Controller P22000 PDF

CONTROLLER
1. Outline.......................................................................................................................... 4-2
1.1 System Configuration............................................................................................................................ 4-2
1.2 External View ........................................................................................................................................ 4-4
1.2.1 VCM-3 ......................................................................................................................................................... 4-4
1.2.2 VCM-3OP.................................................................................................................................................... 4-5
1.2.3 ECU............................................................................................................................................................. 4-6
1.2.4 Meter panel ................................................................................................................................................. 4-7
1.2.5 Input unit ..................................................................................................................................................... 4-8
1.2.6 Output unit................................................................................................................................................... 4-9
2. Service Tool Functions............................................................................................... 4-10

2.1 Menu ................................................................................................................................................... 4-10
4
2.2 Input Monitor and Output Monitor ....................................................................................................... 4-11
2.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)................................................................... 4-11
2.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP) ........................................................ 4-13
2.2.3 MP input monitor (VCM-3 → MP) ............................................................................................................. 4-14
2.2.4 ECU input monitor and output monitor (VCM-3 → ECU) .......................................................................... 4-15
2.3 Fault Status......................................................................................................................................... 4-16
2.4 Fault History........................................................................................................................................ 4-17
3. Chassis Error Code List ............................................................................................. 4-18
4. Troubleshooting ......................................................................................................... 4-19

4.1 General Information ............................................................................................................................ 4-19
4.1.1 Before replacing controllers ...................................................................................................................... 4-19
4.1.2 Connection of service tool......................................................................................................................... 4-19
4.1.3 How to clean harness connectors and system components ..................................................................... 4-20
4.2 Troubleshooting .................................................................................................................................. 4-21
4-1
CONTROLLER
1. Outline
1.1 System Configuration The controllers are connected on the Controller Area Net-
The controller system consists of the vehicle control con- work (CAN) and communicate mutually to control the lift
trollers (VCM-3 and VCM-3OP), engine control controller truck.
(ECU), meter panel, input unit and output unit.
Gateway
ECU
VCM-3OP
Input unit
Meter panel
N
1
VCM-3
Output unit
212331
4-2
CONTROLLER
CAN connection
CAB harness Harness A Harness B Harness C

Connector Connector Connector
201 205 205
200 204 204
396 395
396 395
201 200 201 200 205 204
396 395
Meter
panel VCM-3 VCM-3OP
Input
unit
286 394
VCM-3 Output
285
GSE unit 393
209
288 208
VCM-3OP Gateway
GSE 858
287
857
857
ECU
858
212332
4-3
CONTROLLER
1.2 External View

1.2.1 VCM-3
A'
B B'
SECTION A 㧙 A'
Connector pin number Connector pin number

(from view B) (from view B')
CN1 CN2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 26 27 28 29 30 31 32 33 34
212333
4-4
CONTROLLER
1.2.2 VCM-3OP
A'
B B'
SECTION A 㧙 A'
Connector pin number Connector pin number

(from view B) (from view B')
CN1 CN2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 26 27 28 29 30 31 32 33 34
212333
4-5
CONTROLLER
1.2.3 ECU
A
B
C
D
E
Connector pin number
A: GF34A B: GF35A C: GF32A D: GF35B E: GF31A
212334
4-6
CONTROLLER
1.2.4 Meter panel
CN2 CN1
11 12 13 14 1 2 3 4 5
15 16 17 18 19 20 6 7 8 9 10
CN2 CN1
212335
4-7
CONTROLLER
1.2.5 Input unit

(from view A)
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
212336
4-8
CONTROLLER
1.2.6 Output unit

(from view A)
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
212337
4-9
CONTROLLER
2. Service Tool Functions

2.1 Menu
Monitor menu Tool menu
• Input Monitor • Set-up Option
Indicates the input values of the controllers. Indicates or sets the Setup Option data.
• Output Monitor • Oscilloscope
Indicates the output values of the controllers. Graphs the input/output values. The oscillograph can
• Custom Monitor be stored as data.
Indicates the input/output values of the item • Active Test
selected. Outputs the signal forcibly to check the operation of
• Fault Status the equipment selected.
Indicates all error codes occurring. • Connection Change
• Fault History Designates the controller operated by the service
Indicates the fault data, such as the error codes and tool and the controller connected to it.
hour meter data, stored in the controller. • Firmware Update
Updates the firmware of the controller connected.
212338
4-10
CONTROLLER
2.2 Input Monitor and Output Monitor

These screens indicate the input and output values of each controller.
2.2.1 VCM-3 input monitor and output monitor (VCM-
3 → VCM-3)
(InputUnit)
212339
4-11
CONTROLLER
(OutputUnit ) [ V ]
(OutputUnit )
(OutputUnit )
212340
4-12
CONTROLLER
2.2.2 VCM-3OP input monitor and output monitor

(VCM-3 → VCM-3OP)
212341
4-13
CONTROLLER
2.2.3 MP input monitor (VCM-3 → MP)
212342
4-14
CONTROLLER
2.2.4 ECU input monitor and output monitor (VCM-3

→ ECU)
Accel pedal position (unfiltered)

Accel pedal position (filtered)
Reference injection quantity
212343
4-15
CONTROLLER
2.3 Fault Status

This screen indicates all error codes occurring.
OutputUnit Communication error

InputUnit Communication error
212344
4-16
CONTROLLER
2.4 Fault History

This screen indicates the fault data, such as the error codes
and hour meter data, stored in the controller.




212345
4-17
CONTROLLER
3. Chassis Error Code List

Error Page Error Page
Description Description
Code No. Code No.
F01 VCM-3 Memory Check Error 4-21 F54 Lift Solenoid Leak 4-90
F02 VCM-3 Battery Voltage Error 4-22 F55 Tilt Forward Solenoid Error 4-94
F03 VCM-3 Communication Error 4-24 F57 Tilt Backward Solenoid Error 4-96
F04 ECM Communication Error 4-26 F59 Tilt Solenoid Leak 4-98
F07 MP Communication Error 4-27 F60 Attachment 1A Solenoid Error 4-102
F10 Lift Lever Neutral Error 4-29 F62 Attachment 1B Solenoid Error 4-104
F11 Tilt Lever Neutral Error 4-31 F64 Attachment 1 Solenoid Leak 4-106
F12 Attachment 1 Lever Neutral Error 4-33 F65 Attachment 2A Solenoid Error 4-110
F13 Attachment 2 Lever Neutral Error 4-35 F67 Attachment 2B Solenoid Error 4-112
F14 Attachment 3 Lever Neutral Error 4-37 F69 Attachment 2 Solenoid Leak 4-114
F15 ECU Communication Error 4-39 F70 Attachment 3A Solenoid Error 4-118
F16 Shift Lever Error 4-41 F72 Attachment 3B Solenoid Error 4-120
F17 Vehicle Speed Error 4-43 F74 Attachment 3 Solenoid Leak 4-122
F18 ECU KWP2000 Communication Error 4-45 F75 Unload Solenoid Error 4-126
F19 ECU Speed Sensor Error 4-47 F79 Unload Solenoid Leak 4-128
F20 Lift Lever Error 4-49 F80 Knob Position Solenoid Error 4-131
F22 Tilt Lever Error 4-51 F84 Knob Position Solenoid Leak 4-133
F24 Attachment 1 Lever Neutral Error 4-53 F85 Transmission Forward Solenoid Error 4-136
F26 Attachment 2 Lever Neutral Error 4-55 F87 Transmission Backward Solenoid Error 4-138
F28 Attachment 3 Lever Neutral Error 4-57 F89 Transmission Solenoid Leak 4-140
F29 Joystick Lever Error 4-59 F90 VCM-3OP Sensor Voltage Error 4-143
F31 VCM-3 Sensor Voltage Error 4-61 F91 VCM-3OP Memory Check Error 4-146
F33 VCM-3OP Lift Oil Pressure Sensor Error 4-63 F92 VCM-3OP Battery Voltage Error 4-147
F34 Vehicle Speed Sensor Error 4-65 F93 VCM-3OP Speed Change Solenoid 1 Error 4-149
F36 Tire Angle Sensor Error 4-67 F94 VCM-3OP Speed Change Solenoid 2 Error 4-151
F39 VCM-3OP Tilt Angle Sensor Error 4-69 F95 VCM-3OP Speed Change Solenoid Leak 4-153
F40 Steering Error 4-71 F96 VCM-3OP EAT Setting Error 4-155
F41 Output Unit Error 4-73 F97 VCM-3OP Communication Error 4-156
F42 Output Unit Life Control Signal 4-74 L03 VCM3 Communication Error
F43 Output Unit Memory Check Error 4-75 L04 ECM/ECU Communication Error
F44 Output Unit PWM Voltage Error 4-76 L07 MP Communication Error
F45 Output Unit Communication Error 4-79 L08 TMS Communication Error
F46 Input Unit Error 4-81 P03 VCM3 Communication Error
F47 Input Unit Life Control Signal 4-82 P04 ECM/ECU Communication Error
F48 Input Unit Memory Check Error 4-83 P07 MP Communication Error
F49 Input Unit Communication Error 4-84 P08 TMS Communication Error
F50 Lift Up Solenoid Error 4-86 P22 Shift Lever Error Signal
F52 Lift Down Solenoid Error 4-88
4-18
CONTROLLER
4. Troubleshooting
4.1 General Information
4.1.1 Before replacing controllers
Do not replace controllers casually even if replacement is
required as a result of troubleshooting. Be sure to check the
following items before replacing controllers.
• 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 con-
nectors and system components” on the next page.
• Ensure that the main harness is not short-circuited
to the truck body.
If any of these items (above items) is a source of the trou-
ble, the controller will be damaged even if it is replaced
with a new one. Be sure to check the above items and
replace carefully.
4.1.2 Connection of service tool

