FB16KT Felkoder

TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ............................................................................... 2– 1

Electrical System Diagram .................................................................. 2– 3
Alarm List ................................................................................................. 2– 5
E0 Right Motor, Overheating .............................................................. 2– 7
E1 Left Motor, Overheating ................................................................ 2– 9
E2 Pump Motor, Overheating ............................................................. 2 – 11
E3 Controller, Overheating ................................................................. 2 – 13
E4 Right Motor, Worn Brushes .......................................................... 2 – 15
E5 Left Motor, Worn Brushes ............................................................. 2 – 17 2
E6 Pump Motor, Worn Brushes ......................................................... 2 – 19
Brake Oil, Low Level ....................................................................... 2 – 21
10 Right Motor, Faulty Armature Circuit ......................................... 2 – 23
11 Right Motor, Transistor Wire Breakage ..................................... 2 – 26
12 Right Motor, Shorted Transistor .................................................. 2 – 28
13 Right Motor, Faulty Transistor Drive .......................................... 2 – 30
14 Right Motor, Faulty Current Sensor ............................................ 2 – 32
15 Right Motor, Armature Over-current .......................................... 2 – 34
16 Right Motor, Stall Timer ................................................................. 2 – 36
17 Right Motor, Faulty Field Circuit ................................................. 2 – 38
18 Right Motor, Faulty Field Drive .................................................... 2 – 40
19 Right Motor, Field Over-current ................................................... 2 – 42
20 Left Motor, Faulty Armature Circuit ............................................ 2 – 44
21 Left Motor, Transistor Wire Breakage ........................................ 2 – 47
22 Left Motor, Shorted Transistor ..................................................... 2 – 49
23 Left Motor, Faulty Transistor Drive ............................................. 2 – 51
24 Left Motor, Faulty Current Sensor .............................................. 2 – 53
25 Left Motor, Armature Over-current ............................................. 2 – 55
26 Left Motor, Stall Timer .................................................................... 2 – 57
27 Left Motor, Faulty Field Circuit .................................................... 2 – 59
28 Left Motor, Faulty Field Drive ....................................................... 2 – 61
29 Left Motor, Field Over-current ..................................................... 2 – 63
30 Pump Motor, Faulty Circuit ........................................................... 2 – 65
31 Pump Motor, Transistor Wire Breakage .................................... 2 – 68
32 Pump Motor, Shorted Transistor ................................................. 2 – 70
33 Pump Motor, Faulty Transistor Drive ......................................... 2 – 72
34 Pump Motor, Faulty Current Sensor .......................................... 2 – 74
35 Pump Motor, Armature Over-current ......................................... 2 – 76
40 Line Contactor, Abnormality ......................................................... 2 – 78
41 Regeneration Contactor, Abnormality ....................................... 2 – 80
43 Regeneration Diode, Abnormality ............................................... 2 – 82
44 Right Armature Diode, Abnormality ........................................... 2 – 84
45 Left Armature Diode, Abnormality .............................................. 2 – 86
46 Pump Armature Diode, Abnormality .......................................... 2 – 88
47 Right Motor, Wire Breakage ......................................................... 2 – 90
48 Left Motor, Wire Breakage ............................................................ 2 – 92
49 Pump Motor, Wire Breakage ........................................................ 2 – 94
50 Steering Sensor, Abnormality ...................................................... 2 – 96
51 Accelerator, Abnormality ............................................................... 2 – 98
52 Right Vehicle Speed Sensor, Abnormality ................................ 2 – 100
53 Left Vehicle Speed Sensor, Abnormality ................................... 2 – 102
54 FC Lever, Abnormality .................................................................... 2 – 104
55 FC Solenoid, Abnormality ............................................................. 2 – 106
57 FC Controller, Abnormality ........................................................... 2 – 108
E Direction Lever and Accelerator, Faulty Setting ..................... 2 – 110
(E) Seat Switch, Faulty Setting .......................................................... 2 – 112
H1 Lift Lever, Faulty Setting ............................................................... 2 – 114
H2 Tilt Lever, Faulty Setting ............................................................... 2 – 116
H3 Attachment 1 Lever, Faulty Setting ........................................... 2 – 118
H4 Attachment 2 Lever, Faulty Setting ........................................... 2 – 120
H5 FC Controller Lever, Faulty Setting ............................................ 2 – 122
60 Data Communication, Abnormality ............................................ 2 – 124
61 EEPROM, Abnormality ................................................................... 2 – 126
65 Logic Card, Faulty Initial Setting ................................................. 2 – 127
66 Controller, Abnormality .................................................................. 2 – 128
68 Battery Voltage, Excessively Low
(For 48-V Vehicles Only) ................................................................ 2 – 129
Electrical System Diagram .................................................................. 2 – 131

Electrical Schematic (DC motor models FC) .................................. 2 – 133
Electrical Schematic (DC motor models MC) ................................. 2 – 135
NOTE
For your reference, most pages are provided with
schematics of pertinent electrical circuits. Before
conducting troubleshooting, read the procedures
carefully and also refer to the Electrical Schematics.
General Information
Before replacing boards

Do not replace boards immediately even if replacement is required as a result of troubleshooting. Be sure to check
the following items before replacing boards (logic card, drive board and H bridge board).
• Loose battery connector
• Abnormal harness externals
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See "How to clean harness connectors and system components" on page 2-2.
If any of these items (above items) is a source of the trouble, the board will be damaged even if it is replaced with a
new one. Be sure to check the above items and carefully replace.
2-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust, together with greasy
matter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, for worse, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at when servicing the truck. Instead of a
commonly used solvent, use electronic parts cleaner (in
the manner illustrated on the right).
Electronic parts Three Bond 29D or

cleaner Pow-R-Wash CZ* 205046
NOTE
The cleaner liquid is volatile. All you have to do is just
give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Install and
remove the connector several times to wet the surfaces
thoroughly with the activator liquid. After coupling up Electronic parts
cleaner
the connector, check to be sure that it 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
205047
2-2
Item Alarm Detection Method/Condition Detecting Location

in Logic Card
Thermal switch signal input for right motor
E0 Right Motor, Overheating CN1-26
[150°C (302°F)]
Thermal switch signal input for left motor
E1 Left Motor, Overheating CN1-28
[150°C (302°F)]
Thermal switch signal input for pump motor
E2 Pump Motor, Overheating CN1-30
[150°C (302°F)]
Thermal sensor signal input for controller
E3 Controller, Overheating CN2-43
[80°C (176°F) thermistor]
E4 Right Motor, Worn Brushes Brush wear signal input for right motor CN1-27
E5 Left Motor, Worn Brushes Brush wear signal input for left motor CN1-29
E6 Pump Motor, Worn Brushes Brush wear signal input for pump motor CN1-31
Brake Oil, Low Level Level sensor signal input for brake oil (CN1-32)
Right Motor, Faulty Armature Combination from

