Nissan PDF

CONTROL SYSTEM
SECTION CS
CONTENTS
TECHNICAL DESCRIPTION .............................. CS-2 TROUBLE DIAGNOSTIC PROCEDURES ....... CS-74
System ........................................................... CS-2 Precautions .................................................. CS-74
METER PANEL ................................................. CS-13 How To Follow Flow Chart ........................... CS-75
Meters, Indicators and Lamps ...................... CS-13 Symbol Identification .................................... CS-76
Setting Adjustment Items (Normal Mode) .... CS-13 Voltage and Resistance Measurement
Meter Panel Explanation .............................. CS-14 Procedures ................................................... CS-77
LCD MONITOR ................................................. CS-23 TROUBLE DIAGNOSIS FOR CONTROLLER
Adjustment Mode ......................................... CS-23 SYSTEM ............................................................ CS-78
Diagnostic Mode ........................................... CS-32 TROUBLE DIAGNOSIS FOR DRIVING
Table of Error Code ...................................... CS-43 SYSTEM ............................................................ CS-87
PRECAUTIONS ................................................ CS-44 TROUBLE DIAGNOSIS FOR LOADING
LOCATION OF UNITS (LAYOUT) .................... CS-45 SYSTEM ............................................................ CS-93
Standard Equipment ..................................... CS-45 TROUBLE DAIGNOSIS FOR POWER
Tilt Leveling Device (Option) ........................ CS-46 STEERING SYSTEM ...................................... CS-100
CONTROLLER .................................................. CS-47 TROUBLE DIAGNOSIS FOR TURN
Removal and Installation .............................. CS-47 SIGNAL LAMP SYSTEM ................................ CS-101
Construction ................................................. CS-48 REFERENCE DATA OF CONTROL
Connector (Terminal layout) ......................... CS-50 SYSTEM .......................................................... CS-102
Controller Element Inspection ...................... CS-54 Main Print Board ......................................... CS-102
UNIT INSPECTION AND ADJUSTMENT ......... CS-60 FET Drive for Drive Control ........................ CS-106
Control System ............................................. CS-60 FET Drive for Pump Control ....................... CS-106
Knob Position Control System (Option) ........ CS-70 Condenser Board ....................................... CS-107
Tilt Leveling Device (Option) ........................ CS-71
Bulletins issued
Technical bulletin Issue date
SB-BX-CS-0702 Added steering neutral setting function 29-11-2007
SB-BX-CS-0703 New motor and controller 01-12-2007
TECHNICAL DESCRIPTION
System
COMPARISON OF PREVIOUS TYPE AND NEW TYPE
Previous model (P01/P02)
CSM0224
CS-2
System (Cont’d)
New model (1B1/1B2)
ghế ngồi
thách lưng ghếu

chân ga
đèn báo xinhan
cảm biến độ nghiêng
cảm biến áp lực dầu
cảm biến góc lái
cảm biến tốc độ
cảm biến nhiệt độ
CSM0225
CS-3
System (Cont’d)
CORRELATION DIAGRAM OF SYSTEM
Drive system
CSM0226
CS-4
System (Cont’d)
AC motor control
cần số
cần ben
màn hình
máy đổi điện
CSM0227
DRIVE SYSTEM FUNCTION
Item Function Outline
Drive control Drive control type Induction motor AC inverter vector control
Drive control Speed control (With turning speed/acceleration control)
Regeneration control Switchback, brake, accelerator off regeneration
Performance adjustment Power level (3 steps+ accurate adjustment 5 steps)/Acceleration Level (8 steps),
Regeneration level (8 steps each)
Anti-roll (8 steps)
Anti-roll control Anti-roll braking force control on slope
Various limitation Speed, high lift height, power cut (brake, parking brake)
Pump control Drive control Induction motor AC inverter vector control
Drive control Speed control by loading operation
Regeneration control Loading regeneration when loading operation stopped
Performance adjust. Power level (3 steps + accurate adjust 5 steps) Acceleration Level (8 steps)
Various limitation High lift height, high driving speed, cutout when reverse drive, pump cut
Mast lowering control Mast lowering lock when key switch is off
PS control Drive control type Electronic controlled hydraulic power steering
Drive control method Common pump motor control for loading
Control function Starting with steering operation detected/steering speed sensing control
Knob position control (OPTION) Compensate steering angle and tire angle offset by magnetic valve control
CS-5
System (Cont’d)
Item Function Outline
System control Inhibitor control Accelerator, FR SW, Loading, Seat

Meter communication Trace truck mode changeover by meter indication
Meter display of various truck conditions, diagnoses and adjustments
Log in function Setting of each truck by pass word input
Diagnosis function Diagnosis function in normal mode/self checking/dialog checking
Adjustment function Drive, pump, power steering system adjustment and memory
Accessory control Automatic power off/Parking brake warning
Cooling fan drive/External accessory source relay/Flasher
Truck model variation Automatic model variation change by harness
FEATURE OF DRIVE SYSTEM

Maintenance free AC Traction/Pump Motors
Pump motor is used for PS
Accessories concentrated control

Various model changing function (Same controller for various models)
Lift lowering, PS valve control
Flasher control
Cooling fan control (Including external fan)
Electric source relay (Auto power off, valve electric source)
High technology for superior function and high reliability by adoption of sensors with high performance
AC motor digital control adopting 32bit RISC CPU
Adoption of HEV (Hybrid Electric Vehicle) high responsible items such as resolver
CAN (Controller Area Network) communication between units
CS-6
System (Cont’d)
COMPARISON OF FORKLIFT MOTOR CONTROL
CSM0089
CS-7
System (Cont’d)
CSM0090
CSM0091
CS-8
System (Cont’d)
PRINCIPLE OF AC MOTOR
CSM0092
CS-9
System (Cont’d)
KNOB POSITION CONTROL SYSTEM (OPTION)
Knob position control
This ensures that the steering knob position constantly reflects the
correct tire angle.
NOTE:
The neutral level for the tire angle sensor must be adjusted
individually for each vehicle. (To absorb any variants in sensor
mounting and vehicle differences.)
Input Output
Steering wheel angle sensor

angle 1 signal
Steering wheel Power steering correction
angle 2 signal
solenoid
neutral signal
Tire angle sensor
CS-10
System (Cont’d)
Knob position control system
CSM0203
CS-11
System (Cont’d)
TILT LEVELING DEVICE (OPTION)
When forward tilt is commanded while the tilt leveling switch is ON, the tilt operation automatically stops as soon as
the fork is held at a level position.
Tilt leveling switch Mast angle Fork level
Vehicle
Rearward to Forward to Set level or Tilt operation
condition ON OFF Set level or less
forward rearward more
Unladen — — — Stops at a level position
— — —
— — — Normal operation
— — —
— No tilt leveling
Loaded — — — Stops at a level position
— — — Stops when switch is pressed.
— — — Normal operation
— — —
• No tilt leveling is performed in backward tilting.

• When the fork is loaded and at a lift up level, the tilt operation is stopped as soon as the tilt leveling switch is
pressed.
• Once the tilt leveling is activated, the operator cannot perform further tilt operations unless the tilt leveling switch
and tilt operation lever are restored.
NOTE:
The neutral level for the tilt angle sensor must be adjusted individually for each vehicle. (To absorb any variants in
sensor mounting and mast differences.) With a completed vehicle, hold the mast upright (with the fork held at a level
position) and register the tilt angle sensor value at that time in controller.
CS-12
METER PANEL
METER PANEL
Meters, Indicators and Lamps
CSM0257
Setting Adjustment Items (Normal Mode)

Adjustment item Shift to adjust mode Adjustment Details Function lock ON
Push FN1 The letters are dark and the display is dimmed.
LCD contrast – Lock OFF
Push FN2 The letters are light and the display is brightened.
Traction and loading P H M E
– Push FN3 Lock ON
power mode
Hour meter select – Push FN4 Lock ON

Push FN3 Hour Minute Day
Clock setting Push FN1 + FN2 Lock OFF
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Alarm setting Push FN2 + FN4 Lock OFF
Push FN1 The digit is increased, or the day is advanced.
Push FN2 The digit is decreased, or the day is set back.
Push FN3 D-ACC P-LEVEL
Push FN4 D-ACC P-LEVEL
Acceleration level Push FN1 + FN4 Lock ON
Push FN1 Increase
Push FN2 Decrease
Push FN2 + FN5
+
Push FN5
+
Push FN2
The function LCD contrast, clock setting and alarm setting are
Function lock/unlock + – –
disabled in the lock ON position.
Push FN3
+
Push FN5
+
Push FN5
Help menu – Push FN5 longer The explanation of the function switch. –
CS-13
METER PANEL
Meter Panel Explanation

DESCRIPTION
The meter panel consists of two sections: LCD (Liquid Crystal
Display) monitor and function keys.
1. Function keys
Function keys control the LCD contrast, display changes and
other adjustments. Function key operation is described in the
individual part descriptions and in the items related to
adjustment.
NOTE:
In case an incorrect operation is performed, the malfunction code
shall be displayed occasionally. If the malfunction code is displayed,
turned the key switch to the OFF position and then turn it to the ON
position again.
2. LCD
When the key switch is in the ON position, backlighting makes
the displays clearly visible to the forklift operator. It displays
normal operation (battery capacity meter, hour meter, clock,
steering wheel angle gauge, speedometer, etc.), malfunction
and adjustment data.
DRIVER RECOGNITION MODE
CSM0258
Registering a password can restrict the drivers of the forklift.

