internal failure
Parking brake switch main body : Open failure Installation of parking brake switch : Switch is off. Parking brake switch harness : Wire breakage (harness, connector)
Parking brake switch main body : Open failure Installation of parking brake switch : Switch is off. Parking brake switch harness : Wire breakage (harness, connector)
• Replace the main controller.
• Check the switch, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• If the buzzer does not sound, replace the display.
• Check the switch, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• If the buzzer does not sound, replace the display.
Check the parking brake switch, using Analyzer. (The switch can also be checked by checking if the parking indicator on the display goes on and out.) : Direction switch is in neutral. Operate the parking brake lever to see if the switch turns on and off normally.
• Check the switch, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the set value on the Option Set screen. • Change the setting
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Check the parking brake switch, using Analyzer. (The switch can also be checked by checking if the parking indicator on the display goes on and out.) : Direction switch is in neutral. Operate the parking brake lever to see if the switch turns on and off normally.
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Check that the built-in buzzer sounds a short beep when the MODE switch (microswitch) is pressed.
Display : Built-in buzzer is broken.
Check that the built-in buzzer sounds a short beep when the MODE switch (microswitch) is pressed. Check the parking brake switch, using Analyzer. (The switch can also be checked by checking if the parking indicator on the display goes on and out.) : Direction switch is in neutral. Operate the parking brake lever to see if the switch turns on and off normally.
Main controller : Internal failure
Action and remedies
Check the set value on the Option Set screen. • Change the setting
How to check
Parking brake switch main body : Short circuit Installation of parking brake switch : Switch is held down. Parking brake switch harness : Short circuit (harness or connector)
The parking brake lever reminder Display setting does not sound. : Parking brake reminder buzzer disabled (Option Set 1 14/ PKB BUZZER)
When the vehicle runs with the parking brake lever released, the parking brake release reminder sounds.
The parking brake lever release reminder does not sound.
Display : Built-in buzzer is broken.
The load handling OPS return-to- Display setting neutral warning does not sound. : Return-to-neutral warning buzzer disabled (Option Set 1 12/ BUZZER SPEC)
Phenomena on the vehicle
5-212
Failed portions and failure modes
–
Check the matching value on the matching screen.
Lifting height sensor lowermost position matching value : no agreement with the vehicle state
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally. Check the lifting height sensor, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if voltage changes.
Main controller : Internal failure
• Replace the main controller.
• Check the switch, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• If the buzzer does not sound, replace the display.
• Check the seat and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
• Replace the main controller.
• Perform matching again.
• Check the sensor, and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the set value on the Option Set screen. • Change the setting
–
Check the parking brake switch, using Analyzer. : MODE switch is in neutral. Operate the parking brake lever to see if the switch turns on and off normally.
–
Check that the built-in buzzer sounds a short beep when the MODE switch (microswitch) is pressed.
Check the seat switch, using Analyzer. : Check if the switch turns on and off normally, sitting in the seat or standing beside it.
How to check
Lifting height sensor main body : Dragging and improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit or leakage (harness, connector)
The lifting stop position cannot be Lifting height switch main body (FSV mast) set. : Low lifting height is always detected. Lifting height switch harness : Wire breakage, short circuit (harness or connector)
Display setting : Height selector function disabled (Option Set H-SELECTOR)
Main controller : Internal failure
Although the parking brake lever Parking brake switch main body is pulled up, the parking brake : Short circuit reminder does not stop sounding. Installation of parking brake switch : Switch is held down. Parking brake switch harness : Short circuit (harness or connector)
Main controller : Internal failure
Display : Built-in buzzer is broken.
The parking brake lever reminder Seat switch main body does not sound. : Short circuit Seat switch harness : Short circuit (harness or connector)
Phenomena on the vehicle
Height selector The height selector function (option) setting screen does not appear.
Buzzer-related control
Control systems
5-213
Phenomena on the vehicle
The fork stop position is far away from the lifting height set position (100 mm or more).
Although the height selector switch is pressed, the automatic height control does not work.
Although the lifting height limit switch is not pressed, the lifting height limiter works.
Although the lifting height limit switch is pressed, the lifting height limiter does not work.
Height selector Maximum height limiter does not (option) work.
Control systems
If the loading conditions, the tilt angle of the mast, etc at that time are different from those when the lifting height was set, the fork stop position may not agree with the set position.
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–
• Replace the main controller.
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Main controller : Internal failure
• Change the setting.
• Replace the main controller.
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the height selector switch, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the set value on the lifting stop position setting screen.
–
Check the lifting height switch, using Analyzer. : Vehicle stopped Operate the lifting height switch to see if the switch turns on and off normally.
• Replace the main controller.
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• Change the setting.
• Change the setting.
Action and remedies
Lifting height change-over switch main body Check the lifting height change-over switch, : Open failure, short circuit using Analyzer. Mechanical detection unit of lifting height : Vehicle stopped change-over switch Operate the lifting height change-over : Gap in detection unit is improperly adjusted. switch to see if it turns on and off normally. Lifting height change-over switch harness : Wire breakage, short circuit (harness or connector)
Display setting : The automatic height control is not set.
Main controller : Internal failure
Lifting height limit switch main body : Short failure Lifting height limit switch harness : Short circuit (harness, connector)
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Check the lifting height switch, using Analyzer. : Vehicle stopped Operate the lifting height switch to see if the switch turns on and off normally.
Lifting height limit switch main body : Open failure Lifting height limit switch harness : Wire breakage (harness, connector) Main controller : Internal failure
Check the set value on the lifting stop position setting screen.
Check the set value on the lifting stop position setting screen.
How to check
Display setting : The lifting height limiter is not set.
Display setting : The maximum lifting height is not set.
Failed portions and failure modes
5-214
Phenomena on the vehicle
Shock sensor (option) –
–
Way in which the vehicle collides : The degree of shock that the shock sensor receives vary depending on the way and direction in which the vehicle collides and the object with which it collides. The shock sensor does not necessarily detect all kinds of shock. Display setting : A too large (improper) value is set for shock detection.
Although shock is applied, the shock detection alarm does not go on.
• Check the positional relationship among automatic height control, maximum lifting height and lifting height limit, and set them properly.
• Replace the main controller.
