TDO06-G0402E

SERVICE TOOL

Install Manual
 Index

1. Before Installation ........................................................................................................................................................... 1

2. Installation of USB-CAN driver ....................................................................................................................................... 3

3. Installation of Service Tool .............................................................................................................................................. 6

1. BEFORE INSTALLATION

Before installation, prepare the following products.

(1) Driver CD for Kvaser Leaf Light
(2) Application CD for service tool
(3) CD Drive

2. INSTALLATION OF USB-CAN DRIVER

(1) Insert the Driver CD in the CD drive.

If the CD drive of your PC is set to the auto play ÅgenableÅh, the installation menu starts up automatically.
(Figure 1)

Figure 1 Opening Menu of Driver Installation

When the auto play is set to "disable", double-click the [AutoPlay.EXE]. Then, the menu shown in figure 1 appears.
When the menu appears, click on [CAN Drivers].
Then, the installation starts.

1
 (2) The guidance menu on the installation information appears.
Press the [Yes] button to proceed to the next menu.

Figure 2 Menu of Installation Information

(3) The caution items at installation are displayed on the Internet Explorer.
Close the menu.

Figure 3 Menu of Caution at Installation

2
(4) The welcome menu appears.
Press the [Next >] button.

Figure 4 Welcome Menu

(5) The menu to select the destination directory to be installed appears.

Press the [Next >] button.

Figure 5 Menu to select the destination directory to be installed

3
 (6) The menu to select the name of start menu group for icon appears.
Press the [Next >] button.

Figure 6 Menu to select the name of start menu group for icon

(7) The menu to be ready to install appears.

Press the [Next >] button.

Figure 7 Menu to be ready to install

4
(8) The menu shown in figure 8 appears during installation.

Figure 8 During installation

(9) When the Installation Complete message appears, the operation is finished.
Press the [OK] button to finish the work.

Figure 9 Installation Complete Menu

5
3. INSTALLATION OF SERVICE TOOL

(1) Insert the driver CD in the CD driver.

When the CD drive of your PC is set to the auto play "enable", the installation menu appears automatically.
If the auto play of CD drive is set to "disable", double-click the [SvcSetup.EXE] of CD drive.

(2) When the installation starts, the menu to select the language appears.
Select the [U.S. English], and then press the [OK] button.

Figure 10 Menu to select the language

(3) The [Welcome] menu appears.

Read carefully and press [Next >] button.

Figure 11

6
(4) The menu to choose the destination location (folder) to be installed appears.
The destination folder to be installed in default is as follows.
C:\Program Files\KOMATSU
The destination folder can be changed if required. But, install in the default folder.
* If the destination folder to be installed is changed, other application may not work.

Figure 12 Menu to choose the destination folder to be installed

(5) The menu to select the name of program manager group for icon appears.
Press the [Next >] button.

Figure 13 Menu to select the name of program manager group for icon

7
 (6) The Start Installation menu appears.
Press the [Next >] button.

Figure 14 Start Installation Menu

(7) The menu below appears during installation.

Do not touch any key.

Figure 15 During installation

8
(8) Menu of Installation Complete
When the installation is completed, the menu below appears.
Press the [Finish >] button and confirm that the icon is created on the desktop.

Figure 16 Menu of Installtion Complete

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2-4-1 Shiba-koen, Minato-ku, Tokyo 105-0011, Japan

Printed in Japan
02-07(YC)03001
 TDO06-G0395E

SERVICE TOOL

Setting/Monitoring

Instruction Manual

Warning
If this machine is improperly operated, it may lead to serious
injury or death.
A mechanic, who is responsible for the maintenance, should
read this instruction manual to understand well.
Then, operate, inspect and maintain the vehicle.
Store this manual near the vehicle so that all personnel in charge
of maintenance can read periodically.
 Index

1. To begin with................................................................................................................................................................... 1
1.1 About this manual .................................................................................................................................................. 1
1.2 For repairing and checking safely.......................................................................................................................... 1
1.3 Caution on handling the application....................................................................................................................... 1
1.4 Recommended System Configuration ................................................................................................................... 1
1.5 Overview of service tool......................................................................................................................................... 2
2. Initial Setting (User Registration) .................................................................................................................................... 3
2.1 Start up .................................................................................................................................................................. 3
2.2 Application for the use ........................................................................................................................................... 3
2.3 Enter the approval key........................................................................................................................................... 5
3. Basic Operation .............................................................................................................................................................. 6
3.1 Start up .................................................................................................................................................................. 6
3.2 Select the Vehicle Type ......................................................................................................................................... 6
4. Parameter Setting........................................................................................................................................................... 8
4.1 Writing the set values in the Easy Setting ............................................................................................................. 8
4.2 Writing the user setting .......................................................................................................................................... 8
4.3 Writing the set value in the parameter setting menu ............................................................................................. 9
4.4 Renew the set value ............................................................................................................................................ 10
4.5 Save the set value ................................................................................................................................................11
5. IO Monitor Operation .................................................................................................................................................... 12
5.1 Monitor the values ............................................................................................................................................... 12
6. Error History.................................................................................................................................................................. 14
7. Environment Setting ..................................................................................................................................................... 15
8. Extend the use limit ...................................................................................................................................................... 16
Parameter Sheet ................................................................................................................................................................ 17
1. TO BEGIN WITH

1.1 About this manual

This manual is the guide book for using our product safely and effectively.
Before using the product, ensure to read this manual and understand fully the operation.
Unless you follow the instruction in this manual, it may lead to serious accident.

Warning
If this vehicle is improperly operated, it may lead to serious injury or death.
Store this manual near the vehicle so that all personnel who operate this vehicle can refer to this manual.
• Read this manual thoroughly before operating the vehicle.
• Store this manual near the vehicle so that the manual can be referenced repeatedly.
• If this manual is lost or damaged, contact the dealer you purchased from.
• As the improvement is always done, this manual may differ in details. If any question, please inquire the
dealer of it.