You can register a password for up to 5 persons.
CS-14
METER PANEL
Meter Panel Explanation (Cont’d)

LCD CONTRAST
The display contrast (lighter or darker) can be adjusted in 11 steps.
Push function key FN1, the letters are dark and the display is
dimmed. Push function key FN2, the letter are light and the display is
brightened.
HOUR METER (4 MODE)

This hour meter has 4 modes (functions).
1. Key “ON” time : Equal to the total operating hours when the
key switch is in the ON position.
2. Operating time : Equal to the traveling or loading time (the
time for whichever operation in progress is displayed).
3. Traveling time : Equal to the total time that the traction motor
is operational.
4. Loading time : Equal to the total time that the forks are
operational (tilting and lifting).
The hour meter operates when the key switch is in the ON position,
and it indicates the total operating period in hours (key “ON” time).
CSM0097
SPEEDOMETER
The speedometer shows forklift speed in either kilometers per hour
(km/h) or miles per hour (mph). The maximum vehicle speed and
speed alarm can both be set.
NOTE:
Speedometer factory settings at time of shipping:
Maximum speed: 20 km/h (12 MPH)
Setting speed range: 1 - 20 km/h (3 - 12 MPH)
Forklift speed alarm 1 - 2 setting: 25 km/h (16 MPH)
Forklift speed alarm 1 setting range (WSL1):
5 - 25 km/h (3 - 16 MPH)
Forklift speed alarm 2 setting range (WSL2):
WSL1 - 25 km/h (WSL1 - 16 MPH)
For speed alarm setting, refer to “Adjustment Mode”.
CSM0099
CS-15
METER PANEL

POWER MODE
In this mode, the power level for traveling and loading operation can
be adjusted. Each time function key FN3 is pressed, the power
mode is switched.
Mode M: Manual mode:

The power levels for traveling and loading can be individually set
according to customer requests.
Factory defaults:
Traveling power level: Level 1
CSM0100 Loading power level: Level 1
Adjustable range for traveling and loading power levels: Levels 1 - 5
For traveling and loading power level, refer to “Adjustment Mode”.
Mode E: Economy mode:

For work requiring operation time to be saved or customers using
the machine for a long time (Traveling and loading power levels:
Level 1)
Mode P: Power mode:

Factory setting (Traveling and loading power levels: Level 3)
Mode H: High-power mode:

For work or customers requiring higher power (Traveling and loading
power levels: Level 5)
CLOCK/ALARM/ACCELERATION ADJUSTMENT
Clock/alarm
When the key switch is in the ON position, both the day and time are
displayed.
Push function keys FN1 and FN2 simultaneously. The time set mode
will appear.
AM and PM hour adjustment: The hour display will advance by 1

hour each time function key FN1 or FN2 is pushed.
CSM0101
Minute adjustment: The minute display will advance by 1 minute

each time function key FN1 or FN2 is pushed.
Day-of-the-week adjustment: The day-of-the-week display will

advance by one day each time function key FN1 or FN2 is pushed.
After setting the clock to the correct time, push function key FN5.
The adjusted time will appear, and the clock will return to its original
letter mode.
NOTE:
• Push function key FN1 to increase the numerical value or
advance one day of the week.
• Push function key FN2 to decrease the numerical value or reverse
one day of the week.
• Push function keys FN2 and FN4 simultaneously. The alarm time
set mode will appear. This setting is the same procedure for the
time setting.
CS-16
METER PANEL

• If an alarm is set, “ ” appears next to the time display. When
the preset time is reached, the buzzer sounds to notify the
operator. Press function key FN5 to stop the buzzer. The day of
the week can be set to every day (ALL: every day).
Acceleration adjustment
This control adjusts acceleration during forklift starting and
subsequent operation.
Simultaneously press function keys FN1 and FN4. The clock will
move to the traction acceleration control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function key FN1.

CSM0102
Each time the key is pushed, the acceleration level (speed) will
increase by 1 step.
For slower acceleration (Slow): Push function key FN2.
decrease by 1 step.
For slower acceleration (Slow): Push function key FN2.
decrease by 1 step.
After setting the acceleration level, push function key FN5. The
acceleration level will appear, and clock will return to its original letter
mode.
NOTE:
Acceleration factory setting at time of shipping:
D-ACC NOM SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After acceleration level adjustment, operate the forklift slowly
and carefully until you become accustomed to the new
acceleration level. Be especially careful when the acceleration
level has been increased. Higher acceleration levels can cause
loads to shift, to fall off or to be unstable during starts.
CS-17
METER PANEL

Pump acceleration adjustment
Simultaneously push function keys FN1 and FN4. Next, push
function key FN3. The clock will move to the pump acceleration
control mode.
The acceleration level can be adjusted in a series of 8 steps.
For faster acceleration (Quick): Push function key FN1. Each time
the key is pushed, the acceleration level (speed) will increase by 1
step.
CSM0103
For slower acceleration (Slow): Push function key FN2. Each time
the key is pushed, the acceleration level (speed) will decrease by 1
step.
After setting the acceleration level, push function key FN5. The
pump acceleration level will appear, and the clock will return to its
original letter mode.
NOTE:
Pump acceleration factory setting at time of shipping:
P-LEVEL SET: Level 6
(Permissible setting range: Level 1 - 8)
WARNING:
After pump acceleration level adjustment, operate the forklift
mast control slowly and carefully (up, down and tilt) until you
become accustomed to the new pump acceleration level. Be
especially careful when the acceleration level has been
increased. Higher pump acceleration levels can cause loads to
shift, to fall off or to be unstable during starts.
PARKING BRAKE WARNING MARK

This mark is displayed whenever the parking brake pedal is in the
locked position. The mark disappears whenever the parking brake
pedal is released.
SEAT BELT WARNING MARK

This lamp indicates that the seat belt is not fastened securely. It will
lights up if the seat belt is not fastened when the ignition switch is
turned to the ON position, and it will turn off when the seat belt is
fastened.
CS-18
METER PANEL

MALFUNCTION AND WARNING INDICATIONS
CSM0298
If any malfunction occurs when the key switch is in the ON position,

the LCD will show a wrench mark “ ” or a battery mark “ ”.
Simultaneously, the LCD will display letters explain the details of the
malfunction.
NOTE:
During forklift operation, periodically check the battery capacity.
Make every effort to recharge the battery before the battery warning
mark “ ” and wrench mark “ ” appear.
Wrench mark
The controller and the sensors act together to regulate the forklift’s
electrical system. The wrench mark will appear whenever one of the
malfunctions listed below occurs. Simultaneously, the LCD will show
an indication explaining the details of the malfunction.
• Control system malfunction (Traction, Cargo-handling, Power

steering)
• Overheating controller or motor
• Low brake fluid level
• Low battery fluid level
CS-19
METER PANEL

BATTERY WARNING MARK
Pump cut warning
Pump cut warning is displayed when the battery capacity meter’s
remaining capacity indication changes from 2/6 to 1/6.
When function key FN5 is pressed, the display will switch.
CSM0105
After the pump cut warning has been displayed and ten minutes
have elapsed, the warning buzzer is activated along with the display
shown below.
CSM0106
When function key FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
CSM0105
The vehicle may be operated during the pump cut warning.

However, move the vehicle to a safe location, and promptly charge
the battery.
CSM0106
CS-20
METER PANEL

Low voltage lock warning
If the vehicle is subjected to continuous operation after the pump cut
warning was activated, the low voltage lock warning will be
activated. Then, the display will appear as shown below, and the
warning buzzer will be activated.
When function key FN5 is pressed, the display will switch. The
warning buzzer continues to sound throughout that period.
CSM0105
The vehicle cannot be operated during the low voltage lock warning.
NOTE:
The interval between the first appearance of the battery warning
mark and warning buzzer operation is set at the time of shipping.
Factory setting: 10 minutes
Permissible setting range: 1 - 20 minutes
For pump cut time setting, refer to “Adjustment Mode”.
CSM0106
CS-21
METER PANEL

MALFUNCTION INDICATIONS
Affected system or area Indication Malfunction description
Control system (Traction, D-FET SHORT A malfunction has occurred in NOTE:

Cargo-handling, Power the forklift traction system. A display example is shown on the
steering): Units, Sensors, Further operation of the forklift is left.
Motors, Switches, FETs not possible.
P-FET OPEN A malfunction has occurred in

the forklift cargo-handling
system. Further lifting (lifting
and tilting) operation is not
possible. The forks cannot be
raised or tilted.
TIRE ANGLE SENSOR LOW A malfunction has occurred in

the forklift power steering
system. Forklift steering control
is possible.
D/CONT TEMP SENSOR HIGH TEMP Either the controller or the motor WARNING:
is overheating. Immediately stop • Ignoring the warning
forklift operation. Park the forklift indication and continuing to
in a safe area where there is no operate the forklift can result
pedestrian or vehicular traffic. in serious motor damage.
Allow the controller and/or the Always stop operation
motor to cool. immediately after the warning
Either the controller or the motor indication appears. Have the
P/MO TEMP SENSOR HIGH TEMP
is overheating. Immediately stop forklift inspected.
forklift operation. Park the forklift • Check the specifications of
in a safe area where there is no the forklift you are using
pedestrian or vehicular traffic. before operation as this
Allow the controller and/or the function is not available on
motor to cool. some forklifts.
Essential fluids BRAKE FLUID LEVEL DOWN The brake fluid level has fallen WARNING:
below the specified level. Do not allow open flames in the
BAT FLUID LEVEL DOWN The battery fluid level has fallen battery inspection or fluid
below the specified level. As replenishment area.
NOTE: soon as possible, replenish the
In the case of a local battery, this function is battery fluid with distilled water CAUTION:
not operated without a battery fluid sensor. up to the specified level. Exercise extreme care when
replenishing the battery fluid. Fill
the battery with distilled water to
the specified level only. Do not
overfill. Resulting spillage may
cause a battery short circuit.
CS-22
LCD MONITOR
LCD MONITOR
Adjustment Mode
CSM0107
CS-23
LCD MONITOR
Adjustment Mode (Cont’d)

NOTE:
This mode is only available for qualified technicians to perform
various adjustments on setting values other than traction/loading
acceleration adjustments in the normal mode.
CAUTION:
• Adjustment values can be advanced or retarded by pushing
FN3 or FN4, respectively.
• Following adjustment value settings, do not turn the key
switch to the OFF position before pressing FN5 to return to
the adjustment item display. Doing so will erase adjustment
value settings.
CS-24
LCD MONITOR

MEMO
CS-25
LCD MONITOR
CSM0259
CS-26
LCD MONITOR
CSM0228
CS-27
LCD MONITOR
CSM0260
CS-28
LCD MONITOR
CSM0229
CS-29
LCD MONITOR
CSM0261
CS-30
LCD MONITOR
CSM0230
CS-31
LCD MONITOR
Diagnostic Mode
CSM0231
CS-32
LCD MONITOR
Diagnostic Mode (Cont’d)

There are two types of diagnostic method. One type is self-diagnosis
and the other is interactive diagnosis. Self-diagnosis allows for
controller diagnosis of a system, while the interactive diagnosis is
used for diagnosing switches and sensors. When malfunctions occur
in systems or components, check and eliminate probable causes of
the malfunction using either self-diagnostic or interactive diagnostic
techniques. After the malfunctioning area has been repaired,
confirm the malfunction has been eliminated by using the
appropriate diagnostic method.
NOTE:
When checking each component, operate each component if
necessary.
CS-33
LCD MONITOR
CSM0262
CS-34
LCD MONITOR
CSM0232
CS-35
LCD MONITOR
CSM0263
CS-36
LCD MONITOR
CSM0233
CS-37
LCD MONITOR
CSM0264
CS-38
LCD MONITOR
CSM0234
CS-39
LCD MONITOR
CSM0265
CS-40
LCD MONITOR
OSM0199
CS-41
LCD MONITOR

CAUTION:
If an interactive diagnostic result indicates that a unit is
abnormal, also check the condition of the associated harness
and connector.
NOTE:
• The number of malfunctions which have occurred in each system
is recorded in the “FAIL LOG” row on the display, without regard to
the nature of the malfunctions experienced.
• For unit inspection procedures, refer to “UNIT INSPECTION AND
ADJUSTMENT” on page 60.
RESULT OF SELF-CHECK
If the error is not detected:
CSM0235
If the error is detected:

NOTE:
The 3-digit number in the figure indicates the error code of the
component for which the error is detected. For the error code, refer
to “Table of Error Code” on page 43.
CAUTION:
If a self-diagnostic result indicates that an element or
component is abnormal, also check the condition of the
associated harness and bus bar.
CSM0236
NOTE:
For element inspection procedures, refer to “Controller Element
Inspection” on page 54.
CS-42
LCD MONITOR
Table of Error Code

Error Detect mode Reference Error Detect mode Reference
Failure part Fail mode Remarks Failure part Fail mode Remarks
code Work Self page code Work Self page
CONTROLLER ACTUATOR
Main contactor Short 400 Lift down valve Short 500
CS-56 - CS-68 -
Open 401 Open 501
Main fuse Open 403 CS-57 - PS correction valve Short 502 Knob
Battery voltage Low voltage 404 - Open 503 position
CS-70
control
Over 405 - - -
(Option)
voltage
Tilt Horizontal valve Short 504 Tilt
CONT capacitor Abnormal 406 - - - horizon
Open 505 CS-72
Drive FET Short 408 device
Open 409 (Option)
CS-54 - SENSOR
Pump FET Short 412
F/R Switch Same ON 450 - CS-61 -
Open 413
Accel sensor Low output 452
Drive current U Low output 414 CS-63 -
sensor High output 453
High output 415
CS-55 - Tire angle sensor Low output 454 Knob
V Low output 416
High output 455 position
High output 417 CS-68
control
D/Mo TEMP Abnormal 422 (Option)
sensor CS-58 - Tilt angle sensor Low output 456 Tilt
Overheat 423 -
High output 457 horizon
D/CONT TEMP Abnormal 426 CS-71
- - device
sensor Overheat 427 - (Option)
Pump current U Low output 430 LIFT ACCEL Low output 466 Special
sensor High output 431 - arrange-
CS-55 - ment
V Low output 432
Tilt H switch Short 468 Tilt
High output 433 horizon
Open 469 CS-71
P/Mo TEMP Abnormal 434 device
sensor CS-58 - (Option)
Overheat 435 -
Steer Angle sensor Abnormal 470 - CS-62 -
P/CONT TEMP Abnormal 436
sensor - - Weight sensor Low output 472 Tilt
Overheat 437 -
(Oil pressure sensor) High output 473 horizon
D/Mo REV Abnormal 438 - CS-71
device
sensor (Option)
CS-58 -
P/Mo REV Abnormal 442 -
sensor
CONT Abnormal 444 - - -
communication
CONT type Abnormal 446 - -
select
Meter
Meter Abnormal 558 - - -
communication
CS-43
PRECAUTIONS
PRECAUTIONS
WARNING:
Before starting to remove the controller parts, be sure to
perform either a. and b. bellow.
a. Disconnect battery connector, and connect a 50 to 500Ω
resistor (do not use a metal-film resistor) between the VB
(positive) terminal and — (negative) terminal at controller
ASSY to discharge condenser.
b. Wait at least 10 minutes after battery connector has been
disconnected.
CSM0266
CAUTION:
• Before removing or inserting main/meter print board
connectors, turn the key switch to the OFF position and
remove the battery plug. Failure to do so may cause a
malfunction in the print board.
• Make sure the controller/meter connector cord is free from
twisting when the connector is removed or inserted. A
twisted cord may cause poor connector contact. When
removing the connector, always hold the connector body and
do not pull on the cord.
• When removing wiring harnesses and/or bus bars, note their
relative locations so they can be reinstalled in their original
positions during reassembly.
• When installing a controller element which is used with
insulating film, be sure to place insulating film on the
contacting surface of the element and mating part. If a
controller element is not used with insulating film, apply
silicone-based grease to the contacting surface of the
element and mating part during installation.
• Before checking controller elements during on-vehicle
inspection, remove the wiring harnesses and bus bars.
Inadvertent current flow may damage the element or other
parts being checked.
• Before using flow charts as a guide to troubleshoot units and
parts, become familiar with the instructions outlined under
“TROUBLE DIAGNOSTIC PROCEDURES”.
NOTE:
Controller and unit conditions are determined by checking/
measuring the resistance values (continuity) of, or voltage values
produced across, various parts affected. However, this section deals
with only resistance measurement procedures.
CS-44
LOCATION OF UNITS (LAYOUT)
Standard Equipment
CSM0204
CS-45
Tilt Leveling Device (Option)
CSM0205
CS-46
CONTROLLER
CONTROLLER
Removal and Installation
CSM0206
CS-47
CONTROLLER
Construction
CSM0247
CS-48
CONTROLLER
Construction (Cont’d)
CSM0248
No. QTY. Part name No. QTY. Part name
1 1 Main print board 7 4 Current sensor

2 2 Power source print board 8 7 Fan motor
3 1 Capacitor board 9 6 Film capacitor
4 6 FET module 10 1 Harness assy
5 8 Stud bolt 11 1 Bus bar kit
6 2 Thermistor 12 1 Screw kit
CS-49
CONTROLLER
Connector (Terminal layout)