• Change the setting.
–
Check the set value on the Option Set screen. • Change the setting
Display setting : Shock detection function disabled (Option Set SHOCK SENSOR)
The shock detection function setting screen does not appear.
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–
• Perform matching again.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Change over time of lifting sensor detection unit : No agreement with the vehicle state
Main controller : Internal failure
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
How to check
Lifting height sensor main body : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
The automatic height control does The automatic height control does not work if not work, although it was set for the maximum lifting height or the lifting height sure. limit is set below it.
Height selector The fork stop position is far away (option) from the lifting height set position (100 mm or more).
Control systems
5-215
Shock sensor (option)
Control systems
Main controller : Internal failure
Shock sensor main body : Sensitivity reduced Installation of shock sensor : Improper installation (loosening), interference Shock sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
Main controller : Internal failure
Shock sensor main body : Internal damage (excessive response) Installation of shock sensor : Improper installation (loosening), interference Shock sensor harness : Wire breakage, short circuit, leakage (harness or connector) (Especially if there are half-broken wires in the harness, shock may be detected frequently.)
Although no shock is applied, the Display setting shock detection alarm sets off. : A too small (improper) value is set for shock detection.
Although shock is applied, the shock detection alarm does not go on.
Phenomena on the vehicle
Action and remedies
• Change the setting. (Set a value that corresponds to shock unlikely to be applied during normal operation.)
• Replace the main controller.
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• Replace the main controller.
Check the voltages of shock sensors 1 and 2, • Check the sensor and replace it if using Analyzer. necessary. : Vehicle stopped 2.0 ± 0.21 V • Check the harness and repair or Apply shock to each sensor to see if its replace it if necessary. voltage changes excessively. (Compare the voltages of sensors 1 and 2.)
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–
Check the voltages of shock sensors 1 and 2, • Check the sensor and replace it if using Analyzer. necessary. : Vehicle stopped 2.0 ± 0.21 V • Check the harness and repair or Apply shock to each sensor to see if its replace it if necessary. voltage changes. (Compare the voltages of sensors 1 and 2.)
How to check
5-216
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• Check the wheel, and replace it if necessary. • Check the air pressure and repair it if necessary.
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Display setting : Wheel indicator setting is not set. (Option Set WHEEL IND) The wheel indicator is equipped only for SAS and knob position correcting control specification. Tire specification : Type, diameter, tire pressure
[wheel indicator] After the vehicle run straight, the wheel indicator does not show that wheel is in straight position.
Check the sensor voltage, using Analyzer. : Direction switch is in neutral, drive fully closed. Turn a steering to check the change in voltage.
Check the matching value on the Matching screen.
Tire angle sensor : Internal failure Installation of the tire angle sensor : The installation portion is broken or damaged. Tire angle sensor harness : Wire breakage, short circuit or leakage (harness, connector). Tire angle sensor straight angle matching value : No agreement with the vehicle state
• Perform matching again.
• Check the sensor, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the set value on the Option Set screen. • Change the setting.
* If brake pedal fully closed and operating point matching is finished by simply performing fully closed matching and operating point matching in this order, the setting will not be saved.
* If accelerator pedal fully closed and fully open matching is finished by simply performing fully closed matching and fully open matching in this order, the setting will not be saved.
• Change the setting.
Action and remedies
[Wheel indicator] Although the vehicle is stopped, the wheel indicator is not displayed.
Check the matching value on the Matching screen.
How to check
Multi-function display/ DX (Option)
One of the following matching operations is not performed. • Tire straight running angle matching (SAS, knob position correcting control spec. only) • Forward tilt limit angle matching (SAS only) • Tilt horizontal angle matching (SAS only) • Tilt no-load matching (SAS only) • Accelerator pedal fully closed matching • Accelerator pedal fully open matching • Brake pedal fully closed matching (model without 50- only) • Brake pedal operating point matching (model without 50- only) • Load handling lever neutral voltage matching • Lifting height sensor lowermost position matching value (Height Selector spec.) • Tire diameter data
Failed portions and failure modes
[Diagnostic mode indicator] Although no error code is displayed, the diagnostic mode indicator is left on.
Phenomena on the vehicle
Display
Control systems
5-217
Multi-function display/ DX (Option)
Control systems
–
Main controller : Internal failure
Main controller : Internal failure
Display setting : Cylinder diameter, mast type, zeropoint adjustment, calibration On the Analyzer setting screen, check if each setting is correct.
Check the load sensor voltage, using Analyzer. : In NL Lower and raise the lift to its lowermost and uppermost (relief) positions to check the change in the voltage.
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–
On the Analyzer setting screen, check if each setting is correct.
Traveling Display setting : Cylinder diameter, mast type, zeropoint adjustment
–
How to check
Lift lever is not in neutral position.
Failed portions and failure modes
[Load meter] Load sensor The correct load is not displayed. : Internal failure Load sensor harness : The link or Wire breakage, short circuit or leakage (harness, connector)
[Load meter] The load is always displayed during vehicle is standing.
[Load meter] The load is not displayed.
Phenomena on the vehicle
• Make each setting correctly. * To improve the accuracy, perform adjustment on the LOAD COMPENSATION screen of the load meter matching.
• Check the sensor, and replace it if necessary. • Check the harness and repair it if necessary.
• Replace the main controller.
• Replace the main controller.
• Make each setting correctly.
• Load is not displayed when traveling.
• Load is not displayed when operating the lift lever. Put the lift lever in neutral position.
Action and remedies
5-218
SAS-ε (Option) Turn Control
Multi-function display/ DX (Option)
Control systems Failed portions and failure modes
Check the load sensor voltage, using Analyzer. : In NL Lower and raise the lift to its lowermost and uppermost (relief) positions to check the change in the voltage. Check the lifting switch voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to see if the switch turns on and off normally.
Lifting height switch : Low lifting height is always detected. Lifting height switch harness : Wire breakage and short circuit (harness, connector)
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–
How to check
Load sensor : Internal failure Load sensor harness : The link or Wire breakage, short circuit or leakage (harness, connector)
The vehicle is unstable when Tire specification traveling : Type, diameter, tire pressure (The speed is not limited during a turn.)
