8D100 09 PDF

TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ...................................................................................... 9-1

Before Replacing Devices........................................................................... 9-1
Connection of the Service Tool ................................................................... 9-1
How to Clean Harness Connectors and System Components...................... 9-2
CAN-BUS Reach Truck AC ......................................................................... 9-3
Troubleshooting ............................................................................................ 9-4
E0 Traction Motor, Overheating.................................................................. 9-4
E2 Pump Motor 1, Overheating ................................................................. 9-8
E3 Pump Motor 2, Overheating ................................................................. 9-11
E4 Steer Motor, Overheating ..................................................................... 9-14
E5 Traction Inverter, Overheating............................................................... 9-17
E7 Pump Inverter 1, Overheating .............................................................. 9-20
E8 Pump Inverter 2, Overheating .............................................................. 9-23
E9 Steer Inverter, Overheating .................................................................. 9-26
A5 Traction Motor, Over-Current ............................................................... 9-29
14 Traction Motor Current Sensor Fault ..................................................... 9-32
15 Traction Motor, Over-Current................................................................. 9-34
16 Traction Motor, Stall Timer Speed Fault ................................................ 9-37
34 Pump Motor 1, Current Sensor Fault .................................................... 9-39
35 Pump Motor 1, Over-Current ................................................................ 9-41
40 Line Contactor Fault ............................................................................. 9-44
45 Traction Motor Open ............................................................................. 9-46
47 Pump Motor 1, Open ............................................................................ 9-49
48 Pump Motor 2, Open ............................................................................ 9-52
49 Steer Motor, Open ................................................................................ 9-55
51 Traction Lever Sensor Fault .................................................................. 9-58
52 Traction Motor Pulse Input Fault ........................................................... 9-61
55 FC Solenoid Fault ................................................................................. 9-64
56 FC Solenoid Current Leak .................................................................... 9-67
57 Pump Motor 1 Pulse Input Fault ........................................................... 9-69
58 Pump Motor 2 Pulse Input Fault ........................................................... 9-72
59 Steer Motor Pulse Input Fault ............................................................... 9-75
60 Display Communication Fault ............................................................... 9-78
61 Parameter Write Fault ........................................................................... 9-81
62 Logics Fault .......................................................................................... 9-82
63 Traction Inverter Fault ........................................................................... 9-83
65 Pump Inverter 1 Fault ........................................................................... 9-86
66 Pump Inverter 2 Fault ........................................................................... 9-89
68 Output Unit Fault .................................................................................. 9-92
71 APS Controller Fault ............................................................................. 9-94
78 Battery Voltage Too Low ....................................................................... 9-96
79 Battery Voltage Too High ...................................................................... 9-98
81 Pressure Sensor Fault .......................................................................... 9-100
82 Steer Stepper Motor Fault .................................................................... 9-103
85 Brake Switch Fault ................................................................................ 9-105
86 Height Sensor Fault .............................................................................. 9-107
88 Logic Fault Multipurpose Output #1, Travel Alarm ................................ 9-110
88 Logic Fault Multipurpose Output #2, Horn ............................................ 9-112
94 Pump Motor 2, Current Sensor Fault .................................................... 9-114
95 Pump Motor 2, Over-Current ............................................................... 9-116
(E) Incorrect Start ...................................................................................... 9-119
(H1) Lift Lever, Faulty Setting .................................................................... 9-121
(H2) Tilt Switch, Faulty Setting................................................................... 9-123
(H3) Reach Switch, Faulty Setting ............................................................. 9-125
(H4) Sideshift Switch, Faulty Setting.......................................................... 9-127
(Lo) Battery Low ........................................................................................ 9-129
Component Identification............................................................................. 9-131
Electrical Schematic ..................................................................................... 9-135
General Information
Before replacing devices

Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check
the following items before replacing devices (logics unit, logic card, power supply card, inverters, inverter DSP
cards, output units, display unit and APS unit).
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See “How to clean harness connectors and system components” on page 9-2.
• Ensure that the main harness is not short-circuited to the truck body by using the following procedures.
• Perform “Inspection before replacing controllers” described in the Removal and Installation of the con-
troller.
Disconnect battery plug and discharge the inverters and APS unit
before working on electrical system.
Disconnect power supply connector of logic unit. Check continuity

between XA5_1P/13 and truck body (logic unit installation bolts, etc.).
No continuity Continuity
Normal Repair or replace harness.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced
with a new one. Be sure to check the above items and replace carefully.
Connection of the service tool Error code display

1. Turn off the truck power.
2. Remove the deck cover.
3. Find the connector to the service tool near the log- HB 12345.6 02/27/2004
ics unit. Logic unit

4. Remove the cover and connect the PC as shown.
5. Turn on the truck power.
6. Start the service tool software.
211793
9-1
How to clean harness connectors

and system components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust, together with
greasy matter, forms grime which, in time, pene-
trates electrical connections, resulting in loose
metal-to-metal contact or, for worse, electrical
separation of surfaces in contact. For this reason,
it is essential that the connectors and components
be cleaned at each periodic inspection and at when
servicing the truck. Instead of a commonly used
solvent, use electronic parts cleaner (in the man-
ner illustrated on the right). Electronic parts cleaner
211359
Electronic parts Three Bond 29D or
cleaner Pow-R-Wash CZ*
NOTE
The cleaner liquid is volatile. All you have to do
is just give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash

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

activator or Nyogel 760G*
*: Products contained in Terminal Maintenance Kit (SE000003)
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some
resins (plastic materials). Contact surface
activator
205047
9-2
CAN-BUS Reach Truck AC
Pump Traction 2nd APS Logic Display Output

inverter inverter Pump unit unit unit unit
inverter
CAN_H
CAN_L
211835
Tests 1 and 2 performed at GSE connector X56

Positions 11 and 12
1. Test 1: (Traction Inverter: (right) P15 – Display P4
connectors are Plugged In)
• 60 Ohms. CAN BUS circuit correct!
• If the results are 120 Ohms, CAN BUS circuit
Pump 1 Inverter or Output Unit resistor has
failed open.
• Go to test 2 and 3.
2. Test 2: (Output Unit XA4_1 Connector is
Unplugged)
• 120 Ohms. CAN BUS circuit Pump 1 Inverter:
(right) resistor is good.
• If the results are OL (Open) Ohms, CAN BUS
Pump 1 Inverter resistor is failed open.
3. Test 3: (Pump Inverter: XA2_2 Connector is
Unplugged.)
• 120 Ohms. CAN BUS circuit Output Unit resis-
tor is good.
• Results (OL) (Open) Output Unit resistor is
failed open.
X56
GSE CONNECTOR
9-3
Troubleshooting
Problem: Traction Motor, Overheating (E0)
(1) Situation
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations. Service tool "Fault Status" and "E0" displayed.
(2) Possible cause

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

Motor temperature is out of range of -25 C to 145 C (-13 F to 293 F).
It becomes normal when motor temperature is in range of -20 C to 70 C (-4 F to 158 F).
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
(5) Traction motor becomes normal.
If problem recurs
(6) Disconnect battery plug. Disengage electromagnetic
brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage electromagnetic

brake. Turn off power, rotate front wheels.
Confirm there is no difference in rotation load
between right and left wheels.
No difference Difference
(9) Check if truck is operated on steep up-

grade or used to pull large cargo load.
Normal
(10) Discharge electric charges from inverters and APS

unit. See page 8-30.
(11) Replace traction motor. (12) Replace traction

See Chassis & Mast. motor or drive unit.
Notice: Before See Chassis & mast.
replacing motor, be sure Notice: Before
to check it. If motor is replacing motor, be
normal, perform sure to check it. If
troubleshooting again motor is normal,
from the first step. perform trouble-
shooting again from
the first step.
With service tool
Without service tool
9-4
With service tool
(13) Confirm temperature of traction motor with

Without service tool Input Monitor.
Less than -20 °C(-4 °F) -20 °C to 70 °C
or more than 70 °C(158 °F) (-4 °F to 158 °F)
(14) Disconnect battery plug. Wait until traction motor (15) Disconnect battery plug.
temperature becomes close to room temperature.
(16) Discharge electric charges from inverters and APS (17) Troubleshoot display unit by referring Display
Communication Fault (60)-(4).
(18) Disconnect connector X35 of traction motor thermal
sensor. Measure resistance between X35/1 and X35/2
at motor side.
581 at 20°C (68°F)
(Min 555 , Max. 607 )
For resistance at temperature other than 20°C (68°F),
see table on page 9-7. Out of Range
Thermal
(19) Disconnect connector XA1_2 of traction inverter (20) Replace traction motor.
Check continuity between XA1_2/1and X35/1 See Chassis & Mast.
Check continuity between XA1_2/2and X35/2 Notice: Before replacing motor, be sure to check it.
If motor is normal, perform troubleshooting
Continuity No continuity again from the first step.
Power supply
(21) Disconnect Connector XA5_1P
Check continuity between XA5_1P/3 and XA1_2/17
Continuity No continuity
CAN
(22) Disconnect connector XA5_1 of logic unit
Check continuity between XA5_1/5 and XA1_2/3
(23) Connect connector XA5_1P, then turn on power again. (24) Repair or replace harness.
(25) Measure voltage between XA1_2/17 and XA1_2/20

Confirm value is 14V ± 2V.
Normal Abnormal
(26) Disconnect battery plug.
(27)Replace power supply card of logic unit. See page 8-37.
9-5
(28) Ensure all connectors are connected. Check history

folder data. See page 5-2.
The latest data is "E0". Not "E0"
(29) Disconnect battery (30)Troubleshoot display

plug, then discharge unit by referring to
electric charges from Display Communication
inverters and APS Fault (60)-(4).
(31) Replace DSP card of traction inverter. See page 8-33.
9-6
Logic
XA5_1 XA1_2 Traction inverter (A1)
0 to 5V
CAN 5 0 to 5V
3 H Inside Inside
6 4 L of of
cover case
14
15 Fuse
5 12V 16 P 425A Line contactor
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U
5V * 1 2 Temp
Power supply card GND V
1 Sens
XA5_1P GND Flat
19 cable W
+12V 5
0 to 5V
7
0 to 5V 6
Traction motor
P21
B 6 BLU Speed
G WHT sensor W
5
W 4 RED IM V
BLK U
R 3 Thermal
LB sensor
2 391 [-30 C(-22 F)] to
L 1 1407 [160 C(320 F)]
X35 M1
*1: With motor connector disconnected
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 370 391 411
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
30 86 599 626 652
50 122 694 722 750
70 158 797 826 855
90 194 910 940 970
110 230 1029 1062 1096
130 266 1152 1194 1235
150 302 1282 1334 1385
211794-E0
9-7
Problem: Pump Motor 1, Overheating (E2)

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

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

Motor temperature is out of range of -25 °C to 145 °C (-13 °F to 293 °F).
It becomes normal when motor temperature is in range of -20 °C to 70 °C (-4 °F to 158 °F).
(4) Checks
(5) Pump motor becomes normal.
If problem recurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

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

See Chassis & Mast. pump or piping.
Notice: Before replacing See Chassis & Mast.
motor, be sure to check
it. If motor is normal,
perform troubleshooting
again from the first step.
With service tool
(11) Confirm temperature of pump motor 1 with

Less than -20 °C (-4 °F) -20 °C to 70 °C
or more than 70 °C (158 °F) (-4°F 158 °F)
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
unit. See page 8-30. Communication Fault (60)-(4).
9-8
(16) Disconnect connector X36 of pump motor thermal

sensor. Measure resistance between X36/2 and X36/1.
581Ω at 20°C (68°F) (Min. 555 Ω, Max. 607Ω) For resistance
at temperature other than 20°C (68°F), see table on page 9-10.
Out of range
Thermal
(17) Disconnect connector XA2_2 of pump motor inverter.
Check continuity between XA2_2/1 and X36/1 (18) Repair pump motor. See Chassis & Mast.
Check continuity between XA2_2/2 and X36/2 Notice: Before replacing motor, be sure to check it.
Continuity No Continuity If motor is normal, perform troubleshooting
Power supply
(19) Disconnect Connector XA5_1
CAN
(20) Disconnect connector XA5_1P16 of logic unit.
(21)Connect connector XA5_1P, then turn on power again. (22)Repair or replace harness.
(23) Measure voltage beween XA2_2/17 and XA2_2/20.

