8FBE RM CE206 Section 3 Troubleshooting Vol. 2 - Codigos

3 TROUBLESHOOTING 3-159
3 TROUBLESHOOTING
3
3.1 BEFORE TROUBLESHOOTING........................................................... 159
3.2 SST........................................................................................................ 161
3.3 DIAGNOSIS CODE LIST....................................................................... 161
3.4 WHEN ERROR CODE IS DISPLAYED................................................. 171
3.5 WHEN NO ERROR CODE IS DISPLAYED .......................................... 641
3.1 BEFORE TROUBLESHOOTING
3.1.1 CONNECTOR HANDLING

1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull it at
the harness but hold the connector itself and pull it
after unlocking it.
To connect, push the connector fully until it is locked
in position.
3. Bring a tester probe into contact with a connector

terminal from the rear side of the coupler (harness
side).
4. If insertion from the rear side is impossible, as in
the case of a waterproof connector, bring the tester
probe carefully into contact with the terminal so as
not to cause deformation of the connector terminal.
5. Do not touch connector terminals directly with your
hand.
6. When bringing tester probes into contact with live
terminals, prevent two tester probes from coming into
contact with each other.
3.1.2 WIRE HARNESS AND CONNECTOR INSPECTION

PROCEDURE
When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the
following procedure:
3-160 3 TROUBLESHOOTING
Continuity check
1. Disconnect the connectors at both ends of the cor-
responding harness.
2. Measure the resistance between corresponding
terminals of the connectors at both ends.
Standard: 10 Ω or less
NOTICE!
▪ Measure while lightly shaking the wire har-
ness up and down and sideways
▪ Open circuit at the wire harness occurs rarely
partway through a vehicle wiring but mostly at
connectors. Inspect especially the sensor
connectors with sufficient care.
Short circuit check

1. Disconnect the connectors at both ends of the cor-
responding harness.
2. Measure the resistance between the correspond-
ing connector terminal and N1. Always inspect the
connectors at both ends.
Standard: 1 MΩ or above
NOTICE! : Measure while lightly shaking the wire
harness up and down and sideways.
3. Measure the resistance between a terminal corres-

ponding to the connector terminal and N1. Always in-
spect the connectors at both ends.
Standard: 1 MΩ or above
NOTICE! : The wiring may short-circuit due to
pinching by the body or defective clamping.
Visual and contact pressure checks

▪ Disconnect the connectors at both ends of the
corresponding harness.
▪ Visually inspect that there is neither rust nor for-
eign matter trapped at connector terminals.
▪ Inspect that there is no loosening or damage at
the locked portion. Also, lightly pull the wire har-
ness from the connector to check that it does not
come off.
▪ Insert a male terminal same as that of the ter-

minal to a female connector and check the ex-
tracting force. Defective contact may exist at a
terminal where the extracting force is less than 3
that of other terminals.
NOTICE! : Even if there is rust or foreign matter
trapped at the terminal, or the contact pressure
between male and female terminals is low, abnor-
mal contact condition may be changed to normal
by disconnecting and reconnecting the connector.
In that case, repeat connector connection and dis-
connection several times. If defect is perceived
even once, terminal contact may be defective.
3.2 SST
Use SSTs for quick, accurate troubleshooting of the 8FBU series electrical system.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect con-
nection, careful operation is necessary.
SST No. SST name
Shorting harness
09230-13700-71 (SST)
(for CN91 connector)
Shorting harness
((for CN6, CN19,
CN26,CN52,CN53,CN54, CN55,
CN56, CN86, CN97, CN101, CN102,
09232-13130-71 (SST2)
CN115, CN119, CN120, CN121,
CN122,CN123, CN126, CN129,
CN130, CN138 and CN163 connect-
ors))
CAUTION
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is
kept connected, various boards may be damaged.
3.3 DIAGNOSIS CODE LIST