Main controller : Internal failure
[Load meter] The measurement condition is not correct. The correct load is not displayed.
Phenomena on the vehicle
• Check the switch and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the sensor, and replace it if necessary. • Check the harness and repair it if necessary.
• Check the wheel, and replace it if necessary. • Check the air pressure and repair it if necessary.
• Replace the main controller.
* This load meter measures and calculates pressure on the lift cylinder. So, even if measuring the same load, the measured value may vary depending on the mast height, tilt level, temperature of the hydraulic oil, way to stop load handling, mechanical loss of the mast, leakage from the oil control valve, etc. Use this load meter as a guide, because the accuracy same as a scale is not guaranteed.
• To measure the load correctly, perform a measurement with the load lifted to a height of approx. 500 mm, the mast raised to a vertical position and both material handling and traveling operations stopped.
Action and remedies
5-219
SAS-ε (Option) Turn Control
Control systems Failed portions and failure modes
Check the matching value on the Matching screen.
Tire angle sensor straight angle matching value : No agreement with the vehicle state
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Check the setting value on the option set screen.
Display setting : Setting the curve control value (Option Set CURVE CONT) Main controller : Internal failure
Check the setting value on the matching screen.
Display setting : The setting value of mast type is different from the actual forklift.
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Check the sensor voltage, using Analyzer. : Direction switch in neutral, drive fully closed Turn the steering wheel and check the change in voltage.
Tire angle sensor main body : Internal failure Installation of tire angle sensor : Installation portion is broken or damaged. Tire angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Drive motor speed (rotation) sensor : Internal failure Drive motor speed (rotation) sensor harness : Wire breakage, short circuit, leakage (harness or connector) Drive motor drive circuit : Internal failure
Check the matching value on the Matching screen.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
How to check
Lifting height sensor lowermost position matching value (Height Selector and V mast) : No agreement with the vehicle state.
The vehicle is unstable when Lifting height sensor main body (Height selector and V mast) traveling : Dragging or improper winding of wire (The speed is not limited during a Installation of lifting height sensor turn.) : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Phenomena on the vehicle
• Replace the main controller.
• Change the setting.
• Correct the setting value.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary. • Check the drive motor drive circuit and replace it if necessary.
• Perform matching again.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
5-220
SAS-ε (Option) Tilt control
Control systems Failed portions and failure modes
How to check
When the fork tilted forward for leveling, it does not stop automatically in a horizontal position. (The fork does not stop in a horizontal position.)
• Perform matching again.
Check the matching value on the Matching screen.
Tilt angle sensor leveling matching value : No agreement with the vehicle state
• Replace the main controller. • Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
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Check the tilt angle sensor voltage, using Tilt angle sensor main body : Internal damage Analyzer. Installation of tilt angle sensor : In NL Tilt the mast to its forward and backward tilt : The link or the installation portion is broken limits to check the change in voltage. or damaged. Tilt angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Main controller : Internal failure
• Check the oil control valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the tilt control valve, using Active Test. : Tilt solenoid forcibly turned off (forward tilting stopped) Tilt the fork forward to check the operation.
Oil control valve : Seizure of or leakage from tilt control valve Tilt solenoid harness : Short circuit, leakage (harness or connector)
• Perform matching again. • Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the matching value on the Matching screen.
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
Automatic fork leveling switch Check the automatic fork leveling switch, : Open failure using Analyzer. Mechanical detection unit of automatic fork : Load handling lever in neutral leveling switch Operate the automatic fork leveling switch : Gap in detection unit is improperly adjusted. to see if it turns on and off normally. Automatic fork leveling switch harness : Wire breakage (harness, connector)
Tilt angle sensor leveling matching value : No agreement with the vehicle state
When tilted forward for leveling, Tilt angle sensor main body Check the tilt angle sensor voltage, using the fork does not stop : Internal damage Analyzer. automatically in a horizontal Installation of tilt angle sensor : In NL position. : The link or the installation portion is broken Tilt the mast to its forward and backward tilt (The fork tilts to its forward tilt limit or damaged. limits to check the change in voltage. without stopping in a horizontal Tilt angle sensor harness position.) : Wire breakage, short circuit, leakage (harness or connector)
Phenomena on the vehicle
5-221
SAS-ε (Option) Tilt control
Control systems
Check the matching value on the Matching screen. Check the load sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage. Check the matching value on the Matching screen. Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
Tilt angle sensor leveling matching value : No agreement with the vehicle state Load sensor main body : Internal breakage Load sensor harness : Wire breakage, short circuit, leakage (harness or connector) Load sensor no-load matching value : No agreement with the vehicle state Lifting height switch main body : A high lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector)
When tilted forward for leveling, Tilt angle sensor main body Check the tilt angle sensor voltage, using the fork does not stop : Internal damage Analyzer. automatically in a horizontal Installation of tilt angle sensor : In NL position. : The link or the installation portion is broken Tilt the mast to its forward and backward tilt (When tilted forward for leveling, or damaged. limits to check the change in voltage. the fork stops where it is when the Tilt angle sensor harness automatic fork leveling switch is : Wire breakage, short circuit, leakage pressed.) (harness or connector)
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Check the matching value on the Matching screen.
Load sensor no-load matching value : No agreement with the vehicle state Main controller : Internal failure
Check the load sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Load sensor main body : Internal damage Load sensor harness : Wire breakage, short circuit, leakage (harness or connector)
When the fork tilted forward for leveling, it does not stop automatically in a horizontal position. (The fork does not stop in a horizontal position.)
How to check
Failed portions and failure modes
Phenomena on the vehicle
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• Perform matching again.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
5-222
SAS-ε (Option) Tilt control
Control systems
When the fork is tilted backward for leveling, it does not stop automatically in a horizontal position. (The fork does not stop in a horizontal position.)
When the fork is tilted backward for leveling, it does not stop automatically in a horizontal position. (The fork tilts to its backward tilt limit without stopping in a horizontal position.)
When tilted forward for leveling, the fork does not stop automatically in a horizontal position. (When tilted forward for leveling, the fork stops where it is when the automatic fork leveling switch is pressed.)
Phenomena on the vehicle
• Perform matching again
See "When the fork is tilted forward for leveling, it does not stop automatically in a horizontal position (The fork does not stop in a horizontal position.)"