Confirm value is 14 ± 2V.
Normal Abnormal
(26) Ensure all connectors are connected. Check history (25)Replace power supply card of logic unit. See page 8-37.
(27) Disconnect battery plug, (28) Troubleshoot display

then discharge electric unit by referring Display
charges from inverters and Communication Fault
APS unit. See page 8-30. (60)-(4).
(29) Replace DSP card of pump motor inverter. See page 8-33.
9-9
Logic
XA5_1 XA2_2 Pump inverter 1 (A2)
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U IU
5V* 1 2 Temp
Power supply card GND V IV
1 Sens Flat
XA5_1P GND
19 cable W IW
+12V 5
0 to 5V
6 A
0 to 5V 7 B
P17 Pump motor 1

BLU Speed
6 W PW
WHT sensor
5
4
RED IM V PV
BLK U PU
3 Thermal
sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
*1: With motor connector disconnected X36 M2
AMBIENT RESISTANCE
TEMPERATURE
-30 -22 370 391 411
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
30 86 599 626 652
50 122 694 722 750
70 158 797 826 855
90 194 910 940 970
110 230 1029 1062 1096
130 266 1152 1194 1235
150 302 1282 1334 1385
211796-E2
9-10
Problem: Pump Motor 2, Overheating (E3)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Fault Status" and "E3" displayed.
(2) Possible cause

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

(4) Checks
(5) Pump motor becomes normal.
If problem recurs
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

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

See Chassis & Mast. pump or piping.
Notice: Before replacing See Chassis & Mast.
motor, be sure to check
it. If motor is normal,
perform troubleshooting
With service tool
(11) Confirm temperature of pump motor 2 with

Less than -20 °C (-4 °F) -20 °C to 70 °C
or more than 70 °C (158 °F) (-4°F 158 °F)
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
9-11
(16) Disconnect connector X37 of pump motor thermal

sensor. Measure resistance between X37/2 and X37/1.
at temperature other than 20°C (68°F), see table on page 9-13.
Out of range
Thermal
(17) Disconnect connector XA6_2 of pump motor inverter.
Check continuity between XA6_2/1 and X37/1 (18) Repair pump motor. See Chassis & Mast.
Check continuity between XA6_2/2 and X37/2 Notice: Before replacing motor, be sure to check it.
Power supply
CAN
(20) Disconnect connector XA5_1 of logic unit.
(21)Connect connector XA5_1P

P, then turn on power again. (22)Repair or replace harness.
(23) Measure voltage beween XA2_2/17 and XA2_2/20.

Confirm value is 14 ± 2V.
Normal Abnormal

APS unit. See page 8-30 (60)-(4).
(29) Replace DSP card of pump motor inverter. See page 8-33.
9-12
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U IU
5V* 1 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W IW
+12V 5
0 to 5V
7 A
0 to 5V 6 B
Pump motor 2
BLU Speed
6 W PW
WHT sensor
5
4
RED IM V PV
BLK U PU
3 Thermal
sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
*1: With motor connector disconnected X37 M4
AMBIENT RESISTANCE
TEMPERATURE
-30 -22 370 391 411
-10 14 437 460 483
0 32 474 498 522
10 50 514 538 563
30 86 599 626 652
50 122 694 722 750
70 158 797 826 855
90 194 910 940 970
110 230 1029 1062 1096
130 266 1152 1194 1235
150 302 1282 1334 1385
211796-E3
9-13
Problem: Steer Motor, Overheating (E4)

(1) Situation
Controller/motor overheat indicator ON. Normal traction motor and power steering operations.
Service tool "Fault Status" and "E4" displayed.
(2) Possible cause

Overheating of steer motor, faulty steer motor or thermal sensor, faulty or open harness wiring, faulty steer
motor inverter, faulty display unit.

(4) Checks
(5) Steer motor becomes normal.
With service tool
(6) Confirm temperature of steer motor 1 with

Less than -20 °C (-4 °F) -20 °C to 70 °C
or more than 70 °C (158 °F) (-4°F 158 °F)
(7) Disconnect battery plug. Wait until steer motor (8) Disconnect battery plug.
(9) Discharge electric charges from inverters and APS (10) Troubleshoot display unit by referring to Display
9-14
(16) Disconnect connector XM3 of steer motor thermal

sensor. Measure resistance between XM3 and XM3/6.
at temperature other than 20°C (68°F).
Normal Out of range
Thermal
(17) Disconnect connector XA3 of steer motor inverter.
Check continuity between XA3_1/14 and XM3/5 (18) Replace steer motor. See Chassis & Mast.
Check continuity between XA3_1/16 and XM3/6 Notice: Before replacing motor, be sure to check it.
CAN
(22)Repair or replace harness.
(26) Ensure all connectors are connected. Check history


APS unit. See page 8-30. (60)-(4).
(29) Replace steer motor inverter. See page 8-31.
9-15
Logic
XA5_1 XA3_1 Steer Controller (A3)
0 to 5V
CAN 5 0 to 5V
23 CAN H
6 15 CAN L
Fuse
21 Brake Control +36V P 50A Line contactor
N Battery (-)
7F1
1 KEY on +36V U IU
10A 16
K11 K12 GND
4
}
Thermal Sensor V IV
W IW
0 to 5V
5
0 to 5V
+12V
6
3
} Encodes
Steer motor A3
RED Speed
1 W
WHT sensor
3
2
BLU IM V
BLK U
4 Thermal
sensor
5
391 [-30 C(-22 F)] to
6 1407 [160 C(320 F)]
XM3
211796-E4
9-16
Problem: Traction Inverter, Overheating (E5)

(1) Situation
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations. Service tool "Fault Status" and "E5" displayed.
(2) Possible cause

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

Controller temperature is out of range of -25°C to 100°C (-13°F to 212°F).
Capacitor temperature is out of range of -25°C to 110°C (-13°F to 230°F).
It becomes normal when temperature is in range of -20°C to 70°C (-4°F to 158°F).
(4) Checks
(5) Traction inverter becomes normal.
If problem recurs
(6) Check if truck is operated on steep upgrade or to pull
large cargo load.
Normal
unit. See page 8-30. Check thermal paste applied on
inverter mounting surface. Thermal paste film should
be thin and even.
Normal Abnormal
(8) Replace traction inverter. (9) Clean mouning surface,

See page 8-31. apply thermal paste,
With service tool then reinstall inverter.
See page 8-31.
(10) Confirm temperature of controller and head capacitor

with Input Monitor.
Less than -20°C (-4°C) -20°C to 70°C
or more than 70°C (158°F) (-4°F to 158°F)
(11) Disconnect battery plug. Wait until inverter (12) Disconnect battery plug.
(14) Troubleshoot display unit by referring Display
(13) Discharge electric charges from inverters and APS Communication Fault (60)-(4).
Thermal
(15) Remove traction inverter DSP card cover, then
check harness looseness or wire breakage. See page 8-33.
Normal Abnormal
9-17
Power supply
(16) Disconnect connector XA1_2 of traction inverter. (17) Secure harness if loose.
Disconnect connector XA1_2 of traction inverter. Replace inverter if wire breaks. See page 8-31.
Check continuity between XA5_1P/3 and XA1_2/17.
CAN
(18) Disconnect connector XA5_1of logic unit.
Check continuity between XA5_1/5 and XA1_2/3.
(19) Connect connector XA5_1P, then turn on power again. (20) Repair or replace harness.
(21) Measure voltage between XA1_2/17 and XA1_2/20.

Normal Abnormal
The latest data is "E5" Not "E5"

(60)-(4).
APS unit. See page 8-30.
(27) Replace DSP card of traction inverter. See page 8-33.
If fault remains
(28) Disconnect battery plug, then discharge electric charges
from inverters and APS unit. See page 8-30.
(29) Replace traction inverter. (DSP card is normal.)

See page 8-31.
9-18
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 +12V
16 P Line contactor
+14V
Power 3 +8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U IU
5V * 1 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W IW
+12V
5
0 to 5V
7
0 to 5V 6
Traction motor
DSP flat
cable 6 BLU Speed
sensor W RTW
Inverter 5 WHT
case 4 RED
IM V RTV
U RTU
DSP card 3 BLK Thermal
sensor
2 391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X35 M1
211798-E5
9-19
Problem: Pump Inverter 1, Overheating (E7)

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

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

(4) Checks
(5) Pump inverter becomes normal.
If problem recurs
Normal
be thin and even.
Normal Abnormal
(8) Replace pump inverter. (9) Clean mounting surface,

See page 8-31.

with Input Monitor.
Less than -20°C (-4°C) -20°C to 70°C
Thermal
(15) Remove pump inverter DSP card cover, then check
harness looseness or wire breakage. See page 8-33.
Normal Abnormal
9-20
Power supply
(16) Disconnect connector XA5_1P. (17) Secure harness if loose.
Disconnect connector XA2_2 of pump inverter. Replace inverter if wire breaks. See page 8-31.
CAN
(19)Connect connector XA5_1P, then turn on power again. (20) Repair or replace harness.

Normal Abnormal

(60)-(4).
(27) Replace DSP card of pump inverter. See page 8-33.
If fault remains.
(29) Replace pump inverter. (DSP card is normal.)

See page 8-31.
9-21
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
6 A
0 to 5V 7 B
Pump motor 1
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M2
211800-E7
9-22
Problem: Pump Inverter 2, Overheating (E8)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering
operations. Service tool "Fault Status" and "E8" displayed.
(2) Possible cause

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

(4) Checks
(5) Pump inverter becomes normal.
If problem recurs
Normal
be thin and even.
Normal Abnormal
(8) Replace pump inverter. (9) Clean mounting surface,

See page 8-31.

with Input Monitor.
Less than -20°C (-4°C) -20°C to 70°C
Thermal
(15) Remove pump inverter DSP card cover, then check
harness looseness or wire breakage. See page 8-33.
Normal Abnormal
9-23
Power supply
Disconnect connector XA6_2 of pump inverter. Replace inverter if wire breaks. See page 8-30.
CAN
(19)Connect connector XA5_1P, then turn on power again. (20) Repair or replace harness.

Normal Abnormal

(60)-(4).
(27) Replace DSP card of pump inverter. See page 8-33.
If fault remains.

See page 8-31.
9-24
Logic
0 to 5V 3
CAN 5 0 to 5V 4
Inside Inside
6 of of
cover case
14
15 Fuse
5 12V 16 P 425A
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V* 1 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
7 A
0 to 5V 6 B
Pump motor 2
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X37 M4
211800-E8
9-25
Problem: Steer Inverter, Overheating (E9)

(1) Situation
Controller/motor overheat indicator ON. Normal traction motor and pump motor operations.
Service tool "Fault Status" and "E9" displayed.
(2) Possible cause

Overheating of steer inverter, faulty steer inverter thermal sensor, open harness wiring,
faulty temperature of steer inverter, faulty display unit.

(4) Checks
(5) Steer inverter becomes normal.
With service tool

(6) Confirm temperature of controller

with Input Monitor.
Less than -20°C (-4°C) -20°C to 70°C
(8) Troubleshoot display unit by referring to Display
Thermal
(11) Check harness looseness or wire breakage.
See page 8-31.
Normal Abnormal
9-26
Power supply
Disconnect connector XA6_2 of pump inverter.
CAN
(16) Ensure all connectors are connected. Check history (15) Repair harness or replace fuse 7F1.

then discharge electric unit by referring to
charges from inverters and Display Communication
Fault (60)-(4).