CONTROLLER
CSM0119
Controller assy
Input/
PIN NO. Contents Notes
Output
Input D20 KEY SW 2 (RESTART) For restart of timer auto off (Battery voltage)
D5 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
D6 KEY SW1 (IGN) Key SW input, Controller power (Battery voltage)
Output D1 A.P.O. RELAY DRIVE A.P.O. Relay ON/OFF drive, Coile load; 0.1A
Input D19 FORWARD SWITCH F Switch ON then forward
D25 REVERSE SWITCH R Switch ON then backward
D10 ACCEL SENSOR POWER Sensor power (+5.0V)
D12 ACCEL SENSOR SIGNAL A Steps in the pedal then output voltage increase
D14 ACCEL SENSOR SIGNAL B Steps in the pedal then output voltage increase B = A/2
D8 ACCEL SENSOR GND Sensor GND
P18 LIFT ACCEL SEN. POWER Sensor power +5.0V
P20 LIFT ACCEL SEN. SIGNAL Output voltage increase then lift speed increase
P31 LIFT ACCEL SEN. GND Sensor GND
P7 TIRE ANGLE SEN. POWER Sensor power +5.0V
P14 TIRE ANGLE SEN. SIGNAL Steering right turn then output voltage increase
P11 TIRE ANGLE SEN. GND Sensor GND
P12 STEER ANGLE SEN. POWER Sensor power +12.8V 0.2A
P19 STEER ANGLE SEN. SIGNAL A 45 Pulse per revolution
P21 STEER ANGLE SEN. SIGNAL B 45 Pulse per revolution, Phase late from SIG.A (90 deg)
P22 STEER ANGLE SEN. SIGNAL N For neutral detects, 1 Pulse per revolution
P8 STEER ANGLE SEN. GND Sensor GND
D31 RIGHT TURN SWITCH R SW ON (Low level) then flasher ON/OFF
D35 LEFT TURN SWITCH L SW ON (Low level) then flasher ON/OFF
Output D7 FLASHER POWER Power for flasher Lamp
D2 R FLASHER OUT Flasher drive output Right
Input D22 PARKING BRAKE SWITCH Operates a parking brake then SW ON
D23 BRAKE SWITCH Steps in the brake pedal then SW ON
P28 LIFT UP SWITCH Operates a lift up then SW ON
P29 TILT SWITCH Operates a tilt lever then SW ON
P24 3RD SWITCH Operates a 3rd lever then SW ON
P25 4TH SWITCH Operates a 4th up lever then SW ON
P26 5TH SWITCH Operates a 5th up lever then SW ON
D27 T15L SWITCH For North America: Low then UL EE
D24 HIGH MAST SWITCH Detects SW ON (1 Shot) then Hi-Mast mode
D26 SEAT SWITCH Site on the seat then SW ON
P23 TILT HORIZONTAL SWITCH Detects SW OFF (High level) then tilt auto horizontal mode
D15 MODE SELECT 1 Processes with the harness on vehicle
CS-50
CONTROLLER
Connector (Terminal layout) (Cont’d)

Input/
PIN NO. Contents Notes
Output
Input D18 MODE SELECT 3 Processes with the harness on vehicle
D28 SWITCH GND Switch GND
D29 SWITCH GND Switch GND
Input/ D33 M TO C COMMUNICATION DATA Meter to Controller communication data
Output D34 C TO M COMMUNICATION DATA Controller to Meter communication data
Input P10 TILT ANGLE SENSOR POWER Sensor power +5.0V
P16 TILT ANGLE SENSOR SIGNAL Tilt backward then output voltage increase
P15 TILT ANGLE SENSOR GND Sensor GND
P33 OIL PRESS SEN. POWER Sensor power +5.0V
P34 OIL PRESS SEN. SIGNAL On load then output voltage increase
P35 OIL PRESS SEN. GND Sensor GND
Output P4 PS C SOLENOID (PWM Drive) Drive of the solenoid for PS neutral correction (1.1A at 24V)
P1 LIFT DOWN SOL. (PWM Drive) Drive of the solenoid for lift down (0.5A at 24V)
P2 TILT HORI. SOL. (PWM Drive) Drive of the solenoid for tilt horizontal (0.78A at 24V)
P17 OPT. COOLING FAN Drive of the cooling fan for the controller (0.1A at 48V)
P5 EMERGENCY RELAY 1 Power cut relay 1 for solenoid (0.1A at 48V)
P3 SOL. POWER RETURN Power return for solenoid
Input P54 PM TEMP SENSOR - Sensor GND
P52 PM TEMP SENSOR + Temperature sensor+ for pump motor
D54 DM TEMP SENSOR - Sensor GND
D52 DM TEMP SENSOR + Temperature sensor+ for Right drive motor
P51 PM REV. SEN.SIGNAL SHIELD Revolution sensor signal shield for pump motor
P47 PM REV. SEN. SIGNAL B GND Revolution sensor B GND for pump motor
P45 PM REV. SEN. SIGNAL B Revolution sensor signal B for pump motor
P46 PM REV. SEN. SIGNAL A GND Revolution sensor A GND for pump motor
P44 PM REV. SEN. SIGNAL A Revolution sensor signal A for pump motor
P49 PM REV. SENSOR GND Sensor GND
P48 PM REV. SENSOR POWER + Sensor power+
P50 PM REV. SEN. POWER SHIELD Revolution sensor power shield for pump motor
D51 DM REV. SEN. SIGNAL SHIELD Revolution sensor signal shield for Right drive motor
D47 DM REV. SEN. SIGNAL B GND Revolution sensor B GND for Right drive motor
D45 DM REV. SEN. SIGNAL B Revolution sensor signal B for Right drive motor
D46 DM REV. SEN. SIGNAL A GND Revolution sensor A GND for Right drive motor
D44 DM REV. SEN. SIGNAL A Revolution sensor signal A for Right drive motor
D43 DM REV. SENSOR GND Sensor GND
D42 DM REV. SENSOR POWER + Sensor power +
D50 DM REV. SEN. POWER SHIELD Revolution sensor power shield for Right drive motor
Output D3 MAIN CONTACTOR DRIVE + Main contactor drive +
D4 MAIN CONTACTOR DRIVE - Main contactor drive -
D17 L FLASHER OUT Flasher drive output Left
CS-51
CONTROLLER

METER
System wiring
CSM0237
Input/Output Pin No. Contents Notes
External of meter
Input 1 Battery voltage Meter Wake up, Battery voltage and capacity detect
2 Battery power + Meter power to battery +
3 Blank terminal -
4 Brake fluid level SW Low fluid level then SW: ON
5 Seat belt SW Belt set then SW: ON
6 Parking BK Key Input Key Input for Parking BK Warning Buzzer
7 Blank terminal -
8 Blank terminal -
9 Parking brake SW Brake OFF then SW: ON
10 Battery fluid level sensor Normal output voltage is about 6V. Less than 3.5V:
Low level
11 Power GND Meter GND
12 Blank terminal -
CS-52
CONTROLLER

Input/Output Pin No. Contents Notes
Output 13 OPT relay 2 Output: Coil load 0.1A (Open Collector)

14 OPT relay 1 Output: Coil load 0.1A (Open Collector)
15 Warning buzzer drive relay Key OFF and PBK OFF then drive of relay
16 Blank terminal -
17 Blank terminal -
18 Blank terminal -
Input/Output 19 C to M Communication data Communication data of meter receive
20 M to C Communication data Communication data of meter transmit
Internal of meter
Input M01 Blank terminal -
M02 Blank terminal -
M03 Function SW 1 -
M04 Function SW 2 -
M05 Function SW 3 -
M06 Function SW 4 -
M07 Function SW 5 -
M08 SW GND -
M09 Ambient TEMP. sensor 1 For LCD contrast level
M10 Ambient TEMP. sensor 2
CS-53
CONTROLLER
Controller Element Inspection

CAUTION:
• To check each controller element, use circuit tester and
measure resistance between disconnected terminals to
determine if circuit continuity exists ( Ω).
To check the current sensor, measure voltage only.
• When checking controller elements, also check the
associated harnesses and bus bars.
• The following tables list resistance values measured across
respective terminals and should be used as reference
information. Keep in mind the resistance values vary with the
type of circuit tester (such as analog or digital) used for
measurements.
NOTE:
Measure resistance between terminals after terminals are
disconnected from bus bars to check each element listed in the
following table.
DRIVE FET MODULE, PUMP FET MODULE

Specifications
Item Specification
Type PDM5001
Durable voltage 100V
Service data
Item Normal (Reference value) NG
Tester+ Tester- Resistance Resistance

(Analog tester) (Digital tester)
D1 S1D2 0Ω
S1D2 D1 <5MΩ
D1 G1 3MΩ
G1 D1
G1 S1D2 3MΩ
Module Failed inverter
S1D2 G1 3MΩ
S1D2 S2 0Ω
S2 S1D2 <5MΩ
S1D2 G2 3MΩ
CSM0122
G2 S1D2
G2 S2 3MΩ
S2 G2 3MΩ
TB-BX-CS0701 CS-54, revised

CS-54 01 October 2007
CONTROLLER
Controller Element Inspection (Cont’d)

CURRENT SENSOR
Specifications
Item Specification
Type HC-TSA800V2YP12AR
Actual current ±800A
Output voltage +0.56 ~ +2.56V ~ +4.56V
Service data
Item Normal NG
Output V Approx. 2.5V between 3-4 Failed sensor

Source V Approx. 12.0V between 1-4 Failed CPU board
CSM0123
FAN ASSEMBLY
Specifications
Item Specification
Type 2410ML-05W-B40-BQ1
6 pieces/controller
Numbers of fan
One piece/external fan
Rated voltage 24V
Service data
CSM0124
Item Normal NG
Operation check with