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• Replace the main controller.
Main controller : Internal failure
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• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Main body of automatic fork leveling switch Check the automatic fork leveling switch, : Open failure using Analyzer. Mechanical detection unit of automatic fork : Load handling lever in neutral leveling switch Operate the automatic fork leveling switch : Gap in detection unit is improperly adjusted. to see if it turns on and off normally. Automatic fork leveling switch harness : Wire breakage (harness, connector)
Check the matching value on the Matching screen.
Tilt angle sensor leveling matching value : No agreement with the vehicle state
• Replace the main controller.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
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Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
How to check
Tilt angle sensor main body Check the tilt angle sensor voltage, using : Internal damage Analyzer. Installation of tilt angle sensor : In NL : The link or the installation portion is broken Tilt the mast to its forward and backward tilt or damaged. limits to check the change in voltage. Tilt angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Main controller : Internal failure
Lifting height sensor main body (Height selector and V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
5-223
SAS-ε (Option) Tilt control
Control systems Failed portions and failure modes
How to check
The mast backward tilting speed is not limited.
• Check the oil control valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary. • Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the tilt control valve, using Active Test. : Tilt solenoid forcibly turned on (backward tilting speed limited) Tilt the mast backward to check the operation. Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally. Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Oil control valve : Seizure of tilt control valve Tilt solenoid harness : Wire breakage, short circuit, leakage (harness or connector) Lifting height switch main body : Low lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector) Lifting height sensor main body (Height Selector, V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector)
• Replace the main controller.
• Perform matching again.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
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Check the matching value on the Matching screen.
• Check the sensor, and adjust or replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
Main body of automatic fork leveling switch Check the automatic fork leveling switch, : Open failure using Analyzer. Mechanical detection unit of automatic fork : Load handling lever in neutral leveling switch Operate the automatic fork leveling switch : Gap in detection unit is improperly adjusted. to see if it turns on and off normally. Automatic fork leveling switch harness : Wire breakage (harness, connector)
Main controller : Internal failure
Tilt angle sensor leveling matching value : No agreement with the vehicle state
When the fork is tilted backward Tilt angle sensor main body Check the tilt angle sensor voltage, using for leveling, it does not stop : Internal damage Analyzer. automatically in a horizontal Installation of tilt angle sensor : In NL position. : The link or the installation portion is broken Tilt the mast to its forward and backward tilt (The fork stops where it is when or damaged. limits to check the change in voltage. the automatic fork leveling switch Tilt angle sensor harness is pressed.) : Wire breakage, short circuit, leakage (harness or connector)
Phenomena on the vehicle
5-224
SAS-ε (Option) Tilt control
Control systems
Although the load is lifted high, the mast forward tilting speed is not limited.
The mast backward tilting speed is always slow.
The mast backward tilting speed is not limited.
Phenomena on the vehicle
Display setting : Forward tilting speed setting (Option Set T F-SPD LIM)
Check the set value on the Option Set screen. • Change the setting.
• Replace the main controller.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Lifting height sensor main body (Height Selector, V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector) –
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
Lifting height switch main body : A high lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector)
Main controller : Internal failure
• Check the oil control valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the tilt control valve, using Active Test. : Tilt solenoid forcibly turned off (backward tilting speed not limited) Tilt the mast backward to check the operation.
Oil control valve : Seizure of or leakage from tilt control valve Tilt solenoid harness : Short circuit, leakage (harness or connector)
• Replace the main controller.
• Perform matching again.
Action and remedies
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
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Check the matching value on the Matching screen.
How to check
Main body of automatic fork leveling switch Check the automatic fork leveling switch, : Short circuit using Analyzer. Mechanical detection unit of automatic fork : Load handling lever in neutral leveling switch Operate the automatic fork leveling switch : Gap in detection unit is improperly adjusted. to see if it turns on and off normally. Automatic fork leveling switch harness : Short circuit (harness or connector)
Main controller : Internal failure
Lifting height sensor lowermost position matching value (Height Selector, V mast) : No agreement with the vehicle state.
Failed portions and failure modes
5-225
SAS-ε (Option) Tilt control
Control systems
The mast forward tilting speed is always slow.
Although the load is lifted high, the mast forward tilting speed is not limited.
Phenomena on the vehicle
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• Replace the main controller.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Lifting height sensor main body (Height Selector, V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector) Main controller : Internal failure
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
• Replace the main controller.
Lifting height switch main body : A high lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector)
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Check the matching value on the Matching screen.
Lifting height sensor lowermost position matching value (Height Selector and V mast) : No agreement with the vehicle state. Main controller : Internal failure
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Lifting height sensor main body (Height Selector, V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector) • Perform matching again.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
How to check
Lifting height switch main body : Low lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector)
Failed portions and failure modes
5-226
Knob position correcting control (Option)
or
SAS-ε (Option) Knob position correcting control
Control systems
Check the sensor voltage, using Analyzer. : Direction switch in neutral, drive fully closed Turn the steering wheel and check the change in voltage.
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Main controller : Internal failure
Check the knob position correcting valve, using Active Test. : Tire end Forcibly turn on (bypass) and off (no bypass) the knob position correcting solenoid to check how the steering system operates. Forcibly ON ... Steering idles (light). Forcibly OFF ... Steering does not idles (heavy).
Knob position correcting valve main body : Leakage, seizure (internal damage) Knob position correcting solenoid harness : Wire breakage, short circuit, leakage (harness or connector)
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Check the steering angle sensor, using Analyzer. : Turn the steering wheel to check the input signal.
The steering angle sensor main body : Internal damage Installation of steering angle sensor : Cam or steering wheel is defective. Steering angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
The road surface is inclined.
Check the matching value on the Matching screen.
Check the sensor voltage, using Analyzer. : Direction switch in neutral, drive fully closed Turn the steering wheel and check the change in voltage.