1.2 For repairing and checking safely

When connecting the computer with the vehicle with the cable, pull up the parking brake, turn OFF the key switch
and disconnect the battery connector from the battery.
After connecting the communication cable and battery connector again, turn ON the key switch.
Confirm that the vehicle is in the operating state, and then start up the service tool application.

1.3 Caution on handling the application

• After installing the drive of USB CAN cable on the PC, if the cable is inserted in the port other than the port used
for driver installation, the request of installation is displayed again. According to the installation procedure
supplied with the USB CAN cable, perform the setting.
• If the virus detection software is running, the communication error may occur.
If the error occurs, terminate the virus detection software and use the application.

1.4 Recommended System Configuration

The operation of application is confirmed on the PC with the following environment.
1. Operating System
Windows 2000 Service Pack 3 and higher
Windows XP Service Pack 2 and higher
2. CPU
Intel Celeron M 1.5GHz and higher
3. Memory
256MB and more

1
1.5 Overview of service tool
The functions provided in this application are as follows.

Parameter Setting
By setting the controller of vehicle to details, the vehicle desired by a user is available.
Example 1) The plugging braking (electric braking) is weakened.
• Adjust the FR plugging regenerative item. Default: 60% o 40%
• Adjust the regenerative brake. Default: 90% o 70%

IO Monitor Display
It displays the values of sensor and solenoid in a real time so that an operator can grasp the vehicle state.
When an error occurs, an operator can confirm the content of error on the error history and concisely the values of
sensor.
Example 2) When checking the value of accelerator sensor:
• Check the output voltage of accelerator sensor. When not operated: 0.6V
(The sensor is broken. Breaking of wire) When not operated: 0.0V

Error History Display

The controller-wise error content and the past error history are displayed on the screen.
When an error occurs, the error content, remedy and connector are displayed.
Example 3) Error No. 5206
Content: The key switch is turned ON when the lift lever is in the position other than neutral.
• Poor adjustment of lift lever sensor
• Defective lever sensor
• Defective harness of lift lever sensor
Remedy: 1) Check the lift sensor input signal. Normal: 2.39 – 2.61 (V)
2) If normal in step 1), replace the proportional solenoid valve controller board.
3) If abnormal in step 1), check and repair the harness between the lever sensor and
proportional solenoid valve controller.
4) If the check in step 1) is abnormal and the check in step 3) is normal, repair the lever
sensor.
• For detailed error content and remedy, refer to the shop manual.

2
2. INITIAL SETTING (USER REGISTRATION)

2.1 Start up
To start up the service tool application, double-click the service tool application icon. (or select from the start menu.)

2.2 Application for the use

To use this tool, the approval key issued from the Management Department is required.
After the approval key is issued and the approval key for the use informed from the Management Department is
registered, the tool can be used.
After this tool is installed, when starting up the tool first or every one year after installed, the [Creating the
application form for the use/Approval for the use] selection menu shown below appears.

(1) Check the [Creating the application form for the use] and press the [Next].

Fig.1 Creating the application form for the use.

(2) Check the [Create the application form], and enter for [Name of applicant] and [Applying Department].
Then, press the [Next] button.
Enter as follows.
Name of applicant: A person who manages the PC on which the service tool application is installed or to be
installed.
Applying Department: Company Name

Fig.2 Create the application form for the use.

3
 (3) The folder where the application form for the use is created is displayed.
Send the application form for the use to the Management Department and acquire the approval key.
This tool cannot be used until the approval is entered. To close the menu, press the [Complete].

Fig.3 Application form for the use

The content in the application form for the use is described below. (Sample)
• In the sample, the entry is written in two rows to meet the width of manual.
As application key is created by gathering individual PC information, even if the data in the sample is entered,
the tool does not open.

Computer Created Date of Name of

MAC address OS version Application Key
Name application form file applicant

Windows XP Version 5.1 Ey3A-Ts83-Ewyf-

IBM-884BBFC 000E35E37559 2006/12/14 19:01 PC1
Build 2600 Service Pack 2 yywE-22A5-jkQU

Applying Date/Time issued

Approval Key
Department of approval key

Development
Dept. Battery U

(4) The [ApForm.csv] file is created in the folder displayed on the above menu.
Mail the [ApForm.csv] file. Or open it with Excel or NotePad, print and send KOMATSU FORKLIFT.
Mail to: [email protected]
FAX to: KOMATSU FORKLIFT Customer Support Department
03-XXXX-XXXX

4
2.3 Enter the approval key.
When the registration is completed in the Management Department, the approval key is issued and the
[ApForm.csv], in which the approval key is filled in, will be returned by mail or FAX.
(1) Start up the service tool and check the [Approval for the use] on the 2.1 (1) [Creating the application form for the
use/Approval for the use] selection menu. Then, press the [Next] button.

Fig.4 Approval for the use

(2) Enter the approval key of 24 digits written in the application form for the use and press the Complete] button.
The content in the application form for the use is described below. (Sample)
• In the sample, the entry is written in two rows to meet the width of manual.
As application key is created by gathering individual PC information, even if the data in the sample is entered,
the tool does not open.

Computer Created Date of Name of

MAC address OS version Application Key
Name application form file applicant
Windows XP Version 5.1 Ey3A-Ts83-Ewyf-
IBM-884BBFC 000E35E37559 2006/12/14 19:01 PC1
Build 2600 Service Pack 2 yywE-22A5-jkQU

Applying Date/Time issued

Approval Key
Department of approval key

Development
XXXX-XXXX-XXXX-XXXX-XXXX-XXXX 2006/12/14 19:08
Dept. Battery U

Fig.5 Key Approval

(3) The expiration date is displayed. When the [OK] button is pressed, the service tool can be used.