10 Armature error under various conditions
Circuit CN2-34, 39, 41, 45
Right Motor, Transistor Wire Combination from
11 Armature error under ARM output ON
Breakage CN2-34, 39, 41, 45
Combination from
12 Right Motor, Shorted Transistor Armature error under ARM output OFF
CN2-34, 39, 41, 45
Right Motor, Faulty Transistor Abnormal over-current for right IGBT of drive
13 CN2-30 is less than 1 V
Drive board
Right Motor, Faulty Current Right current sensor error under ARM output Combination from
14
Sensor OFF CN2-34, 39, 41, 45
15 Right Motor, Armature Over-current Right motor armature current is 350 A or more CN2-45 is 2.45 V or more
16 Right Motor, Stall Timer The time set with setup option elapsed
Combination from
17 Right Motor, Faulty Field Circuit Error in line voltage or field current
CN2-15, 34
H bridge board detected abnormal over current
18 Right Motor, Faulty Field Drive CN2-13 is less than 1 V
for right FET
Right motor field over-current is 45 A or more
19 Right Motor, Field Over-current CN2-15 is 4.5 V or more
(continues 5 msec)
Combination from
20 Left Motor, Faulty Armature Circuit Armature error under various conditions
CN2-34, 39, 42, 47
Combination from
21 Left Motor, Transistor Wire Breakage Armature error under ARM output ON
CN2-34, 39, 42, 47
Combination from
22 Left Motor, Shorted Transistor Armature error under ARM output OFF
CN2-34, 39, 42, 47
23 Left Motor, Faulty Transistor Drive Abnormal detection signal from drive board CN2-31 is less than 1 V
Combination from
24 Left Motor, Faulty Current Sensor Left current sensor error under ARM output OFF
CN2-34, 39, 42, 47
25 Left Motor, Armature Over-current Left motor armature current is 350 A or more CN2-47 is 2.45 V or more
26 Left Motor, Stall Timer The time set with setup option elapsed
27 Left Motor, Faulty Field Circuit Error in line voltage or field current Combination from CN2-17, 34
H bridge board detected abnormal over-current
28 Left Motor, Faulty Field Drive CN2-14 is less than 1 V
for left FET
Left motor field over-current is 45 A or more
29 Left Motor, Field Over-current CN2-17 is 4.5 V or more
(continues 5 msec)
Checks voltage level and current level for Combination from
30 Pump Motor, Faulty Circuit
main circuit CN2-34, 39, 40, 49
Pump Motor, Transistor Wire Checks voltage level and current level for Combination from
31
Breakage main circuit CN2-34, 39, 40, 49
Checks voltage level and current level for Combination from
32 Pump Motor, Shorted Transistor
main circuit CN2-34, 39, 40, 49
33 Pump Motor, Faulty Transistor Drive Abnormal detection signal from drive board CN2-32 is less than 1 V
2-5
Item Alarm Detection Method/Condition Detecting Location

in Logic Card
Combination from
34 Pump Motor, Faulty Current Sensor Checks current sensor output
CN2-34, 39, 40, 49
35 Pump Motor, Armature Over-current Pump motor current is 450 A or more CN2-49 is 3.15 V or more
Contactor over-current
40 Line Contactor, Abnormality Contactor error under line contactor ON
(/EERR3)
Contactor error under traction and regeneration Contactor over-current
41 Regeneration Contactor, Abnormality
output (/EERR3)
Combination from
43 Regeneration Diode, Abnormality Error during traction
CN2-34, 39, 41, 42, 45, 47
Combination from
44 Right Armature Diode, Abnormality Armature error under ARM output ON
CN2-34, 39, 41, 45
Combination from
45 Left Armature Diode, Abnormality Armature error under ARM output ON
CN2-34, 39, 42, 47
Checks voltage level and current level for main Combination from
46 Pump Armature Diode, Abnormality
circuit CN2-34, 39, 40, 49
Combination from
47 Right Motor, Wire Breakage Error under ARM output OFF during regeneration
CN2-34, 39, 41, 45
Combination from
48 Left Motor, Wire Breakage Error under ARM output OFF during regeneration
CN2-34, 39, 42, 47
Checks voltage level and current level for main Combination from
49 Pump Motor, Wire Breakage
circuit CN2-34, 39, 40, 49
50 Steering Sensor, Abnormality Input value is "0" or intermittent
51 Accelerator, Abnormality Out of input range CN1-33
Right Vehicle Speed Sensor,
52 Wire breakage or short circuit CN1-43, 45 (/ERR1)
Abnormality
Left Vehicle Speed Sensor,
53 Wire breakage or short circuit CN1-47, 49 (/ERR3)
Abnormality
54 FC Lever Abnormality Abnormal signal from FC controller
55 FC Solenoid, Abnormality Abnormal signal from FC controller
57 FC Controller, Abnormality Abnormal signal from FC controller
Direction Lever and Accelerator, Lever is not in neutral or accelerator is not

E
Faulty Setting "0" when power is turned on
(E) Seat Switch, Faulty Setting No signal input when power is turned on CN1-9
H1 Lift Lever, Faulty Setting Signal input when power is turned on CN1-16, 17
H2 Tilt Lever, Faulty Setting Signal input when power is turned on CN1-18
H3 Attachment 1 Lever, Faulty Setting Signal input when power is turned on CN1-19
H4 Attachment 2 Lever, Faulty Setting Signal input when power is turned on CN1-20
H5 FC Controller Lever, Faulty Setting Abnormal signal from FC controller
Display unit shows undefined characters during Logic power supply failure or
60 Data Communication, Abnormality
no communication made CN1-59, 61
Executes parity check for SUO data when power
61 EEPROM, Abnormality
is turned on
Incorrect DSW setting (no setting for truck speed
65 Logic Card, Faulty Initial Setting
selection)
66 Controller, Abnormality ROM/RAM check when power is turned on
Voltage is less than 42 V when power is turned on
68 Battery Voltage, Excessively Low CN2-33
(48 V truck)
Voltage is more than 42 V when power is turned
69 Battery Voltage, Excessively High CN2-33
on (36 V truck)
Battery voltage is between 22 V to 25 V during
Battery Voltage, Low CN2-33
truck operation
Each voltage is less than 22 V when line contactor
(L0) (Battery Voltage, Low) CN2-34, 39, 40, 41, 42
ON
2-6
Problem: Right Motor, Overheating (E0)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and
power steering operations. (Activation of right traction motor thermal switch)
(1) Situation
Indication: Controller/motor overheat indicator ON ("E0" stored in history folder, but not displayed).
Poor pulling power and acceleration. Normal pump motor and power steering operations.
(2) Possible cause

Overheating of right traction motor, abnormality or wire break in right traction motor thermal switch (temperature
sensor), faulty logic card.
(3) How the error code is triggered

Right motor temperature is over 150 C (302 F).
Software checks following signal and detects fault when the signal keeps more than 200 ms.
Traction Motor Right Thermal SW. (CN1-26)
(4) Checks
Let vehicle cool for 15 minutes.
Overheat indicator ON Normal indication
(5) Disconnect battery plug. Wait until right traction motor (12) Operate vehicle and check overheating of right traction
temperature becomes close to room temperature. motor. If problem recurs, check the following:
Disconnect right traction motor thermal switch. Check Operating cycle for excessive ramp climbing, towing
thermal switch continuity. There should be electric and pushing.
continuity below 150 C (302 F). Brake drag, parking brake adjustment and brake
Continuity No continuity switch operation.
(6) Check continuity between wire 124G (Green) of (11) Replace thermal switch.
thermal switch harness connector and NEG.
Continuity No continuity
(7) Remove logic card cover. Check continuity between (10) Correct or replace wiring.
motor sensor 125Y (Yellow) and logic card CN1-26,
and shorting of these terminals with NEG.
Continuity, No continuity,
no shorting or shorted
(8) Faulty logic card (9) Correct or replace wiring.
2-7
211468
2-8
Problem: Left Motor, Overheating (E1)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and
power steering operations. (Activation of left traction motor thermal switch)
(1) Situation
(2) Possible cause

Overheating of left traction motor, abnormality or wire break in left traction motor thermal switch (temperature

Left motor temperature is over 150 C (302 F).
Traction Motor Left Thermal SW. (CN1-28)
(4) Checks
(5) Disconnect battery plug. Wait until left traction motor (12) Operate vehicle and check overheating of left traction
temperature becomes close to room temperature. motor. If problem recurs, check the following:
Disconnect left traction motor thermal switch. Check Operating cycle for excessive ramp climbing, towing
thermal switch continuity. There should be electric and pushing.
continuity below 150 C (302 F). Brake drag, parking brake adjustment and brake
Continuity No continuity switch operation.
(6) Check continuity between wire 129G (Green) of (11) Replace thermal switch.
motor sensor 130Y (Yellow) and logic card CN1-28,
2-9
211469
2-10
Problem: Pump Motor, Overheating (E2)