Indica- Diagnosis code will be indicated on the display when vehicle trouble occurs.
tion:
Memory: Use this indicated diagnosis code that can be checked on the display when using the service
function DIAG MEMORY.
Indicator:
Spanner
Overheat warning (O/H)
Detection
Indication Memory Indicator Error mode Page
ECU
Drive motor
Drive motor driver power-circuit
DCR A0-1 O/H lighting driver (LH) .page 172
abnormality
(RH)
Pump motor Pump motor driver power-cir-
PCR A0-2 O/H lighting .page 176
driver cuit abnormality
Spanner blink-
A1-1 A1-1 Main controller Main controller high voltage .page 180
ing
Detection
ECU
Spanner blink- Drive motor Drive motor driver LH high
A1-2 A1-2 .page 182
ing driver (LH) voltage
Spanner blink- Drive motor Drive motor driver RH high
A1-3 A1-3 .page 184
ing driver (RH) voltage
Spanner blink- Pump motor
A1-4 A1-4 Pump motor driver high voltage .page 186
ing driver
Main controller overheating ab-
C/R A2-1 O/H lighting Main controller .page 188
normality
Drive motor Drive motor driver circuit
DCR A2-2 O/H lighting driver (LH) board / the condenser over- .page 190
(RH) heating abnormality.
Pump motor driver circuit
Pump motor
PCR A2-3 O/H lighting board / the condenser over- .page 195
driver
heating abnormality
Spanner blink-
A3-1 A3-1 Main controller Battery connection incorrect .page 200
ing
Spanner blink-
A5-1 A5-1 Main controller Seat switch short abnormality .page 201
ing
Spanner blink- Tilt lever switch short abnormal-
A6-3 A6-3 Main controller .page 203
ing ity
Spanner blink-
A8-1 A8-1 Main controller F1 fuse open abnormality .page 205
ing
Spanner blink-
A8-2 A8-2 Main controller F6 fuse open abnormality .page 208
ing
Spanner blink- F7 fuse / solenoid power supply
A9-2 A9-2 Main controller .page 212
ing line open abnormality
Spanner blink- Main controller temperature
AA-1 AA-1 Main controller .page 214
ing sensor (open/short) abnormality
Drive motor driver LH board
Spanner blink- Drive motor
AA-2 AA-2 temperature sensor (open/ .page 215
ing driver (LH)
short) abnormality
Drive motor driver RH board
AA-3 AA-3 temperature sensor (open/ .page 216
ing driver (RH)
short) abnormality
Pump motor driver board tem-
AA-4 AA-4 perature sensor (open/short) .page 217
ing driver
abnormality
Spanner blink-
AB-1 AB-1 Main controller Cooling fan overcurrent .page 218
ing
Spanner blink- Motor driver power delivery ab-
AC-1 AC-1 Main controller .page 222
ing normality
Drive motor driver LH to Main
Spanner blink-
AD-1 AD-1 Main controller controller : communication ab- .page 225
ing
normality
Drive motor driver LH to Main
Spanner blink-
ing
normality
Drive motor driver RH to Main
Spanner blink-
ing
normality
Drive motor driver RH to Main
Spanner blink-
ing
normality
Detection
ECU
Pump motor driver to Main con-
Spanner blink- 3
AD-5 AD-5 Main controller troller : communication abnor- .page 239
ing
mality
Pump motor driver to Main con-
Spanner blink-
AD-6 AD-6 Main controller troller : communication abnor- .page 240
ing
mality
Spanner blink-
AF-1 AF-1 Main controller Main controller CPU error .page 243
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink- Drive motor Drive motor driver LH power-
C0-2 C0-2 .page 251
ing driver (LH) circuit abnormality
Spanner blink- Drive motor Drive motor driver RH power-
C0-4 C0-4 .page 254
ing driver (RH) circuit abnormality
Spanner blink- Drive motor Drive motor driver LH current
C1-1 C1-1 .page 257
ing driver (LH) sensor neutral voltage error
Spanner blink- Drive motor Drive motor driver LH current
C1-2 C1-2 .page 258
ing driver (LH) sensor over current abnormality
Spanner blink- Drive motor Drive motor driver RH current
C1-3 C1-3 .page 261
ing driver (RH) sensor neutral voltage error
Spanner blink- Drive motor Drive motor driver RH current
C1-4 C1-4 .page 262
ing driver (RH) sensor over current abnormality
Drive motor
Drive motor overheating abnor-
DM C2-1 O/H lighting driver (LH) .page 265
mality
(RH)
Spanner blink- Drive motor Drive motor LH temperature
C2-2 C2-2 .page 267
ing driver (LH) sensor (open/short) abnormality
Spanner blink- Drive motor Drive motor RH temperature
C2-3 C2-3 .page 269
ing driver (RH) sensor (open/short) abnormality
Drive motor driver LH power-
C3-1 C3-1 circuit temperature sensor .page 271
ing driver (LH)
(open/short) abnormality
Drive motor driver RH power-
C3-2 C3-2 circuit temperature sensor .page 272
ing driver (RH)
(open/short) abnormality
Spanner blink- Accelerator potentiometer
C4-1 C4-1 Main controller .page 273
ing POT1 open abnormality
ing POT2 open abnormality
Accelerator potentiometer
Spanner blink-
C4-3 C4-3 Main controller POT1VCC short circuit abnor- .page 279
ing
mality
Detection
ECU
Accelerator potentiometer
Spanner blink-
C4-4 C4-4 Main controller POT2VCC short circuit abnor- .page 282
ing
mality
Spanner blink- Accelerator potentiometer off-
ing set abnormality
ing matching value abnormality
Spanner blink- Brake potentiometer POT1
ing open abnormality
Spanner blink- Brake potentiometer POT2
ing open abnormality
Spanner blink- Brake potentiometer POT1VCC
ing short circuit abnormality
Spanner blink- Brake potentiometer POT2VCC
ing short circuit abnormality
Spanner blink- Brake potentiometer matching
ing value abnormality
Spanner blink- Brake potentiometer matching
ing value error.
Spanner blink- Drive motor Drive motor LH rotation sensor
C8-1 C8-1 .page 305
ing driver (LH) open abnormality
Spanner blink- Drive motor Drive motor LH rotation sensor
C8-2 C8-2 .page 309
ing driver (LH) short abnormality
Spanner blink- Drive motor Drive motor RH rotation sensor
C8-3 C8-3 .page 313
ing driver (RH) open abnormality
Spanner blink- Drive motor Drive motor RH rotation sensor
C8-4 C8-4 .page 317
ing driver (RH) short abnormality
Spanner blink-
CB-1 CB-1 Main controller MB contactor open abnormality .page 321
ing
Spanner blink-
CB-2 CB-2 Main controller MB contactor short abnormality .page 325
ing
Spanner blink- MB contactor (coil side) open
CB-3 CB-3 Main controller .page 327
ing abnormality
Spanner blink- MB contactor traveling circuit
ing abnormality
Spanner blink- MB contactor (coil side) short
ing abnormality
Spanner blink- Drive motor Drive motor driver LH CPU ab-
CC-1 CC-1 .page 333
ing driver (LH) normality
CC-2 CC-2 .page 334
CC-3 CC-3 .page 335
CC-4 CC-4 .page 336
CC-6 CC-6 .page 337
Spanner blink- Drive motor Drive motor driver RH CPU ab-
CD-1 CD-1 .page 338
ing driver (RH) normality
CD-2 CD-2 .page 339
CD-3 CD-3 .page 340
Detection
ECU
CD-4 CD-4 .page 341 3
CD-6 CD-6 .page 342
Spanner blink- Pump motor Pump motor driver power-cir-
E0-2 E0-2 .page 343
ing driver cuit abnormality
Spanner blink- Pump motor Pump motor driver current
E1-1 E1-1 .page 346
ing driver sensor neutral voltage error
Spanner blink- Pump motor Pump motor driver current
E1-2 E1-2 .page 347
ing driver sensor over current error
Pump motor Pump motor overheating abnor-
PM E2-1 O/H lighting .page 350
driver mality
Spanner blink- Pump motor Pump motor temperature
E2-2 E2-2 .page 352
ing driver sensor (open/short) abnormality
Pump motor driver power-cir-
E3-1 E3-1 cuit temperature sensor (open/ .page 354
ing driver
short) abnormality
Spanner blink- Pump motor Pump motor rotation sensor
E8-1 E8-1 .page 355
ing driver open abnormality
Spanner blink- Pump motor Pump motor rotation sensor
E8-2 E8-2 .page 358
ing driver short abnormality
Spanner blink- Pump motor Pump motor driver CPU abnor-
EC-1 EC-1 .page 361
ing driver mality
EC-2 EC-2 .page 362
ing driver mality
EC-3 EC-3 .page 363
ing driver mality
EC-4 EC-4 .page 364
ing driver mality
EC-6 EC-6 .page 365
ing driver mality
Spanner blink- Communication line abnormal-
EE-1 EE-1 Main controller .page 366
ing ity : Display to main controller
Spanner blink- Communication line abnormal-
EE-2 EE-2 Main controller .page 367
ing ity : Display to main controller
Communication line abnormal-
Spanner blink-
F1-1 F1-1 Display ity between main controller and .page 368
ing
display
Communication line abnormal-
Spanner blink-
F1-2 F1-2 Display ity between main controller and .page 369
ing
display
Spanner blink-
F4-1 F4-1 Display Display CPU defect .page 372
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Spanner blink-
ing
Detection
ECU
Spanner blink-
ing
Spanner blink-