See page 8-31.
9-27
To Logic
Unit S34
XY31/2
S31
M1
Safety Brake
S31
XY31/1 10F1
K11 KEY
SWITCH
Steering Stepper Motor PNP
K12
S34
A+ A- B+ B-
RED
BLK
YEL
BLU
WH
OR
PNP
7F1
X11/1
X11/3
X11/4
X11/6
10A
21 10 4 11 13 19 1
Brake Signal Signal Steering Reference Key
Gnd
A l B
A3
Steer Motor Controller (APS)
9-28
Problem: Traction Motor, Over-current (A5)

(1) Situation
Display: "A5".All truck operations except for "lower" inhibited. Line contactor OPEN.
(2) Possible cause

Faulty steer inverter, faulty steer motor, faulty contact or wire breakage of steer motor speed
sensor harness, faulty main harness, faulty logic unit.

The circuit, via hardware that limits the current in the motor is always active
(4) Checks
Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.
(5) Check steer motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (7) Replace steer motor.
(U, V, W phases) for steer inverter and motor. Notice: Before replacing motor, be sure to check it.
Normal Abnormal again from the first step.
(10) Confirm connection of steer motor speed (9) Secure cable if loose or connect cable correctly.
sensor connector XM3.
Normal Abnormal
Sensor
(12) Disconnect connectors XA3_1 and XM3. (13) Connect connector securely.
Check continuity between XA3_13 and XM3/1.
Check continuity between XA3_1/5 and XM3/2.
9-29
CAN
(14) Repair or replace harness.
(15) Disconnect battery plug, then discharge electric charges from inverters and APS unit.

unit, then replace steer inverter. (DSP card is normal.)
See page 8-30.
If fault remains
unit, then reinstall steer inverter and replace
steer motor.
Notice: Before replacing motor, be sure to check it.
9-30
Logic
0 to 5V
CAN 5 0 to 5V
23 CAN H
6 15 CAN L
Fuse
21 Brake Control +36V P 50A Line Contactor
N Battery (-)
7F1
1 KEY on +36V U IU
10A 16
K11 K12 GND
4
}
Thermal Sensor V IV
W IW
0 to 5V
5
0 to 5V
+12V
6
3
} Encodes
Steer Motor A3
RED Speed
1 W
WHT sensor
3
2
BLU IM V
BLK U
4 Thermal
sensor
5
391 [-30 C(-22 F)] to
6 1407 [160 C(320 F)]
XM3
211796-A5
9-31
Problem: Traction Motor Current Sensor Fault (14)

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

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

When turning on power, current sensor voltage is out of range of -120A to 120A.
(4) Checks
(5) Disconnect connector XA1_2 of traction inverter and

remove DSP flat cable for looseness or wire breakage.
Normal Abnormal
8V power
supply
(6) Disconnect Connector XA5_1P. (7) Secure DSP flat cable if loose.
Check continuity between XA5_1P/4 and XA1_2/18. Replace inverter if wire breaks. See page 8-33.
Continuity Abnormal and continuity
CAN
Continuity Abnormal and continuity
(9) Connect connector XA5_1P to logic unit, then turn on (10) Repair or replace harness.
power again.

Normal Abnormal
(12) Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.
(13) Replace DSP card of traction inverter. (14) Replace power supply card of logic unit.
See page 8-33. See page 8-37.
If fault remains
unit, then replace traction inverter. (DSP card is
normal.) See pages 8-30 and 8-31.
9-32
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 +12V
16 P 425A Line contactor
+14V
Power 3 +8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U
5V * 1 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V
5
0 to 5V
7
0 to 5V 6
Traction motor
DSP flat
cable 6 BLU Speed
WHT sensor W
Inverter 5
case 4 RED IM V
U
3 BLK Thermal
DSP card sensor
2 391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X35 M1
211798-14
9-33
Problem: Traction Motor, Over-current (15)

(1) Situation
Display: "15". All truck operations except for "lower" inhibited. Line contactor OPEN.
(2) Possible cause

faulty traction inverter, faulty traction motor, faulty contact or wire breakage of traction motor speed
sensor harness, faulty main harness, faulty logic unit.

Motor current is more than 707 Amps (Moment). Motor current is more than 557Amps (Fixed time 1).
Motor current is more than 492 Amps (Fixed time 2).
(4) Checks
(5) Check traction motor and terminal for burning

and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (7) Replace traction motor.
(U, V, W phases) for right traction inverter and motor. Notice: Before replacing motor, be sure to check it.
(8) Disconnect connector XA1_2 of right traction inverter (9) Secure cable if loose or connect cable correctly.
and remove DSP cover. Check DSP flat cable for
looseness or wire breakage.
Normal Abnormal
(10) Confirm connection of right traction motor speed (11) Secure DSP flat cable if loose.
sensor connector X35. Replace inverter if wire breaks. See page 8-33.
Normal Abnormal
Sensor
(12) Disconnect connectors XA1_2 AND X35. (13) Connect connector securely.
Check continuity between XA1_2/5 and X35/4.
Continuity Abnormal and Continuity
9-34
8V power
supply
(14) Disconnect Connector XA5_1P.
CAN
(15) Disconnect Connector XA5_1.
power again.

Normal Abnormal
(20) Replace DSP card of right traction inverter. (21)Replace power supply card of logic unit.
If fault remains
unit, then replace right inverter. (DSP card is normal.)
See pages 8-30 and 8-31.
If fault remains
unit, then reinstall right inverter and replace traction
motor.
9-35
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 +12V
+14V
Power 3 +8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V
5
0 to 5V
7
0 to 5V 6
Traction motor
DSP flat
cable 6 BLU Speed
sensor W
Inverter 5 WHT
case 4 RED
IM V
U
sensor
2 391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X35 M1
211798-15
9-36
Problem: Traction Motor, Stall Timer Speed Fault (16)

(1) Situation
(2) Possible cause

Stall current flowed more than set time in traction motor faulty traction inverter current sensor, shorted harness wiring,
faulty traction inverter DSP card, faulty logic unit, faulty traction motor speed sensor, DSP ribbon cable loose or broken.
(3) How
Stallthe error flowed
current code is more
triggered
thse time (#20) in traction motor, faulty right traction inverter current sensor, shorted
Stall timerwiring,
harness set time is measured
faulty whileinverter
right traction stalling.DSP card, faulty logic unit.
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem recurs Error code 14
(6) See troubleshooting for code "14". See page 9-32.
(5) Check to see if truck is operated with heavy cargo (7) Change set time.
load or on steps when motor stalls.
Notice: The more stall occurs, the more overheating
Normal steps Heavy load
occurs. Operate truck under normal condition.
(8) Check traction motor speed sensor. (10) Operate under normal condition.
See troubleshooting for code "52". See page 9-61.
(9) Disconnect battery plug, then discharge electric

charges from inverters and APS unit. See page 8-30.
(11) Disconnect connector XA1_2 of right traction inverter and remove DSP cover, then check DSP flat cable for looseness
or wire breakage. See page 8-33.
Normal Abnormal
Power supply
(12) Disconnect Connector XA5_1P (13) Secure harness if loose. Replace traction inverter if
Check continuity between XA5_1P/5 and XA1_2/16. wire breaks. See page 8-31.
CAN
Continuity Abnormal and no continuity
(15)Connect connector XA5_1P to logic unit, then turn on (16) Repair or replace harness.
power again.
(17)Measure voltage between XA1_2/16 and XA1_2/20.

Normal Abnormal
(18)Disconnect battery plug, then discharge electric charges from inverters and APS unit. See page 8-30.
(19)Replace DSP card of right traction inverter. (20)Replace power supply card of logic unit.
9-37
Logic
XA5_1 XA1_2 Traction inverter (right) (A1)
0 to 5V G 3
CAN 5 0 to 5V GW 4
Inside Inside
6 of of
cover case
14
15 Fuse
5 12V 6A WB
14V 4A WR 17
Power 3 8V 5A WL 18 N Battery (-)
4 DSP IMS
GND 7B WG card card
6 20 U IU
5V L 2
Power supply card GND LB TEMP V IV
1
XA5_1P GND SENS Flat
19 cable W IW
+12V
5
0 to 5V
0 to 5V
6
Traction motor
38 B 4 Speed
G sensor W
37 2
36 W 3
IM V
U
35
R 1 Thermal
LB sensor
24 2 391 [-30 C(-22 F)] to
23
L 1 1407 [160 C(320 F)]
X35 M1
211802-16
9-38
Problem: Pump Motor 1, Current Sensor Fault (34)

(1) Situation
Display: "34". All truck operations except for "lift down" inhibited. This fault occurs only when turning on power.
OPEN.and steering contactor HOLD.
Line contactor OPEN
(2) Possible cause

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

(4) Checks
(5) Disconnect connector XA2_2 of pump inverter and remove

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between XA5_1P/4 and XA2_2/18. (7) Secure DSP flat cable if loose.
Check continuity between XA5_1P/6 and XA2_2/20. Replace pump inverter if wire breaks. See pages 8-31.
Continuity No Continuity
CAN
(9) Connect connector XA5_1P to logic unit, then turn on power (10) Repair or replace harness.
again.

Normal Abnormal
(13) Replace DSP card of pump inverter. See page 8-33. (14) Replace power supply card of logic unit.
See page 8-37.
If fault remains
(15) Discharge electric charges from inverters and APS unit,
then replace pump inverter. (DSP card is normal.)
See page 8-31.
9-39
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
6 A
0 to 5V 7 B
Pump motor 1
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M2
211800-34
9-40
Problem: Pump Motor 1, Over-current (35)

(1) Situation
(2) Possible cause

inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main harness,
faulty logic unit.

Motor current is more than 1018 Amps (Moment). Motor current is more than 990 Amps (Fixed time 1).
(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(7) Replace pump motor.

(6) Confirm cable looseness and improper connections Notice: Before replacing motor, be sure to check it.
(U, V, W phases) for pump inverter and motor. If motor is normal, perform troubleshooting
(8) Disconnect connector XA2_2 of pump inverter and (9) Secure cable if loose or connect cable correctly.
remove DSP cover. Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector X36. Replace pump inverter if wire breaks. See page 8-33.
Normal Abnormal
Sensor
(12) Disconnect connector XA2_2 and X36. (13) Connect connector securely.
8V power
supply
(14) Disconnect Connector XA5-1P
9-41
CAN
(16) Connect connector XA5_1P to logic unit, then turn (17) Repair or replace harness.
on power again.

Normal Abnormal
(20) Replace DSP card of pump inverter. See page 8-33. (21)Replace power supply card of logic unit. See page 8-37.
If fault remains
See page 8-33.
If fault remains
then reinstall pump inverter and replace pump motor.
9-42
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
6 A
0 to 5V 7 B
Pump motor 1
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M2
211800-35
9-43
(1) Situation
(2) Possible cause

Faulty line contactor K12, faulty main harness, faulty logic unit, faulty traction inverter, faulty pump inverter,
blown 1F2 fuse, blown 10F1 fuse.

Inverter voltage data is checked when contactor is closed (400 ms).
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
Error code 40 Error code 63, 65 or 66
(5) Block wheels, then confirm line contactor operation (6) See troubleshooting for code "63", "65" or "66"
in output check function. See page 8-52. See page 9-83, 9-86 or 9-89.
Not operated Operated
With service tool
(7) Check DC voltage of pump and traction inverters (8)Disconnect battery plug, then discharge electric
with Input Monitor. These values should be same charges from inverters and APS unit. See page 8-30.
as battery voltage.
Traction inverter value Pump inverter value
abnormal abnormal
(11) Replace traction inverter.
(9) Disconnect battery (10)Disconnect battery See page 8-31.
plug, then discharge plug, then discharge If fault remains
electric charges from electric charges from (14) Disconnect battery plug, then discharge electric
inverters and APS unit. inverters and APS charges from inverters and APS unit.
See page 8-30. unit. See page 8-30. See page 8-30.
(12) Replace traction (13) Replace pump
inverter. inverter. (15) Replace pump inverter. See page 8-31.
(16) Disconnect battery plug, then discharge electric

(17) Check to see if line contactor tip moves smoothly.