5
3. BASIC OPERATION

3.1 Start up.

To start up the tool, double-click the service tool icon on the desk top. (Or select the service tool application from
the start menu.)

3.2 Select the Vehicle Type.

All vehicle types supported in this tool are displayed.
(1) Click the desired vehicle type with the mouse or select with [<-] /[->] keys. Then, press the return key.
Or by double-clicking on the menu, the same operation as [the selection + pressing return key] can be
performed.

Fig. 6 Selection of model

(2) Select the desired model on the [Selection of Model] menu and press the [OK] button.
To return to the vehicle type selection menu, press the [Return].

Fig.7 Selection of Model

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(3) Opening Menu

Fig.8 Opening Menu

1. Service Tool Menu
• F1: Parameter.....................Displays the parameter setting menu. For detail, refer to [4. Parameter Setting].
• F2: IO Monitor.....................Displays the IO monitor. For detail, refer to [4.IO Monitor].
• F3: Error History .................Displays the error history menu. For detail, refer to [6.Error History].
• F4: Environment Setting .....Displays the environment menu. For detail, refer to [7. Environment Setting].
• F5 – F12 .............................Depending on the menu, the functions differ.

2. Finish Button
It terminates the service tool application.

3. Parameter Easy Setting Button

Write the set values provided beforehand.

4. Setting/Monitor Display Menu

Nothing is displayed on the opening menu.
When the service menu is selected, the Setting/Monitor Item is displayed.

7
4. PARAMETER SETTING

4.1 Writing the set values in the Easy Setting.

When either of economy, normal or power button is pressed, the set values provided
beforehand in model-wise are written in the vehicle connected.
1. Soft .............. The travel acceleration / deceleration and lift speed softly change.
(But, the maximum travel speed remains unchanged.)

2. Normal......... It sets the values to the factory setting.

3. Power .......... It sets the travel and lift output to the powerful mode.
(But, the maximum travel speed remains unchanged.)

4. User ............. It writes arbitrary setting values. When writing the identical set values in
several vehicles, use this mode. Refer to [4.2 Writing the user setting].

• After pressing the button, the confirmation message appears. Then, when the ]OK]
button is pressed, the vales are changed. When pressing the [Cancel] button, the
values are not changed.
• After writing is finished, the writing completion message appears.
Fig. 9 Easy Setting

4.2 Writing the user setting

When using the user data previously set, press the [User] button.
The [Open files] for selecting a file appears, and then select the created parameter file.

Fig.10 User File Selection Window

When pressing the [Open] button, the confirmation message appears. Next, the value of selected file is written in
the target vehicle when the [OK] button is pressed.

8
4.3 Writing the set value in the parameter setting menu
Press the F1 key among function keys or click with the mouse. Then, the [Parameter Setting] menu appears.

Fig. 11 Function Key

The parameters are divided into the controller-wise tab. When the tab is selected, the set values read from the
vehicle are displayed.

Fig. 12 Parameter Setting Menu

1. Equipment Tab
Select the equipment tab to display it. To select the tab, click the tab or press F7 or F8 key so that the setting
content and item are switched.

2. Item Name
The adjustment items are displayed.

9
 3. Parameter Value
For entering the set value, two methods shown below are provided.
• Enter the numeral directly. The range to be inputted is within the settable range shown in 5.
• Change the value by incrementing or decrementing value to the present value with function keys of F9, F10,
F11 or F12. F9: –5, F10: –1, F11: +1, F12: +5

F key Operation
F9 Decrement the set value by 5. In case of lower than the minimum value, the minimum value is set.
F10 Decrement the set value by 1. In case of lower than the minimum value, the minimum value is set.
F11 Increment the set value by 1. In case of higher than the maximum value, the maximum value is set.
F12 Increment the set value by 5. In case of higher than the maximum value, the maximum value is set.

4. Unit
The unit of set value is displayed. The unit of item such as showing ON/OFF by 1/0 or level of 0 - 3 are not
provided.

5. Settable Range
The range to be inputted is shown. If the value other than the range is inputted, the error message appears.

6. Comment
The content of item is simply explained.

7. Cursor Moving Key

The background of item to be set is the yellow color. Move the cursor with [e] (U) or [r] (D) key to select. The
selection can be made with the mouse.
The timing of writing to the controller is as follows.

Operation Timing of writing to the controller

When moving the set value column with the mouse When the selected set column is defocused, the
parameter values are written.
When selecting the set value column with UP (e) Only when the selected set value is edited, if the
or DOWN (r) key selected set column is defocused, the parameter
values are written.
When pressing the set value change function key The set values of selected parameter are written.
(F9 to F12)
When pressing the [ENTER] key The set values of selected parameter are written.

4.4 Renew the set value.

When the F5 function key or F5: [Renew the display] button is pressed, the data are read from the controller and
the values on the menu are renewed.
• When renewing the turtle setting or lift speed on the meter panel, the parameter menu is not renewed.
Therefore, refresh the menu with the [Renew the display]. (The parameter menu has no automatic renewal
function.)

10
4.5 Save the set value.
When the F6 function key or F6: [Save] button is pressed, the set values are read out and saved in an arbitrary file.
When reading-out is finished, the [Name and save] window is displayed. Then, enter an arbitrary filename and
press the [Save] button.

Fig. 13 Set File Save Menu

11
5. IO MONITOR OPERATION

5.1 Monitor the values.

The parameters are divided into the controller-wise tab.

Fig.14 IO Monitor Menu

1. Equipment Tab
Select the equipment tab to display it. To select the tab, click the tab or press F7 or F8 key so that the setting
content and item are switched.

2. Item Name
The adjustment items are displayed.

3. Monitor Value
The monitor vales, which are recognized by the controller of present vehicle, are displayed.
The display can be adjusted by the refresh speed in 7.