ing
Spanner blink- Battery current sensor neutral
FB-1 FB-1 Main controller .page 380
ing voltage error
Spanner blink- Battery current sensor overcur-
FB-2 FB-2 Main controller .page 383
ing rent
Spanner blink- Power supply circuit for display
FF-1 FF-1 Main controller .page 386
ing over current
Spanner blink- Steering sensor power-supply
FF-2 FF-2 Main controller .page 387
ing circuit over current
Spanner blink- Drive motor Drive motor driver (LH) : con-
32-1 32-1 .page 389
ing driver (LH) troller ID abnormality
Spanner blink- Drive motor Drive motor driver (RH) : con-
32-2 32-2 .page 391
ing driver (RH) troller ID abnormality
Spanner blink- Pump motor Pump motor driver : controller
32-3 32-3 .page 393
ing driver ID abnormality
Main controller to Drive motor
33-1 33-1 driver (LH) : communication ab- .page 395
ing driver (LH)
normality
Main controller to Drive motor
33-2 33-2 driver (RH) : communication .page 398
ing driver (RH)
abnormality
Main controller to Pump motor
33-3 33-3 driver : communication abnor- .page 401
ing driver
mality
Spanner blink-
61-1 61-1 Main controller Load sensor open abnormality .page 404
ing
Spanner blink-
61-2 61-2 Main controller Load sensor short abnormality .page 406
ing
Spanner blink- Tilt angle sensor open abnor-
62-1 62-1 Main controller .page 408
ing mality
Spanner blink- Tilt angle sensor short abnor-
ing mality
Tilt switch forward / backward
Spanner blink-
63-1 63-1 Main controller tilt switch simultaneously short .page 412
ing
abnormality
Spanner blink- Tilt switch forward tilt switch
ing continuously short abnormality
Spanner blink- Tilt switch backward tilt switch
ing continuously short abnormality
Spanner blink- Lift lock solenoid open abnor-
ing mality
Spanner blink- Lift lock solenoid short abnor-
ing mality
Spanner blink- Lift lock solenoid drive circuit
ing abnormality
Spanner blink- Lift lock solenoid (open / short)
ing abnormality
Spanner blink-
65-1 65-1 Main controller Tilt solenoid open abnormality .page 429
ing
Spanner blink-
65-2 65-2 Main controller Tilt solenoid short abnormality .page 432
ing
Detection
ECU
Spanner blink- Tilt solenoid: traveling circuit
65-3 65-3 Main controller .page 435 3
ing abnormality
Spanner blink- Tilt solenoid (open / short) ab-
ing normality
Spanner blink- Outside matching value range
ing for tilt angle error
Spanner blink- Lifting height switch open /
ing short abnormality
Spanner blink- Backward lock solenoid open
ing abnormality
Spanner blink- Backward lock solenoid short
ing abnormality
Spanner blink- Backward lock solenoid drive
ing circuit abnormality
Spanner blink- Backward lock solenoid (open /
ing short) abnormality
Spanner blink- Tire angle sensor open abnor-
ing mality
Spanner blink- Tire angle sensor short abnor-
ing mality
Spanner blink- Tire angle sensor anchoring ab-
ing normality
Spanner blink- Tire angle sensor anchoring ab-
ing normality
Spanner blink- Steering-wheel angle sensor
ing SS2 open abnormality
Spanner blink- Steering-wheel angle sensor
ing SSC open abnormality
Steering-wheel angle sensor :
Spanner blink-
72-4 72-4 Main controller sensor power source open ab- .page 476
ing
normality
Steering knob position syn-
Spanner blink-
73-1 73-1 Main controller chronizer solenoid open abnor- .page 478
ing
mality
Spanner blink-
73-2 73-2 Main controller chronizer solenoid short abnor- .page 481
ing
mality
Spanner blink-
73-3 73-3 Main controller chronizer solenoid power-circuit .page 484
ing
abnormality
Spanner blink-
73-4 73-4 Main controller chronizer solenoid (open / .page 486
ing
short) abnormality
Spanner blink- Tire angle matching: matching
ing value abnormality
Spanner blink- Shock sensor 1 open abnor-
G5-1 G5-1 Main controller .page 492
ing mality
Spanner blink- Shock sensor 1 short abnor-
ing mally
Spanner blink- Shock sensor 1 : neutral
ing voltage error
Spanner blink- Shock sensor 2 open abnor-
ing mality
Detection
ECU
Spanner blink- Shock sensor 2 short abnor-
ing mally
Spanner blink- Shock sensor 2 : neutral
ing voltage error
Spanner blink- Lift lever potentiometer open
H1-1 H1-1 Main controller .page 504
ing abnormality
Spanner blink- Lift lever potentiometer short
ing abnormality
Spanner blink- Lift lever potentiometer : sensor
ing output declination abnormality
Spanner blink- Lift lever potentiometer neutral
ing abnormality CAUTION
Spanner blink- Lift lever potentiometer match-
ing ing value abnormality
Spanner blink- Tilt lever potentiometer open
ing abnormality
Spanner blink- Tilt lever potentiometer short
ing abnormality
Spanner blink- Tilt lever potentiometer : sensor
ing output declination abnormality
Spanner blink- Tilt lever potentiometer neutral
ing error abnormality
Spanner blink- Tilt lever potentiometer match-
ing ing value abnormality
Spanner blink- Attachment 1 lever poten-
ing tiometer open abnormality
ing tiometer short abnormality
Attachment 1 lever poten-
Spanner blink-
H3-3 H3-3 Main controller tiometer : sensor output declin- .page 531
ing
ation abnormality
ing tiometer neutral abnormality
Spanner blink-
H3-5 H3-5 Main controller tiometer matching value abnor- .page 536
ing
mality
ing tiometer open abnormality
ing tiometer short abnormality
Spanner blink-
H4-3 H4-3 Main controller tiometer : sensor output declin- .page 542
ing
ation abnormality
ing tiometer neutral abnormality
Spanner blink-
H4-5 H4-5 Main controller tiometer matching value abnor- .page 547
ing
mality
Lift proportional valve solenoid
Spanner blink-
H5-1 H5-1 Main controller open abnormality (lever pull .page 549
ing
side)
Spanner blink-
H5-2 H5-2 Main controller short abnormality (lever pull .page 552
ing
side)
Detection
ECU
Spanner blink- 3
H5-3 H5-3 Main controller open abnormality (lever push .page 555
ing
side)
Spanner blink-
H5-4 H5-4 Main controller short abnormality (lever push .page 558
ing
side)
Spanner blink- Lift proportional valve solenoid
ing drive circuit abnormality
Spanner blink- Lift proportional valve solenoid
ing (open / short) abnormality
Tilt proportional valve solenoid
Spanner blink-
H6-1 H6-1 Main controller open abnormality (lever pull .page 567
ing
side)
Spanner blink-
H6-2 H6-2 Main controller short abnormality (lever pull .page 570
ing
side)
Spanner blink-
H6-3 H6-3 Main controller open abnormality (lever push .page 573
ing
side)
Spanner blink-
H6-4 H6-4 Main controller short abnormality (lever push .page 576
ing
side)
Spanner blink- Tilt proportional valve solenoid
ing drive circuit abnormality
ing (open / short) abnormality
Attachment 1 proportional valve
Spanner blink-
H7-1 H7-1 Main controller solenoid open abnormality .page 585
ing
(lever pull side)
Spanner blink-
H7-2 H7-2 Main controller solenoid short abnormality .page 588
ing
(lever pull side)
Spanner blink-
ing
(lever push side)
Spanner blink-
ing
(lever push side)
Spanner blink-
H7-5 H7-5 Main controller solenoid : traveling circuit ab- .page 597
ing
normality
Spanner blink-
H7-6 H7-6 Main controller solenoid (open / short) abnor- .page 600
ing
mality
Spanner blink-
ing
(lever pull side)
Spanner blink-
ing
(lever pull side)
Spanner blink-
ing
(lever push side)
Spanner blink-
ing
(lever push side)
Detection
ECU
Spanner blink-
H8-5 H8-5 Main controller solenoid : traveling circuit ab- .page 616
ing
normality
Spanner blink-
H8-6 H8-6 Main controller solenoid (open / short) abnor- .page 619
ing
mality
Proportional valve solenoid
Spanner blink-
HB-1 HB-1 Main controller power supply : RY1 contact .page 623
ing
open abnormality
HB-2 HB-2 Main controller .page 625
ing load-short abnormality
Proportional valve solenoid
Spanner blink-
HB-3 HB-3 Main controller power supply : RY1 over cur- .page 627
ing
rent abnormality
Spanner blink- Unload solenoid open abnor-
HC-1 HC-1 Main controller .page 629
ing mality
Spanner blink- Unload solenoid short abnor-
ing mality
Spanner blink- Unload solenoid drive circuit
ing abnormality
Spanner blink- Unload solenoid (open / short)
ing abnormality
Drive motor
Drive motor driver low temper-
COLD DCR - O/H lighting * driver (LH)
ature
(RH)
Pump motor Pump motor driver low temper-
COLD PCR - O/H lighting *
driver ature
*: Malti-function display shows only the each portion and doesn't indicate O/H light.
3.4 WHEN ERROR CODE IS DISPLAYED