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

44Ω at -30°C (-22°F) to 65Ω at 80°C (176°F)
Within range Out of range
(19) Disconnect connectors XA5_1, XA5-1P, and

terminals A1 and A2 (K12 only). (20) Replace line contactor. See Chassis & Mast.
Check voltage at XA5_1P/13 and XA5_1P/14 (+36V)
Check voltage at A1 (+36V).
Check continuity between XA5_1/59 and A2.
Check continuity between XA5_1P/15 and XA5_1P/16
to battery ground.
Continuity/Voltage No Continuity/No Voltage

(22) Repair or replace harness. Replace 10A fuse(s).
then replace logic card of logic unit. See page 8-36.
9-44
2nd Pump
Controller 425 A
( HP Models
3
Only )
4
A6
Traction
Controller 425 A
3
4
A1
Pump
Controller 425 A
3
4
A2
Steer
Controller 50 A
23
15 11L1
A3 10A
+ A1
– A2
+ A1
10L1
10A KEY SWITCH
– A2
5 6 59 24R150
+
LOGIC CONNECTOR XA5.1 1F1
13 10A
POWER
14
SUPPLY –
LOGICS UNIT CONNECTOR 15
A5 16
XA5.1P 1F2
10A
211804
9-45
Problem: Traction Motor Open (45)

(1) Situation
(2) Possible cause

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

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

looseness and improper contact.
Normal Abnormal
(6) Disconnect traction motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U,V and W phases).
Less than 1Ω 1Ω or more
(8) Check connector XA1_2 of traction inverter for (9) Measure resistance between terminals of both cable
looseness. ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(11) Connect connector securely. (12) Replace traction motor. (13) Replace motor cables.
Notice: Before
replacing motor, be sure
to check it. If motor is
(10) Disconnect connector XA1_2 of traction inverter normal, perform
and remove DSP cover. Check DSP flat cable for troubleshooting again
looseness or wire breakage. from the first step.
Normal Abnormal
Power
supply
(14) Disconnect Connector XA5_1P of power supply.
Check continuity between XA5_1P/5 and XA1_2/16. (15) Secure DSP flat cable if loose.
9-46
CAN
on power again.

Normal Abnormal
(21) Replace DSP card of right traction inverter. (22)Replace power supply card of logic unit. See page 8-37.
See page 8-33.
If fault remains
then replace traction inverter. (DSP card is normal.)
See page 8-31.
9-47
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 +12V
+14V
Power 3 +8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U IU
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W IW
+12V
5
0 to 5V
7
0 to 5V 6
Traction motor
DSP flat
cable 6 BLU Speed
sensor W
Inverter 5 WHT
case 4 RED
IM V
U
sensor
2 391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X35 M1
211798-45
9-48
Problem: Pump Motor 1 Open (47)

(1) Situation
(2) Possible cause

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

Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter. (7) Secure cable if loose.
(8) Check connector XA2_2 of pump inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
(11) Connect connector securely.
(12) Replace pump motor. (13) Replace motor cables.
Notice: Before
(10) Disconnect connector XA2_2 of pump inverter and normal, perform
remove DSP cover. Check DSP flat cable for looseness troubleshooting again
or wire breakage. from the first step.
Normal Abnormal
Power
supply
(14) Disconnect Connector XA5_1P of power supply.
Check continuity between XA5_1P/5 and XA2_2/16. (16) Secure DSP flat cable if loose.
9-49
CAN
on power again.

Normal Abnormal
(21) Replace DSP card of pump inverter. (22) Replace power supply card of logic unit.
If fault remains
See page 8-31.
9-50
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
6 A
0 to 5V 7 B
Pump motor 1
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M2
211800-47
9-51
Problem: Pump Motor 2 Open (48)

(1) Situation
(2) Possible cause

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

Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter. (7) Secure cable if loose.
(8) Check connector XA6_2 of pump inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
(11) Connect connector securely.
(12) Replace pump motor. (13) Replace motor cables.
Notice: Before
(10) Disconnect connector XA6_2 of pump inverter and normal, perform
remove DSP cover. Check DSP flat cable for looseness troubleshooting again
or wire breakage. from the first step.
Normal Abnormal
Power
supply
(14) Disconnect Connector XA5_1P of power supply. (15) Secure DSP flat cable if loose.
9-52
CAN
Check continuity between XA6_2/8, XA6_2/9 and
XA6_2/11.
on power again.

Normal Abnormal
(21) Replace DSP card of pump inverter. (22) Replace power supply card of logic unit.
If fault remains
See page 8-31.
9-53
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
6 B
0 to 5V 7 A
Pump motor 2
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X37 M4
211800-48
9-54
Problem: Steer Motor Open (49)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of steer motor cable, faulty steer motor, faulty contact or wire breakage of steer
inverter connector, wire breakage of main harness, faulty power supply card of logic unit, faulty steer inverter,
when restarting after motor shorted, blown 10A fuse (7F1).

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

looseness and improper contact.
Normal Abnormal
(6) Disconnect steer motor cables from inverter. (7) Secure cable if loose.
(8) Check connector XA3_1 of steer inverter for (9) Measure resistance between terminals of both cable
looseness. ends (between U and U, V and V, and W and W).
Normal Abnormal Less than 1Ω 1Ω or more
(11) Connect connector securely. (12) Replace steer motor. (13) Replace motor cables.
Notice: Before
normal, perform
troubleshooting again
from the first step.
Gate power
supply
(14) Check voltage at XA3_1/1 (key +36V)
Continuity No voltage
9-55
CAN
(16) Repair or replace harness. Check Fuse 7F1.

then replace steer inverter. (DSP card is normal.)
See pages 8-30 and 8-31.
9-56
Logic
XA5-1 XA3_1 Steer Controller (A3)
CAN 5 23 CAN H
6 15 CAN L
Fuse
7F2 P 50A Line contactor
+36V 1
10A N Battery (-)
K12 U
16 Motor Temp
V
4 GND W
6 SIGNAL A
5 SIGNAL B
3 +12V
Steer motor (M3)
1 RED Speed
WHT sensor W
2
3 BLU IM V
BLK U
4 Thermal
sensor
5 391 [-30 C(-22 F)] to
6 1407 [160 C(320 F)]
XM3
211799-49
9-57
Problem: Traction Lever Sensor Fault (51)

(1) Situation
(2) Possible cause

Faulty traction lever sensor, faulty main harness, faulty logic unit.

Traction lever sensor voltage is out of range of 0.05V to 4.95V.
(4) Checks
Raise drive wheel until they clear floor.
Without service tool With service tool
(5) Disconnect battery plug. (6) Check traction lever sensor voltage with Input Monitor
and confirm value is in range of 0.05V to 4.95V.
Abnormal signal Interrupted
(7) Disconnect battery plug. (8) Check joystick.
(9) Discharge electric charges from inverters and APS unit. See page 8-30.

Disconnect connector X14A of traction lever.
(11) Check continuity between XA5_1/20 and X14A/2.

(Sensor voltage)
(12) Check continuity between XA5_1/26 and X14A/1.

Check continuity between XA5_1/25 and X14A/3.
With service tool
Without
service tool
9-58
Without With service tool

service tool
(14) Replace traction lever. (15) Connect connector XA5_1. Turn on power and
check voltage between X14A/1 and X14A/3.
If fault remains 5V Not 5 V

(17) Turn off power. Short-circuit X14A/1 and
X14A/2. Turn on power and check traction
lever voltage with Input Monitor.
(18) Reinstall traction lever, then replace logic card 5V Not 5 V
of logic unit. See page 8-36.
(19) Turn off power. Open X14A/1 and X14A/2.
Short-circuit X14A/2 and X14A/3. Turn on
power and check traction lever voltage with
Input Monitor.
0V Not 0 V
(21) Disconnect battery

(20) Replace traction lever.
plug.
(22) Replace logic card

of logic unit.
9-59
Traction speed
and Direction
X14A
5 6 7 8
1 2 3 4
View
Opposite Wire
Logic Entry
XA5_1
5V RED
26 1
0.5 to 4.5V
2 WHT
20
GND BRN
25 3
X14A
211806-51
9-60
Problem: Traction Motor Pulse Input Fault (52)

(1) Situation
Display: "52". All truck operations except for "lift down" inhibited. Line contactor OPEN.
(2) Possible cause

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

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

phases) are connected to traction inverter properly.
Normal Abnormal
(6) Check to see if connector XA1_2 of traction inverter (7) Connect cables properly.
is fastened securely.
Normal Abnormal
(8) Check to see if connector X35 of traction motor

(9) Fasten connector securely.
speed sensor is fastened securely.
Normal Abnormal
Sensor
(10) Disconnect connector XA1_2 and X35.
Power
supply
(12) Disconnect connector XA5_1P of power supply.
CAN
(14) Connect connector XA5-1P to logic unit, then turn on (15)

Repair or replace harness.
power again.
9-61

Normal Abnormal
(18) Replace traction inverter.

(19) Replace power supply card of logic unit. See page 8-38.
See page 8-31.
If fault remains

then replace traction motor.
9-62
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V
14V
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND card card
6 20 U IU
5V 2
Power supply card GND TEMP V IV
1
XA5_1P GND SENS Flat
19 cable W IW
+12V
5
0 to 5V
7
0 to 5V
6
Traction motor
6 Blu Speed
Wht sensor W
5
4 Red IM V
U
3 Blk Thermal
sensor
2 391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X35 M1
211802-52
9-63
Problem: FC Solenoid Fault (55)

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

Faulty lift solenoid, faulty tilt solenoid, faulty reach and side shift solenoids, faulty main harness, faulty output unit,
blown fuse.

When signal is outputted, current is out of range of 0.16A to 1.9A.
(4) Checks
Operate all hydraulic functions to find faulty solenoid.
Inspect by checking pump motor running sound if attachment is not installed.
Found Not found, with service tool
(5) Find faulty solenoid with Output Monitor.

Solenoid current should flow when hydraulic lever is
operated.

(7) Disconnect connectors XA4_1, XA5_1 and X41 of output unit. Disconnect connectors K3/1, K4/1, and K5/1 of relays.
Direction of
Lift/Lower Reach, Tilt, SS Reach Sideshift Tilt/Sideshift
(8) Check continuity between (10) Check continuity between (12) Check continuity between
XA4_1/21 and XY41_2/1, XA5_1/60 and K3/1. XA5_1/62 and K5/1.
XA4_1/22 and XY41_1/1, X41/1 and XY44_1/1 X41/4 and XY46_1/2
XA4_1/23 and XY41_1/2 and XY44_2/2. and XY46_2/1.
and XY41_2/2. X41/2 and XY44_1/2 X41/1 and XY46_1/1
and XY44_2/1. and XY46_2/2.
XA5_1/53 and K3/3. XA5_1/55 and K5/3.
Check Voltage Check Voltage
K3/5 = +36V. K5/5 = +36V.
K3/4 = Batt Negative. K5/4 = Batt Negative.
Continuity No Continuity Continuity No Continuity Continuity No Continuity
(9) Check continuity between (11) Check continuity between

XA4_1/24 and XY43_1/1, XA5_1/61 and K4/1.
XA4_1/25 and XY43_2/1, X41/3 and XY45_1/2
XA4_1/26 and XY43_1/2 and XY45_2/1.
and XY43_2/2. X41/1 and XY45_1/1
and XY45_2/2.
XA5_1/54 and K4/3.
Check Voltage
K4/5 = +36V.
Continuity No Continuity K4/4 = Batt Negative.
No Voltage
Check/Replace
Fuse 11F2
9-64
(13) Measure resistance of solenoid coil. (14) Repair or replace harness.

30 Ω ± 10 % at 20°C (68°F)
Normal Abnormal
(15) Replace related solenoid.
(16) Lift: Check short circuit between XA4_1/21 and XA4_1/23.