Indication: Controller/motor overheat indicator ON. Pump motor lifting speed slower than normal. Normal traction
motor and power steering operations. (Activation of pump motor thermal switch)
(1) Situation
Pump motor lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Overheating of pump motor, abnormality or wire break in pump motor thermal switch (temperature

Pump motor temperature is over 150 C (302 F).
Pump Motor Thermal SW. (CN1-30)
(4) Checks
(5) Disconnect battery plug. Wait until pump motor (12) Operate vehicle and check overheating of pump motor.
temperature becomes close to room temperature. If problem recurs, check the following:
Disconnect pump motor thermal switch. Check Operating cycle for excessive hydraulic load (heavy
thermal switch continuity. There should be electric load lifting).
continuity below 150 C (302 F).
(6) Check continuity between wire 134W (White) of (11) Replace thermal switch.
motor sensor 135R (Red) and logic card CN1-30,
2-11
211470
2-12
Problem: Controller, Overheating (E3)

Indication: Controller/motor overheat indicator ON. Poor pulling power and acceleration. Pump motor lifting speed
slower than normal. Normal power steering operation. (Controller thermal control activation)
(1) Situation
Indication: Controller/motor overheat indicator ON ("E3" stored in history folder, but not displayed). Poor pulling
power and acceleration. Pump motor lifting speed slower than normal. Normal power steering operation.
(2) Possible cause

Overheating of controller panel, abnormality or wire break in controller thermistor (temperature sensor),
faulty logic card.

Controller panel temperature is over 80 C (176 F).
Software checks following signal and detects fault.
Controller Thermo. (CN2-43)
(4) Checks
(5) Disconnect battery plug. Wait until controller (12) Operate vehicle and check overheating of controller.
temperature becomes close to room temperature. If problem recurs, check power supply to traction and
Disconnect controller thermistor connector. Measure pump motors or operating cycle. Also check if vehicle
thermistor resistance. Measured resistance should be is operated on steep upgrade or to pull or lift large
8 kΩ or higher at temperature below 70 C (158 F). cargo load.
8kΩ or higher Less than 8kΩ
(6) Check continuity between temperature sensor (11) Replace thermal switch.
connector B (Black) and NEG.
logic card CN2-43BrR (Brown, Red) and temperature
sensor connector BrR (Brown, Red).
2-13
211471
2-14
Problem: Right Motor, Worn Brushes (E4)

Indication: Worn brush indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering
operations.
(1) Situation
Indication: Worn brush indicator ON ("E4" stored in history folder, but not displayed).
(2) Possible cause

Worn right motor brushes, short circuit, faulty indication, faulty logic card.

Right motor brush is worn and signal becomes 0 V (GND).
Traction Motor Right Brush SW. (CN1-27)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 126-V (Purple) and 127-O (Orange) from right
traction motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Indicator ON Indicator OFF
(5) Disconnect battery plug. Check continuity in brush (8) Check brushes and replace, if necessary.
wear detector wires. With wires and connectors
disconnected, also check shorting between positive (+)
and negative (-) sides of batteries.
Controller CN1-27W (White) - Right motor
126-V (Purple)/127-O (Orange)
(6) Replace logic card. (7) Correct or replace wiring.
2-15
211468
2-16
Problem: Left Motor, Worn Brushes (E5)

Indication: Worn brush indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering
operations.
(1) Situation
Indication: Worn brush indicator ON ("E5" stored in history folder, but not displayed).
(2) Possible cause

Worn left motor brushes, short circuit, faulty indication, faulty logic card.

Left motor brush is worn and signal becomes 0 V (GND).
Traction Motor Left Brush SW. (CN1-29)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 131-V (Purple) and 132-O (Orange) from left
traction motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Controller CN1-29L (Blue) - Left motor
131-V (Purple)/132-O (Orange)
2-17
211469
2-18
Problem: Pump Motor, Worn Brushes (E6)

Indication: Worn brush indicator ON. Pump motor lifting speed slower than normal. Normal traction motor and
power steering operations.
(1) Situation
Indication: Worn brush indicator ON ("E6" stored in history folder, but not displayed). Pump motor
lifting speed slower than normal. Normal traction motor and power steering operations.
(2) Possible cause

Worn pump motor brushes, short circuit, faulty indication, faulty logic card.

Pump motor brush is worn and signal becomes 0 V (GND).
Pump Motor Brush SW. (CN1-31)
(4) Checks
Disconnect battery plug. Disconnect brush wear detector wires 136-R (Red) and 137-Y (Yellow) from pump
motor. Reconnect battery plug, and close key switch. Check to see if indicator turns OFF.
Controller CN1-31V (Purple) - Pump motor
136-R (Red)/137-Y (Yellow)
2-19
211470
2-20
Problem: Brake Oil, Low Level

Indication: Low brake oil indicator ON. Normal vehicle operation.
(1) Situation
Indication: Low brake oil indicator ON. Normal vehicle operation.
(2) Possible cause

Insufficient brake oil, wire breakage, faulty indication, faulty logic card.

Software checks following signal and detects fault.
Brake Fluid Sensor SW. (CN1-32)
(4) Checks
Check oil level in brake oil reservoir tank.
Oil level higher than LOW mark Oil level lower than LOW mark
(5) Disconnect battery plug. Disconnect level sensor (10) Add brake oil.
connector CN10, and check continuity.
No continuity Continuity
(9) Replace level sensor.
(6) With connector CN10 disconnected, check continuity

between harness connector socket wire 140L(Blue)
and NEG, and between 139O (Orange) and controller
CN1-32.
2-21
211472
2-22
Problem: Right Motor, Faulty Armature Circuit (10)

Indication: "10" display. Vehicle operation (traction and pump motors) disabled.
(1) Situation
Indication: "10" display. Vehicle operation disabled.
(2) Possible cause

Faulty right motor armature circuit, faulty line contactor, faulty regeneration contactor, faulty D1R diode, faulty D2
diode, faulty right motor armature wiring, faulty head capacitor, faulty T1R IGBT, faulty CS1 current sensor, faulty
wiring in other parts, faulty logic card, faulty drive board, faulty H bridge board.

Right motor armature fault is detected.
Software checks following signals and detects fault.
Pump Motor Voltage (CN2-34) R. Tr. Voltage (CN2-41)
L. & R. Armature Voltage (CN2-39) R. Armature Current (CN2-45)
(4) Checks
Disconnect battery plug. Check line and regeneration contactor tips for wire breakage and melting. Make sure each
contactor tip moves freely. See page 1-41.
No broken or shorted wire Broken or shorted wire
(5)Check right motor armature wiring for wire breakage (18) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor, line contactor).
No broken or Broken or
shorted wire shorted wire
(6) Check T1R IGBT, D1R diode, D2 diode and head (17) Correct or replace right motor, or correct or replace
capacitor for abnormality. Check wiring between D1R wiring.
and logic card for abnormality.
See pages 1-50, 1-47 and 1-39.
Acceptable Unacceptable
(7) Check drive board. Check wiring between T1R and (16) Replace faulty components (T1R, D1R, D2, head
drive board for abnormality. See pages 1-48 to 1-52. capacitor) or wiring.
(8) Check H bridge board. Check wiring between drive (15) Replace drive board or wiring.
motor (R) and H bridge board, and wiring between
POS/NEG and H bridge board for abnormality.
See pages 1-52 to 1-55.
2-23
(9) Check CS1 current sensor for abnormality. Check (14) Replace H bridge board or wiring.
wiring between CS1 and logic card for abnormality.
See page 1-41.
(10)Check logic card, connector and wiring for abnormality. (13) Replace CS1 current sensor or wiring.
Wiring acceptable Wiring unacceptable
(11) Replace logic card. (12) Clean connector or correct wiring, or replace logic
card or wiring.
2-24
211473
2-25
Problem: Right Motor, Transistor Wire Breakage (11)