3
Error Code: A0-1

Failure mode: Drive motor driver power-circuit abnormality
CAUTION
• If AB-1 occurs at same time, perform troubleshooting for AB-1 first.
• Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable and
motor cable loosen.
• Do not leave the vehicle standing in a hot place.
Probable cause
▪ The power cable and motor cable tightening is defective.
▪ Connector contact defect
▪ Harness defect
▪ Cooling fan clogging
▪ Cooling fan defect
▪ Overheating (continuous overload operation)
▪ Drive motor driver LH defect
▪ Drive motor driver RH defect
▪ Main controller defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller
CN112-2
CN250-27 CN250-28
F52 Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Drive motor driver LH Drive motor driver RH
Temperature sensor Temperature sensor
STEP1
Apply the cooling fan compulsorily by using Active Test and
check the rotary condition.
[ANL] ACTIVE TEST 2/3

FAN1：OFF → ON
Judgment
Result Procedure
Not running Go to step 5 3
Running Go to step 2
STEP2
Inspection :
Reconfirm the error
Turn on the key switch and check the error occurs.
Judgment
Result Procedure
"DCR" occurs. Go to step 3
Overheating (continuous overload operation)
After falling temperature of drive motor driver, "DCR" is dis-
appeared and the truck can be operated as usual. It is estim-
"DCR" does not occur. ated that the continuously running in overloaded condition
cause this error. So check the usage condition of the truck
and hold back the continuously running in a overloaded con-
dition.
STEP3
Inspection :
Check the temperature and reconfirm the error.
･Drive motor driver power-circuit temperature LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDMDH
Record the temperature of the drive motor driver power-circuit.
Turn off the key switch and leave the truck for approximately for
fifteen minutes. Then turn on the key switch and check the error
occurs.
Judgment
Result Procedure
dition.
STEP4
Inspection :
Reconfirm of the temperature
･Drive motor driver power-circuit temperature LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDMDH
Check the drive motor driver power-circuit temperature and

compare to the recorded value.
Judgment
Result Procedure
All temperatures has lowered by 5°C or
Go to step 3
more.
Drive motor power-circuit board temperat-
Drive motor driver LH defect
ure LH has not lowered by 5°C or more.
Drive motor power-circuit board temperat-
Drive motor driver RH defect
ure RH has not lowered by 5°C or more.
STEP5
Turn off the key switch and disconnect the battery plug.
Check the inside of connector CN112,113 and the caulked por-
tion of wire whether it has defect or not by visual confirm. (Refer
to BEFORE TROUBLESHOOTING)
After joint the connector, connect the battery plug and turn on
the key switch. Then apply the cooling fan compulsorily by us-
ing Active Test and check the rotary condition.

FAN1：OFF → ON
Judgment
Result Procedure
Running Connector contact defect
Not running Go to step 6
STEP6
Inspection : Harness
Disconnect the CN102, CN104, CN112 and CN113 connectors
and check the harnesses.
CN102
[Inspection procedure and standard]
Inspect for continuity and short circuiting of the harness.
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2 Perform this check with the battery plug and the CN102,
28 29 30 31 32 33 34 35 CN104, CN112 and CN113 connectors disconnected, and visu-
ally check inside the connector and the caulked portion of its
CN104 wire for defects.
1 2 3 4 5 6 7
CN113 Refer to BEFORE TROUBLESHOOTING
8 9 10 11 12 13 14 15 16 17 1 2 Portion to be inspected Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-1 to CN112-2 Continuity
CN102-1 to CN113-2 Continuity
Portion to be inspected Standard:

3
CN102-1 to CN104-3 No continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7
Inspection : Cooling fan
Disconnect the battery plug, then connect the CN102, CN104,

CN112 and CN113 connectors. Reconnect the battery plug and
turn on the key switch.

FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect
Not running After replacing cooling fan, if the fan is not running by apply-
ing the cooling fan compulsorily by using Active Test and, it
is possible of other defect. So replace the main controller.
Error Code: A0-2

Failure mode: Pump motor driver power-circuit abnormality
CAUTION
motor cable loosen.
Probable cause
▪ Harness defect
▪ Pump motor driver defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller
CN112-2
CN250-27 CN250-28
F52 Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Pump motor driver
Temperature sensor
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
STEP2
Inspection :
Reconfirm the error 3
Judgment
Result Procedure
"PCR" occurs. Go to step 3
After falling temperature of pump motor driver, "PCR" is dis-
"PCR" does not occur. ated that the continuously running in overloaded condition
dition.
STEP3
Inspection :
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Record the temperature of the pump motor driver power-circuit.
fifteen minutes. Then turn on the key switch and check the error
occurs.
Judgment
Result Procedure
dition.
STEP4
Inspection :
Reconfirm the temperature
[ANL] I/O TEMP/VOLT 3/6 TPMDH
Check the pump motor driver power-circuit temperature and

compare to the recorded value.
Judgment
Result Procedure
It has lowered by 5°C or more. Go to step 3
It has not lowered by 5°C or more. Pump motor driver defect
STEP5

FAN1：OFF → ON
Judgment
Result Procedure
STEP6
CN102
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35 CN104, CN112 and CN113 connectors disconnected, and visu-
CN104 wire for defects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2 Measurement terminals Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-1 to CN112-2 Continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7
3

FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect
Error Code: A1-1

Failure mode: Main controller high voltage
CAUTION
• If CB-1,CB-3 or CB-5 occurs at same time A1-1, perform troubleshooting for CB-1,CB-3 or CB-5 first.
Probable cause
▪ Battery defect
▪ Out of battery electrolyte
▪ Battery plug defect
▪ Battery overvoltage
▪ The battery plug was disconnected during traveling / load handling
Related portion
MB
P2 P3 CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
Main
controller
N1
STEP1
Turn off the key switch and disconnect the battery plug , then
leave over 2 minutes.
Reconnect the battery plug and turn on the key switch to con-
firm error.
Judgment
Result Procedure
A1-1 error occurs. Go to step 3
A3-1 error occurs. Perform troubleshooting for A3-1.
A1-1, A3-1 error does not occur. Go to step 2
STEP2
Check if disconnect the battery plug during traveling or load
handling.
Judgment
Result Procedure
YES
Do not disconnect the battery plug during traveling or load 3
handling.
NO Check the battery.
STEP3
Inspection : Battery voltage check
1 . Turn the key switch OFF and
disconnect the battery plug.
2 . Measure the voltage between both ends of the battery plug
with a circuit tester.
Judgment
Result Procedure
64V or more Check the battery.
Less than 64V Main controller defect
Error Code: A1-2

Failure mode: Drive motor driver LH high voltage
CAUTION
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver LH
STEP1
firm error.
Judgment
Result Procedure
STEP2
handling.
Judgment
Result Procedure
Do not disconnect the battery plug during traveling or load
YES
handling.
STEP3
1 . Turn the key switch OFF and 3
Judgment
Result Procedure
Less than 64V Drive motor driver LH defect
Error Code: A1-3

Failure mode: Drive motor driver RH high voltage
CAUTION
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Drive motor
driver RH
STEP1
firm error.
Judgment
Result Procedure
STEP2
handling.
Judgment
Result Procedure
YES
handling.
STEP3
Judgment
Result Procedure
Less than 64V Drive motor driver RH defect
Error Code: A1-4

Failure mode: Pump motor driver high voltage
CAUTION
Probable cause
▪ Battery defect
Related portion
MB
P1 F1 P4
Pump motor
driver
STEP1
firm error.
Judgment
Result Procedure
STEP2
handling.
Judgment
Result Procedure
YES
handling.
STEP3
Judgment
Result Procedure
Less than 64V Pump motor driver defect
Error Code: A2-1

Failure mode: Main controller overheating abnormality
CAUTION
Probable cause
▪ Temperature sensor defect (Main controller defect)
Related portion
Main controller
Temperature sensor
STEP1
Inspection :
Reconfirm the error
Judgment
Result Procedure
"C/R" occurs. Go to step 2
After falling temperature of main controller, "C/R" is disap-
"C/R" does not occur. peared and the truck can be operated as usual. It is estimated
that the continuously running in overloaded condition cause
this error. So check the usage condition of the truck and hold
back the continuously running in a overloaded condition.
STEP2
Inspection :
Check the main controller board temperature and reconfirm the
error.
[ANL] I/O TEMP/VOLT 4/6 TMCB
Record the main controller board temperature.

thirty minutes. Then turn on the key switch and check the error
occurs.
Judgment 3
Result Procedure
"C/R" occurs. Go to step 3
After falling temperature of main controller, "C/R" is disap-
"C/R" does not occur. peared and the truck can be operated as usual. It is estimated
that the continuously running in overloaded condition cause
this error. So check the usage condition of the truck and hold
STEP3
Inspection :
Reconfirm the the main controller board temperature.
[ANL] I/O TEMP/VOLT 4/6 TMCB
Check the main controller board temperature and compare to

the recorded value.
Judgment
Result Procedure
It has not lowered by 5°C or more. Temperature sensor defect (Main controller defect)
Error Code: A2-2

Failure mode: Drive motor driver circuit board / the condenser overheating
abnormality.
CAUTION
motor cable loosen.
Probable cause
▪ Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller
CN112-2
CN250-27 CN250-28
F52 Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Drive motor driver LH Drive motor driver RH
Temperature sensor Temperature sensor Temperature sensor Temperature sensor

(Circuit board) (Condenser) (Circuit board) (Condenser)
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
Not running Go to step 5 3
STEP2
Inspection :
Reconfirm the error
Judgment
Result Procedure
dition.
STEP3
Inspection :
･Drive motor driver circuit board temperature LH/RH

･Drive motor driver condenser temperature LH/RH
[ANL] I/O TEMP/VOLT 2/6
TDMDB、TDMDC
Record the temperature of drive motor driver circuit board and

drive motor driver condenser.
occurs.
Judgment
Result Procedure
dition.
STEP4
Inspection :
･Drive motor driver circuit board temperature LH/RH

･Drive motor driver condenser temperature LH/RH
TDMDB、TDMDC
Check the the temperature of drive motor driver circuit board

and drive motor driver condenser. Then compare to the recor-
ded value.
Judgment
Result Procedure
Go to step 3
more.
Either drive motor driver circuit board tem-
perature, (drive motor driver) condenser LH Drive motor driver LH defect
or both has lowered by 5°C or more.
Either drive motor driver circuit board tem-
perature, (drive motor driver) condenser RH Drive motor driver RH defect
or both has lowered by 5°C or more.
STEP5

FAN1：OFF → ON
Judgment
Result Procedure
STEP6
CN102
1 2 3 4 5 6 7 CN112 3
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
28 29 30 31 32 33 34 35
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Perform this check with the battery plug and the CN102,
CN104, CN112 and CN113 connectors disconnected, and visu-
wire for defects.
Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7


FAN1：OFF → ON
Judgment
Result Procedure
Cooling fan defect
Error Code: A2-3

Failure mode: Pump motor driver circuit board / the condenser overheating 3
abnormality.
CAUTION
• Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor
and cable loosen.
Probable cause
▪ Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Main Cooling fan 2

CN104-3 (1, CBAT+) CN113-1
controller
CN112-2
CN250-27 CN250-28
F52 Cooling fan 1
CN112-1
CN250-25 CN250-26
F51
Pump motor driver
Temperature sensor Temperature sensor

(Circuit board) (Condenser)
STEP1

FAN1：OFF → ON
Judgment
Result Procedure
STEP2
Inspection :
Reconfirm the error
Judgment
Result Procedure
dition.
STEP3
Inspection :

TPMDB、TPMDC
Record the temperature of pump motor driver circuit board and

pump motor driver condenser.
occurs.
Judgment
Result Procedure
dition.
STEP4
Inspection :

TPMDB、TPMDC
3
Check the the temperature of pump motor driver circuit board
and pump motor driver condenser. Then compare to the recor-
ded value.
Judgment
Result Procedure
All temperature has lowered by 5°C or
Go to step 3
more.
Either pump motor driver circuit board tem-
perature, (pump motor driver) condenser or Pump motor driver defect
both has lowered by 5°C or more.
STEP5

FAN1：OFF → ON
Judgment
Result Procedure
STEP6
CN102
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
28 29 30 31 32 33 34 35
CN104
CN113
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 1 2
18 19 20 21 22 23 24 25
26 27 28 29 30 31

wire for defects.
Judgment
Result Procedure
NG Harness defect
OK Go to step 7
STEP7


FAN1：OFF → ON
Judgment
Result Procedure
Running Connector contact defect 3
Cooling fan defect
Error Code: A3-1

Failure mode: Battery connection incorrect
Probable cause
▪ Battery plug connection defect
▪ Battery connection incorrect
▪ Battery defect
Related portion
Emergency switch (OPT)