4. Unit
The unit of set value is displayed. The unit of item such as showing ON/OFF by 1/0 or level of 0 - 3 are not
provided.

5. Range
The value of specification is displayed.

6. Comment
The content of item is simply explained.

12
7. The refresh speed can be set in a period of 0.5 – 10 seconds.
The actual read-out time per one picture is displayed on the [read-in time]. Referring to the read-in time, adjust
the refresh time.

0.5 seconds 10 seconds

Fig.15 Refresh Speed

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6. ERROR HISTORY

When the F3 function key or F3: [Error History] is pressed, the [Error History] menu opens.

Fig.16 [Error History] menu

6.1 Seeing the errors of each controller

4 pieces of error information at the left side display the contents of latest five errors currently occurring in each
controller. The error code list of each controller is automatically renewed every 10 seconds.

6.2 Seeing the information of error content, remedy, connector and classification
When selecting the error code of controller, the remedy, connector and classification of error code are displayed.

6.3 Seeing the error history

The history of latest 10 errors managed by the meter panel is displayed.
When pressing the [Renew] button, the error history is read out from the meter panel.
But, the refresh display is not performed.

6.4 Renewing the error history column

When pressing the [Renew] button, the data in the [Error History] column can be renewed.

6.5 Saving the data

When pressing the [Save] button, the error content displayed on the present menu can be saved in a file.
The location of saving and filename can be arbitrarily set as desired.

6.6 Returning to the original menu before opening the [Error History] menu
When pressing the [Main Menu] button, the menu returns to the original menu where the [Error History] menu is
opened.

14
7. ENVIRONMENT SETTING

The communication setting is done on this menu. The setting change by a user is not necessary.

Fig. 17 Environment Setting Menu

Perform the CAN communication setting. When pressing the [OK] button, after writing the parameter of current
communication process, the set content is reflected. The set content is retained.

7.1 CAN Channel No.

The settable range is 0 – 16. The default is "0".

7.2 Communication Speed

The communication speed can be selected from items below. The default is 250kbps.
1Mbps / 500kps / 250 kbps / 125 kbps / 100kbps / 83kbps / 62kbps / 50kbps

7.3 Request Transmission Time-out

Set the time-out value of parameter read-in / write-in request transmission.
The settable range is 0 - 3000 milliseconds. The default is 80milliseconds.

7.4 Response Reception Time-out

Set the response time-out value of parameter read-in / write-in.
The settable range is 0 - 3000 milliseconds. The default is 80milliseconds.

7.5 Set the number of re-try times.

The settable range is 0 - 10. The default is 3 times.

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8. EXTEND THE USE LIMIT.

Two weeks before the use limit expires, the following message is displayed. When applying the extension, press
the [OK] button. Then, the [Creating the Application Form for the use / Approval for the use] selection menu is
displayed. Please send the application form for the use.

The operation procedure is the same as [2.2 Apply the use.].

16
 AE50/AM50

Parameter Sheet

for AE50/AM50

17
AE50/AM50

Travel System Parameter Setting Function

Initial
Adjustment Item Content of Function Range Remark
Value

By switching from the low mode to high

2 0: U / 1: L /
Power Level (L/M/H/U) mode, the acceleration increases and the *1
(M) 2: M / 3: H
lift speed becomes faster.

When [0:U] is selected in the power level 1: L

2 Valid when “0” is
Custom (U): Traveling Power setting, the torque characteristics of travel 2: M
(M) selected.
power changes. 3: H

Custom (U): Sets the acceleration. 1: Soft ~

6
Acceleration Adjustment (1: weak acceleration – 8: strong acceleration) 8: Powerful

Acceleration Shock
Level: 1: Big
Soft-Start Property Adjusts the shock and speed at the start. 1 1~3
2: Medium
3: Small

1: Fast,
Adjusts the speed when stepping on the
Accelerator Rate Property 2 1~3 2: Slightly slow
accelerator halfway.
3: Slow

Plugging Regeneration Property Adjust the regenerative braking (electric 0: Invalid

60 0 ~ 100 (%)
Adjustment braking) when switching the F/R switch. 100: Powerful
Adjust the regenerative braking (electric
Brake Regeneration Property 0: Invalid
braking) when stepping on the braking 90 0 ~ 100 (%)
Adjustment 100: Powerful
pedal.

Accelerator Neutral Regeneration Sets the valid/invalid of regenerative 0: OFF

1
ON/OFF Switch braking adjustment (accelerator neutral). 1: ON

Adjusts the regenerative braking (electric

Accelerator Neutral Regeneration 0: Invalid
braking) when releasing the accelerator 30 0 ~ 100 (%)
Property Adjustment 100: Powerful
pedal.

Travel Speed Limit (Tortoise) A managing person (user) sets the travel Settable on the meter
0 1: Tortoise Mark
ON/OFF Switch speed limit. panel
Sets the maximum speed limit when the 15 Available to set with
Travel Speed Limit (Tortoise) 5.0 ~ 17.0 (km/h)
travel speed limit (tortoise) is valid. (km/h) every 0.1 km/h

Sets the upper limit of settable range of

travel speed when the travel speed limit
Travel Speed Limit (Tortoise) Upper 17 Upper limit must be
(tortoise) is valid. When the maximum travel 5.0 ~ 17.0 (km/h)
Limit (km/h) adjustable by operator
speed is set from 17.0km/h to 10.0km/h, the
settable range is 5.0 –10.0km/h.

Sets the maximum travel speed of vehicle

equipped with high lift mast. Travel speed limit in
Travel Speed Limit With High Lift 8
Even if the travel speed is 16.2 km/h and 3.0 ~ 15.0 (km/h) an OFF state of high
Mast (km/h)
the tortoise speed is 15.0 km/h, the speed lift switch
is set the slowest one.
Sets the automatic power shut-down
which works when not traveled or the 0: Invalid
Automatic Power Off 1: Valid
cargo handling is not operated for a 1: Valid
certain period of time (15 minutes).