How to check
Tire angle sensor straight running angle matching value : No agreement with the vehicle state
Tire angle sensor main body : Internal failure Installation of tire angle sensor : Installation portion is broken or damaged. Tire angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Failed portions and failure modes
The knob is displaced from its Tire angle sensor main body : Internal failure normal position. (The knob position is not constant Installation of tire angle sensor during straight running.) : Installation portion is broken or damaged. Tire angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
The knob is displaced from its normal position to a certain position. (10° or more from the straight running position)
Phenomena on the vehicle
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
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• Check the knob position correcting valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Perform matching again.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
5-227
SAS-ε (Option) Traveling control
Knob position correcting control (Option)
or
SAS-ε (Option) Knob position correcting control
Control systems Failed portions and failure modes
Although no load is applied, the speed is limited when the lift is raised high.
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Check the tire diameter data on the Matching screen.
Display setting : The tire diameter data is not in agreement with the data on the actual vehicle state. Heavy attachment, mast with a high lifting height
Check the load sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
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Main controller : Internal failure Load sensor main body : Internal damage Load sensor harness : Wire breakage, short circuit, leakage (harness or connector)
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Check the knob position correcting valve, using Active Test. : Tire end Forcibly turn on (bypass) and off (no bypass) the knob position correcting solenoid to check how the steering system operates. Forcibly ON ... Steering idles (light). Forcibly OFF ... Steering does not idles (heavy).
Check the steering angle sensor, using Analyzer. : Turn the steering wheel to check the input signal.
How to check
PS cylinder system link is defective. : Eccentric pin or kingpin is defective
Knob position correcting valve main body : Leak, seizure Knob position correcting solenoid harness : Wire breakage, short circuit, leakage (harness or connector)
The knob is displaced from its Main body of steering angle sensor : Internal damage normal position. (The knob position is not constant Installation of steering angle sensor during straight running.) : Cam or steering wheel is defective. Steering angle sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Phenomena on the vehicle
• In traveling control, the attachment weight and the mast weight are treated as part of the load weight, because they affect the longitudinal stability of the vehicle. For a very heavy mast or an FSV or FV mast with a high lifting height, if its inner middle mast is rather heavy, a limit may sometimes be placed on the speed even under noload conditions.
• Change the setting.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• Check the cylinder, and repair or replace it if necessary.
• Check the knob position correcting valve, and repair or replace it if necessary. • Check the solenoid and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Action and remedies
5-228
SAS-ε (Option) Traveling control
Control systems
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Main controller : Internal failure
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Check the matching value on the Matching screen.
Lifting height sensor main body (Height Selector and V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector) Lifting height sensor lowermost position matching value (Height Selector and V mast) : No agreement with the vehicle state.
• Perform matching again.
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• When the lift is raised to its uppermost position, the load sensor cannot distinguish this situation from a situation in which a heavy load is carried, because, in that situation, a relief pressure remains in the lift cylinder pressure that the load sensor senses. • After a lift relief, however, it becomes possible to perform operation because the relief pressure is discharged when the lift is lowered even a little.
Action and remedies
Lifting height switch main body : Low lifting height is always detected. Lifting height switch harness : Wire breakage, short circuit (harness or connector)
Check the load sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
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How to check
Lift relief pressure detected.
Failed portions and failure modes
Although a load is carried, the Load sensor main body speed is not limited when the lift is : Internal damage raised high. Load sensor harness : Wire breakage, short circuit, leakage (harness or connector)
Although no load is applied, the speed is limited when the lift is raised high.
Phenomena on the vehicle
5-229
On-vehicle charger (option)
SAS-ε (Option) Traveling control
Control systems Failed portions and failure modes
Action and remedies
Check the setting value.
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Check the tire diameter data on the Matching screen.
Display setting : The tire diameter data is not in agreement with the data on the actual vehicle state. Main controller : Internal failure
Check the set value.
Display setting : Maximum speed limit is set very low.
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• Change the setting.
• Replace the main controller.
• Change the setting
• Change the setting
• Replace the main controller.
• Check the sensor and replace it if necessary. • Check the harness and repair or replace it if necessary.
Check the lifting sensor voltage, using Analyzer. : In NL Raise and lower the lift to its uppermost (relief) and lowermost positions to check the change in the voltage.
Lifting height sensor main body (Height Selector and V mast) : Dragging or improper winding of wire Installation of lifting height sensor : Breakage of sensor installation portion, breakage of wire routing portion Lifting height sensor harness : Wire breakage, short circuit, leakage (harness or connector) Main controller : Internal failure
• Check the switch, and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Replace the main controller.
• Change the setting.
Check the lifting height switch, using Analyzer. : In NL Raise and lower the lift to its uppermost and lowermost positions to see if the switch turns on and off normally.
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Check the tire diameter data on the Matching screen.
Check the set value on the Option Set screen. • Change the setting.
How to check
Lifting height switch main body : High lifting height is always detected. Lifting switch harness : Wire breakage, short circuit (harness or connector)
Although the AC plug is Display setting connected, charging screen does : Charger unit is invalid not appear on the display (Option Set 1 23/ CHARGER UNIT)
A limit is always placed on the speed regardless of whether a load is carried or not.
Although the fork is not raised high, the speed is limited when a load is carried.
Main controller : Internal failure
Display setting : The tire diameter data is not in agreement with the data on the actual vehicle state.
Although a load is carried, the Display setting speed is not limited when the lift is : Traveling control setting disabled raised high. Load sensing speed restriction disabled (Option Set ASC W/LOAD, MODE)
Phenomena on the vehicle
5-230
On-vehicle charger (option)
Control systems Failed portions and failure modes
Charging does not complete (Able to start charging)
Charging does not start, even though charging screen appears on the display.
Although the AC plug is disconnected, charging screen appears on the display.
• Check the harness and repair or replace it if necessary. • Check the charger panel and replace it if necessary.
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Display : Internal failure Charger panel harness : Wire breakage, short circuit, leakage (harness or connector) Charger panel : Internal failure
• Check the display and replace it if necessary.
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Charger panel harness : Wire breakage, short circuit, leakage (harness or connector) Charger panel : Internal failure
• Check the harness and repair or replace it if necessary. • Check the charger panel and replace it if necessary.
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• Check the magnet switch and replace it if necessary. • Check the harness and repair or replace it if necessary.
• Check the display and replace it if necessary.
• Check the harness and repair or replace it if necessary. • Check the charger panel and replace it if necessary.
• Check the AC cable and repair or replace it if necessary.