CN176-1 (41, SWE+) CN176-2 (41, SWE-)
P1 CN250-49 F5
CN250-50 (41) CN104-1 (41, B48V)
Main
controller
BATTERY Emergency switch Less
N1
STEP1
Reconnect the battery plug correctly and turn on the key switch.
Judgment
Result Procedure
Battery plug connection defect or battery connection incor-
A3-1 error does not occur.
rect
STEP2
1 . Turn the key switch OFF and
Judgment
Result Procedure
Error Code: A5-1

Failure mode: Seat switch short abnormality 3
Probable cause
▪ Seat switch defect
▪ Harness defect
Related portion
CN102-10 (51, LS-) CN44-1
Main Seat swtich

controller
CN104-18 (67, SDM) CN44-2
STEP1
Inspection :
Check of seat switch condition
Turn off the key switch and disconnect the battery plug, discon-
nect the CN44 connector, and visually check inside the con-
nector and the caulked portion of its wire for defects. Refer to
BEFORE TROUBLESHOOTING
Connect the connector, connect the battery plug, and then turn
on the key switch without sitting in the seat.
[ANL] I/O M.HANDLING 1/8 SDM
Judgment
Result Procedure
"0 " occurs. Connector contact defect
"1 " occurs. Go to step 2
STEP2
Inspection :
Check of seat switch condition
Disconnect the CN44 connector, connect the battery plug, and
[ANL] I/O M.HANDLING 1/8 SDM

Judgment
Result Procedure
"0 " occurs. Seat switch defect
"1 " occurs. Go to step 3
STEP3
Disconnect the CN102, CN104 and CN44 connectors and
check the harnesses.
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN102, CN104
28 29 30 31 32 33 34 35 CN44 and CN44 connectors disconnected, and visually check inside
the connector and the caulked portion of its wire for defects.
1 2
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 CN102-10(51) to CN44-1(51) Continuity
26 27 28 29 30 31
CN104-18(67) to CN44-2(67) Continuity
CN44-1(51) to CN44-2(67) No continuity
Judgment
Result Procedure
NG Harness defect
OK Main controller defect
Error Code: A6-3

Failure mode: Tilt lever switch short abnormality 3
CAUTION
• The error may occur if the battery plug is connected and turn on the key switch while the tilt lever is
being operated. But if the error does not occur after stopping the tilt lever operation, it is normal.
Probable cause
▪ The battery plug is connected while the tilt lever is being operated.
▪ Tilt lever switch defect
▪ Tilt lever switch installation defect.
▪ Harness defect
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2
STEP1
Connector contact inspection :
After disconnection the CN89 connector, check the inside of
connector and the caulked portion of wire whether it has defect
or not by visual confirm. (Refer to BEFORE TROUBLESHOOT-
ING)
Connect the CN89 connector, connect the battery plug.
Turn on the key switch to see if an error occurs.
Judgment
Result Procedure
A6-3 error does not occur. Connector contact defect
STEP2
Inspection : Tilt switch
Disconnect the CN89 connector.
Reconnect the battery plug and turn on the key switch.
Check if an error occurs.
Judgment
Result Procedure
Tilt lever switch defect .
A6-3 error does not occur.
Tilt lever switch installation defect.
STEP3
Disconnect the CN89 and CN102 connectors and check the

harnesses for their continuities.
CN102
CN89
Perform this check with the battery plug and the CN89 and
1 2 3 4 5 6 7 CN102 connectors disconnected, and visually check inside the
1 2
8 9 10 11 12 13 14 15 16 17 18 19 connector and the caulked portion of its wire for defects.
20 21 22 23 24 25 26 27 3 4
28 29 30 31 32 33 34 35 Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect
Error Code: A8-1

Failure mode: F1 fuse open abnormality 3
CAUTION
• If CB-1, CB-3, CB-5, A8-2 or A9-2 occurs, perform troubleshooting with priority given to CB-1, CB-3,
CB-5, A8-2 or A9-2.
Probable cause
▪ Tightening the terminal defect
▪ Motor driver defect
▪ F1 fuse installation defect
▪ F1 fuse defect
▪ Cable defect
Related portion
F6
CN250-51 CN250-52 (44)
MB F1 P4
P3
Battery CN104-2 (44, VBMB)
N1
Drive motor drive Main
circuit (LH) controller
Drive motor drive

circuit (RH)
Pump motor drive

circuit
STEP1
Inspection of tightening the terminal :
Visually check each terminal for loose bolts (positive terminal,

negative terminal, P4 terminal and N1 terminal of each motor
driver).
Connect the battery plug and turn on the key switch to confirm
error.
Judgment
Result Procedure
A8-1 error does not occur. Tightening the terminal defect
STEP2
Check the voltage of power supply for motor driver :
Connect the battery plug, and turn on key switch, then measure
the voltage between the positive and negative terminals of mo-
tor driver (LH)
Turn off the key switch, and disconnect the battery plug, then
visually check if there is any abnormality of the copper bar for
connecting positive terminal and negative terminal. (e.g. break,
crack and so on)
Judgment
Result Procedure
0V Go to step 3
[48 V battery] : Approx. 48 V, [36 V bat-
All motor driver defect
tery] : Approx. 36 V
STEP3
F1 fuse installation check
Check the mounting F1 fuse it has defect or not by visual con-

firm.
error.
Judgment
Result Procedure
A8-1 error does not occur. F1 fuse installation defect
STEP4
Inspection : F1 fuse
After removing F1 fuse, measure the resistance for both ends of

F1 fuse.
* : Motor driver defect

remove the copper bar for the connecting positive terminal of
motor driver. 3
Measure the resistance between positive terminal and negative
terminal of motor driver.
When using analog tester, apply the black prove for positive ter-
minal and red prove for negative terminal.
Motor drivers are defective if their resistance measured is 10 Ω
or less.
Judgment
Result Procedure
0Ω Motor driver defect *
F1 fuse defect
∞Ω
or motor driver defect, or short between P4 and N1.
Error Code: A8-2

Failure mode: F6 fuse open abnormality
CAUTION
• If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
Probable cause
▪ F6 fuse defect
▪ F6 fuse box defect
▪ Harness defect
Related portion
F6
CN250-51 CN250-52 (44)
MB F1 P4
P3
N1
CN102-3 (19, VBMBSL) Main
CN102-4 (19, VBMBSL) controller
STEP1
After disconnection the CN104 connector and F6 fuse, check

the inside of connector and the caulked portion of wire whether
it has defect or not by visual confirm. (Refer to BEFORE
TROUBLESHOOTING)
Connect the CN104 connector and F6 fuse, connect the battery
plug.
Judgment
Result Procedure 3
STEP2
VBMBSL voltage inspection:
[ANL] I/O TEMP/VOLT 5/6 VBMBSL
Judgment
Result Procedure
25V or more Go to step 3
Less than 25 V Perform CB-1 troubleshooting
STEP3
Check fuse installation:

firm.
Judgment
Result Procedure
A8-2 error does not occur. F6 fuse installation defect
STEP4

F6 fuse.
Judgment
Result Procedure
0Ω Go to step 5
F6 fuse defect
∞Ω
After replacing F6 fuse, go to STEP6
STEP5
Inspection : Fuse box
Connect the F6 fuse, and disconnect the connector of F6 fuse

box.
Measure the resistance for both ends of the connector for F6

fuse box.
Judgment
Result Procedure
0Ω Go to step 6
∞Ω F6 fuse box defect
STEP6
If disconnect the F6 fuse box connector in the former step, con-

nect the connector.
Disconnect the CN104 connector and F6 fuse and check the

harnesses.
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN250
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60

Perform this check with the battery plug and the CN104 con-
nector and F6 fuse disconnected, and visually check inside the
connector and the caulked portion of its wire for defects.