0: No output
Sets the relay output condition from the 1: Forward
R Motor F/R Relay Output Switch 1 0~3
travel (R) controller. 2: Reverse
3: Forward/Reverse

0: No output
Sets the relay output condition from the 1: Forward
L Motor F/R Relay Output Switch 2 0~3
travel (L) controller. 2: Reverse
3: Forward/Reverse

Sets the maximum travel speed limit When the

Travel Speed Limit 3 16.2 1.0 ~ 17.0
travel speed limit is slower than the tortoise
(Manager Set Travel Speed Limit) (km/h) (km/h)
speed, This travel speed becomes valid.

Sets the very slow travel speed when descending

Slope Regeneration ON/OFF 0:OFF
the slope When the FR switch is set to ON, the 1
Switch 1:ON
travel speed is controlled to 1 to 2 km/h.

18
 AE50/AM50

Cargo Handling System Parameter Setting Function

Initial
Adjustment Item Content of Function Range Remark
Value

When [0:U] is selected in the power level 1: Low Power Setting

Custom (U): Materials Handling
setting, the torque characteristics of travel 2 2: Middle Valid when “0” is
Power
power changes. 3: High selected.

100 Adjustable by every

Custom (U): Lift Speed Sets the lifting-up speed of lift. 1 ~ 100%
(%) 10 percent

100 Adjustable by every

Custom (U): Tilt Speed Sets the tilt speed. 1 ~ 100%
(%) 10 percent

100 Adjustable by every

ATT1 Speed Sets the speed of attachment 1. 1 ~ 100%
(%) 10 percent

100 Adjustable by every

ATT2 Speed Sets the speed of attachment 2. 1 ~ 100%
(%) 10 percent

100 Adjustable by every

ATT3 Speed Sets the speed of attachment 3. 1 ~ 100%
(%) 10 percent

Sets the shock level when stopped during 0: A Little ~

Lifting Shock-less Level 3 0~7
lifting-up of lift. 7: Big

Sets the shock level when stopped during 0: A Little ~

Lowering Shock-less Level 3 0~7
lifting-down of lift. 7: Big
When the battery remaining is less than
20%, the operating output of cargo 0
Lift Interrupt 1: Valid
handling is dropped to reduce the battery (Invalid)
consumption.

19
AE50/AM50

Operating Function System Parameter Setting Function

Initial
Adjustment Item Content of Function Range Remark
Value

To inhibit the meter panel setting by an 1 1: Display

Custom (U) Function (ON/OFF)
operator, set to [0]. (Display) available

0: Operating hours
Sets the display/non-display of operating 0 of key switch ON.
Hour-Meter Display Switch hours (or actual operating hours) of travel/ (Non- 1: Operating hours
cargo handling. display) of motors switch
ON

1 and up: Alarm

Sets a time of starting to beep the alarm sound start time after
Alarm Start Time Warning No 3
sound for no parking brake when an 1 ~ 240 (sec) operator leaving a
Parking Brake (sec)
operator leaves the seat. seat without parking
brake.

5 and up: Alarm

Sets a time of continuation of beeping the
Alarm Continuation Time Warning 30 sound continuation
alarm sound for no parking brake after the 5 ~ 240 (sec)
No Parking Brake (sec) time after starting the
alarm starts.
alarm.

Sets a time of continuation of beeping the 5 and up: Alarm

Alarm Sound Continuation Time Warning alarm sound for no parking brake after the 5 sound continuation
5 ~ 240 (sec)
No Parking Brake When Key Switch ON alarm starts when the key switch is turned (sec) time after key switch
OFF. ON.

Load Meter Parameter Setting Function

Initial
Adjustment Item Content of Function Range Remark
Value

In case of triple/full free mast, the pressure After replacing the

Lift Cylinder Pressure Receiving receiving area at the lift cylinder piston 15.9 mast, change to meet
0.00 ~ 50.00
Area indicates the numeral of main cylinder (rear (cm2) the type and height of
side). mast.

After replacing the

Shows the oil pressure applied to the lift
16.5 mast, change to meet
Zero Point Setting Oil Pressure cylinder oil pressure receiving area when 5.00 ~ 20.00
(cm2) the type and height of
unloaded.
mast.

After replacing the

Load Capacity Calculation Coefficient used to calculate the load from mast, change to meet
1 0 ~ 2.0
Coefficient the oil pressure the type and height of
mast.

After replacing the

Sets ON/OFF of buzzer to beep when the
Oil Pressure Obtaining Device 0 mast, change to meet
cargo load exceeds the alarm level set 1 or 2
Switch (OFF) the type and height of
beforehand.
mast.
After replacing the
Sets ON/OFF of buzzer to beep when the
Overload alarm Function ON/OFF 0 mast, change to meet
cargo load exceeds the alarm level set 1: ON
Switch (OFF) the type and height of
beforehand.
mast.

After replacing the

The cargo load when the buzzer beeps 1.62 0.50 ~ 3.00 mast, change to meet
Overload Alarming Load
for overload (ton) (ton) the type and height of
mast.

After replacing the

The cargo load to be unloaded to stop the 0.3 0.10~ 0.40 mast, change to meet
Overload Alarm OFF Load Difference
overload alarm buzzer (ton) (ton) the type and height of
mast.