(1) Situation
(2) Possible cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

Right motor transistor opens when armature voltage output is on.
(4) Checks
Check T1R for abnormality. See page 1-50.
(5)Check drive board. Check wiring between T1R and (12) Replace faulty component (T1R).
drive board for abnormality. See pages 1-48 to 1-52.
(6) Check CS1 for abnormality. Check wiring between (11) Replace drive board or wiring.
CS1 and logic card for abnormality. See page 1-41.
(7) Check logic card, connector and wiring for abnormality. (10) Replace CS1 current sensor or wiring.
(8)Replace logic card. (9) Clean connector or

correct wiring, or replace
logic card or wiring.
2-26
211473
2-27
Problem: Right Motor, Shorted Transistor (12)

(1) Situation
(2) Possible cause

Shorting in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

Right motor transistor shorts when armature voltage output is off.
(4) Checks
Check T1R for abnormality. See page 1-50.
(5)Check drive board. See pages 1-48 to 1-52. (12) Replace faulty component (T1R).
(6) Check CS1 for abnormality. Check wiring between (11) Replace drive board.

2-28
211473
2-29
Problem: Right Motor, Faulty Transistor Drive (13)

(1) Situation
(2) Possible cause

Wire break in T1R, faulty drive board, faulty CS1 current sensor, faulty logic card, faulty wiring.

When right IGBT detects over-current.
Software checks following signal and detects fault when the signal is under 1V.
R. Armature Error (CN2-30)
(4) Checks
Disconnect battery plug. Check T1R for abnormality. See page 1-50 .
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1R).
and logic card, and between drive board and T1R for
abnormality. See pages 1-48 to 1-52.
(6) Check CS1 current sensor for abnormality. Check (11) Replace drive board or wiring.
See page 1-41.

2-30
211474
2-31
Problem: Right Motor, Faulty Current Sensor (14)

(1) Situation
(2) Possible cause

Faulty CS1 current sensor, faulty wiring, faulty logic card.

Right armature current sensor is detected when armature voltage output is off and right current sensor is faulty.
(4) Checks
Check CS1 current sensor. See page 1-41.
(5) Check logic card, connector and wiring for abnormality. (8) Replace CS1 current sensor.

2-32
211473
2-33
Problem: Right Motor, Armature Over-current (15)

(1) Situation
(2) Possible cause


When right armature current is over 350A.
Software checks following signal and detects fault when the signal is over 2.45V.
R. Armature Current (CN2-45)
(4) Checks
Disconnect battery plug. Check regeneration and line contactor tips for melting (shorting). Make sure each contactor
tip moves freely. See page 1-41.
No shorted wire Shorted wire
(5) Check CS1 current sensor. See page 1-41. (11) Correct or replace faulty contactors.
(6) Replace output T1R IGBT. See page 1-65. (10) Replace CS1 current sensor.
(7) If replacement of output IGBT does not correct

problem, check logic card, connector and wiring for
(8) Replace logic card. (9) Clean connector or

2-34
211475
2-35
Problem: Right Motor, Stall Timer (16)

(1) Situation
(2) Possible cause

Stall current flowed more than set time in right traction motor. Faulty CS1 current sensor, faulty wiring,
faulty logic card.

Stall timer set time (set by Setup Option #20) is measured during stalling.
(4) Checks
Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
Operated under normal condition Operated under heavy load
(5) Check CS1 current sensor. Check wiring between CS1 (10) Do not operate vehicle for more than set time under a
and logic card for abnormality. See page 1-41. condition that causes motor to stall.
Acceptable Unacceptable If necessary, adjust Setup Option #20.
(6) Check logic card, connector and wiring for (9) Replace CS1 current sensor, or correct or replace
abnormality. See pages 1-32 to 1-38. wiring.
(7) Replace logic card. (8) Clean connector or correct wiring, or replace
2-36
211475
2-37
Problem: Right Motor, Faulty Field Circuit (17)

(1) Situation
(2) Possible cause

Faulty right motor field circuit (wire breakage, shorting), faulty logic card.

Right motor field fault is detected.
R. Field Current (CN2-15) Pump Motor Voltage (CN2-34)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See pages 1-52 to 1-55.
(5) Check logic card, connector and wiring for abnormality. (8) Replace H bridge board.

2-38
211476
2-39
Problem: Right Motor, Faulty Field Drive (18)

(1) Situation
(2) Possible cause

Faulty right motor field circuit, faulty H bridge board, faulty logic card, faulty controller harness.

When H bridge board detects over-current for right FET.
R. Field Error (CN2-13)
(4) Checks
Disconnect battery plug. Check right motor field cable terminals, logic card CN2-13 terminal and H bridge board
CN2-16 terminal for abnormality.
(5) Check continuity between following terminals. (11) Correct or replace cables.
Right motor field cables
Logic card CN2-13 and CN2-63 (NEG)
No shorted Shorted
(6) Turn on key switch and confirm "18" is displayed. (10) Correct or replace faulty circuit.
(7) Confirm voltage between CN2-13 and CN2-63 (NEG)

with multi-meter.
About 0V About 15V
(8) Replace H bridge board. (9) Replace logic card.
2-40
211477
2-41
Problem: Right Motor, Field Over-current (19)

(1) Situation
(2) Possible cause

Faulty right motor field circuit, faulty logic card.

Software checks following signal and detects fault when the signal (over 4.5V) keeps more than 5 ms.
R. Field Current (CN2-15)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See page 1-52.
(5) Check right motor field wiring for abnormality. (8) Replace H bridge board.
See page 3-15.
Unacceptable Acceptable
(6) Replace right motor field wiring. (7) Replace logic card.
2-42
211478
2-43
Problem: Left Motor, Faulty Armature Circuit (20)

(1) Situation
(2) Possible cause

Faulty left motor armature circuit, faulty line contactor, faulty regeneration contactor, faulty D1L diode, faulty D2
diode, faulty left motor armature wiring, faulty head capacitor, faulty T1L IGBT, faulty CS2 current sensor, faulty
wiring in other parts, faulty logic card, faulty drive board, faulty H bridge board.

Left motor armature fault is detected.
Pump Motor Voltage (CN2-34) L. Tr. Voltage (CN2-42)
L. & R. Armature Voltage (CN2-39) L. Armature Current (CN2-47)
(4) Checks
(5)Check left motor armature wiring for wire breakage (18) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor, line contactor).
(6) Check T1L IGBT, D1L diode, D2 diode and head (17) Correct or replace left motor, or correct or replace
capacitor for abnormality. Check wiring between D1L wiring.
and logic card for abnormality.
See pages 1-50, 1-47 and 1-39.
(7) Check drive board. Check wiring between T1L and (16) Replace faulty components (T1L, D1L, D2, head
(8) Check H bridge board. Check wiring between drive (15) Replace drive board or wiring.
motor (L) and H bridge board, and wiring between
POS/NEG and H bridge board for abnormality.
2-44
(9) Check CS2 current sensor for abnormality. Check (14) Replace H bridge board or wiring.
See page 1-43.
card or wiring.
2-45
211479
2-46
Problem: Left Motor, Transistor Wire Breakage (21)

(1) Situation
(2) Possible cause

Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

Left motor transistor opens when armature voltage output is on.
(4) Checks
Check T1L for abnormality. See page 1-50.
(5)Check drive board. Check wiring between T1L and (12) Replace faulty component (T1L).

2-47
211479
2-48
Problem: Left Motor, Shorted Transistor (22)

(1) Situation
(2) Possible cause

Shorting in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

Left motor transistor shorts when armature voltage output is off.
(4) Checks
Check T1L for abnormality. See page 1-50.
(5)Check drive board. See pages 1-48 to 1-52. (12) Replace faulty component (T1L).