CN250-52(44, fuse side) to P3 Continuity
3
CN104-2(44) to N1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: A9-2

Failure mode: F7 fuse / solenoid power supply line open abnormality
Probable cause
▪ Harness defect
Related portion
MB
CN102-3 (19, VBMBSL)
P3 CN102-4 (19, VBMBSL)
Main
controller
CN250-51 CN250-52 (44)
F6
N1
STEP1

ING)
Judgment
Result Procedure
STEP2
VBMB voltage inspection:
[ANL] I/O TEMP/VOLT 5/6 VBMB

Judgment
Result Procedure
25V or more Go to step 3 3
Less than 25 V Perform CB-1 troubleshooting
STEP3
Disconnect the CN102 connector and check the harnesses.

CN102
1 2 3 4 5 6 7 nector disconnected, and visually check inside the connector
8 9 10 11 12 13 14 15 16 17 18 19 and the caulked portion of its wire for defects.
20 21 22 23 24 25 26 27
CN102-3(19) to P3 Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: AA-1

Failure mode: Main controller temperature sensor (open/short) abnormality
CAUTION
• If AA-1 occurs, the Main controller is defective, so replace it.
Probable cause
Related portion
Main controller
Temperature sensor
Error Code: AA-2

Failure mode: Drive motor driver LH board temperature sensor (open/short) 3
abnormality
CAUTION
• If AA-2 occurs, the drive motor driver circuit is defective, so replace it.
Probable cause
Related portion
Drive motor driver LH
Temperature sensor
Error Code: AA-3

Failure mode: Drive motor driver RH board temperature sensor (open/short)
abnormality
CAUTION
• If AA-3 occurs, the drive motor driver circuit is defective, so replace it.
Probable cause
Related portion
Drive motor driver RH
Temperature sensor
Error Code: AA-4

Failure mode: Pump motor driver board temperature sensor (open/short) abnormality 3
CAUTION
• If AA-4 occurs, the pump motor driver circuit is defective, so replace it.
Probable cause
Related portion
Pump motor driver
Temperature sensor
Error Code: AB-1

Failure mode: Cooling fan overcurrent
CAUTION
• When check if AB-1 error occurs, wait 100 seconds after turning on the FAN1, FAN2 by using Active
Test.
(It takes 100 second by confirming the error AB-1)
Probable cause
▪ Motor driver cooling fan 1 defect
▪ Motor driver cooling fan 2 defect
▪ Motor cooling fan defect
▪ Harness defect
Related portion
CN102-1 (98, FANDC1) CN113-2
Cooling fan 2
Main CN104-3 (1, CBAT+) CN113-1
controller CN250-27 CN250-28
F52
CN102-2 (99, FANDC2) CN112-2
CN104-1 (41, B48V) Cooling fan 1

CN112-1
CN250-25 CN250-26
+ F51
CN118-2
Motor fan
CN118-1
CN250-29 CN250-30
F53
STEP1
Inspection :
Check the inside of connector CN112,113, CN118 and the
caulked portion of wire whether it has defect or not by visual
confirm. (Refer to BEFORE TROUBLESHOOTING)
ing Active Test and check if an error occurs.

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure 3
AB-1 error does not occur. Connector contact defect
AB-1 error occurs. Go to step 2
STEP2
Inspection : Cooling fan circuit
After disconnect the CN112, CN113, CN118 connector, connect
the battery plug and turn on the key switch. Then apply the
cooling fan compulsorily by using Active Test and check if an
error occurs.

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB-1 error does not occur. Go to step 3
AB-1 error occurs. Go to step 5
STEP3
Inspection : Motor driver cooling fan 1
After connecting CN113 and disconnecting the CN112, CN118
connector, connect the battery plug and turn on the key switch.
Then apply the cooling fan compulsorily by using Active Test
and check if an error occurs.

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB-1 error does not occur. Go to step 4
AB-1 error occurs. Motor driver cooling fan 1 defect
STEP4
Inspection : Motor driver cooling fan 2
After connecting CN112 and disconnecting the CN113, CN118

connector, connect the battery plug and turn on the key switch.
Then apply the cooling fan compulsorily by using Active Test

FAN1：OFF → ON
FAN2：OFF → ON
Judgment
Result Procedure
AB-1 error does not occur. Motor cooling fan defect
AB-1 error occurs. Motor driver cooling fan 2 defect
STEP5
Disconnect the CN102, CN104, CN112, CN113, CN118 con-
nectors and check the harnesses.
CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN104
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

CN104, CN112, CN113, CN118 connectors disconnected, and
visually check inside the connector and the caulked portion of
its wire for defects.
Judgment
Result Procedure
NG Harness defect 3
Error Code: AC-1

Failure mode: Motor driver power delivery abnormality
Probable cause
▪ Harness defect
Related portion
+
Drive motor
CN109-8 (42) driver LH
MB
P2 P4 +
Drive motor
CN110-8 (42) driver RH
+ F1
+
N1 Pump motor
CN111-8 (42) driver
-
CN103-4 (42, KYSAT)
Main
CN250-49 CN250-50 (41) CN104-1 (41, B48V) controller
F5 CN101-4 (41, VBBT)
STEP1
Disconnect the CN101, CN103, CN104, CN109, CN110,
CN111 connectors and check the harness.
CN103
1 2 3 4 5 6
CN109 3
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
CN110 CN111
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23

Perform the continuity check of CN103 to CN109, CN110,

CN111 connectors with the battery plug and the CN101,
CN103, CN104, CN109, CN110, CN111 connectors disconnec-
ted, and visually check inside the connector and the caulked
portion of its wire for defects.
Inspect for continuity between the harness and N1.
CN103-4 (42) to N1 No continuity
CN103-4 (42) to CN109-8 (42) Continuity
Judgment
Result Procedure
NG Harness defect
OK Go to step 2
STEP2
Inspection : Main controller
Disconnect the CN109, CN110, CN111 connectors, then con-
nect the CN101, CN103, CN104 connectors.
error.
Judgment
Result Procedure
AC-1 error occurs. Main controller defect
AC-1 error does not occur. Go to step 3
STEP3
Inspection : Drive motor driver LH
Disconnect the CN110, CN111 connectors, then connect the
CN101, CN103, CN104, and CN109 connectors.
error.
Judgment
Result Procedure
AC-1 error occurs or not. Go to step 4
STEP4
Inspection : Drive motor driver RH
error.
Judgment
Result Procedure
AC-1 error occurs or not. Go to step 5
STEP5
Inspection : Pump motor driver
error.
Judgment
Result Procedure
AC-1 error occurs at STEP3 Drive motor driver LH defect
AC-1 error occurs at STEP4 Drive motor driver RH defect
AC-1 error occurs at STEP5 Pump motor driver defect
Error Code: AD-1