(1) Turn off the truck power.
(2) Find the service tool connector in the CAB harness. CAB harness
(3) Remove the cover and connect the PC as shown.
(4) Turn on the truck power. VCM-3OP
GSE
(5) Start the service tool software.
GSE cable VCM-3

GSE
212346
4.1.3 Diagnostic Precautions (4) When performing measurement with the tester, handle
(1) Before measuring voltage, check the battery for the test bar carefully so that it does not damage internal
charged condition and specific gravity. If system circuit and other electrical parts of the electronic con-
inspection is performed with the battery uncharged or trol unit to result in a short-circuit failure between ter-
reduced in specific gravity, accurate measurements minals in connector or between connector and truck
cannot be achieved. body.
(2) To avoid having electrical parts damaged, set the starter (5) Resistance is affected by temperature. Determine the
switch to OFF before disconnecting and reconnecting necessity of resistance measurement following given
battery cables. temperature specification as a guide. Otherwise, use
(3) Before disconnecting connectors, set the starter switch normal temperature (10 to 35°C) as the measuring con-
to OFF then allow at least 20 seconds. Voltage may dition.
remain in electric parts or connected circuit.
4-19
CONTROLLER
4.1.4 How to clean harness connectors and system

components
(1) Open-circuits are often caused by dirty harness connec-
tors and components. Dust, together with greasy mat-
ter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, for worse, electrical separation of surfaces in con-
tact. For this reason, it is essential that the connectors
and components be cleaned at each periodic inspection
and when servicing the truck. Instead of a commonly
used solvent, use the electronic parts cleaner (in the
manner illustrated on the right).
Electronic parts cleaner
Electronic parts Three Bond 29D or 212347
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 the
contact surface activator onto contact surfaces.
Install and remove the connector several times to wet
the surfaces thoroughly with the activator liquid.
After coupling up the connector, check to be sure that it Electronic parts
cleaner
is in locked state.
Contact surface Three Bond 2501S (aerosol)

activator or Nyogel 760G*
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins (plastic
materials).
*: Products contained in Terminal Maintenance kit
(SE000003)
Contact surface
activator
212348
4-20
CONTROLLER
4.2 Troubleshooting
Problem: VCM-3 Memory Check Error (F01)
(1) Situation
Indication: "F01" flickering. Drive and hydraulic operations disabled.
(2) Possible cause
Faulty VCM-3, faulty truck type setting data in VCM-3.
(3) How the error code is triggered

Software checks sum value of ROM and EEPROM in CPU, and detects fault.
(4) Checks
Check truck type setting data.
Normal Abnormal
(5) Enter truck type setting data again.
(6) Enter shipment default value into VCM-3.

Normal Abnormal
(7) Perform standard setting, then enter truck type setting

data again.
(8) Write updated software into VCM-3.
Normal Abnormal
(9) Faulty software writing. (10) Replace VCM-3.
4-21
CONTROLLER
Problem: VCM-3 Battery Voltage Error (F02)
(1) Situation
(2) Possible cause
Poor battery charge, faulty battery, faulty VCM-3, faulty harness, faulty DC-DC converter.

When VCM-3 input voltage is less than 7V or more than 21V.
(4) Checks
Measure battery terminal voltage.
Normal (18V to 32V) 7V or less 32V or more
(5) Charge battery.
Error remains
(6) Replace battery.
(7) Measure output voltage and input voltage of DC-DC converter.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 12V
2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). 24V
Normal Input voltage abnormal Output voltage abnormal
(8) Replace harness. (9) Replace DC-DC converter.
(10) Measure input voltage of VCM-3.

1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25).
7V or less 7V to 21V
(11) Replace harness. (12) Replace VCM-3.
4-22
CONTROLLER
DC-DC
CONVERTER
VCM-3
CN1
0.85B/L
131 105 107 1.25B/L 107 12V GND
0.85B/L 2R/Y
130 40 40 12V MAIN
1.25R/Y 1.25B
41 40 104 104 24V GND
1.25R/Y
40 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1
301 12V BATT
15R
9 245 1
17 224 223 10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26
FLW 0.85R
105
100
60B 60B
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212349
4-23
CONTROLLER
Problem: VCM-3 Communication Error (F03)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty harness.

When CAN communication of VCM-3 is interrupted.
(4) Checks
Check to see if other errors occur simultaneously.
F03 only Other errors occur
(5) See troubleshooting for errors occurred.
(6) Check continuity of CAN communication cables.
1. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and
200(VCM-3: CN2-32) and 200(Meter panel: 19)
2. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and
200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).
3. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and
200(VCM-3: CN2-32) and 393(Output unit: 14).
4. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and
200(VCM-3: CN2-32) and 395(Input unit: 8).
࡮In case of diesel engine
5. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and
200(VCM-3: CN2-32) and 208(Gateway: A24).
࡮In case of Iasoline engine
6. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and
200(VCM-3: CN2-32) and (ECM: 86).
Continuity No continuity
(7) Replace VCM-3. (8) Replace faulty harness.
4-24
CONTROLLER
CN2
9 277 279 281 1

17 254 273 253 10
VCM-3 25 258 18 VCM-OP
CN2 34 205 204 295 294 293 292 26 CN2
0.85L/R
CAN H 201 201
0.85B/W 0.85B/W
CAN L 200 200 204 204 CAN L
0.85L/R
205 205 CAN H
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
METER PANEL
25 384 222 238 237 18
34 200 201 299 298 297 296 26
0.85L/R CAN H
201 201
0.85B/W CAN L
200 200
OUTPUT UNIT
0.85L/R
394 13 CAN H
0.85B/W
393 14 CAN L
INPUT UNIT
(HARNESS, IN FC)
0.85L/R 0.5B
396 396 7 CAN H
0.85B/W 0.5B/W
395 395 8 CAN L
GATEWAY
(Diesel engine)
208
209
0.85B/W
0.85L/R
94 ECM
86 (Gasoline engine)
212350
4-25
CONTROLLER
Problem: ECM Communication Error (F04)
(1) Situation
Indication: "F04" flickering.
(2) Possible cause

Faulty VCM-3, faulty harness, faulty ECM.

When CAN communication from ECM to VCM-3 is interrupted.
(4) Checks
Check continuity of CAN communication cables.
VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM:86).
(5) Replace VCM-3. (6) Replace harness.
Error remains
(7) Replace ECM.
4-26
CONTROLLER
Problem: MP Communication Error (F07)
(1) Situation
Indication: "F07" flickering. Drive operations disabled.
(2) Possible cause
Faulty meter panel, faulty VCM-3, faulty harness.

When CAN communication from meter panel to VCM-3 is interrupted.
(4) Checks
VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32)
and 200(Meter panel: 19).
(5) Replace meter panel. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-27
CONTROLLER
METER PANEL
BRAKE F
FUEL
78 FUEL GAGE
PKB
SIGNAL PROCESSOR
77 WATER TEMP GAGE
OIL
79 BRAKE LAMP
TEMP
83 OIL PRESSURE LAMP
R
82 TORQ CONV OIL TEMP LAMP
N
80 INTERLOCK LAMP
81 F
VCM-3 MULTIPURPOSE WARNING LAMP
CN2
GLOW GLOW LAMP (LPG)
48
0.85L/R 0.85L/R CAN H MAST INTERLOCK LAMP
201 201 201 201
0.85B/W 0.85B/W CAN L SEAT BELT LAMP
200 200 200 200
12V
45
49 LAMP
ALT R
CN2 ALT L CHARGE LAMP
46
102 GND
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212351
4-28
CONTROLLER
Problem: Lift Lever Neutral Error (F10)
(1) Situation
Indication: "F10" flickering. Hydraulic operations disabled.
(2) Possible cause

Lift lever operated when turning on key switch, faulty lift lever, faulty input unit, faulty harness.