Lower: Check short circuit between XA4_1/22 and XA4_1/23.
Reach, Tilt, Side Shift: Check short circuit between XA4_1/24 and XA4_1/26.
Check short circuit between XA4_1/25 and XA4_1/26.
Not Shorted Short
(17) Replace output unit. See page 8-38. (18) Repair or replace harness.
9-65
A4 A5
RIO1 BOARD LOGIC BOARD

XA4_1/23
XA4_1/22
XA4_1/21
XA4_1/26
XA4_1/24
XA4_1/25
XA5_1/60
XA5_1/53
XA5_1/61
XA5_1/54
XA5_1/62
XA5_1/55
+36V 0V
11L2 11M1
1/26 1/26
1 1 1
R3 R4 R5
5R6/50W 2 5R6/50W 2 5R6/50W 2
F103 F104 F105
2 2 2
2,2u 2,2u 2,2u
1 4 1 4 1 4
K3
63V + K4
63V + K5
63V
+
5 3 120R 5 3 120R 5 3 120R
11M2
1/26
1 1 1
0-24V 0-24V
X111 X112 X113
0-24V 0-24V
BLK/BRN
GRY/YEL
GRY/GRN
X41/ 1
X41/ 2
X41/ 3
X41/ 4
X42/ 1
X42/2
X41/5
GRY
GRN
IN THE MAST
20-24V 20-24V 20-24V
E56
+
-
X79 X88
XY41.1/ 1
XY41.2/ 1
XY43.1/ 1
XY43.2/ 1
36V
BLK/GRY
GRY/YEL
GRY/GRN
GRY/BWN
XY44.1: 2
XY44.2: 1
XY45.1: 2
XY45.2: 1
XY46.1: 2
XY46.2: 1
TILT ASSISTANT
Y41 Y43 Y44 Y45 Y46
Y41.1 Y41.2 Y43.1 Y43.2 Y44.1 Y44.2 Y45.1 Y45.2 Y46.1 Y46.2
(m1) (m2) (m3) (m4) (S5) (S6) (S9) (S10) (S7) (S8)
m4 A1
B1 m3
XY41.1/ 2
XY41.2/ 2
XY44.1: 1
XY43.1/ 2
XY43.2/ 2
XY44.2: 2
XY45.1: 1
XY45.2: 2
XY46.1: 1
XY46.2: 2
m1 m2
LOWER LIFT A1 FW, L DN B1 BW, R UP

DIRECTION OF
REACH, TILT, SSHIFT REACH SIDESHIFT TILT/SIDESHIFT
9-66
Problem: FC Solenoid Current Leak (56)

(1) Situation
Display: "56". Pump motor operations inhibited "lower" operation enabled.
Line contactor HOLD.
(2) Possible cause

Faulty lift solenoid, faulty tilt solenoid, faulty reach and side shift solenoids, faulty main harness, faulty output unit.

When signal is not outputted, current is more than 0.18A.
(4) Checks
(5) Disconnect connector XA4_1.

Disconnect connectors XY41_1, XY41_2,
XY43_1 and XY43_2 of solenoids.
(6) Check short circuit between all pin patterns.

XA4_1/21 to XA4_1/26 and at solenoid connectors
on chassis valve.
Not shorted Shorted
(7) Measure solenoid coil resistance. (8) Repair or replace harness.

30 Ω ± 10 % at 20°C (68°F)
Normal Abnormal
(9) Replace output unit. See page 8-38. (10) Replace related solenoid.
9-67
OUTPUT 23 22 21 26 24 25
UNIT XA4_1
0-24V 0-24V
0-24V 0-24V M4 M3
XY41.1/1
XY41.1/1
XY41.2/1
XY41.2/1
M1 M2
XY41.2/2
XY41.2/2
XY43.2/2
XY41.1/2
Y41.1 Y41.2 Y41.1 Y41.2

M1 M2 M1 M2
Lower Lift 1 Reach Tilt Sideshift

211807-56
9-68
Problem: Pump Motor 1 Pulse Input Fault (57)

(1) Situation
(2) Possible cause

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

Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor.
Motor rotates in reverse.
(4) Checks
(5) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector XA2_2 of pump inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector X36 of pump motor speed (9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal

Power
Supply
CAN
power again.
9-69

Normal Abnormal
(18) Replace DSP card of pump inverter. See page 8-33. (19) Replace power supply card of logic unit. See page 8-37.
If fault remains

then replace pump motor. (DSP card is normal.)
9-70
Logic
G 0 to 5V G 3
CAN 5 GW 2C
0 to 5V
2D
GW Inside Inside
6 3C 3D 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V 17 contactor
Power 3 8V 18 N Battery (-)
4 DSP IMS
GND 20 card card
6 U IU
5V 2
1 Flat
XA5_1P GND
19 cable W IW
+12V 5
0 to 5V
6 A
0 to 5V 7 B
Pump motor 1
6 BLU Speed
WHT sensor W
5
4 RED IM V
U
3 BLK
Thermal
sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M2
211808-57
9-71
Problem: Pump Motor 2 Pulse Input Fault (58)

(1) Situation
(2) Possible cause

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

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

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector XA6_2 of pump inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector X37 of pump motor speed (9) Fasten connector securely.
Normal Abnormal

Power Supply
CAN
power again.
9-72

Normal Abnormal
(18) Replace DSP card of pump inverter. See page 8-33. (19) Replace power supply card of logic unit. See page 8-37.
If fault remains

then replace pump motor. (DSP card is normal.)
9-73
Logic
G 0 to 5V
CAN 5 GW 2C
0 to 5V
3 Inside Inside
6 3C 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U IU
5V 2
1 Flat
XA5_1P GND
19 cable W IW
+12V 5
0 to 5V
7 B
0 to 5V 6 A
Pump motor 2
6 BLU Speed
WHT sensor W
5
4 RED IM V
U
3 BLK
Thermal
sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X37 M4
211808-58
9-74
Problem: Steer Motor Pulse Input Fault (59)

(1) Situation
(2) Possible cause

Faulty connection of steer motor connector and cable, faulty 12V input voltage of steer inverter, faulty contact or wire
breakage of steer motor speed sensor harness, faulty steer motor speed sensor, motor turning in opposite direction
of command.

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

are connected to steer inverter properly.
Normal Abnormal
(6) Check to see if connector XA3_1 of steer inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector XM3 of pump motor speed (9) Fasten connector securely.
Normal Abnormal
Sensor
(10) Disconnect connector XA3_1 and XM3.
Check continuity between XA3_1/3 and XM3/1. (11) Fasten connector securely.
9-75

Normal Abnormal
(15) Replace power steer controller. See page 8-39.
If fault remains

then replace steer motor. (DSP card is normal.)
9-76
Logic
0 to 5V
CAN 5 0 to 5V
23 CAN H
6 15 CAN L
Fuse
21 Brake Control +36V P 50A Line contactor
N Battery (-)
7F1
1 KEY on +36V U IU
10A 16
K11 K12 GND
4
}
Thermal Sensor V IV
W IW
0 to 5V
5
0 to 5V
+12V
6
3
} Encodes
Steer motor A3
RED Speed
1 W
WHT sensor
3
2
BLU IM V
BLK U
4 Thermal
sensor
5
391 [-30 C(-22 F)] to
6 1407 [160 C(320 F)]
XM3
211796-59
9-77
Problem: Display Communication Fault (60) or (LOGIC FAULT)

(1) Situation
Display: "60" or "LOGIC FAULT." Truck operation inhibited.
(2) Possible cause

Faulty main harness, faulty display unit, faulty logic unit, faulty K11 contactor, blown 1F1/1F2 fuse.

CAN communication is impossible.
(4) Checks
CAN
Disconnect connector XA7_J1L of display unit.
Check voltage at XA7_J1L/1 and XA7_J1L/13 = +36 VDC.
Check continuity between XA7_J1L/2 and NEG (Inverter).
Check continuity between XA7_J1L/17 and NEG (Inverter).
Check continuity between XA7_J2L/1 and XA5_1/5.
Check continuity between XA7_J2L/2 and XA5_1/6.
Continuity No Continuity/Voltage
(7) Disconnect connectors XA1_2 of traction inverter, XA2_2

of pump inverter 1, XA6_2 of pump inverter 2, XA5_1 of
logics, XA7_J1L of display and XA3_1 of APS unit.
Measure resistance of CAN between X56/11 and X56/12.
120 Ω + 5% Out of Range
(9) Connect connector XA2_2 of pump inverter 1, then (8) Perform CAN check of output unit.
measure resistance of CAN between X56/11 and X56/12.
60 Ω ± 5 % Out of range
(10) Replace Pump Inverter 1.
9-78
(11) Disconnect connector XA2_2 of pump inverter 1. Connect one connector of connectors disconnected from controllers,
then measure resistance of CAN between X56/11 and X56/12.
60 Ω ± 5% 60 Ω ± 5% in all connectors Out of range
Repeat above for (12) Check CAN harness of controller for abnormality.
all connectors.
Normal Abnormal
(14) Repair or replace

(13) Replace controller.
harness.
(15) Check to see if these are shorted to other signal cables.

Not shorted Shorted
(16) Replace output unit. (17) Repair or replace harness.
If fault remains

(19) Replace logic card of logic unit. See page 8-37.
9-79
Can H
3
XA2-2 Pump
120Ω
Inverter 1
4 A2
Can L
3
Pump
XA6-2
Inverter 2
4 A6
E stop
Key Switch
3 1F1
Traction
XA1-2
Inverter 1 10A
4 A1
23
APS
XA3-1
15 A3
5
Logics
XA5-1
6 A5 19
1 1
Display 13
2
XA7-J1L
2 A7 17
1F2
Filter 10A
Can L
3 24R
50W
Output
120Ω
Unit
4 A4
Can H
To Truck
Components
K12
K11
9-80
Problem: Parameter Write Fault (61)

(1) Situation
Display: "61". All truck operations inhibited. Line contactor OPEN and steering contactor OPEN.
(2) Possible cause

Writing parameter to eeprom memory failed. Faulty Setup Option data,
faulty logic unit.

Setup Options
(4) Checks
Set Setup Option Group 3 data. See page 5-3.
(5) Turn off power.
(6) Turn on power.
If fault remains
(7) With service tool, set Setup Option data.
If fault remains
(9) Replace logic unit. See page 8-35.
9-81
Problem: Logics Fault (62)

(1) Situation
Display: "62". All truck operations inhibited. Line contactor OPEN.
(2) Possible cause

Faulty EEPROM data, faulty logic unit.

ROM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from check
data. RAM of logic card is faulty.
(4) Checks
Set Setup Options. See page 5-3.
(5) Turn off power.
(6) Turn on power.

Error code "61"
If fault remains "62"
(7) Disconnect battery plug, then discharge electric charges (8) See troubleshooting for code "61". See page 9-81.
9-82
Problem: Traction Inverter Fault (63)

(1) Situation
(2) Possible cause

faulty traction inverter, faulty main harness, faulty logic unit.

Traction inverter is connected as pump inverter 1 (XA1_2/9 is connected to GND) or pump inverter 2
(XA6_2/8 and XA6_2/9 are connected to GND). ROM SUM value of traction inverter is different from
check data. RAM of traction inverter is faulty. Communication with traction inverter is impossible.
(4) Checks
(5) Disconnect connector XA1_2 of traction inverter and

or wire breakage.
Normal Abnormal
Power
supply
(6) Disconnect connector XA5_1P of power supply. (7) Refasten flat cable or replace inverter. See page 8-31.
CAN
(8) Disconnect connector XA5_1
(9) Measure resistance of CAN with connectors XA1_2 and

XA5_1 disconnected.
Resistance between X56/11 and X56/12.

60Ω + 5% Other than 60Ω + 5%
(10) Perform CAN check of pump

inverter 1 (65) or output unit fault
(68).
9-83
(11) Connect connector XA1_2 of traction inverter.

Measure resistance of CAN with connector XA5_1 disconnected.
Resistance between X56/11 and X56/12

60 Ω ± 5% Other than 60 Ω ± 5%
power again.

Normal Abnormal
(17) Replace DSP card of traction inverter. (18) Replace power supply card of logic unit.
9-84
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15
5 12V
16 P
14V
Power 3 8V
17
N
4 18 DSP IMS
GND card
6 20 card U
8
Power supply card V
9
XA5_1P Flat
cable W
DSP flat
cable
Inverter
case
DSP card
211810-63
9-85
Problem: Pump Inverter 1 Fault (65)

(1) Situation
Display: "65". All truck operations except for "lower" inhibited. Line contactor OPEN and steering contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter 1, faulty DSP card of pump inverter 1, faulty pump
inverter 1, faulty main harness faulty logic unit.