20
 AE50/AM50

Travel System Monitoring (Analog) Item

Monitoring Item Content of Function Range Normal Value Remark

0 ~ 17.0 0 ~ 16.2 (km/h)

R Motor Travel Speed Displays the travel (R) speed.
(km/h) (Recommended value)

0 ~ 17.0 0 ~ 16.2 (km/h)

L Motor Travel Speed Displays the travel (L) speed.
(km/h) (Recommended value)

0.5 ~ 4.70 0.7±0.2 ~

Accelerator Sensor Input Voltage Displays the voltage of accelerator sensor.
(V) 4.50±0.2 (V)

0 ~100
Acceleration Rates Displays the rate of accelerator stepping-on. 0 ~100 %
%

–32768 ~
–3500 ~ Right revolution (+)
R Motor Rotation Speed Displays the travel (R) motor rotation. +32767
+3500 (rpm) Left revolution (–)
(rpm)

–32768 ~
–3500 ~ Right revolution (+)
L Motor Rotation Speed Displays the travel (L) motor rotation. +32767
+3500 (rpm) Left revolution (–)
(rpm

Displays the temperature in the travel (R) 0 ~ 200 0 ~ 160 Caution: 163 °C
R Motor Inside Temperature
motor. (°C) (°C) Warning: 175 °C

Displays the temperature in the travel (L) 0 ~ 200 0 ~ 160 Caution: 163 deg °C
L Motor Inside Temperature
motor. (°C) (°C) Warning: 175 °C

R Motor Controller Inside Displays the temperature in the travel (R) 0 ~ 200 0 ~ 105 Caution: 108 °C
Temperature controller. (°C) (°C) Warning: 130 °C

L Motor Controller Inside Displays the temperature in the travel (R) 0 ~ 200 0 ~ 105 Caution: 108 °C
Temperature controller. (°C) (°C) Warning: 130 °C

Steered Wheel(s) Steering Angle Displays the value of motor steering angle 0~
0 ~ 4096 Neutral: 2048
Sensor sensor. 4096

–128 ~
–128 ~ 127
Steered Wheel(s) Steering Angle Displays the motor steering angle. 127 Neutral:From –1 to 1
(deg)
(deg)

0.25 ~
Steering WheelAngle Sensor Displays the voltage of steering wheel 0.25 ~ 4.75
4.75
Input Voltage steering angle sensor. (V)
(V)

–180 ~
–180 ~ 179
Steering Wheel Angle Displays the steering wheel steering angle. 179
(deg)
(deg)

21
AE50/AM50

Travel System Monitoring (Digital) Item

Monitoring Item Content of Function Range Normal Value Remark

0: OFF
When FR switch is shifted to [F], [1] is
Directional F Switch 1: ON —
displayed.
(Forward)

0: OFF
When FR switch is shifted to [R], [1] is
Directional R Switch 1: ON —
displayed.
(Reverse)

When stepping on the accelerator pedal

0: OFF
Accelerator Switch more than the certain depth, [1] is —
1: ON
displayed.
When stepping on the brake pedal more 0: OFF
Brake Switch —
than the certain depth, [1] is displayed. 1: ON

0: Leaving a seat
Seat1 Switch When seated, [1] is displayed. —
1: Taking a seat

0: Taking a seat
Seat2 Switch When seated, [0] is displayed. —
1: Leaving a seat

0: Parking brake ON
Parking Brake Switch When in the parking state, [0] is displayed. —
1: Parking brake OFF

1: Small
Small Special Vehicle Selection In case of the small special vehicle, [1] is
0/1 — special
Switch displayed.
vehicle

When the seat1 switch is turned on and

0: No operator presence
OPS System Detection the seat2 switch is turned off, [1] is —
1: Taking a seat
displayed.

0: Parking brake OFF

Parking Brake Motion Detection When in the parking state, [0] is displayed. —
1: Parking brake ON

When the FR lever or accelerator switch

0: Normal
Neutral Safety is turned ON, if the key switch is turned —
1: Abnormal
ON, [1] is displayed.
When not operated for 15 minutes, [1] is 0: OFF
Auto Power OFF Motion Flag —
displayed. 1: ON

When the accelerator is operated in the

0: Not available
Traveling OPS Detection operator leaving detection ON, [1] is —
1: Available
displayed.

When in the tortoise mark mode, [1] is

R Motor Travel Speed Limit (Tortoise) 1: Tortoise mark mode
displayed.

When in the tortoise mark mode, [1] is

L Motor Travel Speed Limit (Tortoise) 1: Tortoise mark mode
displayed.

When the wiring of lifting height switch is 0: OFF

Lifting Height A Switch
connected, [1] is displayed. 1: ON

When the main contactor turns on, [1] is 0: OFF

Main Contactor ON/OFF
displayed. 1: ON

22
 AE50/AM50

Cargo Handling System Monitoring 1 Item

Monitoring Item Content of Function Range Normal Value Remark

When the lift is fine-operated, 0: OFF

Lift1 Switch —
[1] is displayed. 1: ON

When the lift is operated in the 0: OFF

Lift2 Switch —
maximum state, [1] is displayed. 1: ON

When the tilt is operated, [1] is 0: OFF

Tilt Switch —
displayed. 1: ON

When the attachment1 is operated, 0: OFF

ATT1 Switch —
[1] is displayed. 1: ON

When the attachment2 is operated, 0: OFF

ATT2 Switch —
[1] is displayed. 1: ON

When the attachment3 is operated, 0: OFF

ATT3 Switch —
[1] is displayed. 1: ON

When No Operator Seating Operation

0: OFF
Lifting OPS Detection Detection is ON, if the cargo handling —
1: ON
is operated, [1] is displayed.
When the battery remaining is less
1: ON (DBI: less
Lift Interrupt Flag than 20% and the travel and cargo —
than 20%)
handling are limited, [1] is displayed.