2-49
211479
2-50
Problem: Left Motor, Faulty Transistor Drive (23)

(1) Situation
(2) Possible cause

Wire break in T1L, faulty drive board, faulty CS2 current sensor, faulty logic card, faulty wiring.

When left IGBT detects over-current.
L. Armature Error (CN2-31)
(4) Checks
Disconnect battery plug. Check T1L for abnormality. See page 1-50.
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1L).
and logic card, and between drive board and T1L for
See page 1-43.

2-51
211480
2-52
Problem: Left Motor, Faulty Current Sensor (24)

(1) Situation
(2) Possible cause


Left armature current sensor is detected when armature voltage output is off and left current sensor is faulty.
(4) Checks

2-53
211479
2-54
Problem: Left Motor, Armature Over-current (25)

(1) Situation
(2) Possible cause


When left armature current is over 350A.
Software checks following signal and detects fault when the signal is over 2.45V.
L. Armature Current (CN2-47)
(4) Checks
(6) Replace output T1L IGBT. See page 1-65. (10) Replace CS2 current sensor.
(7) If replacement of output IGBT does not correct

problem, check logic card, connector and wiring for
(8) Replace logic card. (9) Clean connector or

2-55
211481
2-56
Problem: Left Motor, Stall Timer (26)

(1) Situation
(2) Possible cause

Stall current flowed more than set time in left traction motor. Faulty CS2 current sensor, faulty wiring,
faulty logic card.

Stall timer set time (set by Setup Option #20) is measured during stalling.
(4) Checks
Check to see if vehicle is operated on steep upgrade or to pull large cargo load when motor stalls.
Operated under normal condition Operated under heavy load
(5) Check CS2 current sensor. Check wiring between CS2 (10) Do not operate vehicle for more than set time under a
and logic card for abnormality. See page 1-43. condition that causes motor to stall.
Acceptable Unacceptable If necessary, adjust Setup Option #20.
(6) Check logic card, connector and wiring for (9) Replace CS2 current sensor, or correct or replace
abnormality. See pages 1-32 to 1-38. wiring.
(7) Replace logic card. (8) Clean connector or correct wiring, or replace
2-57
211481
2-58
Problem: Left Motor, Faulty Field Circuit (27)

(1) Situation
(2) Possible cause

Faulty left motor field circuit (wire breakage, shorting), faulty logic card.

Left motor field fault is detected.
L. Field Current (CN2-17) Pump Motor Voltage (CN2-34)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See pages 1-52 to 1-55.
(5) Check logic card, connector and wiring for abnormality. (8) Replace H bridge board.

2-59
211482
2-60
Problem: Left Motor, Faulty Field Drive (28)

(1) Situation
(2) Possible cause

Faulty left motor field circuit, faulty H bridge board, faulty logic card, faulty controller harness.

When H bridge board detects over-current for left FET.
L. Field Error (CN2-14)
(4) Checks
Disconnect battery plug. Check left motor field cable terminals, logic card CN2-14 terminal and H bridge board
CN2-15 terminal for abnormality.
(5) Check continuity between following terminals. (11) Correct or replace cables.
Left motor field cables
Logic card CN2-14 and CN2-63 (NEG)
No shorted Shorted
(10) Correct or replace faulty circuit.

(6) Turn on key switch and confirm "28" is displayed.
(7) Confirm voltage between CN2-14 and CN2-63 (NEG)

with multi-meter.
About 0V About 15V
(8) Replace H bridge board. (9) Replace logic card.
2-61
211483
2-62
Problem: Left Motor, Field Over-current (29)

(1) Situation
(2) Possible cause

Faulty left motor field circuit, faulty logic card.

Software checks following signal and detects fault when the signal (over 4.5V) keeps more than 5 ms.
L. Field Current (CN2-17)
(4) Checks
Disconnect battery plug. Check H bridge board for abnormality. See page 1-52.
(5) Check left motor field wiring for abnormality. (8) Replace H bridge board.
See page 3-15.
Unacceptable Acceptable
(6) Replace left motor field wiring. (7) Replace logic card.
2-63
211484
2-64
Problem: Pump Motor, Faulty Circuit (30)

(1) Situation
(2) Possible cause

Faulty pump motor circuit, faulty line contactor, faulty regeneration contactor, faulty D1P diode, faulty pump motor
wiring, faulty head capacitor, faulty T1P IGBT, faulty CS3 current sensor, faulty wiring in other parts, faulty logic
card, faulty drive board.

Pump Motor Voltage (CN2-34) Pump Tr. Voltage (CN2-40)
L. & R. Armature Voltage (CN2-39) Pump Current (CN2-49)
(4) Checks
(5)Check pump motor wiring for wire breakage (16) Correct or replace faulty components (regeneration
and shorting. See page 3-15. contactor or line contactor).
(6) Check T1P IGBT, D1P diode and head capacitor for (15) Correct or replace pump motor, or correct or replace
abnormality. Check wiring between D1P and logic wiring.
card for abnormality.
See pages 1-50, 1-47 and 1-39.
(7) Check drive board. Check wiring between T1P and (14) Replace faulty components (T1P, D1P, head
See page 1-45.
2-65
card or wiring.
2-66
211485
2-67
Problem: Pump Motor, Transistor Wire Breakage (31)

(1) Situation
(2) Possible cause

Wire break in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signals and detects fault when pump motor rotates.
(4) Checks
Check T1P for abnormality. See page 1-50.
(5)Check drive board. Check wiring between T1P and (12) Replace faulty component (T1P).

2-68
211485
2-69
Problem: Pump Motor, Shorted Transistor (32)

(1) Situation
(2) Possible cause

Shorting in T1P, faulty pump motor drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signals and detects fault when line contactor closes and pump motor does not rotate.
(4) Checks
Check T1P for abnormality. See page 1-50.
(5)Check drive board. See pages 1-48 to 1-52. (12) Replace faulty component (T1P).

2-70
211485
2-71
Problem: Pump Motor, Faulty Transistor Drive (33)

Indication: "33" display. Vehicle operation (traction and pump motors) disabled..
(1) Situation
(2) Possible cause

Wire break in T1P, faulty drive board, faulty CS3 current sensor, faulty logic card, faulty wiring.

Software checks following signal and detects fault when line contactor closes.
Pump Error (CN2-32)
(4) Checks
Disconnect battery plug. Check T1P for abnormality. See page 1-50.
(5)Check drive board. Check wiring between drive board (12) Replace faulty component (T1P).
and logic card, and between drive board and T1P for
See page 1-45.

2-72
211486
2-73
Problem: Pump Motor, Faulty Current Sensor (34)

(1) Situation
(2) Possible cause


Software checks following signals and detects fault when line contactor closes and pump motor does not rotate.
(4) Checks

2-74
211485
2-75
Problem: Pump Motor, Armature Over-current (35)

(1) Situation
(2) Possible cause


Software checks following signal and detects fault during software running.
Pump Current (CN2-49)
Software detects fault when pump current (CN2-49) is more than 3.5V and it continues longer than 5 msec.
(4) Checks
(6) Check T1P IGBT. See page 1-50. (11) Replace CS3 current sensor.
(7) Check logic card, connector and wiring for abnormality. (10) Replace T1P IGBT.

2-76
211487
2-77
Problem: Line Contactor, Abnormality (40)

(1) Situation
(2) Possible cause

Faulty line contactor (wire breakage, shorting), faulty logic card.