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• Check the harness and repair or replace it if necessary. • Check the display and replace it if necessary.
• Check the harness and repair or replace it if necessary. • Check the charger panel and replace it if necessary.
Action and remedies
Magnet switch : Internal failure Charger panel harness : Wire breakage, short circuit, leakage
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Display : Internal failure
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AC cable : Wire breakage, short circuit, leakage –
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AC power supply : Power supply defect, electricity failure
Charger panel harness : Wire breakage, short circuit, leakage (harness or connector) Charger panel : Internal failure
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How to check
Display power supply and ground harness : Wire breakage, short circuit, leakage (harness or connector) Display : Internal failure
Although the AC plug is Charger panel harness connected, charging screen does : Wire breakage, short circuit, leakage not appear on the display (harness or connector) Charger panel : Internal failure
Phenomena on the vehicle
5-231
Battery protective function (Option)
On-vehicle charger (option)
Control systems Failed portions and failure modes
Battery electrolyte level warning indicator is still turned on after refilling electrolyte.
Charging lamp on the charger panel does not light on.
• Check the CN35 connector and connect it if disconnected. • Check the electrolyte level/ temperature unit and replace it if necessary.
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Electrolyte level/ temperature unit : Internal failure (Breakage of internal electrolyte level harness, electrolyte level sensor failure)
• Change the setting according to the battery. B:Conventional unit (unit with LED screen) C:Electrolyte level/ temperature unit
• Check the harness and repair or replace it if necessary. • Check the charger panel and replace it if necessary.
• Check the display and replace it if necessary.
• Replace the main controller.
• Check the battery and replace it if necessary. • Perform an equalization charge.
• Use the transformer that is compatible with the battery capacity. • Adjust tap changer. • Check the transformer and replace it if necessary.
Action and remedies
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Check the setting value.
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Perform the timer test of the charger.
Measure the voltage of the battery voltage and compare it with the battery voltage of the analyzer.
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How to check
Electrolyte level/ temperature unit harness :Connector disconnected
Display setting : Different battery setting (Option Set 1 02/ B UNIT)
Charger panel harness : Wire breakage, short circuit, leakage (harness or connector) Charger panel : Internal failure
Display : Internal failure
Main controller : Internal failure
Battery : Uneven voltage between cells : Capacity decline (Operating life)
Charging completes normally, but Transformer not fully charged. : Incompatible capacity : Tap adjustment defect Transformer main body : Internal failure
Phenomena on the vehicle
5-232
5-233
z Error Code - (Although the AC power plug is disconnected, the charging screen appears on the display) Related portion
CN69-2
CN70-25 (129, CHAC)
Operation panel
Display CN69-3
CN70-2 (130, CGND)
Probable cause: (1) Wire connection defect (2) Operation panel defect Inspection: Wire connection check 1. Turn off the key switch and disconnect the battery plug. 2. Check if the CN69 and CN70 connectors are connected correctly.
(3) Display defect
NG
Wire connection defect
OK Inspection: Check of AC 200V detection 1. Disconnect the CN69 connector and connect the battery plug. 2. Check the display screen. NG (Charging screen does not disappear) Display defect
OK (Charging screen disappears)
Operation panel defect
5-234
z Error Code - (Although the AC power plug is connected, the charging screen does not appear on the display) Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermoswitch FCH
P2
Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N1,N1)
N2
AC Power supply
AC Power plug Power cable
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
(95, MSCH)
Probable cause: (1) Wrong setting of charger unit (2) AC power supply defect (3) Power cable defect (4) Wire connection defect
(5) Operation panel defect (6) Harness defect (7) Display defect
DISPLAY
5-235 Inspection: Check of the charger unit setting STD display: 3-OPT → 1 OPTSET → 1 23 Multifunction display: [OPT] CHARGER UNIT
NO
Wrong setting of the charger unit (Set “YES”)
YES Inspection: Operation check of the vehicle 1. Connect the AC power plug. 2. Turn on the key switch, and operate a vehicle.
NG (The vehicle does not move)
Display defect
OK (The vehicle moves) Inspection 1: Check of AC power supply voltage 1. Turn off the key switch and disconnect the AC power NG plug. 2. Check each power supply terminal.
AC power supply defect Electricity failure
OK Inspection 2: Check of AC power plug terminal voltage 1. Check each power plug terminal
NG
Power cable defect
OK Inspection 3: Check of wire connection 1. Turn off the key switch and disconnect the battery plug. 2. Perform check of the wire connection
NG
Wire connection defect
OK Inspection 4: Harness check 1. Disconnect the CN69 and CN70 connectors and perform the check.
NG
Harness defect
OK Inspection 5: Check of display function of the charging screen. 1. Disconnect the CN69 connector and perform the check NG (The charging screen does not appear) Display defect
OK (The charging screen appears)
Operation panel defect
5-236 Inspection 1: Check the voltage of the AC power supply Portions to be checked
Standard
Each AC power supply terminal
191 to 220V
Inspection 2: Check the AC power plug Portions to be checked
Standard
Each AC power plug terminal
191 to 220V
Inspection 3: Check the wire connection Remove the operation panel and check the wire connection of the terminal R and S on the back of the insert point of the AC power plug.
Back of the insert point of the AC power plug
Terminal R
Terminal S
Inspection 4: Check the harness. Disconnect the CN69 and CN70 connectors and visually check inside each connector and the caulked portion of each wire for defects and then check each harness. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-2 to CN70-25
Continuity
CN69-3 to CN70-2
Continuity
Inspection 5: Check the display function of the charging screen Disconnect the CN69 connector and short-circuit the CN69-2 and CN69-3 connectors on the main harness side. Check if the charging screen appears on the display.
5-237
Error Code
- (The magnet switch is not closed when a START button is pressed)
Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermoswitch FCH
P2
Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N1,N1)
N2
AC Power supply
AC Power plug Power cable
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
(95, MSCH)
Probable cause: (1) Wire connection defect (4) Magnet switch defect (2) Harness defect (5) Display defect (3) Operation panel defect *For causes other than listed above, refer to ALTHOUGH THE AC POWER PLUG IS CONNECTED, THE CHARGING SCREEN DOES NOT APPEAR ON THE DISPLAY.