Pump inverter 1 is connected as traction inverter (XA2_2/9 is opened) or pump inverter 2 (XA2_2/9 and
XA2_2/8 are connected to GND). ROM SUM value of pump inverter is different from check data. RAM
of pump inverter is faulty. Communication with pump inverter is impossible.
(4) Checks
(5) Disconnect connector XA2_2 of pump inverter 1 and

or wire breakage.
Normal Abnormal
Power
supply
(6) Check continuity between XA5_1P/4 and XA2_2/18. (7) Refasten flat cable or replace inverter. See page 8-31.
CAN
(9) Measure resistance of CAN with connectors

XA2_2 and XA5_1 disconnected.
120Ω + 5% Other than 60Ω + 5%
(10) Perform CAN check of Output

Unit Fault (68).
9-86
(11) Connect connector XA2_2 of pump inverter 1.

Measure resistance of CAN with connector XA5_1 disconnected.

60 Ω ± 5% Other than 60 Ω ± 5%
(12) Replace DSP card of pump

inverter 1. See page 8-33.
Mode
(13) Check continuity between XA2_2/11 and XA2_2/9.
power again.

Normal Abnormal
(17) Replace DSP card of pump inverter 1. See page 8-33. (18) Replace power supply card of logic unit. See page 8-37.
9-87
Logic
0 to 5V
CAN 5 0 to 5V
3
120Ω Inside
Inside
6 4 of of
cover case
14
15
5 12V 16 P
14V
Power 3 8V
17
N
4 18 DSP IMS
GND 20 card card
6 U
8 mode 1
Power supply card mode 2
V
9 Flat
XA5_1P
cable W
11 GND
DSP flat
cable
Inverter
case
DSP card
211812-65
9-88
Problem: Pump Inverter 2 Fault (66)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter 2, faulty DSP card of pump inverter 2,
faulty pump inverter 2, faulty main harness, faulty logic unit.

Pump inverter is connected as pump inverter 1 (XA6_2/9 is connected to GND and XA6_2/8 is opened) or
traction inverter (XA6_2/8 and XA6_2/9 are opened). ROM SUM value of pump inverter 2 is different from
check data. RAM of pump inverter 2 is faulty. Communication with pump inverter 2 is impossible.
(4) Checks
(5) Disconnect connector XA6_2 of pump inverter 2 and

or wire breakage.
Normal Abnormal
Power
supply
(6) Check continuity between XA5_1P/4 and XA6_2/18. (7) Refasten flat cable or replace inverter. See page 8-31.
CAN
(9) Measure resustance of CAN with connectors XA6_2 and XA5_1 disconnected.
60 Ω ± 5% Other than 60 Ω ± 5%
(10) Perform CAN check of pump inverter 1.

Fault (65) or Output Unit Fault (68).
9-89
Mode
(11) Check continuity between XA6_2/11, and XA6_2/8 and XA6_2/9.
(13) Connect connector XA5_1P to logic unit, then turn on

power again. (12) Repair or replace harness.

Normal Abnormal
(16) Replace DSP card of pump inverter 1. See page 8-33. (17) Replace power supply card of logic unit. See page 8-37.
9-90
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15
5 12V 16 P
14V
Power 3 8V
17
N
4 18 DSP IMS
GND 20 card card
6 U
8 mode 1
Power supply card mode 2
V
9 Flat
XA5_1P
cable W
11 GND
DSP flat
cable
Inverter
case
DSP card
211811-66
9-91
Problem: Output Unit Fault (68)

(1) Situation
Display: "68". Pump motor operations inhibited. Line contactor HOLD.
(2) Possible cause

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

Emergency switch is detected. ROM/RAM SUM value of output unit is different from check data.
Communication with output unit is impossible.
(4) Checks
(5) Check output unit status with Output Monitor.
Normal Error
(6) Turn off power. (7) Disconnect battery plug, then replace output unit.
See page 8-38.
(8) Disconnect connector XA4_1 of output unit, then

measure voltage between XA4_1/20 and XA4_1/1
Confirm value is 14V + 2V.
Normal Abnormal
(9) Disconnect battery plug, then discharge electric charges (10) Disconnect battery plug, then discharge electric
from inverters and APS unit. See page 8-30. charges from inverters and APS unit. See page 8-30.
CAN
(11) Disconnect connector XA5_1 of logic unit. (12) Check continuity between XA5_1P/11, XA4_1/1
Check continuity XA5_1/5 and XA4_1/13 and XA4_1/2.
Check continuity XA5_1/6 and XA4_1/14 Check continuity between XA5_1P/12, XA4_1/3
Continuity No Continuity and XA4_1/4.
(15) Measure resistance of CAN of Continuity No Continuity
connectors XA4_1 disconnected.
(13) Replace power supply (14) Repair or replace
120Ω + 5% Other than 120Ω + 5% card of logic unit. main harness.
See page 8-37.
(16) Connect connector XA4_1 of output unit.
Measure resistance of CAN.
60Ω + 5% Other than 60Ω + 5%
(17) Perform CAN check

of pump inverter 1
fault (65).
(18) Replace output unit.
(19) Check proper insertion of pins XA4_1/15 and XA4_1/16. (20) Repair or replace main harness.
Normal Abnormal
9-92
XA4-1 P13
Power Supply
4 XA5_1P
3
12 GND
2
1 11 GND
SEL 0 36
Output
SEL 1 37 unit 1 20 9 +VL
GND 38
13 5 H
120 CAN
Ω 14 6 L
15
Logic
16 XA5_1
Battery K11
voltage T5 T18
5
6
7 A2 A1
8
Key switch
24R
50W
E-Stop 10F1
Battery -
211813-68
9-93
Problem: APS Controller Fault (71)

(1) Situation
Display: "71". Pump motor operations except for “lower” inhibited. Line contactor HOLD.
(2) Possible cause

Faulty APS, faulty main harness, faulty steer sensor, no communication, incorrect start sequence, blown 7F1 fuse,
faulty logic unit.

Steering feedback sensor out of range. Key voltage not reaching nominal voltage within 10 seconds.
Controller initiation fault.
(4) Checks Reference codes 49, 59, and 82

(5) Check output unit status with Output Monitor.

Normal Error
(6) Turn on power. (7) Disconnect battery plug, then replace APS controller.
See page 8-39.
(8) Disconnect connector XA3_1 of APS, then measure

voltage at XA3_1/1. Confirm value is +36 VDC.
Normal Abnormal
(13) Check Steering feedback sensor's (10) Check 7F1 Fuse.

connectors are fully inserted. Fuse Good Blown
(14) Disconnected connector XA5_1 of logic unit. (11) Repair main harness. (12) Replace fuse.
(15) Turn on power.

Check voltage at XA3_1/21.
Confirm value is +36 VDC.
Normal Abnormal
(16) Check continuity between XA3_1/21

and XY31/1 (brake connector).
(17) Replace output unit 2. See page 8-39. (18) Repair or replace main harness.
9-94
To Logic
Unit S34
XY31/2
S31
M1
Safety Brake
S31
XY31/1 1
10F1
K11 KEY
4 SWITCH

3
K12
S34
1
A+ A- B+ B-
4
RED
BLK
YEL
BLU
WH
ORG
3
PNP
7F1
X11/1
X11/3
X11/4
X11/6
10A
21 10 4 11 13 19 1 XA3-1
Gnd
A B
A3
9-95
Problem: Battery Voltage Too Low (78)

(1) Situation
(2) Possible cause

Faulty or discharged battery, low voltage battery, improper battery voltage adjustment setting (BDI reset),
faulty main harness, faulty logic unit, blown 1F1 fuse.

Battery voltage is too low. Battery voltage is corrected with #46 value.
36 V battery: less than 32.4 VDC
(4) Checks
Disconnect battery plug. Measure battery voltage with multimeter.
32 V to 42 V Abnormal
(5) #3 of setup option Group 1 (BDI Reset). (6) Charge battery or replace with proper battery.
(7) Turn off power and turn on power again.
If fault remains

(9) Check continuity between XA5_1/19 and contactor

X12/2 (key switch).
(10) Check fuse 1F1

Fuse Good Blown
(11) Replace fuse.

(13) Repair or replace main harness.
9-96
Line contactor K11 24Ω/50W

Logic Key Switch
XA5_1
19
+
1F1
52 10A
POS
+
Battery
211818-78
9-97
Problem: Battery Voltage Too High (79)

(1) Situation
(2) Possible cause

Faulty or highly charged battery, high voltage battery, improper battery voltage adjustment setting (BDI Reset),
faulty logic unit.

Battery voltage is too high.
36 V battery: more than 43.2 VDC
(4) Checks
Disconnect battery plug. Measure battery voltage with multimeter.
42 V to 43 V Abnormal
(5) #3 of setup option Group 1 (BDI Reset). (6) Replace with proper battery.
(7) Turn off power and turn on power again.
If fault remains


X12/2 (key switch).
(10) Discharge electric charges from inverters and APS unit, (11) Repair or replace main harness.
9-98

Logic Key Switch
XA5_1
19
+
1F1
52 10A
POS
+
Battery
211818-79
9-99
Problem: Pressure Sensor Fault (81)

(1) Situation
Display: "81". Reduced performance.
(2) Possible cause

Faulty load sensor, faulty main harness, faulty logic unit.

Load sensor voltage is out of range of 0.1 V to 4.9 V.
(4) Checks
Check to see if load sensor is installed.
Installed Not installed
(5) Install sensor.
(6) Turn off power, then turn on power again. Check to

see if fault remains.
Fault remains Fault disappears
Normal operation
With service tool
(7) Disconnect battery plug. (8) Check load sensor voltage with Input Monitor and
confirm value is in range of 0.1V to 4.9V.
Abnormal signal Interrupted
(9) Disconnect battery plug. (10) Adjust load sensor

installation.
(12) Disconnect connectors XA5_1 of logic unit.

Disconnect connector XB42 of load sensor.
(13) Check continuity between XB42/2 and XA5_1/21.

(Sensor signal)
9-100
(14) Check continuity between XB42/1 and XA5_1/26.

Check continuity between XB42/3 and XA5_1/25.

With service tool
Without
service tool
(16) Replace load sensor. (17) Connect connectors XA5_1. Turn on power
and check voltage between XB4/1 and
If fault remains XB42/3.
5V Not 5 V
(19) Turn off power. Short-circuit XB42/1 and

XB42/12. Turn on power and check load
(20) Reinstall load sensor, then replace logic card sensor voltage with Input Monitor.
of logic unit. See page 8-36. 5V Not 5 V
(21) Turn off power. Open XB42/1 and XB42/2.

Short-circuit XB42/2 and XB42/3.
Turn on power and check load sensor voltage
with Input Monitor.
0V Not 0 V
(22) Replace load sensor. (23) Disconnect battery

plug.
(24) Replace logic card

of logic unit.
9-101
Logic
XA5_1 XB42 Pressure Sensor
+5V
26 1 L+ P
2 OUT
Signal 3 GND S42

21
GND
43
211819-81
9-102
Problem: Steer Stepper Motor Fault (82)

(1) Situation
Display: "82". Inhibited truck operation.
(2) Possible cause

Faulty stepper motor, faulty main harness, faulty steer controller.

Stepper motor error due to shorted or broken wire or open phase.
(4) Checks
Checks to see if stepper motor connector (X11) is connected.
Connected
(5) With connector X11 connected, probe position X11/1

with positive lead of multimeter. Probe X11/3 with
negative lead. Check voltage. Correct readings will be
between 0 t0 10 VAC as the steer tiller is being operated.
Repeat procedure while probing X11/4 (+) and X11/6 (-).
Normal readings Abnormal
(6) Replace Stepper Motor.
(7) Disconnect connectors X11 and XA3_1.