Software checks following signals and detects fault when line contactor closes.
Pump Motor Voltage (CN2-34) L. Armature Current (CN2-47)
L. & R. Armature Voltage (CN2-39) R. Field Current (CN2-15)
R. Tr. Voltage (CN2-41) L. Field Current (CN2-17)
R. Armature Current (CN2-45) Pump Tr. Voltage (CN2-40)
L. Tr. Voltage (CN2-42) Pump Current (CN2-49)
(4) Checks
Disconnect battery plug. Check line contactor tip for wire breakage and shorting (melting).
Check that contactor tip moves freely. See page 1-41.
(5) Check logic card, connector and wiring for abnormality. (8) Correct or replace faulty component (line contactor).
card or wiring.
2-78
211488
2-79
Problem: Regeneration Contactor, Abnormality (41)

(1) Situation
(2) Possible cause

Faulty regeneration contactor (wire breakage, shorting), faulty logic card.

Pump Motor Voltage (CN2-34) R. Armature Current (CN2-45)
L. & R. Armature Voltage (CN2-39) L. Tr. Voltage (CN2-42)
R. Tr. Voltage (CN2-41) L. Armature Current (CN2-47)
(4) Checks
Disconnect battery plug. Check regeneration contactor tip for wire breakage and shorting (melting).
Check that contactor tip moves freely. See page 1-41.
(5) Check logic card, connector and wiring for abnormality. (8) Correct or replace faulty component (regeneration
See pages 1-32 to 1-38. contactor).
card or wiring.
2-80
211489
2-81
Problem: Regeneration Diode, Abnormality (43)

(1) Situation
(2) Possible cause

Faulty regeneration diode (wire breakage, shorting), faulty CS1/CS2 current sensor, faulty logic card.

Software checks following signals and detects fault while motor is powering.
R. Tr. Voltage (CN2-41) L. Armature Current (CN2-47)
(4) Checks
Disconnect battery plug. Check D2 regeneration diode for abnormality. See page 1-47.
(5)Check CS1 and CS2 current sensors for abnormality. (10) Replace faulty component (D2).
Check wiring between CS1 and T1R, and between CS2
and T1L. See pages 1-41 to 1-45.
(6) Check logic card, connector and wiring for abnormality. (9) Replace CS1 and/or CS2 current sensor or wiring.
card or wiring.
2-82
211490
2-83
Problem: Right Armature Diode, Abnormality (44)

(1) Situation
(2) Possible cause

Faulty right armature diode (wire breakage, shorting), faulty CS1 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check right armature diode D1R for abnormality.
See page 1-47.
(5) Check CS1 current sensor for abnormality. Check (10) Replace faulty component (D1R).
wiring between CS1 and D1R for abnormality.
See page 1-41.
card or wiring.
2-84
211473
2-85
Problem: Left Armature Diode, Abnormality (45)

(1) Situation
(2) Possible cause

Faulty left armature diode (wire breakage, shorting), faulty CS2 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check left armature diode D1L for abnormality.
See page 1-47.
(5) Check CS2 current sensor for abnormality. Check (10) Replace faulty component (D1L).
wiring between CS2 and D1L for abnormality.
See page 1-43.
(7)Replace logic card. (8) Clean connector or correct wiring, or replace logic
card or wiring.
2-86
211479
2-87
Problem: Pump Armature Diode, Abnormality (46)

(1) Situation
(2) Possible cause

Faulty pump armature diode (wire breakage, shorting), faulty CS3 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Check pump armature diode D1P for abnormality.
See page 1-47.
(5) Check CS3 current sensor for abnormality. Check (10) Replace faulty component (D1P).
wiring between CS3 and D1P for abnormality.
See page 1-45.
card or wiring.
2-88
211485
2-89
Problem: Right Motor, Wire Breakage (47)

(1) Situation
(2) Possible cause

Wire breakage in right motor, faulty CS1 current sensor, faulty logic card.

Software checks following signals and detects fault during regeneration.
(4) Checks
Disconnect controller terminals A1R, A2R and field wiring connector (4pins), and check resistance between A1R
and A2R and between S1R and S2R.
Resistance detected Wire break
(5) Check CS1 current sensor for abnormality. Check (10) Replace right motor, or correct or replace right motor
wiring between A1R and A2R for abnormality. wiring.
See page 1-41.
card or wiring.
2-90
211491
2-91
Problem: Left Motor, Wire Breakage (48)

(1) Situation
(2) Possible cause

Wire breakage in left motor, faulty CS2 current sensor, faulty logic card.

Software checks following signals and detects fault during regeneration.
(4) Checks
Disconnect controller terminals A1L, A2L and field wiring connector (4pins), and check resistance between A1L
and A2L and between S1L and S2L.
(5) Check CS2 current sensor for abnormality. Check (10) Replace left motor, or correct or replace left motor
wiring between A1L and A2L for abnormality. wiring.
See page 1-43.
card or wiring.
2-92
211492
2-93
Problem: Pump Motor, Wire Breakage (49)

(1) Situation
(2) Possible cause

Wire breakage in pump motor, faulty CS3 current sensor, faulty logic card.

(4) Checks
Disconnect battery plug. Disconnect controller terminals PA1 and PS2, and check resistance between
PA1 and PS2.
(5) Check CS3 current sensor for abnormality. Check (10) Replace pump motor, or correct or replace pump
wiring between PA1 and PS2 for abnormality. motor wiring.
See page 1-45.
card or wiring.
2-94
211493
2-95
Problem: Steering Sensor, Abnormality (50)

(1) Situation
(2) Possible cause

Faulty steering sensor, faulty wiring (wire breakage, shorting), faulty logic card.

Software checks following signals and detects fault when all signals are in High (15V).
Steering 1 (CN1-10) Steering 3 (CN1-12)
Steering 2 (CN1-11) Steering 4 (CN1-13)
(4) Checks
Check continuity between steering sensor and logic card.
CN12-117L (blue) - CN1-13L (blue)
CN12-116Y (yellow) - CN1-12Y (yellow)
CN12-115W (white) - CN1-11W (white)
CN12-114G (green) - CN1-10G (green)
CN12-112R (red) - CN1-1R (red)
CN12-113B (black) - NEG
(5) Check logic card, connector and wiring for abnormality. (8) Correct or replace wiring.
See pages 1-32 to 1-38. "50" display remains
(6)Replace logic card. (7) Clean connector or correct (9) Replace steering sensor.
wiring, or replace logic
card or wiring.
2-96
211494
2-97
Problem: Accelerator, Abnormality (51)

Indication: "51" display. Faulty accelerator circuit. Traction and pump motors disabled.
(1) Situation
Indication: "51" display. Faulty accelerator circuit.
(2) Possible cause

Faulty accelerator, faulty wiring (wire breakage, shorting), faulty logic card, faulty accelerator adjustment.

Software checks following signals and detects fault when key switch is turned on.
Accel Pedal Angle (CN1-33)
Accel Switch (CN1-14)
When each condition keeps longer than 2 ms, software detects fault.
When accelerator pedal angle is under 0.2 V or over 4.8 V
When accelerator pedal angle is over 0.3 V and accelerator switch is closed
When accelerator pedal angle is over 1.41 V and accelerator switch is opened
(4) Checks
Check condition when this fault occurred.
When key switch When accelerator pedal When accelerator pedal When error
is turned on is fully depressed is slightly depressed occurs occasionally
(10) Adjust accelerator pedal stroke. (11) Replace accelerator. (12) Replace accelerator.
See "Vehicle Electrical Components" If error recurs, replace
of Chassis Service Manual. logic card.
(5) Check continuity between following terminals and

wire breakage.
CN7-141R - Logic card CN1-39R
CN7-142G - Logic card CN1-33G
CN7-143B - Logic card CN1-37L
CN7-144L - Logic card CN1-14L
Continuity, no breakage No continuity, breakage
(6) Check following two conditions are satisfied. (9) Correct or replace wiring.
• Accelerator switch opens when accelerator pedal
is not depressed.
• Accelerator switch closes when accelerator pedal
is depressed 2 to 3 mm (0.08 to 0.12 in.).
Satisfied Not satisfied
(7) Replace logic card. (8) Adjust accelerator pedal mounting condition.
See "Vehicle Electrical Components" of Chassis
Service Manual.
2-98
211495
2-99
Problem: Right Vehicle Speed Sensor, Abnormality (52)

Indication: "52" display. Faulty right speed sensor circuit. Traction and pump motors disabled.
(1) Situation
Indication: "52" display. Traction and pump motors disabled.
(2) Possible cause

Faulty right speed sensor, faulty right speed sensor wiring (wire breakage, shorting), faulty logic card.