Operation Failed cooling fan
Constant voltage
CS-55
CONTROLLER

CONTACTOR ASSEMBLY
Specifications
Item Specification
Rated current 300A

Cutout current 2500A
Mechanical life 100 M cycle
Service data
Item Normal NG
CSM0125
Coil resistance 30 ~ 70Ω
Abnormal contact
Contact wear limit Movable/fixed 0.7 mm Max
CSM0300
CS-56
CONTROLLER

Fuse
Specifications
Model Capacity
1B1, C1B1 420A
1B2, C1B2 500A
CSM0127
Inspection
Using a circuit tester, check continuity of each fuse.
Normal indication Abnormal (open-circuit) indication
Continuity
NOTE:
The circuit tester range selector must be set to “x1 Ω”.
CST0019
CS-57
CONTROLLER

MOTOR (TRACTION, LOADING)
CSM0238
Temperature sensor
Specifications
Item Specification
R 100°C (212°F) = Approx. 3.3 kΩ

Resistance
R 25°C (77°F) = Approx. 50 kΩ
Service data
Item Normal NG
Sensor resistance
CSM0129 Resistance Failed temp. Sensor
25°C (77°F) = Approx. 50 kΩ
Revolution sensor
Specifications
Item Specification
Temperature range -55 to +155°C (-67 to 311°F)

Anti vibration 20G
Anti impact force 100G
Type Magnetic induce
Service data
CSM0130
Item Normal NG
Revolution sensor Self check by revolution Failed revolution sensor

sensor IC detection
CS-58
CONTROLLER

CAUTION:
When installing the revolution sensor to the motor, harness
connection A should be forward (motor rear side) (Refer to MM
section).
MMM0020
CS-59
UNIT INSPECTION AND ADJUSTMENT
Control System
CAUTION:
• Before measuring resistance values, be sure to turn the key
switch to the OFF position, and disconnect the battery plug.
• When checking a unit, also check the condition of the
associated harness and connector.
• All units can be checked using interactive diagnostic
procedures. (Refer to “LCD MONITOR” on page 32.)
NOTE:
• The relative condition of a unit is evaluated by making required
voltage or resistance value measurements.
• This section deals with only resistance measurement procedures
for unit inspection.
FORWARD REVERSE SWITCH
ELM0321
CS-60
Control System (Cont’d)

Inspection
Check continuity at each lever position between the following
terminals.
Lever position Terminal with continuity
Forward -
Neutral -
Reverse -
CSM0132
CS-61

STEERING WHEEL ANGLE SENSOR
Specifications
Rated voltage (V) 12

Rated load current (mA) 10 - 50
Output voltage (V) Low Less than 0.5
High 2.5 - 3.5
Pulse (1, 2) (pulse/rotation) 45
Neutral position signal (pulse/rotation) 1
Service data
Measuring points (terminals) Standard value (V)

- 12
CSM0133
CSM0134
CS-62

ACCELERATOR SENSOR
CSM0208
Specification
Vcp1 - Ep1 2.5 - 5.0 (Reference value)
Total resistance (kΩ)
Vcp2 - Ep2 5.0 - 10.0 (Reference value)
Service data
Measuring
Standard value
points Remarks
(V)
(terminals)
Vcp1 - Ep1 (GND) 5.02 - 5.22 Always

CSM0138 Aps1 - Ep1 (GND) 0.668 - 0.868 When the accelerator pedal is released.
4.454 - 4.654 When the accelerator pedal is fully
depressed.
Adjustment
If the accelerator sensor output is not within the specified range,
adjust it as follows.
1. Call up accelerator sensor diagnostic screen from interactive
diagnostic display.
2. Loosen accelerator sensor securing screws.
3. While observing the accelerator sensor output on the display to
check if it is within the specified range, rotate the accelerator
sensor.
4. Tighten accelerator sensor securing screws.
CSM0139 : 1.5 - 1.8 N•m (0.15 - 0.19 kg-m, 13 - 16 in-lb)
CS-63
CSM0209
Linkage stroke adjustment

Fully-closed position adjustment
1. Depress the accelerator pedal until the accelerator linkage is
fully opened.
2. Rotate the stopper bolt counterclockwise by 180 degrees, and
then tighten the nut.
CAUTION:
• The accelerator linkage operation should move smoothly
with no binding. When releasing the pedal, immediately
return it to the fully-closed position.
• The return spring should be securely installed as shown in
the figure.
• Move the accelerator pedal, and then check that the
accelerator pedal roller moves smoothly in the groove.
CS-64

BRAKE SWITCH
Inspection
Check continuity between brake switch terminals when the brake
pedal is depressed 8 to 12 mm (0.31 to 0.47 in). Continuity must
exist.
<Reference data>
Brake switch ON/OFF Pedal height: 100 mm (3.94 in) (1.5 - 2.5 ton)
switching point 111 mm (4.37 in) (3.0, 3.5 ton)
(from floor upper surface)
CSM0141
Adjustment
CSM0210
1. Adjust the height of brake pedal point P to 107 mm (4.21 in) (1.5
- 2.5 ton), 117 mm (4.61 in) (3.0, 3.5 ton) from the floor upper
surface by the stopper bolt, and then tighten the lock nut.
: 12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
2. When depressing the pedal within 8 - 12 mm (0.31 - 0.47 in)
(pedal height: 100 mm (3.94 in) (1.5 - 2.5 ton), 111 mm (4.37 in)
(3.0, 3.5 ton)), adjust the brake switch so that the brake switch is
“ON”, and then tighten the lock nut.
: 12 - 15 N•m (1.3 - 1.5 kg-m, 9 - 11 ft-lb)
3. Make sure that the brake switch is “OFF” when the pedal is
released.
CS-65

CONTROL VALVE SWITCHES (LIFT, TILT, 3RD, 4TH,
5TH SWITCHES)
Inspection
When the control lever is operated, continuity must exist between
terminals affected.
NOTE:
• Circuit continuity must be checked after removing the affected
switch connector.
• Check for audible sounds which indicate control valve switches
are operating.
• If switches do not operate, adjust the switch position, then recheck
the switches operation. Refer to “Adjustment” on page 67.
CSM0142
CS-66

Adjustment
Using adjusting nuts and , adjust the dog-to-switch clearance
to specifications indicated in the figure below.
CAUTION:
The control valve must be set in Neutral and switches must be
freed during clearance adjustments.
CST0038
Centering adjustment
Loosen bracket securing bolts, then align the center of the control
valve switch and that of the dog.
CST0039
CS-67

LIFT SOLENOID (MECHANICAL CONTROL VALVE)
Specifications

Coil resistance (Ω) 36 at 20°C (68°F)
(Reference value)
44 at 90°C (194°F)
Inspection
Measure resistance between lift solenoid terminals.
<Reference value>
CSM0211
36Ω 20°C (68°F)
44Ω 90°C (194°F)
TIRE ANGLE SENSOR

Specifications
Total resistance (kΩ) 1.6 - 2.4 (Reference value)
Service data
Measuring
points Standard value Remarks
(terminals)
- 0Ω 2 kΩ The resistance value decreases as the

shaft is rotated.
- 2 kΩ The resistance value remains unchanged
regardless of the shaft rotation.
CSM0207
CS-68

Adjustment
CSM0239
Tire angle sensor fixes the kingpin plate to the kingpin as shown in
the above figure, and it is a structure in the hole of the kingpin plate
to transmit the turn of the kingpin to the tire angle sensor by
engaging the shaft of the tire angle sensor. Therefore, it is necessary
to assemble the tire angle sensor correctly to make the knob position
control system function correctly. Notes concerning assembly are as
follows.
1. When the kingpin plate is installed in the kingpin, it is necessary
to insert the plate vertically in the direction shown in the above
figure.
2. When the sensor shaft is engaged in the kingpin plate, it is
necessary to set the plane part of the sensor shaft to the spring and
the other side of the kingpin plate (left side in the above figure).
3. Securely insert plate into side groove of kingpin hole.
CAUTION:
When the tire angle sensor is removed, installed, and replaced,
the neutral level adjustment must be performed for the new
sensor.
CSM0240
CS-69
Knob Position Control System (Option)

PS KNOB POSITION SOLENOID VALVE
Specifications

Coil resistance (Ω) 21.8±5%
(Reference value) at 20°C (68°F)
Inspection
Check resistance between terminals using circuit tester.
21.8±5% 20°C (68°F)
CSM0152
Neutral setting
1. Set rear tire to the straight-ahead position.
2. Call up “ADJUSTMENT MODE” → “1-2. SENSOR” → “16
SENSOR INITIAL SET”.
3. Push function key FN3 to set the vehicle to the straight-ahead
position.
CS-70
Tilt Leveling Device (Option)

INSPECTION
Tilt horizontal switch
Check continuity.
When press button: Continuity should not exist.
When do not press button: Continuity should exist.
CSM0245
Mast height sensor

Key switch is turned on with the harness connected, and move the
metal close to the lift up level detection switch. At this time, make
sure that switch operation indicator lamp turns on.
CSM0246
Oil pressure sensor

Key switch is turned on and check out put voltage while connecting
harness.
Output voltage (V): 0.25 - 4.75
Battery voltage (V): 5 ± 0.5 (Power supply - GND)
CSM0299
Tilt angle sensor