Check continuity between X11/1 and XA3_1/10.
(8) Repair harness.
(9) Discharge electric charges from inverters and APS.
(10) Replace Steer Controller.
9-103
To Logic
Unit S34
XY31/2
S31
M1
Safety Brake
S31
XY31/1 1
10F1
K11 KEY
4 SWITCH

3
K12
S34
1
A+ A- B+ B-
4
RED
BLK
YEL
BLU
WH
ORG
3
PNP
7F1
X11/1
X11/3
X11/4
X11/6
10A
21 10 4 11 13 19 1 XA3-1
Gnd
A B
A3
9-104
Problem: Brake Switch Fault (85)

(1) Situation
(2) Possible cause

Faulty OPP (operator prsence pedal), faulty brake switch, faulty regeneration switch, faulty main harness, faulty
logic unit.
(3) How
Stallthe errorflowed
current code ismore
triggered
thse time (#20) in traction motor, faulty right traction inverter current sensor, shorted
Presence switch isfaulty
harness wiring, turned off traction
right and regeneration switch
inverter DSP is turned
card, on. unit.
faulty logic
(4) Checks
Disconnect battery plug.
(6) Disconnect connectors

Stall current X13thse
flowed more OPPtime
and(#20)
XA5_1 of logic motor,
in traction unit. faulty right traction inverter current sensor, shorted
Check continuity of between XA5_1/38 and X13/4, XA5_1/39 and X13/3,
harness wiring, faulty right traction inverter DSP card, faulty logic unit. XA5_1/30
and X13/2, and XA5_1/9 and X13/1.
(7) Measure resistance between the following terminals.

• When pedal is released.
Between XA5_1/38 and XA5-1/9 Open.
Between XA5_1/39 and XA5-1/9 0 Ω.
• When pedal is slightly depressed.
• When pedal is fully depressed.
Between XA5_1/38 and XA5-1/9 0Ω.
Normal Abnormal
(9) Replace logic card of logic unit. (10)Repair or replace OPP.
9-105
Logic
Operator presence pedal (OPP)
XA5_1
X13
S12
30 2 Operator presence
39 3 Regen breaking
38 4
GND S11
1
OPP
Operator presence OFF
Pedal released
OFF
Regen switch
ON
ON
Pedal depressed
Operator presence Regen switch
switch
211821-85
9-106
Problem: Height Sensor Fault (86)

(1) Situation
Display: "86". Inhibited truck operation, except for “lower”.
(2) Possible cause

Faulty height sensor, faulty pulse encoder, faulty main harness, faulty logic unit.

No pulse input movement detected when it should be charging.
Encoder pulses detected before mast height reference state change is detected.
(4) Check to see if height sensor is setup.

Setup Not Setup
(5) Setup option #22 to correct height.
Normal operation
(7) Fault remains
(10) Check height sensor for installation.
Normal Abnormal
(11) Adjust height sensor

installation.
(14) Discharge electric charges from inverters and APS unit.

See page 8-30.
(15) Disconnect connector XA5_1 of logic unit

Disconnect connector XB41 (pulse encoder)
and XS43 (Free height sensor).
(16) Check continuity between XA5_1/10 and XB41/1,

and XA5_1/10 and XS43/1.
9-107
(17) Check continuity between XA5_1/43 and XB41/4.

Check continuity between XA5_1/43 and XS43/3.
Check continuity between XA5_1/12 and XB41/2.
Check continuity between XA5_1/11 and XB41/3.
Check continuity between XA5_1/45 and XS43/2.

With service tool
Without
service tool
(19) Replace height sensor and/or pulse encoder. (20) Connect connectors XA5_1, XB41 and XS43.
Turn on power and check free height sensor
If fault remains signal.
0V Not 0 V
(22) Turn off power. Short-circuit X46/6 and

X46/7. Turn on power and check height
(23) Reinstall height sensor and/or pulse encoder, then sensor signal with input monitor.
replace logic unit. See page 8-36. 0V Not 0 V
(24) Replace load sensor. (25) Disconnect

Disconnect battery
battery
plug.
plug.
(26) Replace logic unit.
9-108
B41 S43 NPN

out V+ V_
+ _
V A B V
RED WHT BLU BLK BRN BLK BLU
XB41/1
XB41/2
XB41/3
XB41/4
XS43/1
XS43/2
XS43/3
X46/1
X46/2
X46/3
X46/4
X46/5
X46/6
X46/7
10 12 11 43 45
12V GND XA5-1
sensor supply
LOGIC BOARD A5
9-109
Problem: Logic Fault Multipurpose Output #1, Travel Alarm (88)

(1) Situation
Display: “88”. Travel alarm output OFF. Normal pump motor, traction motor and power steering operations.
(2) Possible cause

Faulty travel alarm, faulty main harness, faulty logic unit, faulty K31 relay.

With short circuit detection signal of logic card.
(4) Checks
(5) Disconnect connector XA5_1 of logic unit. Disconnect terminals K31/5 and K31/1 of horn relay (K31).
(6) Check short circuit between K31/5 and K32/1 on harness side.
Not shorted Shorted
(7) Repair main harness.

(8) Check short circuit between travel alarm side
connectors. Measure coil resistance.
[Approx. 1.6MΩ]
Connect positive (+) terminal of multimeter to (+) and
negative (-) terminal to (-).
Normal Abnormal
(9) Disconnect terminal K31/3 of travel alarm relay. (10) Replace travel alarm.
(11) Check short circuit between K31/3 and ground.

Shorted Not Shorted
(12) Repair main harness. (13) Check short circuit between travel alarm relay tabs
Check fuse 12 F2. 1 and 5. Measure coil resistance.
[Approx. 1.2kΩ]
Normal Abnormal
(14) Replace logic card of logic unit. See page 8-36 (15) Replace travel alarm relay.
9-110
11F1 12F1 12F2

10A 10A 10A
5 3
Logic
1 4
XA5-1 XESS
+
44 1
Travel alarm
(Backup alarm)
2
-
211817-88
9-111
Problem: Logic Fault Multipurpose Output #2, Horn (88)

(1) Situation
Display: "88". Chime output OFF . Normal pump motor, traction motor and power steering operations.
(2) Possible cause

Faulty horn, faulty main harness, faulty logic unit, faulty K32 relay.

With short circuit detection signal of logic card.
(4) Checks
(5) Disconnect connector XA5_1 of logic unit. Disconnect terminals K32/5 and K32/1 of horn relay (K32).
(6) Check short circuit between K32/5 and K32/1 on harness side.
Shorted Not shorted
(7) Repair main harness. (8) Measure coil resistance.

[Approx. 1.2KΩ]
Connect positive (+) terminal of multimeter to K32/1
and negative (-) terminal to K32/5 of relay.
Shorted Not Shorted
(9) Replace relay. (10) Replace logic unit.

See page 8-35.
9-112
11F1
10A
Logic K32
XA5_1 Relay 3
+
57 5
58
1
-
4
To Horn
211816-88
9-113
Problem: Pump Motor 2, Current Sensor Fault (94)

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

inverter, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connector XA6_2 of pump inverter and remove

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between XA5_1P/4 and XA6_2/18. (7) Secure DSP flat cable if loose.
Check continuity between XA5_1P/6 and XA2_2/20. Replace pump inverter if wire breaks. See pages 8-33.
CAN
(9) Connect connector XA5_1P to logic unit, then turn on power (10) Repair or replace harness.
again.
(11) Measure voltage between XA6-2/18 and XA6-2/20.

Confirm value is 8V ± 2V. -
Normal Abnormal
(13) Replace DSP card of pump inverter. See page 8-33. (14) Replace power supply card of logic unit.
See page 8-37.
If fault remains
See page 8-31.
9-114
Logic
0 to 5V
CAN 5 0 to 5V
3 Inside Inside
6 4 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V* 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
7 B
0 to 5V 6 A
Pump motor 2
DSP flat BLU Speed
cable 4 W
sensor
2 WHT
Inverter
3 RED
IM V
case BLK U
1 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X36 M4
211800-94
9-115
Problem: Pump Motor 2, Over-current (95)

(1) Situation
(2) Possible cause

inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main harness,
faulty logic unit.

Motor current is more than 1018 Amps (Moment). Motor curret is more than 990 Amps (Fixed time 1).
(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(7) Replace pump motor.

(6) Confirm cable looseness and improper connections Notice: Before replacing motor, be sure to check it.
(U, V, W phases) for pump inverter and motor. If motor is normal, perform troubleshooting
(8) Disconnect connector XA6_2 of pump inverter and (9) Secure cable if loose or connect cable correctly.
or wire breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector X37. Replace pump inverter if wire breaks. See page 8-33.
Normal Abnormal
Sensor
(12) Disconnect connector XA6_2 and X37. (13) Connect connector securely.
8V power
supply
(14) Disconnect Connector XA5-1P
9-116

on power again.

Normal Abnormal
(20) Replace DSP card of pump inverter. See page 8-33. (21)Replace power supply card of logic unit. See page 8-37.
If fault remains
See page 8-33.
If fault remains
then reinstall pump inverter and replace pump motor.
9-117
Logic
0 to 5V 3
CAN 5 0 to 5V 4
Inside Inside
6 of of
cover case
14
15 Fuse
5 12V 16 P 425A Line
14V contactor
Power 3 8V
17
N Battery (-)
4 18 DSP IMS
GND 20 card card
6 U
5V * 2 Temp
1 Sens Flat
XA5_1P GND
19 cable W
+12V 5
0 to 5V
7 B
0 to 5V 6 A
Pump motor 2
DSP flat BLU Speed
cable 6 W
sensor
5 WHT
Inverter
4 RED
IM V
case BLK U
3 Thermal
DSP card sensor
2
391 [-30 C(-22 F)] to
1 1407 [160 C(320 F)]
X37 M4
211800-95
9-118
Problem: Incorrect Start (E)

(1) Situation
Display: "E" flickering. All truck operations inhibited. Line contactor OPEN when turning on
power, Line contactor OPEN (when truck stops).
(2) Possible cause

Power turned on while depressing OPP, power turned on while operating traction lever, traction lever operated
before depressing OPP, presence pedal not depressed, faulty OPP switch, faulty traction lever sensor, faulty main
harness, faulty logic unit.

Stall current
Detects flowedsignal
following more0aaa00 thsmeon
when turning (#20) in traction motor, faulty right traction inverter current sensor, shorted
power.
harness wiring,
OPP : ON faulty rightTraction lever voltage:card
traction inverter DSP Lessfaulty logic ±uni
than 2.3V 0.2V or 2.7V ± 0.2V or more
(4) Checks
Release OPP and release traction lever to neutral.
If fault remains
(5) Turn off power. Release OPP, release traction
lever to neutral, then turn on power again.
With service tool
(6) Check OPP and traction lever operations with (7) Confirm input signals of OPP and traction
Input Monitor. lever with data monitor function.
(8) Turn off power. (faulty unit only)

Traction pedal Traction lever
(9) Disconnect connector X13 of traction pedal, then

(10) Refer to error code "51". See page 9-58.
measure resistance between between following terminals.
• When OPP is released.
Between X13/2 and X13/1: Open.
Between X13/4 and X13/1: Open.
• When OPP is pressed.
Between X13/2 and X13/1: 0Ω.
Between X13/4 and X13/1: 0Ω.
Abnormal Normal
(11) Replace traction pedal. (12) Disconnect connectors XA5_1 of logic unit
(13) Check short circuit between X13/2 and XA5_1/30,

X13/4 and XA5_1/38.
Not shorted Shorted
(15) Repair or replace main

(14) Disconnect battery plug. harness.
9-119
Logic
Operator presence pedal (OPP)
XA5_1
X13
S12
30 2 Operator presence
39 3 Regen breaking
38 4
GND S11
1
9 Traction speed
and Direction
X14A
5 6 7 8
1 2 3 4
View opposite wire entry
Logic
XA5_1
X14A
5V RED
26 1
0.5 to 4.5V WHT
20 2
GND BRN
25 3
211822-E
9-120
Problem: Lift Lever, Faulty Setting ((H1))

(1) Situation
Display: "H1" flickering. All truck operations inhibited. Line contactor OPEN when turning on power.
Line contactor OPEN (when truck stops).
(2) Possible cause

Power turned on while operating lift lever, presence pedal pressed while operating lift lever, faulty lift lever sensor,
faulty main harness, faulty logic unit.