5-238
Inspection: Check of the display screen.
Charging screen does not Refer to ALTHOUGH THE AC appear. POWER PLUG IS CONNECTED, THE CHARGING SCREEN DOES NOT APPEAR ON THE DISPLAY.
Charging screen appears. Inspection 1 : Wire connection check 1. Turn off the key switch and disconnect the AC power NG plug and battery plug. 2. Check the wire connection.
Wire connection defect
OK Inspection 2 : Operation button check 1. Disconnect the CN69 connector and perform the check.
NG
Operation panel defect
OK Inspection 3 : Harness check 1. Disconnect the CN69 and CN70 connectors and perform the check.
NG
Harness defect
OK Inspection: Check of display function of the charging screen. 1. Connect the battery plug and AC power plug. 2. Press “START” button of the charger and check the display.
NG (Charging screen does not appear)
Display defect
OK (Charging screen appears) Inspection 4 : Check of the voltage of the magnet switch. OK 1. Turn off the key switch and disconnect the power plug and battery plug. 2. Disconnect the CN61 connector and connect the battery plug and AC power plug to perform the check.
Magnet switch defect
NG Inspection 5: Harness check 1. Turn off the key switch and disconnect the AC power NG plug and battery plug. 2. Disconnect the CN69 and 70 connectors and perform the check.
Harness defect
OK Operation panel defect (*1) *1 If the symptom persists after replacement of the operating panel, there should be any other problems, so replace the Display.
5-239
Inspection 1: Check the wire connection. Check if the CN69 and CN70 connectors are connected correctly. Inspection 2: Check the operation button. Disconnect the CN69 connector and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Operation
Portions to be checked
Standard
Hold down the "STOP" button
CN69-5 to CN69-3 (Operation panel side)
Continuity
Hold down the "START" button
CN69-7 to CN69-3 (Operation panel side)
Continuity
Release the "STOP" button
CN69-5 to CN69-3 (Operation panel side)
No continuity
Release the "START" button
CN69-7 to CN69-3 (Operation panel side)
No continuity
Inspection 3: Check the harness Disconnect the CN69 and CN70 connectors and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-7 to CN70-22
Continuity
CN69-5to CN70-24
Continuity
CN70-22 to CN70-24
No continuity
CN70-22 to CN70-2
No continuity
CN70-22 to CN70-3
No continuity
CN70-22 to CN70-4
No continuity
CN70-22 to CN70-36
No continuity
5-240
Inspection 4: Check the voltage of the magnet switch. Disconnect the CN61 connector, connect the AC power plug and press the “START” button of the charger. Portions to be checked
Standard
A1 to 96
191 to 220V
Press the “STOP” button of the charger. Portions to be checked
Standard
A1 to 96
0V
A1
FW-1S
96
CLK-50JT
Inspection 5: Check the harness Disconnect the CN69 and CN70 connectors and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING). Portions to be checked
Standard
CN69-1 to CN70-33
Continuity
CN69-1to CN69-3
No continuity
5-241
Error Code
- (Although the charging is complete, the battery is not fully charged)
Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermoswitch FCH
P2
Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY) CN70-36 (N1,N1)
AC Power supply
CN61
N2
AC Power plug Power cable
Operation panel
Magnet switch (95, MSCH)
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
5-242
Probable cause: (1) Incompatible capacity of the battery and the transformer (2) Tap adjustment defect (3) Transformer defect (4) Decline of battery capacity due to a decrease in temperature of the electrolyte. (5) Decline of battery capacity due to battery wear-out. (6) Battery defect (7) Main controller defect Inspection : Check the compatibility of the capacity of the battery and the transformer. (Refer to REPAIR MANUAL)
NG
Incompatible capacity of the battery and the transformer
OK Inspection : Tap changer check (Refer to REPAIR MANUAL)
NG
Tap adjustment defect
OK Inspection : Check of the transformer as a single unit (Refer to REPAIR MANUAL)
NG
Transformer defect
OK Inspection: Voltage check of the battery Compare the indicated value on the display and the actual measured value (between P2 and N2).
Displayed value is outside the range of ± 10% of actual measured value
STD display: [ANL] 2 IO1 2-10 Multifunction display: [ANL] I/O TEMP/ VOLT 4/5
Main controller defect
Displayed value is in the range of ± 10% of actual measured value. Inspection: Check of the specific gravity and temperature of battery electrolyte after charging completes (Refer to REPAIR MANUAL)
NG
Battery defect (Check if the battery revives by equalization charging)
OK
• Decline of battery capacity due to a decrease in temperature of the electrolyte. • Decline of battery capacity due to battery wear-out.
5-243
Error Code
- (LED lamp on operation panel does not light on)
Related portion 3 ton series F6
CN104-1 (18, B80V)
Main controller
CN104-1 (41, B48V)
Main controller
1·2 ton series F5
CN101-4 (41, VBBT)
Transformer Thermoswitch FCH
P2
Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND) CN70-5 (16, D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY)
CN61
CN70-36 (N1,N1)
N2
AC Power supply
AC Power plug Power cable
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
(95, MSCH)
Probable cause: (1) Operation panel defect (2) Display defect (3) Harness defect *For causes other than listed above, refer to ALTHOUGH THE START BUTTON IS PRESSED, THE MAGNET SWITCH DOES NOT CLOSE.
5-244 Inspection 1 : Applied voltage check of LED 1. Turn off the key switch and disconnect the AC power OK plug. 2. Disconnect the CN69 connector and check the applied voltage of LED
Operation panel defect
NG Inspection 2 : Harness check 1. Disconnect the battery plug and the AC power plug. 2. Disconnect the CN69 and CN70 connectors and check the harnesses for their contuinuities.