Software detects fault when right speed sensor error input signal keeps more than 200 ms.
(4) Checks
Check resistance between CN16-145Y (yellow) and CN16-146B (black) of right speed sensor. See page 1-71.
Acceptable (1.8 to 2.2 kΩ) Unacceptable
(10) Replace right speed sensor.
(5) Remove logic card cover.

Check continuity between following terminals and shorting to negative (-) side.
CN16-145Y - CN11-145Y - Logic card CN1-43Y (yellow)
CN16-146B - CN11-146B - Logic card CN1-45B (black)
Continuity, no shorting No continuity, or shorted
card or wiring.
2-100
211496
2-101
Problem: Left Vehicle Speed Sensor, Abnormality (53)

Indication: "53" display. Faulty left speed sensor circuit. Traction and pump motors disabled.
(1) Situation
Indication: "53" display. Traction and pump motors disabled.
(2) Possible cause

Faulty left speed sensor, faulty left speed sensor wiring (wire breakage, shorting), faulty logic card.

Software detects fault when left speed sensor error input signal keeps more than 200 ms.
(4) Checks
Check resistance between CN15-147L (blue) and CN15-148G (green) of left speed sensor. See page 1-71.
Acceptable (1.8 to 2.2 kΩ) Unacceptable
(10) Replace left speed sensor.
(5) Remove logic card cover.

Check continuity between following terminals and shorting to negative (-) side.
CN15-147L - CN11-147L - Logic card CN1-47L (blue)
CN15-148G - CN11-148G - Logic card CN1-49G (green)
Continuity, no shorting No continuity, or shorted
card or wiring.
2-102
211497
2-103
Problem: FC Lever, Abnormality (54)

Indication: "54" display. Faulty operation circuit. Related hydraulic function disabled. (This fault is detected for FC
models only.)
(1) Situation
Indication: "54" display. Related hydraulic function disabled.
(2) Possible cause

Faulty operating lever, faulty lever wiring (wire breakage, shorting), faulty FC controller.

FC controller software checks FC control lever voltage and detects fault.
When fault is detected, FC controller LED flickers and informs main controller of fault.
(4) Checks
Check continuity according to troubleshooting for FC controller. See "Vehicle Electrical Components"
of Chassis Service Manual.
2-104
211498
2-105
Problem: FC Solenoid, Abnormality (55)

Indication: "55" display. Faulty solenoid excitation circuit. Related hydraulic function disabled. (This fault is
detected for FC models only.)
(1) Situation
Indication: "55" display. Related hydraulic function disabled.
(2) Possible cause

Faulty solenoid, faulty solenoid wiring (wire breakage, shorting), faulty FC controller.

FC controller software checks solenoid current when FC control lever is operated.
When fault is detected, solenoid current stops, FC controller LED flickers and informs main controller of fault.
(4) Checks
2-106
211499
2-107
Problem: FC Controller, Abnormality (57)

Indication: "57" display. Faulty FC controller. All hydraulic functions disabled. (This fault is detected for FC models
only.)
(1) Situation
Indication: "57" display. All hydraulic functions disabled.
(2) Possible cause

Faulty FC controller, faulty wiring (wire breakage, shorting) between FC controller and main controller.

Main controller software checks signals from FC controller and detects fault when all signals become open.
(4) Checks
2-108
211500
2-109
Problem: Direction Lever and Accelerator, Faulty Setting (E)

Indication: "E" display. Vehicle operation disabled.
(1) Situation
Indication: "E" display. Vehicle operation disabled.
(2) Possible cause

Key switch turned on while direction lever was left either in forward or reverse position. Key switch turned on while
accelerator pedal was depressed. Faulty direction lever switch, faulty accelerator, faulty logic card.

Software checks following signals and detects fault when key switch is turned on.
Forward Sig (CN1-5) Accel Switch (CN1-14)
Reverse Sig (CN1-6) Accel Pedal Angle (CN1-33)
(4) Checks
Shift direction lever to neutral, and release accelerator pedal. Turn on key switch again, shift direction lever to
forward or reverse, then press accelerator pedal.
No change Vehicle operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that direction lever
component. See page 1-19. be in neutral position and accelerator pedal be in OFF
position when key switch is turned on.
(6) If faulty component cannot be located, replace logic

card.
2-110
211501
2-111
Problem: Seat Switch, Faulty Setting ((E))

Indication: Flashing "E" display. Vehicle operation disabled.
(1) Situation
Indication: Flashing "E" display. Vehicle operation disabled.
(2) Possible cause

Operator not seated, faulty seat switch (option), wire breakage, faulty logic card, open circuit in seat switch.

Software checks following signal and detects fault when key switch is turned on.
Seat Switch (CN1-9)
(4) Checks
Disconnect battery plug. Remove logic card cover. Disconnect connector CN1. Check continuity between harness
connector CN1-9Y (yellow) and CN1-22G (green). Circuit must close when seat is pressed, and must open
when no force is applied on seat.
No continuity Continuity
(5)With seat pressed, check continuity between seat switch (10) Replace logic card.
wires 111-Y (yellow) and 110-G (green) on switch side.
(6) Check continuity between seat switch harness 111-Y (9) Correct connector contacts or replace seat switch.
(yellow) and logic card CN1-9Y (yellow), and
between 110-G (green) and CN1-22G (green).
2-112
211502
2-113
Problem: Lift Lever, Faulty Setting (H1)

Indication: "H1" display. Lift operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H1" display. Lift operation disabled.
(2) Possible cause

Key switch turned on while lift lever was in ON position, faulty lift lever switch, faulty logic card.

Software checks initial condition of lift lever switch when turning on key switch and detects fault if lift lever switch
is closed.
Lift Lever SW. 0 (CN1-16)
Lift Lever SW. 1 (CN1-17)
(4) Checks
Set lift lever to OFF, then to ON again.
No change Lift function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that lift lever
component. See page 1-19. be in OFF position when key switch is turned on.

card.
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211503
2-115
Problem: Tilt Lever, Faulty Setting (H2)

Indication: "H2" display. Tilt operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H2" display. Tilt operation disabled.
(2) Possible cause

Key switch turned on while tilt lever was in ON position, faulty tilt lever switch, faulty logic card.

Software checks initial condition of tilt lever switch when turning on key switch and detects fault if tilt lever switch
is closed.
Tilt Lever SW. (CN1-18)
(4) Checks
Set tilt lever to OFF, then to ON again.
No change Tilt function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that tilt lever
component. See page 1-19. be in OFF position when key switch is turned on.

card.
2-116
211504
2-117
Problem: Attachment 1 Lever, Faulty Setting (H3)

Indication: "H3" display. ATT1 operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H3" display. ATT1 operation disabled.
(2) Possible cause

Key switch turned on while ATT1 lever was in ON position, faulty ATT1 lever switch,
faulty logic card.

Software checks initial condition of ATT1 lever switch when turning on key switch and detects fault if ATT1 lever
switch is closed.
Aux 1 (CN1-19)
(4) Checks
Set ATT1 lever to OFF, then to ON again.
No change ATT1 function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that ATT1 lever be
component. See page 1-19. in OFF position when key switch is turned on.

card.
2-118
211505
2-119
Problem: Attachment 2 Lever, Faulty Setting (H4)

Indication: "H4" display. ATT2 operation disabled. (This fault is detected for MC models only.)
(1) Situation
Indication: "H4" display. ATT2 operation disabled.
(2) Possible cause

Key switch turned on while ATT2 lever was in ON position, faulty ATT2 lever switch,
faulty logic card.