Key switch is turned on and check out put voltage while connecting
harness.
Output voltage (V): 0.5 - 4.5 (2 - 3)
Battery voltage (V): 5 ± 0.5 (1 - 3)
CSM0242
CS-71
Tilt Leveling Device (Option) (Cont’d)

Tilt horizontal solenoid valve
Check resistance.
Item Resistance
Normal (Ω) 30 - 77
Malfunction (Ω) 0 or
CSM0243
REMOVAL AND INSTALLATION

Mast height sensor
CSM0212
CS-72
Tilt Leveling Device (Option) (Cont’d)

Tilt angle sensor
CSM0213
SETTING
1. Park the vehicle on a flat, level road.
2. Set the mast to vertical.
3. Raise the fork approximately 300 mm (11.8 in) from the ground.
4. After calling up “ADJUSTMENT MODE” → “1-2. SENSOR” →
“16 SENSOR INITIAL SET”, push function key FN3 and turn
“OFF” to “ON”.
NOTE:
Perform the following setting only when retrofitting the tilt leveling
device at local modification.
Push function keys FN1+FN5 to turn the normal display to the tilt
horizontal setting display. Push function key FN5 to set the tilt
leveling condition.
CONFIRMATION OF OPERATION
Except for North America
1. Lift up the mast to pass the mast height sensor, and then lower
the lift.
2. Check the movement of following table at tilt forward (with tilt
switch: ON) from tilt back.
3. Stop angle tilt back 1°±1° (mast standard).
Low mast High mast

No load Stop angle tilt back 1°±1° Stop angle tilt back 1°±1°
(Mast standard) (Mast standard)
1G load About horizontal No movement
For North America

1. Check the movement of following table at tilt forward (with tilt
switch: ON) from tilt back.
2. Stop angle tilt back 1°±1° (mast standard).
Low mast High mast

No load Stop angle tilt back 1°±1° Stop angle tilt back 1°±1°
(Mast standard) (Mast standard)
1G load No movement No movement
CSM0244
CS-73
TROUBLE DIAGNOSTIC PROCEDURES
Precautions
CAUTION:
• Before performing self-diagnosis, check condition of blade
fuses, fusible links, etc.
• After repairing trouble areas, operate the vehicle to confirm
that malfunctions have been eliminated.
• When checking the traction system, raise the front wheels off
the ground using a jack. Refer to GI section for details.
• When malfunction occurs, do not attempt to inspect
connectors, harnesses, etc. but perform self-diagnosis and/
or interactive diagnosis. This can avoid unnecessary repair
or replacement.
• Basic trouble diagnostic procedures must be performed as
follows:
Malfunction occurrence
Confirm trouble message and

malfunctioning symptom.
Perform self-diagnosis.
Does self-diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
NO to “SELF-DIAGNOSIS”.
Perform interactive diagnosis.
Does interactive diagnosis pinpoint YES Check malfunctioning

malfunctioning part? part and the circuit. Refer
NO to topic “Unit inspection”.
Use troubleshooting flow charts, wiring

diagrams and circuit diagrams as a
guide to locate and eliminate trouble
causes.
NOTE:
Test probes of a circuit tester are too large to be inserted into
connectors during voltage measurements on the print board side. It
is advisable to have the tips of the test probes fastened with thin
conductive wire to be used as an extension lead. In this way,
connector terminals are prevented from sustaining damage. (Such
an extension lead will be referred to as a temporary tool in
troubleshooting flow charts.)
CST0062
CS-74
How To Follow Flow Chart

Trouble diagnostic procedures for controllers (including charging
system) are indicated in flow charts. Inspection and confirmation
procedures are shown in illustrations, making the respective flow
charts more comprehensive. Circuit diagrams are also included
where necessary, along with applicable flow charts.
NOTE:
The entire system wiring diagram and circuit diagram are included at
the end of this manual. Refer to these diagrams as necessary during
diagnostic procedures.
MALFUNCTIONING SYMPTOMS
Typical trouble symptom entries are treated as titles.
PROBABLE TROUBLE AREAS CAUSING

MALFUNCTIONS
Probable trouble areas or parts are indicated in relation to
malfunctions that may occur.
WORK FLOW
Confirmation of malfunction
Inspection and/or confirmation Inspection and confirmation procedures

procedures must be explained
as required in the illustration.
Specifications, judgment and/or (Use a temporary tool.)
evaluation
*Tester range
Remedial procedures
* Examples of tester range selection

V
100 : Voltage measurement in 100-volt range (DC)
V
500
: Voltage measurement in 500-volt range (AC)
R
X1
: Resistance measurement in 1Ω range
CAUTION:
Always use the digital tester to measure the resistance of the
sensor (potentiometer). If the analog tester is used, the sensor
(potentiometer) may be damaged by the internal battery of the
analog tester.
A
: Current measurement in 50-ampere range (AC)
50
About temporary tool:

A temporary tool refers to a circuit tester whose test probe ends are
temporarily wrapped with thin conductive wires. The tip ends of
respective wires are attached to connector terminals on the print
board side during required voltage measurements. Refer to
“Precautions” on page 74.
CS-75
Symbol Identification
HARNESS CONNECTOR SYMBOLS
Male and female connectors
• Connector guides for male terminals are shown in black.
• Connector guides for female terminals are shown in white.
CST0063
Connector direction
• Connector symbols shown from the terminal side (in direction A)
are enclosed by a single line.
• Connector symbols shown from the harness side (in direction B)
are enclosed by a double line.
CST0064
Controller or other single unit connectors

Controller connector symbols are indicated so that connectors are
being shown from the terminal side; enclosed by a single line with
connector guides shown in black.
CST0065
KEY TO SYMBOLS
Symbol Explanation Symbol Explanation
Check after disconnecting Turn key switch to the OFF
harness connector. position.
Check after connecting Turn key switch to the ON

harness connector. position.
Check after disconnecting Check after connecting

battery plug. battery plug.
CS-76
Voltage and Resistance Measurement

Procedures
VOLTAGE MEASUREMENT
• Connector terminals on the print board side are too closely
arranged so it is difficult for test probes of a conventional circuit
tester to gain access to them. For this reason, it is advisable to
wrap thin conductive wires around the ends of the test probes and
use the wires as test probe extensions (which are referred to as
the temporary tools in troubleshooting flow charts).
• To facilitate voltage measurements for parts or terminals
(adjacent to controllers), it is best to use an alligator clip with the
black (ground) test probe of a circuit tester and fasten it to the
battery ground terminal during measurements.
CST0066
RESISTANCE MEASUREMENT
• Before measuring resistance, turn the key switch to the OFF
position, remove the battery plug, then remove the connector and
the part whose resistance is to be measured.
• A broken wiring circuit must be measured between connector
terminals affected using a circuit tester.
CST0067
CS-77
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEM
WARNING:
Before starting to remove the controller parts, be sure to
perform either a. and b. bellow.
a. Disconnect battery connector, and connect a 50 to 500Ω
resistor (do not use a metal-film resistor) between the VB
(positive) terminal and — (negative) terminal at controller
ASSY to discharge condenser.
b. Wait at least 10 minutes after battery connector has been
disconnected.
CSM0266
CAUTION:
• To perform an accurate diagnosis, carefully listen to the
user’s complaints and check the actual vehicle to fully
understand under what conditions the symptoms occur.
• For checking each controller element, use circuit tester and
measure resistance between terminals to determine whether
circuit continuity exists or not ( Ω).
For checking the current sensor, only measure voltage.
• When checking controller elements, also check the
associated harnesses and bus bars.
• If the cause of the malfunction may be in the mechanical
systems, always check the mechanical systems that are not
included in the flowchart.
CS-78
SYMPTOM:
The meter does not display. The forklift also does not operate
(in any operation of traction/loading/power steering).

MALFUNCTIONS
Battery, Main fuse, Auxiliary fuse, Fusible link, key switch, Main
contactor, Main print board, Harness, cable and Insulation
resistance
CSM0267
CSM0268
CSM0269
CS-79
CSM0270
CSM0271
CSM0272
CS-80
CSM0273
CSM0274
CS-81
SYMPTOM:
The meter does not display. The forklift operates (in any
operation of traction/loading/power steering).

MALFUNCTIONS
Auxiliary fuse, A.P.O. relay, Harness and Meter print board
CSM0276
CSM0277
CS-82
SYMPTOM:
The meter displays. The forklift does not operate (in any
operation of traction/loading/power steering).

MALFUNCTIONS
Battery, Main fuse, Auxiliary fuse, Insulation resistance Main
contactor, Main print board, Capacitor board, FET board, Drive
current sensor, D/Mo. REV. sensor, Traction motor, Pump FET,
Pump current sensor, P/Mo. REV. sensor, Pump motor, Harness,
cable and Seat switch
NOTE:
For these items, the fuse 1 and the main contactor can be checked
at the self-diagnosis.
CSM0279
CSM0275
CS-83
CSM0267
CSM0269
CSM0270
CS-84
CSM0271
CSM0272
CSM0273
CS-85
CSM0278
CS-86
TROUBLE DIAGNOSIS FOR DRIVING SYSTEM
SYMPTOM:
Cannot move forward and backward.