Pump Motor Rotation Speed Displays the pump motor rotation. +65535 (rpm) —

Pump Motor Inside Displays the temperature in the pump 0 ~ 200 0 ~ 160 Caution: 163 °C
Temperature motor. (°C) (°C) Warning: 175 °C
Pump Motor Controller Inside Displays the temperature in the cargo 0 ~ 200 0 ~ 105 Caution: 108 deg C
Temperature handling controller. (°C) (°C) Warning: 130 deg C

23
AE50/AM50

Cargo Handling System Monitoring (Proportional Solenoid Valve 1) Item

Monitoring Item Content of Function Range Normal Value Remark

Lift Lever Potentiometer Input Displays the voltage outputted from 0~5 0.70 ~ 4.30
Neutral 2.39 ~ 2.61 (V)
Voltage the lift operating lever potentiometer. (V) (V)

When the lift operating lever is in the

0: OFF
Lift Lever Switch Output position other than neutral, [1] is —
1: ON
displayed.

Tilt Lever Potentiometer Input Displays the voltage outputted from 0~5 0.70 ~ 4.30
Neutral 2.39 ~ 2.61 (V)
Voltage the tilt operating lever potentiometer. (V) (V)

When the tilt operating lever is in the

0: OFF
Tilt Lever Switch Output position other than neutral, [1] is —
1: ON
displayed.

ATT1 Lever Potentiometer Input Displays the voltage outputted from the 0~5 0.70 ~ 4.30
Neutral 2.39 ~ 2.61 (V)
Voltage ATT1 operating lever potentiometer. (V) (V)

When the ATT1 operating lever is in

0: OFF
ATT1 Lever Switch Output the position other than neutral, [1] is —
1: ON
displayed.

ATT2 Potentiometer Input Displays the voltage outputted from the 0~5 0.70 ~ 4.30
Neutral 2.39 ~ 2.61 (V)
Voltage ATT2 operating lever potentiometer. (V) (V)

When the ATT2 operating lever is in

0: OFF
ATT2 Lever Switch Output the position other than neutral, [1] is —
1: ON
displayed.

ATT3 Lever Potentiometer Input Displays the voltage outputted from the 0~5 0.70 ~ 4.30
Neutral 2.39 ~ 2.61 (V)
Voltage ATT3 operating lever potentiometer. (V) (V)

When the ATT3 operating lever is in

0: OFF
ATT3 Lever Switch Output the position other than neutral, [1] is —
1: ON
displayed.

Pump Motor DUTY Signal Displays the command value outputted to

0 ~ 5 (V) 0 ~ 5 (V) Feedback Value
Voltage Monitor the cargo handling controller in voltage.

Displays the current value inputted 0 ~ 930 0 ~ 781

Lift Solenoid Current Monitor
from the solenoid valve. (mA) (mA)

Displays the current value inputted 0 ~ 770 0 ~ 614

Tilt Solenoid Current Monitor
from the solenoid valve. (mA) (mA)

Displays the current value inputted 0 ~ 930 0 ~ 781

ATT1 Solenoid Current Monitor
from the solenoid valve. (mA) (mA)

Displays the current value inputted 0 ~ 930 0 ~ 781

ATT2 Solenoid Current Monitor
from the solenoid valve. (mA) (mA)

Displays the current value inputted 0 ~ 930 0 ~ 781

ATT3 Solenoid Current Monitor
from the solenoid valve. (mA) (mA)

Display of present
Displays the tilt horizontal present –10.23 ~
Fork Leveling Angle Adjustment — fork leveling setting
setting value. +10.23 deg
value

24
 AE50/AM50

Cargo Handling System Monitoring (Proportional Solenoid Valve 2) Item

Monitoring Item Content of Function Range Normal Value Remark

Lift Pressure Sensor Output Displays the voltage outputted from 0.32 ~ 4.72 0.33 ~ 4.30
Voltage the lift pressure sensor. (V) (V)

Displays the value of input to the lift 0.00 ~ 215.00 0.0 ~ 193.9
Lift Pressure Sensor Input Value
pressure sensor in kg/cm2. (kg/cm2) (kg/cm2)

Displays the voltage outputted from 0.30 ~ 4.70 0.40 ~ 4.60

Tilt Angle Sensor Output Voltage
the tilt angle sensor. (V) (V)

When the tilt horizontal button is Link to the indicator display

Fork Leveling Button 1: ON —
pressed, [1] is displayed. on the meter panel

When the tilt horizontal function is 0: OFF During operation: 1/0 reverse
Fork Leveling Indicator —
working, the signal changes. 1: ON Horizontal position: 1

When setting the tilt horizontal position,

0: OFF
Tilt Offset Switch if the external wire is connected, [1] is —
1: ON
displayed.

Displays the command value inputted

Pump Motor Duty Factor (External 0 ~ 100 0 ~ 100
from the proportional solenoid valve
Command Input) (%) (%)
in ratio.

Lift Solenoid Output Command Displays the command current value 0 ~ 930 0 ~ 750
Current outputted to the solenoid valve. (mA) (mA)

Tilt Solenoid Output Command Displays the command current value 0 ~ 770 0 ~ 590
Current outputted to the solenoid valve. (mA) (mA)

ATT1 Solenoid Output Command Displays the command current value 0 ~ 930 0 ~ 750
Current outputted to the solenoid valve. (mA) (mA)

ATT2 Solenoid Output Command Displays the command current value 0 ~ 930 0 ~ 750
Current outputted to the solenoid valve. (mA) (mA)
ATT3 Solenoid Output Command Displays the command current value 0 ~ 930 0 ~ 750
Current outputted to the solenoid valve. (mA) (mA)

Displays the tilt angle.

Preset Tilt Angle Sensor2.64 V = 0 deg
(OP tilt horizontal function)

25
AE50/AM50

Meter Monitor Item

Monitoring Item Content of Function Range Normal Value Remark

BDI Displays the battery remaining capacity. 0 ~ 100%

Battery Voltage Displays the battery voltage. 30.0 ~ 60.0 (V) 47.0 ~ 55.0 (V)

Key ON Time Displays the accumulated key ON hours. 0 ~ 99999.9 (h)

Display of the cumulative

Displays the accumulated F/R lever ON time during an ON state
R Motor Operating Hours 0 ~ 99999.9 (h) 0 ~ 99999.9 (h)
hours. of the F/R lever switch
driven by the right motor.