OK
Display defect
NG Harness defect
Inspection 1: Check the applied voltage of LED. Disconnect the CN69 connector and perform check of the applied voltage to each LED within 2 seconds after short-circuit the CN69-2 and CN69-3 connectors on the main harness side. (If checking the applied voltage of more than one LED, it is necessary to short-circuit the the CN69-2 and CN69-3 connectors each time.) Portions to be checked
Standard
NORMAL LED
CN69-10 to CN69-3 (Main harness side)
5V
EQUAL LED
CN69-9 to CN69-3 (Main harness side)
5V
UP LED
CN69-8 to CN69-3 (Main harnessside)
5V
Inspection 2: Check the harness Check each harness for its continuity. Disconnect the CN69 and CN70 connectors and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
NORMAL LED
EQUAL LED
UP LED
Portions to be checked
Standard
CN69-10 to CN70-30 (Main harness side)
Continuity
CN69-10 to CN70-2 (Main harness side)
No continuity
CN69-10 to CN70-4 (Main harness side)
No continuity
CN69-10 to CN70-3 (Main harness side)
No continuity
CN69-9 to CN70-29 (Main harness side)
Continuity
CN69-9 to CN70-2 (Main harness side)
No continuity
CN69-9 to CN70-4 (Main harness side)
No continuity
CN69-9 to CN70-3 (Main harness side)
No continuity
CN69-8 to CN70-32 (Main harnessside)
Continuity
CN69-8 to CN70-2 (Main harnessside)
No continuity
CN69-8 to CN70-4 (Main harnessside)
No continuity
CN69-8 to CN70-3 (Main harnessside)
No continuity
5-245
Error Code
- (Although the AC power plug is not connected, LED lamps on charger panel light on/ blink)
Related portion CN70-5 (16 D7V) CN70-15 (146, CAN1L) CN70-16 (145, CAN1H) CN70-18 (43, VBKY) Operation panel
CN69-4
CN70-1 (128, CH7V)
CN69-3
CN70-2 (130, CGND)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
Probable cause: (1) Harness defect (2) Operation panel defect (3) Display defect Inspection : Lighting/ blinking LED check 1. Turn off the key switch. 2. Check the “UP” LED whether it is lighting or blinking without connecting the AC power plug. “UP” LED is blinking.
“UP” LED is lighting.
LED other than “UP” is lighting/ blinking.
Inspection :Check of display function of the charging screen. 1. Check if the screen indicates that charging is complete. Not charging complete screen
Inspection : Error check with the AC power plug connected 1. Connect the AC power plug with the key switch turned off. 2. Check the error code indicated on the display.
Charging complete screen. Normal
* If the AC power plug is disconnected without any switch pressed after charging completes, the “UP” LED keeps lighting. This is not a defect, so press the “STOP” button to turn off the display and use the devise as it is.
Check the error code. Perform troubleshooting of that error. Inspection 1: LED signal check
OK
Operation panel defect
NG Inspection 2: Harness check 1. Turn off the key switch and disconnect the battery plug and the AC power plug. 2. Disconnect the CN69 and CN70 connectors and check harnesses for their continuities. OK Display defect
NG
Harness defect
5-246 Inspection 1: Check the LED signal. Disconnect the CN69 connector without connecting the AC power plug, perform the LED signal check. Portions to be checked
Standard
CN69-10 to CN69-3 (Main harness side)
0V
CN69-9 to CN69-3 (Main harness side)
0V
CN69-8 to CN69-3 (Main harness side)
0V
Inspection 2: Check the harness Check each harness for its continuity. Disconnect the CN69 and CN70 connectors and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING)
NORMAL LED
EQUAL LED
UP LED
Portions to be checked
Standard
CN70-30 to CN70-1 (Main harness side)
No continuity
CN70-30 to CN70-5 (Main harness side)
No continuity
CN70-30 to CN70-15 (Main harness side)
No continuity
CN70-30 to CN70-16 (Main harness side)
No continuity
CN70-30 to CN70-18 (Main harness side)
No continuity
CN70-29 to CN70-1 (Main harness side)
No continuity
CN70-29 to CN70-5 (Main harness side)
No continuity
CN70-29 to CN70-15 (Main harness side)
No continuity
CN70-29 to CN70-16 (Main harness side)
No continuity
CN70-29 to CN70-18 (Main harness side)
No continuity
CN70-32 to CN70-1 (Main harnessside)
No continuity
CN70-32 to CN70-5 (Main harnessside)
No continuity
CN70-32 to CN70-15 (Main harnessside)
No continuity
CN70-32 to CN70-16 (Main harnessside)
No continuity
CN70-32 to CN70-18 (Main harnessside)
No continuity
5-247
Error Code
- (Although the START button is not pressed, the magnet switch closes)
Related portion Transformer Thermoswitch Transformer
CN68-2
CN70-4 (14, DGND)
CN68-1
CN70-28 (139, SWTT) CN70-3 (169, TGND)
CN61
CN70-36 (N1,N1)
Operation panel
Magnet switch
CN69-1
CN70-33 (132, CHMS)
CN69-2
CN70-25 (129, CHAC)
CN69-3
CN70-2 (130, CGND)
CN69-4
CN70-1 (128, CH7V)
CN69-5
CN70-24 (121, SW3)
CN69-7
CN70-22 (123, SW1)
CN69-8
CN70-32 (124, LED4)
CN69-9
CN70-29 (125, LED3)
CN69-10
CN70-30 (126, LED2)
DISPLAY
(95, MSCH)
Probable cause: (1) Operation panel defect (2) Harness defect (3) Display defect Inspection 1 : Magnet switch signal check 1. Turn off the key switch and disconnect the battery plug and the AC power plug. 2. Disconnect the CN70 connector.
NG (Continuity)
Display defect
OK (No continuity) Inspection 2 : Harness check 1. Disconnect the CN69 and CN70 connectors and check the harnesses for their contuinuities. OK Operation panel defect
NG
Harness defect
5-248 Inspection 1: Check the magnet switch signal. Disconnect the CN70 connector and perform the magnet switch signal check. Portions to be checked
Standard
CN70-33 to CN70-2 (Display side)
No continuity
Inspection 2: Check the harness Check each harness for its continuity. Disconnect the CN69 and CN70 connectors and visually check inside the connector and the caulked portion of each wire for defects. (Refer to BEFORE TROUBLESHOOTING) Portions to be checked
Standard
CN69-3 to CN70-33
No continuity
CN70-33 to CN70-2
No continuity
CN70-33 to CN70-3
No continuity
CN70-33 to CN70-4
No continuity
CN70-33 to CN70-36
No continuity
Published by
1st Printing: Jan. 2012
Pub. No. CE350 Printed in Japan DA