MALFUNCTIONS
D/CONT. TEMP. sensor, FR-SW, Accel. sensor, Brake switch,
Parking BK switch, Traction motor, Main print board, Cable and
Harness
CAUTION:
The self-diagnosis results in flowchart describe the possible
parts (error code), but all of them are not always displayed.
Only the parts that can be checked with interactive diagnosis
are displayed from these parts as the interactive diagnosis
item. Always check the malfunctioning parts of interactive
diagnosis even if it is a unit. Then, check the related harness
condition.
CSM0279
CSM0280
CSM0281
CS-87
SYMPTOM:
Cannot drive forward or backward.

MALFUNCTIONS
FR-SW, Main print board and Harness
CAUTION:
condition.
CSM0282
CSM0280
CS-88
SYMPTOM:
The traction speed is slow. The acceleration is slow. Or, there
is no power.

MALFUNCTIONS
D/Mo. TEMP. sensor, D/CONT. TEMP. sensor, Cooling fan, Main
print board and Harness
CAUTION:
condition.
CSM0283
CSM0284
CS-89
CSM0285
CSM0286
CSM0287
CSM0280
CS-90
CSM0288
CS-91
SYMPTOM:
Regenerative braking malfunction

MALFUNCTIONS
Brake switch, Main print board and Harness
CAUTION:
condition.
CSM0289
CSM0280
CS-92
TROUBLE DIAGNOSIS FOR LOADING SYSTEM
SYMPTOM:
Loading malfunction (in any operation of lift/tilt/3rd/4th)

MALFUNCTIONS
P/CONT. TEMP. sensor, HYD-control valve switch, Pump motor,
Main print board, Cable and Harness
CAUTION:
condition.
CSM0290
CSM0280
CSM0291
CS-93
SYMPTOM:
An operation of lift/tilt/attachment (3rd/4th) does not operate.

MALFUNCTIONS
HYD-control valve switch, Main print board and Harness
CAUTION:
condition.
CSM0280
CS-94
SYMPTOM:
The mast does not lower (but can be raised).

MALFUNCTIONS
EMG relay, Lift down valve, Main print board and Harness
CAUTION:
condition.
CSM0292
CSM0293
CSM0280
CS-95
SYMPTOM:
The loading speed is slow. The acceleration is slow. Or, there
is no power.

MALFUNCTIONS
P/Mo. TEMP. sensor, P/CONT. TEMP. sensor, Cooling fan, Main
CAUTION:
condition.
CSM0283
CSM0284
CSM0294
CS-96
CSM0295
CSM0280
CSM0288
CS-97
SYMPTOM:
Tilt horizontal device malfunction

MALFUNCTIONS
Tilt horizontal switch, oil pressure switch, tilt horizontal valve, tilt
angle sensor, mast height sensor, main print board, auxiliary fuse
(5A: option), cable and harness
CAUTION:
condition.
CSM0296
CSM0280
CS-98
CSM0241
CS-99
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEM
SYMPTOM:
Power steering malfunction (include the knob position
malfunction of OPT mechanism)

MALFUNCTIONS
PS correction valve, Tire angle sensor, Steering angle sensor, Main
CAUTION:
condition.
CSM0297
CSM0280
CS-100
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEM
SYMPTOM:
Turn signal lamp malfunction

MALFUNCTIONS
Main print board, Bulb, Lighting switch and Harness
CS-101
REFERENCE DATA OF CONTROL SYSTEM
Main Print Board

Terminal
No. Possible error mode/
Items Characteristic/Specification Related trouble diagnosis
(Print board Related symptom
side)
D20 KEY SW2 (RESTART) VB level (key switch 2 ON) • The auto power-off mode –
cannot be restarted
D5 KEY SW1 (IGN) VB level (key switch 1 ON) • The controller does not –
operate
D6 KEY SW1 (IGN)
D81 Capacitor voltage VB level (main relay ON) • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
• Low voltage protection • Battery low voltage: 404
D1 A.P.O. RELAY DRIVE Operation (key ON) • The meter does not operate • Controller communication
malfunction: 444
D19 FORWARD SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved forward
D25 REVERSE SWITCH GND level (switch ON) • The traction is not possible • FR-SW short: 450
• Cannot be moved backward
D10 ACCEL SENSOR POWER 5.0±0.2V • The traction is not possible • Accelerator pedal position
• Poor acceleration/maximum sensor output large: 453
D12 ACCEL SENSOR SIGNAL A 0.2 - 4.7V (normal)
speed • Accelerator pedal position
D14 ACCEL SENSOR SIGNAL B 0.2 - 4.7V (normal) sensor output small: 452
D8 ACCEL SENSOR GND GND connection
P18 LIFT ACCEL SEN. POWER 5.0±0.2V • The loading system does • Lift accelerator output
not operate small: 466
P20 LIFT ACCEL SEN. SIGNAL 1.0 - 4.5V (normal)
P31 LIFT ACCEL SEN. GND GND connection
P7 TIRE ANGLE SEN. POWER 5.0±0.2V • Straight-line instability • Tire angle sensor output
P14 TIRE ANGLE SEN. SIGNAL 0.5 - 4.8V (normal) • Poor turning ability large: 455
• Knob position malfunction • Tire angle sensor output
P11 TIRE ANGLE SEN. GND GND connection small: 454
P12 STEER ANGLE SEN. POWER 12.8±1V • Knob position malfunction • Steering angle sensor
P19 STEER ANGLE SEN. SIGNAL A 0 - 3.5V rectangular pulse • The steering is not possible malfunction: 470
• Steering force malfunction
P21 STEER ANGLE SEN. SIGNAL B 0 - 3.5V rectangular pulse
P22 STEER ANGLE SEN. SIGNAL N 0 - 3.5V rectangular pulse
P8 STEER ANGLE SEN. GND GND connection
D31 RIGHT TURN SWITCH GND level (switch ON) • Turn signal does not blink –
D35 LEFT TURN SWITCH GND level (switch ON) • Turn signal continues
blinking
D7 FLASHER POWER VB input • Turn signal does not turn on –
D2 RIGHT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D17 LEFT FLASHER OUT Turn signal lamp drive (PWM) • Turn signal does not turn on –
D22 PARKING BRAKE SWITCH GND level (switch ON) • The traction is not possible –
D23 BRAKE SWITCH GND level (switch ON) • The traction is not possible –
• Brake regenerative
malfunction
P28 LIFT UP SWITCH GND level (switch ON) • The lift does not rise –
• The loading motor does not
rotate
P29 TILT SWITCH GND level (switch ON) • No tilt operation –
rotate
P24 3RD SWITCH GND level (switch ON) • No 3rd operation –
rotate
P25 4TH SWITCH GND level (switch ON) • No 4th operation –
rotate
CS-102
Main Print Board (Cont’d)

Terminal
side)
P26 5TH SWITCH GND level (switch ON) • No 5th operation –

rotate
D27 T15L SWITCH GND connection or open • For North America: Does –
according to the mode setting not operate due to
characteristic of EE
specification
D24 HIGH MAST SWITCH At a lift up level • No limited operation at a lift –
• 1 shot type: GND level up level
Open
• N.C type: Open
• N.O type: GND level
D26 SEAT SWITCH GND level (switch ON) • No traction/loading/PS –
operation
• Seat switch warning
P23 TILT HORIZONTAL SWITCH GND level (switch ON) • The automatic tilt horizontal • Tilt horizontal switch
function (horizontal stop) open: 469
does not normal operate • Tilt horizontal switch
short: 468
D15 MODE SELECT 1 GND connection or open • The designated • Model select malfunction:
according to the mode setting performance is not shown 446
D16 MODE SELECT 2
because the model type
D18 MODE SELECT 3 setting is incorrect
D11 MODE SELECT 4
D28 SWITCH GND GND • No GND level at each switch –
ON
D29 SWITCH GND GND • The switch signal detection –
is not possible
P10 TILT ANGLE SEN. POWER 5.0±0.2V • Automatic tilt horizontal stop • Tilt angle sensor output
position malfunction large: 457
P16 TILT ANGLE SEN. SIGNAL 0.5 - 4.7V (normal)
• Automatic tilt horizontal stop • Tilt angle sensor output
P15 TILT ANGLE SEN. GND GND connection does not operate small: 456
D33 METER TO CONTROLLER Rectangular wave (meter • The meter communication is • Controller communication
COMMUNICATION DATA output) not possible malfunction: 444
D34 CONTROLLER TO METER Rectangular wave (controller • The meter communication is • Controller communication
COMMUNICATION DATA output) not possible malfunction: 558
• CAN communication
between main print board
and option controller cannot
be performed
P4 PS C SOLENOID (PWM Drive) PS correction solenoid (PWM) • Knob position malfunction • PS correction solenoid
• PS correction solenoid open: 503
malfunction • PS correction solenoid
short: 502
P1 LIFT DOWN SOL. (PWM Drive) Lift down solenoid (PWM) • The lift cannot be lowered • Lift down solenoid valve
open: 501
• Lift down solenoid valve
short: 500
P2 TILT HORI SOL. (PWM Drive) Tilt horizontal solenoid PWM • Automatic tilt horizontal • Tilt horizontal valve open:
does not stop 505
• Tilt is not possible • Tilt horizontal valve short:
• Automatic tilt horizontal stop 504
position malfunction
CS-103