Software checks initial condition of ATT2 lever switch when turning on key switch and detects fault if ATT2
lever switch is closed.
Aux 2 (CN1-20)
(4) Checks
Set ATT2 lever to OFF, then to ON again.
No change ATT2 function operates
(5) Use self-diagnosis function to locate faulty circuit or (7) Proper starting procedure requires that ATT2 lever be
component. See page 1-19. in OFF position when key switch is turned on.

card.
2-120
211506
2-121
Problem: FC Controller Lever, Faulty Setting (H5)

Indication: "H5" display. Faulty operating lever setting. All functions disabled. (This fault is detected for FC models
only.)
(1) Situation
Indication: "H5" display. All functions disabled.
(2) Possible cause

Operating lever not in proper neutral position, faulty wiring (wire breakage, shorting) of lever, faulty FC controller,
faulty FC control lever.

FC controller software checks FC control lever voltage and detects fault.
When fault is detected, FC controller LED flickers and informs main controller of fault.
(4) Checks
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2-123
Problem: Data Communication, Abnormality (60)

Indication: "60" display.
(1) Situation
Indication: "60" display.
Vehicle operation enabled Vehicle operation disabled
(2) Possible cause (9) Possible cause

Faulty display, faulty wiring, faulty logic card. Faulty wiring, faulty logic card.
(3) How the error code is triggered (10) Checks

Display unit checks following signals and detects fault Connect battery plug. Turn key switch on, then check
when display unit cannot communicate with logic card. voltage between logic card CN1-1R (red) and logic card
Display TXD (CN1-59) CN2-63B or 64B (black). Checked voltage should be
Display RXD (CN1-61) same as battery voltage.
Voltage acceptable Voltage unacceptable
(4) Checks
Disconnect battery plug. Check continuity between (11) Check logic card. (14)Correct or replace
display CN4-149W (white) and logic card CN1-59W Remove logic card cover. wiring or related
(white), and between CN4-150B (black) and CN1-61B Connect battery plug and turn devices.
(black). key switch on, then check
Continuity No continuity LED (green) on logic card.
Flashing No fashing
(5) Check logic card. (8) Correct or replace

(Tr1 on logic card may be wiring. (13) Replace logic card. (D9 on logic card
defective. See page 1-38.) may be defective. See page 1-38.)
(12) Data communication error and another defect have

(6) Replace display unit. (7)Replace logic card. occurred simultaneously. First, check the data
communications by using the procedures above.
After repairing data communications, confirm error
code and troubleshoot by using its own checking
procedure.
2-124
211507
2-125
Problem: EEPROM, Abnormality (61)

(1) Situation
(2) Possible cause

Faulty EEPROM. During access to EEPROM, some faults occur. Faulty logic card.

When the logic software starts, first it reads the Setup Option data and then the check sum data from the EEPROM.
The software compares both data. When there is a difference, error 61 occurs.
(4) Checks
Set "default values" (See page 1-19). Turn off key switch, then turn on key switch again.
"61" display remains Normal vehicle operation
(5) Replace logic card. (6) Vehicle operates normally.
2-126
Problem: Logic Card, Faulty Initial Setting (65)

(1) Situation
(2) Possible cause

Faulty DIP switch (DSW) setting on logic card, model selection not set, faulty logic card.

Software checks DSW2, 3 and 8 settings and detects fault if settings are not correct.
(4) Checks
Check that DSW2, 3 and 8 settings correspond to vehicle type. If vehicle model is not set, make setting.
See page 1-27.
(5) If correct settings do not solve problem, replace logic

card.
2-127
Problem: Controller, Abnormality (66)

(1) Situation
(2) Possible cause

Faulty logic card (faulty logic circuit, faulty microprocessor MPU, faulty memory, faulty initial setting).

Software checks ROM and RAM and detects fault.
(4) Checks
Perform initial adjustment of controller. (Set default values. See page 1-22.)
"66" display remains Normal vehicle operation
(5) Replace logic card. (6) Vehicle operates normally.
2-128
Problem: Battery Voltage, Excessively Low (68) (For 48-V Vehicles Only)
(1) Situation
Indication: "68" display. Vehicle operation disabled. Low battery voltage. Faulty battery discharge indicator (BDI)
circuit.
(2) Possible cause

Discharged battery or faulty battery, faulty logic card, faulty BDI adjustment.

When key switch is turned on, software checks battery voltage and detects fault if it is less than 42V.
(4) Checks
Connect battery plug. Turn key switch on, close seat switch, then check voltage between line contactor (POS)
and NEG. Checked voltage should be 42 V or higher.
Voltage acceptable Low voltage
(5) Adjust battery discharge indicator (BDI) according to (6) Check battery connection, and charge or replace battery.
specification.
Adjust dial on logic card (See page 1-18, "Setting").
If BDI cannot be adjusted, replace logic card.
2-129
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TROUBLESHOOTING FOR CONTROL CIRCUITS

General Information ............................................................................... 2– 1

Electrical System Diagram .................................................................. 2 – 131

Before replacing boards

How to clean harness connectors and system

Electronic parts Three Bond 29D or

2. After checking the connector for continuity, wash it as

Contact surface Three Bond 2501S (aerosol)

*: Products contained in Terminal Maintenance Kit

Item Alarm Detection Method/Condition Detecting Location

Right Motor, Faulty Armature Combination from

Item Alarm Detection Method/Condition Detecting Location

Direction Lever and Accelerator, Lever is not in neutral or accelerator is not

Problem: Right Motor, Overheating (E0)

(2) Possible cause

(3) How the error code is triggered

(8) Faulty logic card (9) Correct or replace wiring.

Problem: Left Motor, Overheating (E1)

(2) Possible cause

(3) How the error code is triggered

(8) Faulty logic card (9) Correct or replace wiring.

Problem: Pump Motor, Overheating (E2)

(2) Possible cause

(3) How the error code is triggered

(8) Faulty logic card (9) Correct or replace wiring.

Problem: Controller, Overheating (E3)

(2) Possible cause

(3) How the error code is triggered

(8) Faulty logic card (9) Correct or replace wiring.

Problem: Right Motor, Worn Brushes (E4)

(2) Possible cause

(3) How the error code is triggered

(6) Replace logic card. (7) Correct or replace wiring.

Problem: Left Motor, Worn Brushes (E5)

(2) Possible cause

(3) How the error code is triggered

(6) Replace logic card. (7) Correct or replace wiring.

Problem: Pump Motor, Worn Brushes (E6)

(2) Possible cause

(3) How the error code is triggered

(6) Replace logic card. (7) Correct or replace wiring.

Problem: Brake Oil, Low Level

(2) Possible cause

(3) How the error code is triggered

(9) Replace level sensor.

(6) With connector CN10 disconnected, check continuity

(7) Faulty logic card (8) Correct or replace wiring.

Problem: Right Motor, Faulty Armature Circuit (10)

(2) Possible cause

(3) How the error code is triggered

Problem: Right Motor, Transistor Wire Breakage (11)

(2) Possible cause

(3) How the error code is triggered

(8)Replace logic card. (9) Clean connector or

Problem: Right Motor, Shorted Transistor (12)

(2) Possible cause

(3) How the error code is triggered

(8)Replace logic card. (9) Clean connector or

Problem: Right Motor, Faulty Transistor Drive (13)

(2) Possible cause

(3) How the error code is triggered

(8)Replace logic card. (9) Clean connector or

Problem: Right Motor, Faulty Current Sensor (14)

(2) Possible cause