Lift lever is not in neutral when turning on key switch.
(4) Checks
Shift lift lever in neutral, then turn on key switch.
Normal Error remains
Fail-safe operation
(5) Check continuity between lift lever and input unit.

1. Between 468(Input unit: CN1-25) and 468(Lift lever).
(6) Replace harness.
(7) Replace lift lever with another section lever.
Error transition Error remains
(8) Replace lift lever. (9) Replace input unit.
4-29
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
ATT1 ATT2/3 9 CAN R+
LIFT TILT (OP) (OP) 10 CAN R-
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
16 SW INPUT 2(SPEED SEL)
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-30
CONTROLLER
Problem: Tilt Lever Neutral Error (F11)
(1) Situation
(2) Possible cause

Tilt lever operated when turning on key switch, faulty tilt lever, faulty input unit, faulty harness.

Tilt lever is not in neutral when turning on key switch.
(4) Checks
Shift tilt lever in neutral, then turn on key switch.
Fail-safe operation
(5) Check continuity between tilt lever and input unit.

1. Between 470(Input unit: CN1-27) and 470(Tilt lever).
(7) Replace tilt lever with another section lever.
(8) Replace tilt lever. (9) Replace input unit.
4-31
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-32
CONTROLLER
Problem: Attachment 1 Lever Neutral Error (F12)
(1) Situation
(2) Possible cause

Attachment 1 lever operated when turning on key switch, faulty attachment 1 lever, faulty input unit, faulty harness.

Attachment 1 lever is not in neutral when turning on key switch.
(4) Checks
Shift attachment 1 lever in neutral, then turn on key switch.
Fail-safe operation
(5) Check continuity between attachment 1 lever and input unit.

1. Between 472(Input unit: CN1-29) and 472(ATT1 lever).
(7) Replace attachment 1 lever with another section lever.
(8) Replace attachment 1 lever. (9) Replace input unit.
4-33
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-34
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
Shift attachment 2 lever in neutral, then turn on key switch.
Fail-safe operation

1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever).
4-35
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-36
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
Shifts attachment 3 lever in neutral, then turn on key switch.
Fail-safe operation

4-37
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-38
CONTROLLER
Problem: ECU Communication Error (F15)
(1) Situation
Indication: "F15" flickering. Drive operations restricted.
(2) Possible cause

Faulty ECU, faulty VCM-3, faulty gateway, faulty harness.

When CAN communication from ECU(gateway) to VCM-3 is interrupted.
(4) Checks
VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and

200(VCM-3: CN2-32) and 208(Gateway: A24).
Gateway to ECU: Between 857(Gateway: A26) and 857(ECU: 157), and
858(Gateway: A27) and 858(ECU: 158).
(5) Replace gateway. (6) Replace harness.
Error remains
(7) Replace VCM-3.
Error remains
(8) Replace ECU.
4-39
4-40
9
17
34
25
384
CONTROLLER
CN2
VCM-3
222 238
200 201 299 298 297 296
CN2
CAN L 200
CAN H 201
234 235 233 232 231 230 221 220

237
227228 1
18
10
26
0.85L/R
0.85B/W
201
200
0.85B/W
208
0.85L/R
209
0.85W
GATEWAY
858
0.85R
857
0.85Or
846 SVC POWER - 1 146
0.85Y/B
847 SVC POWER - 2 147
0.85G/W
854 AIR TEMP. SENSOR 154
0.85R/B
855 WATER TEMP. SENSOR 155
0.85R
(e e)
857 CAN - 1(H) 157

0.85W
858 CAN - 1(L) 158
0.85V
862 FUEL TEMP. SENSOR - 1(LEAK) 162
0.85Lg
CONTROL UNIT, ECG
863 FUEL TEMP. SENSOR - 2 163

212353
CONTROLLER
Problem: Shift Lever Error (F16)
(1) Situation
(2) Possible cause

Faulty meter panel, faulty VCM-3, faulty harness.

When F, N and R signals of shift lever are inputted simultaneously.
(4) Checks
Check continuity between meter panel and shift lever.
1. N: Between 272(Shift lever: 1) and 80 (Meter panel).
2. F: Between 81(Shift lever: 3) and 81(Meter panel).
3. R: Between 62(Shift lever: 5) and 82 (Meter panel).
4. GND: Between 126(Shift lever: 2) and 102(Meter panel), and 127(Shift lever: 4) and 102(Meter panel).
(5) Replace meter panel. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-41
CONTROLLER
FNR LEVER DIODE DIODE METER PANEL
1 2 34 5 BRAKE F
F1 FUEL
N 78 FUEL GAGE
R1 PKB
77
0.85Y/L 272
SIGNAL PROCESSOR
80
WATER TEMP GAGE
62
82
62 272 OIL
79 BRAKE LAMP
82 80 TEMP
0.85G/L
83 OIL PRESSURE LAMP
0.85L/W
0.85L/G
0.85L/W R
82 TORQ CONV OIL TEMP LAMP
272
N
127
0.85Y/L
126
81
62
80 INTERLOCK LAMP
0.85G/R F
81
0.85G/L
0.85G/R
MULTIPURPOSE WARNING LAMP

0.85B
0.85L/G
0.85B
127 126 GLOW GLOW LAMP (LPG)

48
81 272 62
CAN H MAST INTERLOCK LAMP
201
CAN L SEAT BELT LAMP
200
12V
45
49 LAMP
ALT R
ALT L CHARGE LAMP
46
1.25B GND
102
212354
4-42
CONTROLLER
Problem: Vehicle Speed Error (F17)
(1) Situation
(2) Possible cause

Vehicle speed over limit, Faulty VCM-3, faulty harness.

When vehicle speed is 35 km/h or more.
(4) Checks
Check continuity between VCM-3 and vehicle speed sensor connectors.
1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +).
2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).
(5) Replace VCM-3. (6) Replace harness.
4-43
CONTROLLER
VCM-3
Harness A Harness B Harness C

0.85R/G
SPEED SENSOR 220 220 220
0.85G/B
0.85Y/G
AUTO LIGHT OUT 222
0.85W/L
SPEED METER 384
0.85G/B
0.85R/G
220 221
CN2
221
220
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
SPEED
SENSOR
212355
4-44
CONTROLLER
Problem: ECU KWP2000 Communication Error (F18)
(1) Situation
(2) Possible cause

Faulty ECU, faulty gateway, faulty harness.

When KWP2000 communication from ECU to gateway is interrupted.
(4) Checks
Check continuity of KWP2000 communication cable.
1. Between 719(Gateway) and 719(ECU).
Error remains
(7) Replace ECU.
4-45
4-46
CONTROLLER
GATEWAY
0.85L/R
719
2Y/R
705 +VB-1(ECU POWER) 5
1.25Y/R
1.25Y/R
708 TACHO OUT (SIG) 8
1.25B
718 CASE GND 18
0.85L/R
719 MUT-3 (KWP2000) 19
0.85G/L
ACCEL SENSOR-1 (SIG) 21
(ea)
721
0.85G/B
722 ACCEL SENSOR-2 (SIG) 22
726 PTO MAX. REV. SET (SIG) 26
0.85G/Y
727 VEHICLE SPEED SENSOR (SIG) 27
CONTROL UNIT, ECG
730 IDLE VOLUME (SIG) 30

731 PTO ACCEL SENSOR (SIG) 31
734 EGR TEMP. SENSOR 34
212356
CONTROLLER
Problem: ECU Speed Sensor Error (F19)
(1) Situation
Indication: "F19" flickering. Drive operations restricted.
(2) Possible cause

Faulty gateway, faulty VCM-3, faulty ECU, faulty harness.