Display of the cumulative

R Motor Actual Operating Displays the accumulated operating hours
0 ~ 99999.9 (h) 0 ~ 99999.9 (h) operating hours driven by
Hours by the travel (R) motor command.
the right motor command.

The right motor operating

R Motor Hour-Meter Reading The hours displayed on the meter panel 0 ~ 99999.9 (h) 0 ~ 99999.9 (h) hours displayed on the
hour-meter.

Display of the cumulative

Displays the accumulated F/R lever ON time during an ON state
L Motor Operating Hours 0 ~ 99999.9 (h) 0 ~ 99999.9 (h)
hours. of the F/R lever switch
driven by the left motor.

Display of the cumulative

L Motor Actual Operating Displays the accumulated operating hours
0 ~ 99999.9 (h) 0 ~ 99999.9 (h) operating hours driven by
Hours by the travel (L) motor command.
the left motor command.

The right motor operating

L Motor Hour-Meter Reading The hours displayed on the meter panel 0 ~ 99999.9 (h) 0 ~ 99999.9 (h) hours displayed on the
hour-meter.

Display of the cumulative

Displays the accumulated cargo handling time during an ON state of
Pump Motor Operating Hours 0 ~ 99999.9 (h) 0 ~ 99999.9 (h)
lever ON hours. the control lever switch
driven by the pump motor.

Display of the cumulative

Pump Motor Actual Operating Displays the accumulated operating hours
0 ~ 99999.9 (h) 0 ~ 99999.9 (h) operating hours driven by
Hours by the cargo handling motor command.
the pump motor command.

The pump motor operating

Pump Hour-Meter Reading The hours displayed on the meter panel 0 ~ 99999.9 (h) 0 ~ 99999.9 (h) hours displayed on the
hour-meter.

Motor (R) Hour-Meter Startup When the hour meter startup wire is 1: The hour-meter startup
—
Switch State connected, [1] is displayed. switch wiring is connected.

Motor (L) Hour-Meter Startup When the hour meter startup wire is 1: The hour-meter startup
—
Switch State connected, [1] is displayed. switch wiring is connected.

Pump Motor Hour-Meter When the hour meter startup wire is 1: The hour-meter startup
—
Startup Switch State connected, [1] is displayed. switch wiring is connected.

When the battery electrolyte level is normal, 0: Low

Electrolyte Level Switch —
[1] is displayed. 1: Normal

Electrolyte Level Sensor When the battery electrolyte level sensor 0: Not available
—
Availability Signal is equipped with, [1] is displayed. 1: Available

When the controller cooling fan is rotating, 0:OFF

Controller Cooling Fan ON/OFF —
[1] is displayed. 1: ON

When the [MODE] button of meter panel 0:OFF

Mode Switch / Set Switch —
is pressed, [1] is displayed. 1: ON

Shift Switch / Hour-Meter When the Left Arrow button of meter 0:OFF
—
Selection Switch panel is pressed, [1] is displayed. 1: ON

Up Switch / Power Selection When the UP button of meter panel is 0:OFF

—
Switch pressed, [1] is displayed. 1: ON

DOWN Switch / Tortoise Mark When the DOWN button of meter panel is 0:OFF
—
Select ion Switch pressed, [1] is displayed. 1: ON

When the key switch is turned ON, [1] is 0:OFF

Key Switch —
displayed. 1: ON

26
 AE50/AM50

Recommended Parameter Setting

• When carrying the unstable products, the following settings are recommended.
These settings make the acceleration/deceleration mild and perform softly the cargo handling speed and lift stop.

Name Initial Value Soft Message

Power Level Setting (H/M/L/U) 2 0 0: U / 1: L / 2: M / 3: H

User Setting Mode Travel Power 2 1 1: L / 2: M / 3: H

User Setting Mode ES Volume 6 1 1: Weak Acceleration / 8: Strong Acceleration

Travel Accelerator Stage Characteristics 2 3 1: Fast when half-operated / 2: Standard / 3: Slow

Regenerative Braking Adjustment (FR Plugging) 60 20 0: Invalid / 100: Powerful

Regenerative Braking Adjustment (Brake) 90 60 0: Invalid / 100: Powerful

Regenerative Braking Adjustment (Accelerator Neutral) 30 20 0: Invalid / 100: Powerful

User Setting Mode Cargo Handling Power 2 1 1: L / 2: M / 3: H

User Setting Mode Lift Speed 100 70 Adjustable by every 10%

User Setting Mode Tilt Speed 100 40 Adjustable by every 10%

Attachment1 Speed 100 50 Adjustable by every 10%

Attachment2 Speed 100 50 Adjustable by every 10%

Attachment3 Speed 100 50 Adjustable by every 10%

Lifting Shock-less Level 3 1 Greater the value is, larger the shock is.

Lowering Shock-less Level 3 1 Greater the value is, larger the shock is.

* When the [Soft] button in the easy setting is pressed, the above settings are available.

• Setting for performing powerfully the work

Name Initial Value Soft Message

Power Level Setting (H/M/L/U) 2 0 0: U / 1: L / 2: M / 3: H

User Setting Mode Travel Power 2 3 1: L / 2: M / 3: H

Travel Accelerator Stage Characteristics 2 1 1: Fast when half-operated / 2: Standard / 3: Slow

User Setting Mode Cargo Handling Power 2 3 1: L / 2: M / 3: H

* When the [Power] button in the easy setting is pressed, the above settings are available.

27
AE50/AM50

MEMO

28
 AE50/AM50

MEMO

29
2-4-1 Shiba-koen, Minato-ku, Tokyo 105-0011, Japan

Printed in Japan
02-07(YC)03001