Terminal
side)
P17 OPT. COOLING FAN Optional cooling fan operation • Optional cooling fan –
(GND level at driving) malfunction
P5 EMERGENCY RELAY 1 Operation at starting the • PS correction solenoid • PS correction solenoid
controller (GND level at malfunction open: 503
driving) • Lift down valve malfunction • Lift down solenoid valve
• Knob position malfunction open: 501
• The lift cannot be lowered
P3 SOL. POWER RETURN (Solenoid chopper return line) • Unstable valve control at –
open
P33 OIL PRESS SEN. POWER 5.0±0.2V When automatic tilt horizontal • Weight sensor output
control small: 472
P34 OIL PRESS SEN. SIGNAL 0.25 - 4.75V (normal)
• Does not stop at a lift up • Weight sensor output
P35 OIL PRESS SEN. GND GND connection level large: 473
• No limited speed at forward
tilting
P54 PM TEMP SENSOR - Voltage between P52 and P54: • Loading speed decrease • PM temperature rise: 435
Approx. 3.8V (25°C) • PM temperature sensor
P52 PM TEMP SENSOR +
malfunction: 434
D54 TM TEMP SENSOR - Voltage between D52 and • Traction speed decrease • TM temperature sensor rise:
D52 TM TEMP SENSOR + D54: Approx. 3.8V (25°C) 423
• TM temperature sensor
malfunction: 422
P51 PM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • PM motor revolution sensor
P47 PM REV. SEN. SIGNAL B GND GND operate malfunction: 442
P45 PM REV. SEN. SIGNAL B (The measurement is not

possible)
P46 PM REV. SEN. SIGNAL A GND GND
P44 PM REV. SEN. SIGNAL A (The measurement is not
possible)
P49 PM REV. SENSOR GND (The measurement is not
possible)
P48 PM REV. SENSOR POWER + (The measurement is not
possible)
P50 PM REV. SEN. POWER SHIELD GND connection
D51 TM REV. SEN. SIGNAL SHIELD GND connection • The controller does not • TM motor revolution sensor
D47 operate malfunction: 438
TM REV. SEN. SIGNAL B GND GND
D45 TM REV. SEN. SIGNAL B (The measurement is not
possible)
D46 TM REV. SEN. SIGNAL A GND GND
D44 TM REV. SEN. SIGNAL A (The measurement is not
possible)
D43 TM REV. SENSOR GND (The measurement is not
possible)
D42 TM REV. SENSOR POWER + (The measurement is not
possible)
D50 TM REV. SEN. POWER SHIELD GND connection
CS-104

Terminal
side)
D3 MAIN CONTACTOR DRIVE + VB level • The controller does not • Main contactor open: 401
operate • Main contactor short: 400
D4 MAIN CONTACTOR DRIVE - PWM drive (VB-GND)
• The main contactor is not
input
D68 Traction current sensor power 12.5±1V • The controller does not • Traction U-phase current
D70 supply operate sensor output large: 415
• Traction U-phase current
D71 sensor output small: 414
D72 • Traction V-phase current
sensor output large: 417
D73 U-phase traction current sensor At no motor driving: 2.5±0.1V
• Traction V-phase current
signal
sensor output small: 416
D75 W-phase traction current sensor
signal
D62 Traction current sensor power GND
supply GND
D69
D74
D80
P70 Loading current sensor power 12.5±0.1V • The controller does not • Loading U-phase current
supply operate sensor output large: 431
P71
• Loading U-phase current
P72 sensor output small: 430
P73 Loading U-phase traction cur- At no motor driving: 2.5±0.1V • Loading V-phase current
rent sensor signal sensor output large: 433
• Loading V-phase current
P75 Loading V-phase traction current
sensor output small: 432
sensor signal
P74 Loading current sensor power GND
P78 supply GND
D64 Cooling fan power supply At fan driving: 24.0±3V • Internal cooling fan • Drive Cont. temperature
D65 malfunction sensor malfunction: 426
• Loading Pump Cont.
temperature sensor
malfunction: 436
D102 Traction controller temperature + Voltage between D102 and • The controller does not • Drive Cont. temperature
D103: Approx. 3.8V (25°C) operate sensor rise: 427
D103 Traction controller temperature -
• Traction speed decrease • Drive Cont. temperature
sensor malfunction: 426
P85 Loading controller temperature + Voltage between P85 and P86: • The controller does not • Pump Cont. temperature
P86 Loading controller temperature - Approx. 3.8V (25°C) operate rise: 437
• Loading speed decrease • Pump Cont. temperature
sensor malfunction: 436
CS-105
FET Drive for Drive Control

Terminal
Possible error mode/Related
No. (Print Items Characteristic/Specification Related trouble diagnosis
symptom
board side)
D99 INV-RESET Inverter block signal: Inverter • Traction malfunction • Traction FET short: 408
stops at 5V or more • Traction FET open: 409
D100 FAIL Inverter malfunction diagnosis
at GND level
D101 GND-C GND
D104 KEY1 VB level
D105 12V 12.5±1V
D106 INV DIA At normal inverter: Range of 1/
4VB - 3/4VB
FET Drive for Pump Control

Terminal
symptom
board side)
P99 INV-RESET Inverter block signal: Inverter • Loading malfunction • Loading FET short: 411
stops at 5V or more • Loading FET open: 413
P100 FAIL Inverter malfunction diagnosis
at GND level
P101 GND-C GND
P104 KEY1 VB level
P105 12V 12.5±1V
P106 INV DIA At normal inverter: Range of
1/4VB - 3/4VB
CS-106
Condenser Board
Terminal
symptom
board side)
E1 Batt+ • VB level (E16-E15) • The controller does not • CONT condenser

(contactor input) operate malfunction: 406
E4 Batt+
• Main contactor short: 400
E7 Batt+ • Main contactor open: 401
E10 Batt+ • Main fuse open: 403
E13 Batt+
E16 Batt+
E3 Batt-
E6 Batt-
E9 Batt-
E12 Batt-
E15 Batt-
E18 Batt-
F1A Controller cooling fan 1 power Voltage between F1* and F2* • Controller internal cooling • Right Drive Cont.
supply At fan driving: 24.0±3V fan malfunction temperature sensor
malfunction: 426
F1B Controller cooling fan 2 power
• Loading Pump Cont.
supply
temperature sensor
F1C Controller cooling fan 3 power malfunction: 436
supply
F1D Controller cooling fan 4 power
supply
F1E Controller cooling fan 5 power
supply
F1F Controller cooling fan 6 power
supply
F1G Controller cooling fan 7 power
supply
F2A Controller cooling fan 1 GND
F2B Controller cooling fan 2 GND
F2C Controller cooling fan 3 GND
F2D Controller cooling fan 4 GND
F2E Controller cooling fan 5 GND
F2F Controller cooling fan 6 GND
F2G Controller cooling fan 7 GND
CS-107
MEMO
CS-108

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CONTROL SYSTEM

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cảm biến áp lực dầu

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máy đổi điện

DRIVE SYSTEM FUNCTION

Item Function Outline

System control Inhibitor control Accelerator, FR SW, Loading, Seat

FEATURE OF DRIVE SYSTEM

Accessories concentrated control

Steering wheel angle sensor

• No tilt leveling is performed in backward tilting.

Meters, Indicators and Lamps

Setting Adjustment Items (Normal Mode)

Hour meter select – Push FN4 Lock ON

Meter Panel Explanation

DRIVER RECOGNITION MODE

Registering a password can restrict the drivers of the forklift.

Meter Panel Explanation (Cont’d)

HOUR METER (4 MODE)

For speed alarm setting, refer to “Adjustment Mode”.

Meter Panel Explanation (Cont’d)

Mode M: Manual mode:

Mode E: Economy mode:

Mode P: Power mode:

Mode H: High-power mode:

AM and PM hour adjustment: The hour display will advance by 1

Minute adjustment: The minute display will advance by 1 minute

Day-of-the-week adjustment: The day-of-the-week display will

Meter Panel Explanation (Cont’d)

The acceleration level can be adjusted in a series of 8 steps.

For faster acceleration (Quick): Push function key FN1.

For slower acceleration (Slow): Push function key FN2.

For slower acceleration (Slow): Push function key FN2.

Meter Panel Explanation (Cont’d)

The acceleration level can be adjusted in a series of 8 steps.

PARKING BRAKE WARNING MARK

SEAT BELT WARNING MARK

Meter Panel Explanation (Cont’d)

If any malfunction occurs when the key switch is in the ON position,

• Control system malfunction (Traction, Cargo-handling, Power

Meter Panel Explanation (Cont’d)

When function key FN5 is pressed, the display will switch.

The vehicle may be operated during the pump cut warning.

Meter Panel Explanation (Cont’d)

For pump cut time setting, refer to “Adjustment Mode”.

Meter Panel Explanation (Cont’d)

Control system (Traction, D-FET SHORT A malfunction has occurred in NOTE:

P-FET OPEN A malfunction has occurred in

TIRE ANGLE SENSOR LOW A malfunction has occurred in

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)

Adjustment Mode (Cont’d)