When vehicle speed pulse signal to ECU is interrupted.
Abnormal signal is sent from ECU.
(4) Checks
Check continuity between ECU and gateway.
1. Between 727(ECU) and 727(Gateway).
Error remains
(7) Replace VCM-3.
Error remains
(8) Replace ECU.
4-47
4-48
CONTROLLER
GATEWAY
0.85G/Y
727
2Y/R
705 +VB-1 (ECU POWER) 5
1.25Y/R
1.25Y/R
708 TACHO OUT (SIG) 8
1.25B
718 CASE GND 18
0.85L/R
719 MUT-3 (KWP2000) 19
(ea)
0.85G/L
0.85G/B
726 PTO MAX. REV. SET (SIG) 26
0.85G/Y
CONTROL UNIT, ECG
727 VEHICLE SPEED SENSOR (SIG) 27

730 IDLE VOLUME (SIG) 30
731 PTO ACCEL SENSOR (SIG) 31
212357 734 EGR TEMP. SENSOR 34
CONTROLLER
Problem: Lift Lever Error (F20)
(1) Situation
Indication: "F20" flickering. Lift up and lift down operations disabled.
(2) Possible cause

Faulty lift lever, faulty input unit, faulty harness.

When lift lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between lift lever and input unit.
(6) Replace lift lever with another section lever.
(7) Replace lift lever. (8) Replace input unit.
4-49
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-50
CONTROLLER
Problem: Tilt Lever Error (F22)
(1) Situation
Indication: "F22" flickering. Tilt forward and tilt backward operations disabled.
(2) Possible cause

Faulty tilt lever, faulty input unit, faulty harness.

When tilt lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between tilt lever and input unit.
(6) Replace tilt lever with another section lever.
(7) Replace tilt lever. (8) Replace input unit.
4-51
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-52
CONTROLLER
Problem: Attachment 1 Lever Error (F24)
(1) Situation
Indication: "F24" flickering. Attachment 1 operation disabled.
(2) Possible cause

Faulty attachment 1 lever, faulty input unit, faulty harness.

When attachment 1 lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between attachment 1 lever and input unit.
4-53
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-54
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-55
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-56
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-57
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-58
CONTROLLER
Problem: Joystick Lever Error (F29)
(1) Situation
Indication: "F29" flickering. Corresponding hydraulic operation disabled.
(2) Possible cause

Faulty FC lever, faulty input unit, faulty harness.

Voltage data between main signal and sub-signal is different when FC lever is not operated.
(4) Checks
Check to see if other FC lever errors occur.
F20 F22 F24 F26 F28
To (5) To (6) To (7) To (8) To (9)
(5) Replace lift lever. (6) Replace tilt lever.
(7) Replace attachment 1 lever. (8) Replace attachment 2 lever.
(9) Replace attachment 3 lever.
4-59
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
0.5B
0.5B
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-60
CONTROLLER
Problem: VCM-3 Sensor Voltage Error (F31)
(1) Situation
(2) Possible cause

Faulty tire angle sensor, faulty VCM-3, faulty harness.

When VCM-3 sensor power voltage is 3.85V or less.
(4) Checks
Check continuity between sensor and VCM-3.
1. Between 231(Tire angle sensor: +5V) and 231(VCM-3: CN2-13: +5V).

2. Between 232(Tire angle sensor: GND) and 232(VCM-3: CN2-14: GND).
(6) Check short circuit between sensor power and GND in sensor terminal.
Shorted Not shorted
(7) Replace tire angle sensor.
(8) Check short circuit between sensor and VCM-3

1. Between 231(Tire angle sensor: +5V) and 232(VCM-3: CN2-14: GND).
2. Between 232(Tire angle sensor: GND) and 231(VCM-3: CN2-13: +5V).
Shorted Not shorted
4-61
CONTROLLER
VCM-3

0.85Br/Y
TIRE ANGLE SEN 230 230 230 230
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
CN2 231 232 230
231
232
230
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
TIRE ANGLE
SENSOR
212358
4-62
CONTROLLER
Problem: VCM-3OP Lift Oil Pressure Sensor Error (F33)
(1) Situation
Indication: "F33" flickering. Tilt horizontal function operation disabled.
(2) Possible cause

Faulty lift oil pressure sensor, faulty VCM-3OP, faulty harness.

When lift oil pressure sensor signal voltage is out of range of 0.5V to 4.5V.
(4) Checks
Check continuity between lift oil pressure sensor and VCM-3OP.
1. Between 267(VCM-3OP: CN1-14: +5V) and 267(Lift oil pressure sensor: Vcc).
2. Between 268(VCM-3OP: CN1-15: SIG) and 268(Lift oil pressure sensor: SIG).
3. Between 269(VCM-3OP: CN1-17: GND) and 269(Lift oil pressure sensor: GND).
(6) Turn on key switch, then measure lift oil pressure sensor signal voltage between VCM-3OP connector terminals.
1. Between 268(Lift oil pressure sensor: SIG) and 269(Lift oil pressure sensor: GND).
Normal (0.5V to 4.5V) Abnormal (out of 0.5V to 4.5V)
(7) Replace VCM-3OP. (8) Replace lift oil pressure sensor.
4-63
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
HYD PRESSURE 267 267
TILT ANGLE SEN. 264
TILT ANGLE SEN. 265
TILT ANGLE SEN. 266
0.85Lg/B
0.85B/W
0.85Lg
SPEED PULSE 290
269 268 267
CAB OPEN IND1 257
P. SOURCE 1 42
P. SOURCE 2 43
267
269
268
GND1 135
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
LIFT OIL PRESSURE

SENSOR (OP)
212359
4-64
CONTROLLER
Problem: Vehicle Speed Sensor Error (F34)
(1) Situation
Indication: "F34" flickering. Drive speed change operation disabled.
(2) Possible cause

Faulty vehicle speed sensor, faulty VCM-3, faulty harness.

When vehicle speed sensor signal voltage is out of range of 1.3V to 4.9V.
(4) Checks
Check continuity between VCM-3 and vehicle speed sensor.
1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +).
2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).
(6) Measure resistance between vehicle speed sensor terminals.

220(Speed sensor: +) and 221(Speed sensor: -).
Normal [2kǡto 3kǡ at 25 °C (77 °F)] Abnormal
(7) Replace VCM-3. (8) Replace vehicle speed sensor.
4-65
CONTROLLER
VCM-3

0.85R/G
0.85G/B
0.85Y/G
AUTO LIGHT OUT 222
0.85W/L
SPEED METER 384
0.85G/B
0.85R/G
220 221
CN2
221
220
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
SPEED
SENSOR
212355
4-66
CONTROLLER
Problem: Tire Angle Sensor Error (F36)
(1) Situation
Indication: "F36" flickering. Knob position control disabled.
(2) Possible cause

Faulty tire angle sensor, faulty VCM-3, faulty harness.

When tire angle sensor signal voltage is out of range of 0.27V to 4.72V.
(4) Checks
Check continuity between VCM-3 and tire angle sensor.
1. Between 231(VCM-3: CN2-13) and 231(Tire angle sensor: SIG).
2. Between 230(VCM-3: CN2-12) and 230(Tire angle sensor: Vcc).
3. Between 232(VCM-3: CN2-14) and 232(Tire angle sensor: GND).
Normal Abnormal
(6) Measure resistance between tire angle sensor terminals. (Place tires in straight-ahead position.)
1. Between 230(Tire angle sensor: Vcc) and 231(Tire angle sensor: SIG). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F)
2. Between 231(Tire angle sensor: SIG) and 232(Tire angle sensor: GND). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F)
3. Between 230(Tire angle sensor: Vcc) and 232(Tire angle sensor: GND). ࡮࡮࡮1.6kǡ to 2.4kǡ‫ޓ‬at 25͠ (77 ˚F)
Normal Abnormal
(7) Replace VCM-3. (8) Replace tire angle sensor.
4-67
CONTROLLER
VCM-3

0.85Br/Y
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
CN2 231 232 230
231
232
230
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
TIRE ANGLE
SENSOR
212358
4-68
CONTROLLER
Problem: VCM-3OP Tilt Angle Sensor Error (F39)
(1) Situation
Indication: "F39" flickering. Tilt auto stop control function operation disabled.
(2) Possible cause

Faulty tilt angle sensor, faulty VCM-3OP, faulty harness.

When tilt angle sensor signal voltage is out of range of 0.1V to 4.9V.
(4) Checks
Check continuity between VCM-3OP and tilt angle sensor.
1. Between 264(VCM-3OP: CN1-27: +5V) and 264(Tilt angle sensor: +5V).
2. Between 265(VCM-3OP: CN1-28: SIG) and 265(Tilt angle sensor: SIG).
3. Between 266(VCM-3OP: CN1-29: GND) and 266(Tilt angle sensor: GND).
(6) Replace tilt angle sensor. (5) Replace harness.
Error remains
(8) Replace VCM-3OP.
4-69
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
HYD PRESSURE 267
HYD PRESSURE 268
HYD PRESSURE 269
TILT ANGLE SEN. 264 264
SPEED PULSE 290
0.85B/Y
CAB OPEN IND1 257
0.85R/B
0.85Y/B
P. SOURCE 1 42
P. SOURCE 2 43
266 265 264
GND1 135
264
265
266
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
TILT ANGLE
SENSOR (OP)
212360
4-70
CONTROLLER
Problem: Steering Error (F40)
(1) Situation
Indication: "F40" flickering. Knob position control disabled.
(2) Possible cause

Faulty steering sensor, faulty tire angle sensor, faulty VCM-3, faulty harness.