Detects lift lever sensor signal when turning on power.
Lift lever sensor voltage: Less than 2.3V ± 0.2V or 2.7V ± 0.2V or more.
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(5) Turn on presence pedal, then stop pump motor

operation.
If fault remains Normal
Fail-safe function
(6) Turn off power. Release presence pedal, then turn on

power again without lift operation.
If fault remains
(7) Check continuity between X14A/8 and X14A/7: Open

Check voltage at X14A5: Neutral = 2.5V, Lower = 4.5v and Lift = 0.5V.
Normal Abnormal
(8) Replace logics (9) Replace lift

unit. lever.
9-121
Lower
X14A
5 6 7 8
Logic 1 2 3 4
XA5_1 View opposite wire entry
+5V
26 Lift
Logic
XA5_1
22
Joystick
X14A
Logic
XA5_1 7
8
+5V
26 4
0.5V to 4.5V
27 5
GND
25 6
211820-H1
9-122
Problem: Tilt Switch, Faulty Setting ((H2))

(1) Situation
Display: "H2" flickering. All truck operations inhibited. Line contactor OPEN when turning on
power. Line contactor OPEN (when truck stops).
(2) Possible cause

Power turned on while operating tilt switch, presence pedal pressed while operating tilt switch, faulty tilt switch,
faulty main harness, faulty logic unit.

Detects tilt switch when turning on power.
(4) Checks
(5) Release presence pedal, then stop pump motor

operation.
Fail-safe function

power again without tilt operation.
If fault remains
(7) Turn off power.
(8) Disconnect connector X14B of handle. Turn on

presence pedal, then turn on power again.

(10) Check handle.
(11) Check continuity between X14B/3 and XA5_1/43.

Check continuity between X14B/6 and XA5_1/41.
Check short between X14B/6 and XA5_1/43.
Continuity, not shorted No continuity, shorted
(12) Disconnect battery plug. (13) Repair or replace main harness.
9-123
Logic Joystick
XA5_1 X14B
Tilt Up
41 6
Tilt Down
40 7
GND
3
Logic
XA5_1 X14B
43 5 10
4 9
3 8 View opposite wire entry
2 7
1 6
211823-H2
9-124
Problem: Reach Switch, Faulty Setting ((H3))

(1) Situation
(2) Possible cause

Power turned on while operating reach switch, presence pedal pressed while operating reach switch,
faulty reach switch, faulty main harness, faulty logic unit.

Detects reach switch when turning on power.
(4) Checks

operation.
Fail-safe function

power again without reach operation.
If fault remains
(7) Turn off power.
(8) Disconnect connector X14B of handle. Turn on

(9) Disconnect battery plug, then discharge electric (10) Check handle.

9-125
Logic
Joystick
XA5_1
X14B
Reach Out
47 4
Reach In
48 5
SShift Left
36 8
SShift Right
37 9
GND
3
Logic X14B
XA5_1 5 10
4 9 View opposite
43 wire entry
3 8
2 7
1 6
211824-83
9-126
Problem: Sideshift Switch, Faulty Setting ((H4))

(1) Situation
(2) Possible cause

Power turned on while operating sshift selector switch, presence pedal pressed while operating sshift
switch, faulty sshift selector switch, faulty main harness, faulty logic unit.

Detects sshift switch when turning on power.
(4) Checks

operation.
Fail-safe function

power again without sshift operation.
If fault remains
(7) Turn off power.
(8) Disconnect connector X14B of switch. Release

(9) Disconnect battery plug, then discharge electric (10) Check handle.

9-127
Logic
Joystick
XA5_1
X14B
Reach Out
47 4
Reach In
48 5
SShift Left
36 8
SShift Right
37 9
GND
3
Logic X14B
XA5_1 5 10
4 9 View opposite
43 wire entry
3 8
2 7
1 6
211824-84
9-128
Problem: Battery Low ((Lo))

(1) Situation
Display: "Lo" flickering. All truck operations except for "lowerî inhibited.
(2) Possible cause

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

Corrected battery voltage is less than 15.5V. Battery voltage is corrected with #3 (BDI Reset) value.
(4) Checks
Disconnect battery plug.
(5) Check battery voltage.

15.5V or more Less than 15.5V
(6) Set #3 of Setup Option Group 1. See page 5-2. (7) Charge battery or replace with new battery.
If fault remains
(8) Discharge electric charges from inverters and APS unit.
See page 8-30.

X12/2 (key switch).
(10) Check fuse 1F1

Fuse good Blown
(12) Replace logic card of logic unit. See page 8-36. (11) Replace fuse.
(13) Repair or replace main harness.
9-129

Logic Key Switch
XA5_1
19
+
1F1
52 10A
POS
+
Battery
211818-Lo
9-130
Component Identification
Identifier Description
1F1 B + (10A) fuse to Key Switch
1F2 B - (10A) fuse to Key Switch
2F1 B + K12 (425A) fuse to Drive Motor Controller
3F1 B + (10A) fuse to Auxiliary Devices
3F2 B - (10A) fuse to Auxiliary Devices
4F1 B + K12 (425A) fuse to Pump Motor Controller
5F1 B + K12 (50A) fuse to Steer Motor Controller
6F1 B + K12 (325A) fuse to 2nd Pump Motor Controller*
9F1 B + K11 (10A) fuse to Controller Circuit
12F1 B + (10A) fuse Auxiliary Control Devices
12F2 B - (10A) fuse to Auxiliary Control Devices
A1 Traction Motor Controller
A2 Pump Motor Controller
A3 Steer Motor Controller
A4 RT01 Valve Controller
A5 Logics Controller
A6 2nd Pump Motor Controller
A7 Display Unit
B11 Steering Wheel Sensor
B21 Traction Speed and Direction Sensor
B31 Speed and Direction Encoder (Drive motor)
B32 Speed Encoder (Hydraulic Pump Motor)
B33 Speed Encoder (Steer Motor)
B34 Speed Encoder (2nd Hydraulic Pump Motor)*
B41 Pulse Encoder Level Sensor (Option)
B42 Pressure Sensor (Future Option)
E51 Cabin Light (Option)
E52 Working Light (Option)
E53 Working Light (Option)
E54 Warning Light (Option)
E55 Reverse Travel/Horn (Option)
F101 K11 coil
G1 36V Battery 36 volt
H1 Horn
H2 SICOS/Display Unit Buzzer
H55 Reverse Travel/Horn (Option)
K11 K11 Contactor Tips (B +) to 9F1, 10F1, 11F1, 12F1
* High Performance only.
9-131
K11 (24V in box) K11 Coil
K12 K12 Contactor Tips (B +) to 3F1, 4F1, 5F1, 6F1, 8F1
K12 (24V in box) K12 Coil
K32 Horn B + Tips in K32 Relay
K32 (box) K11 Coil
M1 Traction Motor
M2 Hydraulic Pump Motor
M3 Steer Motor
M4 2nd Hydraulic Pump Motor*
M7 Motor Compartment Fan Fan
M8 Controller Fan
M9 El-Panel Input Fan
M10 El-Panel Output Fan
M51 Driver Fan
R1 25R/50W Resistor (K11 Coil)
R7 56R/10W Resistor (Motor Comp Fan)
R8 56R/10W Resistor (Motor Comp Fan)
R9 56R/10W Resistor (Controller Fan)
R10 25R/10W Resistor (Controller Fan)
R31 Temperature Sensor (Traction Motor)
R32 Temperature Sensor (Hydraulic Pump Motor)
R33 Temperature Sensor (2nd Hydraulic Pump Motor)*
R34 Temperature Sensor (Steer Motor)
R51 56R/10W Resistor (Driver Fan)
R343 120R Heater (Steering Wheel) Cold Storage
R344 120R Heater (Brake Pedal) Cold Storage
S1 Emergency Stop Switch
S2 Key Switch
S11 Brake Pedal Switch
S12 Operator Presence Switch
S13 Horn Button
S14 Reach (Out) Switch
S15 Reach (In) Switch
S16 Tilt (Up) Switch
S17 Tilt (Down) Switch
S18 Sideshift (Left) Switch
S19 Sideshift (Right) Switch
S36 Battery Lock Switch (Option)
S43 Lifting Height Reference Sensor (Option)
S51 Cabin Light Switch (Option)

9-132
S52 Working Light Switch (Option)
S53 Undefined Switch (Option)
S54 Driver Fan Switch (Option)
S55 (_) Up Key on the Display
S56 (_) Down Key on the Display
S57 (__) Down/Left Enter Key on the Display
S58 (-) Right Key on the Display
S59 (-) Enter Key on the Display
S60 (X) Escape Key on the Display
S531 Steering End Limit Sensor (Sensor A)
S534 Steering Feedback Sensor (Sensor B)
S342 Switch steering wheel heater
SM2 + 50° C. N/O Thermostat
X1: - Battery SB Connector (Negative)
X1: + Battery SB Connector (Positive)
X2: - Battery Negative (Panel Ground)
Y31 (36V in box) Service Brake Coil
Y41 Lift/Lower Solenoid Coil (M1-M2 Coil)
Y43 Direction of Sideshift, Tilt, Reach (DIRA-DIRB)
Y44 Reach/Retract Solenoid (S5-S6)
Y45 Sideshift Solenoid (S7-S8)
Y46 Tilt/Sideshift
Z1 Zener Diode (12 volt / 5W)
9-133

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TROUBLESHOOTING FOR CONTROL CIRCUITS

General Information ...................................................................................... 9-1

Before replacing devices

Disconnect power supply connector of logic unit. Check continuity

Normal Repair or replace harness.

Connection of the service tool Error code display

ics unit. Logic unit

How to clean harness connectors

2. After checking the connector for continuity, wash

Contact surface Three Bond 2501S (aerosol)

CAN-BUS Reach Truck AC

Pump Traction 2nd APS Logic Display Output

Tests 1 and 2 performed at GSE connector X56

(2) Possible cause

(3) How the error code is triggered

(5) Traction motor becomes normal.

(7) Adjust brake.

(8) Lift front wheels, and disengage electromagnetic

(9) Check if truck is operated on steep up-

(10) Discharge electric charges from inverters and APS

(11) Replace traction motor. (12) Replace traction

With service tool

(13) Confirm temperature of traction motor with

(25) Measure voltage between XA1_2/17 and XA1_2/20

(26) Disconnect battery plug.

(27)Replace power supply card of logic unit. See page 8-37.

(28) Ensure all connectors are connected. Check history

(29) Disconnect battery (30)Troubleshoot display

(31) Replace DSP card of traction inverter. See page 8-33.

Problem: Pump Motor 1, Overheating (E2)

(2) Possible cause

(3) How the error code is triggered

(5) Pump motor becomes normal.

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

(8) Check oil pressure of gear pump and hydraulic lines.

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

With service tool

(11) Confirm temperature of pump motor 1 with

(16) Disconnect connector X36 of pump motor thermal

(23) Measure voltage beween XA2_2/17 and XA2_2/20.

(24) Disconnect battery plug.

(27) Disconnect battery plug, (28) Troubleshoot display

P17 Pump motor 1

*1: With motor connector disconnected X36 M2

Problem: Pump Motor 2, Overheating (E3)

(2) Possible cause

(3) How the error code is triggered

(5) Pump motor becomes normal.

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

(8) Check oil pressure of gear pump and hydraulic lines.

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

With service tool

(11) Confirm temperature of pump motor 2 with

(16) Disconnect connector X37 of pump motor thermal

(21)Connect connector XA5_1P

(23) Measure voltage beween XA2_2/17 and XA2_2/20.

(24) Disconnect battery plug.

(27) Disconnect battery plug, (28) Troubleshoot display

*1: With motor connector disconnected X37 M4