Steering angle is changed when tire angle remains unchanged.
Tire angle is changed when steering angle remains unchanged.
(4) Checks
Check to see if tire angle sensor error (F36) occurs.
F36 occurs Not occurs
(5) See F36 troubleshooting.
(6) Check continuity between VCM-3 and steering sensor.

1. Between 132(VCM-3: CN1-20: GND) and 132(Steering angle sensor: +5V).
2. Between 218(VCM-3: CN1-23: NT) and 218(Steering angle sensor: NT).
3. Between 217(VCM-3: CN1-22: ST2) and 217(Steering angle sensor: ST2).
4. Between 216(VCM-3: CN1-21: ST1) and 216(Steering angle sensor: ST1).
5. Between 215(VCM-3: CN1-19: +12V) and 215(Steering angle sensor: +12V).
(8) Confirm tire angle with service tool when steering wheel is operated.
Change Not change
(9) Replace VCM-3. (10) Replace steering sensor.
4-71
CONTROLLER
VCM-3

0.85Br/Y
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
Harness A
0.85G/Y 231 232 230
231
232
230
ST. ANGLE SEN 215 215
0.85Br
0.85Br/Y
0.85W/G
0.85B/G
0.85W/G
0.85Br/Y
0.85G/Y
0.85B/G
0.85Br
CN1 CN2 217 215 218
218
217
216
215
216 132
132
9 245 1 9 227228 1
17 224 223 10 17 234 235 233 232 231 230 221 220 10
25 130 218 217 216132 215 40 18 25 384 222 238 237 18 TIRE ANGLE
34 131 229 411 211 41 26 34 200 201 299 298 297 296 26 SENSOR
R/E
STEERING ANGLE
SENSOR
212361
4-72
CONTROLLER
Problem: Output Unit Controller Error (F41)
(1) Situation
(2) Possible cause
Faulty output unit.

(4) Checks
Write updated software into output unit.
Faulty software writing (5) Replace output unit.
4-73
CONTROLLER
Problem: Output Unit Life Control Signal (F42)
(1) Situation
(2) Possible cause

Faulty output unit.

When output unit is being initialized.
(4) Checks
4-74
CONTROLLER
Problem: Output Unit Memory Error (F43)
(1) Situation
(2) Possible cause
Faulty output unit.

(4) Checks
4-75
CONTROLLER
Problem: Output Unit PWM Voltage Error (F44)
(1) Situation
(2) Possible cause
Poor battery charge, faulty VCM-3, faulty DC-DC converter, faulty harness.

When output unit PWM voltage is 7V or less.
(4) Checks
Normal (18V to 32V) 7V or less
(5) Charge battery.
Error remains
4-76
CONTROLLER
(7) Measure DC-DC converter output voltage and input voltage.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107(DC-DC converter: GND). ࡮࡮࡮ (12V)
2. Input voltage: Between 8(DC-DC converter: +24V) and 104(DC-DC converter: GND). ࡮࡮࡮࡮ (24V)
(10) Measure VCM-3 input voltage.

7V or less 7V to 21V
4-77
CONTROLLER
DC-DC
CONVERTER
VCM-3
CN1
0.85B/L
131 105 107 1.25B/L 107 12V GND
0.85B/L 2R/Y
130 40 40 12V MAIN
1.25R/Y 1.25B
41 40 104 104 24V GND
1.25R/Y
40 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1
301 12V BATT
15R
9 245 1
17 224 223 10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26
FLW 0.85R
105
100
60B 60B
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212349
4-78
CONTROLLER
Problem: Output Unit Communication Error (F45)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty harness, faulty output unit.

When CAN communication from output unit to VCM-3 is interrupted.
(4) Checks
VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32)
and 393(Output unit: 14).
(5) Replace output unit. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-79
CONTROLLER
OUTPUT UNIT
1 GND
2 GND
3 +VE
4 +VE
5 N.C.
6 N.C.
7 SWITCH IN GND
8 SWITCH IN GND
9 SWITCH IN GND
VCM-3 10 RS-232 Tx
CN2 11 RS-232 Rx
12 RS-232 GND
0.85L/R 0.85L/R
201 201 394 13 CAN H
0.85B/W 0.85B/W
200 200 393 14 CAN L
15 N.C.
16 N.C.
17 BOOT
CN2
18 FWE
9 227228 1
19 0V
17 234 235 233 232 231 230 221 220 10 20 DC 12V
25 384 222 238 237 18
34 200 201 299 298 297 296 26 21 PWM 1+
22 PWM 2+
23 PWM 1-/PWM 2-
24 PWM 3+
25 PWM 4+
26 PWM 3-/PWM4-
27 PWM 5+
28 PWM 6+
29 PWM 5-/PWM 6-
30 PWM 7+
31 PWM 8+
32 PWM 7-/PWM 8-
33 PWM 9+
34 PWM 10+
35 PWM 9-/PWM 10-
36
212362
4-80
CONTROLLER
Problem: Input Unit Controller Error (F46)
(1) Situation
(2) Possible cause
Faulty input unit.

Software checks sum value of ROM in CPU, and detects fault.
(4) Checks
Write updated software into input unit.
Faulty software writing (5) Replace input unit.
4-81
CONTROLLER
Problem: Input Unit Life Control Signal (F47)
(1) Situation
(2) Possible cause
Faulty input unit.

When input unit is being initialized.
(4) Checks
4-82
CONTROLLER
Problem: Input Unit Memory Error (F48)
(1) Situation
(2) Possible cause
Faulty input unit.

Software checks sum value of ROM in CPU, and detects fault.
(4) Checks
4-83
CONTROLLER
Problem: Input Unit Communication Error (F49)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty harness, faulty input unit.

When CAN communication from input unit to VCM-3 is interrupted.
(4) Checks
VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32)
and 395(Input unit: 8).
(5) Replace input unit. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-84
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
1 GND
2 Vcc 19V
3 FWE
VCM-3 4 RS-232 Tx
CN2 5 RS-232 Rx
6 RS-232 GND
0.85L/R 0.85L/R 0.5B
201 201 396 396 7 CAN H
0.85B/W 0.85B/W 0.5B/W
200 200 395 395 8 CAN L
9 CAN R+
10 CAN R-
11 BOOT
CN2
12 SEL0
13 SEL1
9 227228 1
17 234 235 233 232 231 230 221 220 10 14 SW GND
25 384 222 238 237 18
34 200 201 299 298 297 296 26 15 SW INPUT 1
17 SW INPUT 3(4V/5V)
18 SW INPUT 4(F)
19 SW INPUT 5(N)
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
23 5V
24 GND
25 LIFT 1
26 LIFT 2
27 TILT 1
28 TILT 2
29 ATT 1-1
30 ATT 1-2
31 ATT 2-1
32 ATT 2-2
212363
4-85
CONTROLLER
Problem: Lift Up Solenoid Error (F50)
(1) Situation
Indication: "F50" flickering. Lift operation disabled.
(2) Possible cause

Faulty output unit, faulty lift up solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when lift up solenoid signal is outputted.
(4) Checks
Check continuity between output unit and lift up solenoid.
1. Lift up: Between 480(Output unit: CN1-21) and 480(Lift A solenoid).
2. Lift return: Between 482(Output unit: CN1-23) and 482(Lift A solenoid).
(6) Measure resistance of lift up solenoid.

1. Lift up: Between 480(Lift A solenoid) and 482(Lift A solenoid).
Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)? Abnormal
(7) Replace output unit. (8) Replace lift up solenoid.
4-86
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497
(BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK)
LIFT A LIFT B TILT A TILT B ATT1 A ATT1 B

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499

(BLACK) (BLACK) (BLACK) (BLACK)
ATT2 A ATT2 B ATT3 A ATT3 B

212364
4-87
CONTROLLER
Problem: Lift Down Solenoid Error (F52)
(1) Situation
Indication: "F52" flickering. Lift operation disabled.
(2) Possible cause

Faulty output unit, faulty lift down solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when lift down solenoid signal is outputted.
(4) Checks
Check continuity between output unit and lift down solenoid.
1. Lift down: Between 481(Output unit: CN1-22) and 481(Lift B solenoid).
2. Lift return: Between 482(Output unit: CN1-23) and 495(Lift B solenoid).
(6) Measure resistance of lift down solenoid.

1. Lift down: Between 481(Lift B solenoid) and 495(Lift B solenoid).
Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] Abnormal
(7) Replace output unit. (8) Replace lift down solenoid.
4-88
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-89
CONTROLLER
Problem: Lift Solenoid Leak (F54)
(1) Situation
(2) Possible cause

Faulty output unit, faulty lift solenoids, faulty harness.

Current is 0.18A or more when lift lever is not operated.
(4) Checks
Check hydraulic operations when error occurred.
(6) Tilt operation (7) Attachment 1 (8) Attachment 2 (9) Attachment 3

(5) Not operate operation operation operation
Forward Backward A B A B A B
To (13) To (16) To (19) To (22) To (25) To (28) To (31) To (34)
(10) Measure resistance of corresponding solenoid.
(11) Replace output unit. (12) Replace faulty solenoid.
4-90
CONTROLLER
(13) Check continuity between lift section and tilt section.

Between 483(Output unit: CN1-24) and 482(Output unit: CN1-23).
Continuity (Several tenǡ or less) No continuity (Several Mǡ)
(14) Insulate wires in harness or replace harness. (15) Replace output unit.
(16) Check continuity between lift section and tilt section.

(19) Check continuity between lift section and attachment 1 section.


4-91
CONTROLLER




4-92
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-93
CONTROLLER
Problem: Tilt Forward Solenoid Error (F55)
(1) Situation
Indication: "F55" flickering. Tilt operation disabled.
(2) Possible cause

Faulty output unit, faulty tilt forward solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when tilt forward solenoid signal is outputted.
(4) Checks
Check continuity between output unit and tilt forward solenoid.
1. Tilt forward: Between 483(Output unit: CN1-24) and 483(Tilt A solenoid).
2. Tilt return: Between 485(Output unit: CN1-26) and 485(Tilt A solenoid).
(6) Measure resistance of tilt forward solenoid.

1. Lift up: Between 483(Tilt A solenoid) and 485(Tilt A solenoid).
(7) Replace output unit. (8) Replace tilt forward solenoid.
4-94
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-95
CONTROLLER
Problem: Tilt Backward Solenoid Error (F57)
(1) Situation
Indication: "F57" flickering. Tilt operation disabled.
(2) Possible cause

Faulty output unit, faulty tilt backward solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when tilt backward solenoid signal is outputted.
(4) Checks
Check continuity between output unit and tilt backward solenoid.
1. Tilt backward: Between 484(Output unit: CN1-25) and 484(Tilt B solenoid).
2. Tilt return: Between 485(Output unit: CN1-26) and 496(Tilt B solenoid).
(6) Measure resistance of tilt backward solenoid.

1. Tilt backward: Between 484(Tilt B solenoid) and 496(Tilt B solenoid).
(7) Replace output unit. (8) Replace tilt backward solenoid.
4-96
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-97
CONTROLLER
Problem: Tilt Solenoid Leak (F59)
(1) Situation
(2) Possible cause

Faulty output unit, faulty tilt solenoids, faulty harness.

Current is 0.18A or more when tilt lever is not operated.
(4) Checks
(6) Lift operation (7) Attachment 1 (8) Attachment 2 (9) Attachment 3

(5) Not operate operation operation operation
Up Down A B A B A B
4-98
CONTROLLER
(13) Check continuity between tilt section and lift section.

(16) Check continuity between tilt section and lift section.

(19) Check continuity between tilt section and attachment 1 section.


4-99
CONTROLLER




4-100
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-101
CONTROLLER
Problem: Attachment 1A Solenoid Error (F60)
(1) Situation
Indication: "F60" flickering. Attachment operation disabled.
(2) Possible cause

Faulty output unit, faulty attachment 1A solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when attachment 1A solenoid signal is outputted.
(4) Checks
Check continuity between output unit and attachment 1A solenoid.
1. Attachment 1 A: Between 486(Output unit: CN1-27) and 486(ATT1 A solenoid).
2. Attachment 1 return: Between 488(Output unit: CN1-29) and 488(ATT1 A solenoid).
(6) Measure resistance of attachment 1A solenoid.

1. Attachment 1A: Between 486(ATT1 A solenoid) and 488(ATT1 A solenoid)
(9) Replace output unit. (8) Replace attachment 1A solenoid.
4-102
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-103
CONTROLLER
Problem: Attachment 1B Solenoid Error (F62)
(1) Situation
Indication: "F62" flickering. Attachment operation disabled.
(2) Possible cause

Faulty output unit, faulty attachment 1B solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when attachment 1B solenoid signal is outputted.
(4) Checks
Check continuity between output unit and attachment 1B solenoid.
1. Attachment 1B: Between 487(Output unit: CN1-28) and 486(ATT1 B solenoid).
2. Attachment 1 return: Between 488(Output unit: CN1-29) and 497(ATT1 B solenoid).
(6) Measure resistance of attachment 1B solenoid.

1. Attachment 1B: Between 487(ATT1 B solenoid) and 497(ATT1 B solenoid)
(9) Replace output unit. (8) Replace attachment 1B solenoid.
4-104
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-105
CONTROLLER
Problem: Attachment 1 Solenoid Leak (F64)
(1) Situation
(2) Possible cause

Faulty output unit, faulty attachment 1 solenoids, faulty harness.

Current is 0.18A or more when attachment 1 lever is not operated.
(4) Checks
(6) Lift operation (7) Tilt operation (8) Attachment 2 (9) Attachment 3
(5) Not operate operation operation
Up Down Forward Backward A B A B
4-106
CONTROLLER
(13) Check continuity between attachment 1 section and lift section.


(19) Check continuity between attachment 1 section and tilt section.


4-107
CONTROLLER
(25) Check continuity between attachment 1 section and attachment 2 section.




4-108
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-109
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
1. Attachment 2A: Between 489(Output unit: CN1-30) and 489(ATT2 A solenoid).

4-110
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-111
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks

4-112
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-113
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-114
CONTROLLER




4-115
CONTROLLER




4-116
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-117
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
1. Attachment 3A: Between 492(Output unit: CN1-33) and 492(ATT3 A solenoid).

4-118
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-119
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks

4-120
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-121
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-122
CONTROLLER




4-123
CONTROLLER




4-124
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
0.85L/R
491
498
494
490
489
499
492
493
489 491 490 498 492 494 493 499


212364
4-125
CONTROLLER
Problem: Unload Solenoid Error (F75)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty unload solenoid, faulty harness.

Current is 0.16A or less, or 2.4A or more, when unload solenoid signal is outputted.
(4) Checks
Check to see if emergency button is pushed.
Pushed Not pushed
(5) Release emergency button and restart.
Error remains
(6) Check continuity between VCM-3 and unload solenoid.

1. Between 211(VCM-3: CN1-30) and 211(Unload solenoid).
2. Between 411(VCM-3: CN1-32) and 411(Input unit).
3. Between 212(Input unit) and 212(Unload solenoid).
(8) Measure resistance of unload solenoid.

1. Between 211(Unload solenoid) and 212(Unload solenoid).
(9) Replace VCM-3. (10) Replace unload solenoid.
4-126
CONTROLLER
VCM-3
0.85Lg/R Harness A Harness B Harness C

UNLOAD SOL 211 211 211
0.85G/B
UNLOAD RETURN 411
0.85B/W Harness B
CAN L 200
0.85L/R 212 212
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40 EMERGENCY SW
1.25R/Y
P. SOURCE 2 41 Harness A
0.85B/L
GND 1 130
0.85B/L
GND 2 131
Harness C
0.85Br/B
0.85G/B
INPUT UNIT
CN1
0.85Br/B
0.85Lg/R
937
395
212
245
411
397
396
9 1
17 224 223 937 396 212
10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26 397 395 411
211
212
212
211
211 212
(BLACK)
UNLOAD
212365
4-127
CONTROLLER
Problem: Unload Solenoid Leak (F79)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty unload solenoid, faulty harness.

Current is 0.18A or more when hydraulic operation signal is not outputted.
(4) Checks
Check operating condition when error occurred.
(6) Drive operation (7) When knob position control

function is installed
(5) Not operate.
Forward Reverse During steering operation
To (11) To (14) To (17)
(8) Measure resistance of unload solenoid.
(9) Replace VCM-3. (10) Replace unload solenoid.
4-128
CONTROLLER
(11) Check continuity between transmission section and unload section.

Between 233(VCM-3: CN2-15) and 411(VCM-3: CN1-32).
(12) Insulate wires in harness or replace harness. (13) Replace VCM-3.
(14) Check continuity between transmission section and unload section.

(17) Check continuity between knob position solenoid and unload section.
4-129
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
TIRE ANGLE SEN. 231 234
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
233
P/S SOL 237
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-130
CONTROLLER
Problem: Knob Position Solenoid Error (F80)
(1) Situation
Indication: "F80" flickering. Knob position control fuunction disabled.
(2) Possible cause

Faulty VCM-3, faulty knob position solenoid, faulty harness.

Current is 0.16A or less, or 3.54A or more, when knob position solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and knob position solenoid.
1. Between 237(VCM-3: CN2-18) and 237(PS CARIB solenoid).
2. Between 238(VCM-3: CN2-20) and 238(PS CARIB solenoid).
(6) Measure resistance of knob position solenoid.

1. Between 237(PS CARIB solenoid) and 238(PS CARIB solenoid).
(7) Replace VCM-3. (8) Replace knob position solenoid.
4-131
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233
1.25B/L
T/M GND 234
1.25G/L
T/M SOL. R 235
0.85Lg Harness A Harness B
P/S SOL 237 237 237
0.85Lg/B
P/S SOL 238 238 238
0.85W
SEAT SW 227
0.85B/G
SEAT SW
0.85Lg/B
228
0.85Lg
237
238
(BLACK)
237 238
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
PS CARIB
(OP)
212367
4-132
CONTROLLER
Problem: Knob Position Solenoid Leak (F84)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty knob position solenoid, faulty harness.

Current is 0.18A or more when steering wheel is not operated.
(4) Checks
(6) Drive operation

(5) Not operate. (7) During hydraulic operation
Forward Reverse
To (11) To (14) To (17)
(8) Measure resistance of knob position solenoid.
Normal [6.9 to 10.3 at 25 (77˚F)] Abnormal
(9) Replace VCM-3. (10) Replace knob position solenoid.
4-133
CONTROLLER
(11) Check continuity between transmission section and knob position solenoid.
(14) Check continuity between transmission section and knob position solenoid.
(17) Check continuity between unload section and knob position solenoid.
4-134
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
233
P/S SOL 237
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-135
CONTROLLER
Problem: Transmission Forward Solenoid Error (F85)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty transmission forward solenoid, faulty harness.

Current is 0.25A or less, or 3.84A or more, when transmission forward solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and transmission forward solenoid.
1. Between 233(VCM-3: CN2-15) and 233(Solenoid F: +).
2. Between 234(VCM-3: CN2-17) and 234(Solenoid F: -).
(6) Measure resistance of transmission forward solenoid.

1. Between 233(Solenoid F: +) and 234(Solenoid F: -).
(7) Replace VCM-3. (8) Replace transmission forward solenoid.
4-136
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y Harness A Harness B Harness C 1.25G/Y
T/M SOL. F 233 233 233
1.25B/L 1.25B/L
T/M GND 234 234 234 234
1.25G/L
T/M SOL. R 235 235
0.85Lg 1.25B/L
P/S SOL 237 242
0.85Lg/B
P/S SOL 238
0.85W
SEAT SW 227 1.25G/L
0.85B/G 235
233
SEAT SW 228
235
SR SF
SOLENOID(F - R)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212368
4-137
CONTROLLER
Problem: Transmission Backward Solenoid Error (F87)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty transmission backward solenoid, faulty harness.

Current is 0.25A or less, or 3.84A or more, when transmission backward solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and transmission backward solenoid.
1. Between 235(VCM-3: CN2-16) and 235(Solenoid R: +).
2. Between 234(VCM-3: CN2-17) and 242(Solenoid R: -).
(6) Measure resistance of transmission backward solenoid.

Between 235(Solenoid R: +) and 242(Solenoid R: -).
(7) Replace VCM-3. (8) Replace transmission backward solenoid.
4-138
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y Harness A Harness B Harness C 1.25G/Y
T/M SOL. F 233 233 233
1.25B/L 1.25B/L
T/M GND 234 234 234 234
1.25G/L
T/M SOL. R 235 235
0.85Lg 1.25B/L
P/S SOL 237 242
0.85Lg/B
P/S SOL 238
0.85W
SEAT SW 227 1.25G/L
0.85B/G 235
233
SEAT SW 228
235
SR SF
SOLENOID(F - R)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212368
4-139
CONTROLLER
Problem: Transmission Solenoid Leak (F89)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty transmission solenoids, faulty harness.

Current is 0.18A or more when transmission solenoid is in neutral position.
(4) Checks
(7) When knob position control

(6) During hydraulic operation. function is installed
(5) Not operate.
During steering operation
To (11) To (14)
(10) Measure resistance of transmission forward/backward solenoid.
(11) Replace VCM-3. (12) Replace faulty solenoid.
4-140
CONTROLLER
(11) Check continuity between unload section and transmission section.

(14) Check continuity between knob position solenoid and transmission section.
4-141
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
233
P/S SOL 237
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-142
CONTROLLER
Problem: VCM-3OP Sensor Voltage Error (F90)
(1) Situation
(2) Possible cause

Faulty lift oil pressure/tilt angle sensor, faulty VCM-3OP, faulty harness.

When VCM-3OP sensor 5V power voltage is 3.85V or less.
(4) Checks
Check continuity between sensor and VCM-3OP.
1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 267(VCM-3OP: CN1-14: +5V), and
269(Lift oil pressure sensor: GND) and 269(VCM-3OP: CN1-17: GND).
2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 264(VCM-3OP: CN1-27: +5V), and
266(Tilt angle sensor: GND) and 266(VCM-3OP: CN1-29: GND).
(6) Check short circuit between sensor power and GND in sensor connector side.
Shorted Not shorted
(7) Replace faulty sensor(lift oil pressure/tilt angle).
4-143
CONTROLLER
(8) Check short circuit between sensor and VCM-3OP.
1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 269(VCM-3OP: CN1-17: GND), and
269(Lift oil pressure sensor: GND) and 267(VCM-3OP: CN1-14: +5V).
2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 266(VCM-3OP: CN1-29: GND), and
266(Tilt angle sensor: GND) and 264(VCM-3OP: CN1-27: +5V).
Shorted Not shorted
(9) Replace faulty harness. (5) Replace VCM-3OP.
4-144
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
0.85Lg/B
0.85B/W
0.85Lg
SPEED PULSE 290
0.85B/Y
CAB OPEN IND1 257
0.85R/B
0.85Y/B
P. SOURCE 1 42 269 268 267
P. SOURCE 2 43
267
269
268
266 265 264
GND1 135
264
265
266
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
TILT
ANGLE
SENSOR LIFT OIL PRESSURE
(OP) SENSOR (OP)
212369
4-145
CONTROLLER
Problem: VCM-3OP Memory Check Error (F91)
(1) Situation
(2) Possible cause
Faulty VCM-3OP, faulty truck type setting data in VCM-3OP.

(4) Checks
Normal Abnormal
(6) Set shipment default value into VCM-3OP.

Normal Abnormal
(7) Perform standard setting, then enter truck type setting

data again.
(8) Write updated software into VCM-3OP.
Normal Abnormal
(9) Faulty software writing. (10) Replace VCM-3OP.
4-146
CONTROLLER
Problem: VCM-3OP Battery Voltage Error (F92)
(1) Situation
Indication: "F92" flickering. Tilt horizontal control and speed change control disabled.
(2) Possible cause
Poor battery charge, faulty battery, faulty VCM-3OP, faulty harness, faulty DC-DC converter.

When VCM-3OP input voltage is less than 7V or more than 21V.
(4) Checks
Normal (18V to 32V) Less than 7V More than 32V
(5) Charge battery.
Error remains
(7) Measure output voltage and input voltage of DC-DC converter.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 12V
2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). 24V
(10) Measure VCM-3OP input voltage.

1. Between 42(VCM-3OP: CN1-18) and 135(VCM-3OP: CN1-25).
Less than 7V 7V to 21V
(11) Replace harness. (12) Replace VCM-3OP.
4-147
CONTROLLER
DC-DC
CONVERTER
VCM-3OP
CN1
0.85B/L
136 105 107 1.25B/L 107 12V GND
0.85B/L 2R/Y
135 40 40 12V MAIN
1.25R/Y 1.25B
43 42 104 104 24V GND
1.25R/Y
42 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1 301 12V BATT
15R
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26

FLW 0.85R
105
100
60B 60B
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212370
4-148
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid 1 Error (F93)
(1) Situation
Indication: "F93" flickering. EAT control function disabled (speed change step fixed).
(2) Possible cause

Faulty VCM-3OP, faulty change transmission solenoid 1, faulty harness.

Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 1 signal is outputted.
(4) Checks
Check continuity between VCM-3OP and change transmission solenoid 1.
1. Between 253(VCM-3OP: CN2-15) and 255(Solenoid SH: +).
2. Between 254(VCM-3OP: CN2-17) and 254(Solenoid SH: -).
(6) Measure resistance of change transmission solenoid 1.

1. Between 255(Solenoid SH: +) and 254(Solenoid SH: -)
(7) Replace VCM-3OP. (8) Replace change transmission solenoid 1.
4-149
CONTROLLER
VCM-OP CN2
COOLANT 281
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2
9 277 279 281 1
1.25B/W
1.25R/Y
1.25L/Y
17 254 273 253 10
25 258 18
34 205 204 295 294 293 292 26
274
254
255 246
SH S2
SOLENOID
(SPEED SELECT)
212371
4-150
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid 2 Error (F94)
(1) Situation
Indication: "F94" flickering. EAT control function disabled (speed change step fixed).
(2) Possible cause

Faulty VCM-3OP, faulty change transmission solenoid 2, faulty harness.

Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 2 signal is outputted.
(4) Checks
Check continuity between VCM-3OP and change transmission solenoid 2.
1. Between 273(VCM-3OP: CN2-16) and 274(Solenoid S2: +).
2. Between 254(VCM-3OP: CN2-17) and 246(Solenoid S2: -).
(6) Measure resistance of change transmission solenoid 2.

1. Between 274(Solenoid S2: +) and 246(Solenoid S2: -)
(7) Replace VCM-3OP. (8) Replace change transmission solenoid 2.
4-151
CONTROLLER
VCM-OP CN2
COOLANT 281
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2
9 277 279 281 1
1.25B/W
1.25R/Y
1.25L/Y
17 254 273 253 10
25 258 18
34 205 204 295 294 293 292 26
274
254
255 246
SH S2
SOLENOID
(SPEED SELECT)
212371
4-152
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid Leak (F95)
(1) Situation
Indication: "F95" flickering. EAT control function disabled.
(2) Possible cause

Faulty VCM-3OP, faulty corresponding solenoid, faulty harness.

Output signal current is 0.18A or more when vehicle is driving at 3rd speed.
(4) Checks
Measure resistance of change transmission solenoid 1 and 2.
(5) Replace faulty solenoid.
(6) Check continuity between power source and change transmission section.
2. Between 42(VCM-3OP: CN1-18) and 273(VCM-3OP:CN2-16).
(7) Insulate wires in harness or replace harness. (8) Replace VCM-3OP.
4-153
CONTROLLER
DC-DC
CONVERTER
VCM-3OP
CN1
0.85B/L
136 105 107 1.25B/L 107 12V GND
0.85B/L 2R/Y
135 40 40 12V MAIN
1.25R/Y
43 42 104 24V GND
1.25R/Y
42 94 12V LAMP
49 24V LAMP
8 24V BATT
CN2
62 ACC IN
281 301 12V BATT
COOLANT
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2 CN1
9 277 279 281 1 9 252 250 1

1.25B/W
1.25R/Y
1.25L/Y
17 254 273 253 10 17 269 268 267 10
25 258 18 25 135 42 18
205 204 295 294 293 292 26 34 136 257 266 265 264 43 26
34
274
254
255
246
SH S2
SOLENOID
(SPEED SELECT)
212372
4-154
CONTROLLER
Problem: VCM-3OP EAT Setting Error (F96)
(1) Situation
Indication: "F96" flickering. Speed change function disabled (speed change step fixed).
(2) Possible cause
Faulty VCM-3OP, faulty truck type setting data in VCM-3OP

1 When setting value of speed shift point is not in following relations.
2- speed specification vehicle: (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed)
3- speed specification vehicle: (from 2nd-speed to 3rd-speed) (from 3rd-speed to 2nd-speed)
(from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed)
2 When setting data for mode selecting decision is in following conditions.
Mode selecting decision value is out of setting range (0 to 3).
Mode selecting pattern is repeated.
Either of mode selector switch SW1 and SW2 is not set.
3 When setting data for speed change solenoid (SH and S2) is in following conditions.
Speed change solenoid output decision value is out of setting range (0 to 3).
Speed change solenoid output pattern is repeated.
Either of SH and S2 is not set.
(4) Checks
Normal Abnormal
(6) Set shipment default value into VCM-3OP.

Normal Abnormal
(7) Perform standard setting, then enter truck type setting (8) Replace VCM-3OP.
data again.
4-155
CONTROLLER
Problem: VCM-3OP Communication Error (F97)
(1) Situation
Indication: "F97" flickering. Speed change function disabled (current step held).
(2) Possible cause
Faulty VCM-3OP, faulty VCM-3, faulty harness.

When CAN communication from VCM-3OP to VCM-3 is interrupted.
(4) Checks
1. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and

200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).
(6) Replace VCM-3OP.
Error remains
(7) Replace VCM-3.
4-156
CONTROLLER
VCM-OP
CN2
281 COOLANT
AT OIL TEMP
279 AIR DUST
277 W/SEPA
CN2 253 2SP SOL
273 3SP SOL
9 277 279 281 1
254 2SP 3SP SOL
17 254 273 253 10
25 258 18 258 TILT CAB
34 205 204 295 294 293 292 26
VCM-3 TILT CAB
CN2 TILT CAB
TILT CAB
0.85L/R
201 201 TILT CAB
0.85B/W 0.85B/W
200 200 204 204 CAN L
0.85L/R
205 205 CAN H
CN1
CN2
250 SP SEL. S/W 1
9 227228 1
252 SP SEL. S/W 2
17 234 235 233 232 231 230 221 220 10 267 HYD PRESSURE
25 384 222 238 237 18
34 200 201 299 298 297 296 26 268 HYD PRESSURE
269 HYD PRESSURE
264 TILT ANGLE SEN.
265 TILT ANGLE SEN.
266 TILT ANGLE SEN.
290 SPEED PULSE
257 CAB OPEN IND1
42 P. SOURCE 1
43 P. SOURCE 2
135 GND1
136 GND2
212373
4-157

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CONTROLLER

2. Service Tool Functions............................................................................................... 4-10

3. Chassis Error Code List ............................................................................................. 4-18

4. Troubleshooting ......................................................................................................... 4-19

CAB harness Harness A Harness B Harness C

200 204 204

1.2 External View

Connector pin number Connector pin number

Connector pin number Connector pin number

Connector pin number

A: GF34A B: GF35A C: GF32A D: GF35B E: GF31A

1.2.4 Meter panel

Connector pin number

1.2.5 Input unit

Connector pin number

1.2.6 Output unit

Connector pin number

2. Service Tool Functions

2.2 Input Monitor and Output Monitor

2.2.2 VCM-3OP input monitor and output monitor

2.2.3 MP input monitor (VCM-3 → MP)

2.2.4 ECU input monitor and output monitor (VCM-3

Accel pedal position (unfiltered)

Reference injection quantity

2.3 Fault Status

OutputUnit Communication error

2.4 Fault History

OutputUnit Communication error

InputUnit Communication error

InputUnit Communication error

InputUnit Communication error

InputUnit Communication error

InputUnit Communication error

3. Chassis Error Code List

4.1.2 Connection of service tool

GSE cable VCM-3

4.1.4 How to clean harness connectors and system

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

Contact surface Three Bond 2501S (aerosol)

Problem: VCM-3 Memory Check Error (F01)

(2) Possible cause

Faulty VCM-3, faulty truck type setting data in VCM-3.

(3) How the error code is triggered

(5) Enter truck type setting data again.

(6) Enter shipment default value into VCM-3.

(7) Perform standard setting, then enter truck type setting

(8) Write updated software into VCM-3.

(9) Faulty software writing. (10) Replace VCM-3.

Problem: VCM-3 Battery Voltage Error (F02)

(2) Possible cause

(3) How the error code is triggered

(5) Charge battery.

(7) Measure output voltage and input voltage of DC-DC converter.

(8) Replace harness. (9) Replace DC-DC converter.

(10) Measure input voltage of VCM-3.

(11) Replace harness. (12) Replace VCM-3.

Problem: VCM-3 Communication Error (F03)

(2) Possible cause

(3) How the error code is triggered

(5) See troubleshooting for errors occurred.

(6) Check continuity of CAN communication cables.

(7) Replace VCM-3. (8) Replace faulty harness.