Failure mode: Drive motor driver LH to Main controller : communication abnormality 3
CAUTION
• If AC-1 occurs at same time, perform troubleshooting for AC-1 first.
• If AD-2 occurs at same time, perform troubleshooting for AD-2 first.
Probable cause
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
nect the CN103, CN109 connector, and visually check inside
(Refer to BEFORE TROUBLESHOOTING)
After connecting the connector, connect the battery plug and

turn on the key switch to confirm error.
Judgment
Result Procedure
AD-1 or AD-2 error occurs. Perform troubleshooting for AD-2
AD-1 or AD-2 error does not occur. Connector contact defect
Error Code: AD-2

Failure mode: Drive motor driver LH to Main controller : communication abnormality
CAUTION
Probable cause
▪ Wrong motor driver type
▪ Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
Main controller CN109-7
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN70-16 CN111-17 (145, CAN1H)
Display CN70-15 CN111-16 (146, CAN1L)
Pump motor
CN111-6 (152, SETP1) driver
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
check if the part number of motor driver is correct.
Especially if the motor driver has just been replaced, check that
a different model motor driver hasn’t been installed.
Judgment
Result Procedure
Wrong part number Wrong motor driver type 3
Correct part number Go to step 2
STEP2
nect the CN103, CN104, CN109, CN110, CN111, CN70 con-
nector, and visually check inside the connector and the caulked
portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
Especially if the motor driver has just been replaced, check if
the connector is connected correctly.
Judgment
Result Procedure
(1) No error code "with AD" Connector contact defect
(2). The all following items occur
▪ AD-1 or AD-2 error occurs.
Go to step 8
The other cases of (1) and (2) Go to step 3
STEP3
Inspection :
Reconfirm the occured error
Reconfirm the error at STEP2
Judgment
Result Procedure
Go to step 4
AD-2 error occurs.
Record the error code (with starting form "AD")
AD-2 error does not occur. Perform the troubleshooting of the occured error
STEP4
Inspection :
1 . Confirm the identification of drive motor driver LH
Disconnect the CN110 and CN111 connector.
Reconnect the battery plug and turn on the key switch. Record
the occured error.
2 . Check the harness

Connect the CN110, CN111 connector, and disconnect the
CN103, CN109 connector.
Inspect the harness by the error recorded at STEP4.

1 . Check with disconnecting the drive motor driver RH and
pump motor driver to confirm if drive motor driver LH isn't oper-
CN103
ated as drive motor driver RH or pump motor driver.
1 2 3 4 5 6
CN109
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
2 . Inspect for continuity and short circuiting of the harness.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
Perform this check with the battery plug and the CN103,CN109
connectors disconnected, and visually check inside the con-
*1 : Perform in case of "AD-4 error does not occur and AD-6 er-
ror occurs" or "AD-4 error occurs and AD-6 error does not oc-
cur".
*2 : Perform in case of "AD-4 and AD-6 error occur".
Portion to be inspected Standard: Remarks
No continu-
CN109-7 to CN109-23 *1
ity
No continu-
CN109-6 to CN109-23 *1
ity
No continu-
CN109-7 to N2 *1
ity
No continu-
CN109-6 to N2 *1
ity
CN103-4 to CN109-8 Continuity *2
Judgment
Result Procedure
Go to step 5
NG
Harness defect
Go to step 5
OK
STEP5
Confirm the error recorded at STEP3
Judgment
Result Procedure
Only AD-2 error occurs. Replace the defective portion in the STEP4.
AD-2 and AD-4 error occur. Go to step 6
STEP6
Inspection :
1 . Confirm the identification of drive motor driver RH 3
the occured error.
2 . Inspect harness
1 . Check with disconnecting the drive motor driver LH and
pump motor driver to confirm if drive motor driver RH isn't oper-
CN103
ated as drive motor driver LH or pump motor driver.
1 2 3 4 5 6
CN110
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
cur".
No continu-
CN110-6 to CN110-23 *1
ity
No continu-
CN110-6 to N2 *1
ity
Judgment
Result Procedure
Harness defect
NG In addition to the harness, replace the defective portion in the
STEP4.
OK In addition to drive motor driver RH, replace the defective
portion in the STEP4.
STEP7
Inspection :
1 . Confirm the identification of pump motor driver
the occured error.
2 . Inspect harness
1 . Check with disconnecting the drive motor driver LH and RH
to confirm if pump motor driver isn't operated as drive motor
CN103
driver LH or RH.
1 2 3 4 5 6
CN111
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
cur".
No continu-
CN111-7 to CN111-23 *1
ity
No continu-
CN111-7 to N2 *1
ity
Judgment
Result Procedure
Harness defect
NG In addition to the harness, replace the defective portion in the
STEP4.
Pump motor driver defect
OK In addition to pump motor driver, replace the defective por-
tion in the STEP4.
STEP8
Turn off the key switch and disconnect the battery plug. 3
Disconnect the CN103, CN104, CN109, CN110, CN111 and
CN70 connectors and check the harnesses.
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
CN103 16 17 18 19 20 21 22 23
CN110 Perform this check with the battery plug and the CN103,
1 2 3 4 5 6
1 2 3 4 5 6 7 8
CN104, CN109, CN110, CN111 and CN70 connectors discon-
7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 nected, and visually check inside the connector and the caulked
17 18 19 20 21 22 23 24 25 26 27 16 17 18 19 20 21 22 23
28 29 30 31 32 33 34 35
portion of its wire for defects. Refer to BEFORE
CN111 TROUBLESHOOTING
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 Portion to be inspected Standard:
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
OK Go to step 9
STEP9
Inspection: Check the voltage of main controller power supply
Connect the CN103, CN104, CN70 connector, and disconnect
the CN109, CN110, CN111 connector.
Reconnect the battery plug and turn on the key switch. Inspect
the voltage of power supply for motor driver.
Check the voltage between CN109-8 and N2
CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
Judgment
Result Procedure
15V or more Go to step 10
STEP10
the CN110, CN111 connector.
the voltage of power supply for motor driver and check if an er-
ror occurs

CN110
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Check with disconnecting drive motor driver RH and pump mo-
tor driver, and connecting main controller and drive motor driver
LH.
At voltage measurement, check by using the disconnected drive

motor driver RH harness.
Judgment
Result Procedure
Go to step 11
Voltage : less than 15V
Record the result
Go to step 11
Voltage : 15V or more AD-2 error occurs
Record the result
Voltage : 15V or more AD-2 error does not Go to step 11
occur Record the result
STEP11
ror occurs

CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 3
16 17 18 19 20 21 22 23

Check with disconnecting drive motor driver LH and pump mo-
tor driver, and connecting main controller and drive motor driver
RH.

motor driver LH harness.
Judgment
Result Procedure
Go to step 12
Record the result
Go to step 12
Record the result
STEP12
ror occurs

CN109
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

Check with disconnecting drive motor driver LH and RH, and
connecting main controller and pump motor driver.

motor driver LH harness.
Judgment
Result Procedure
Go to step 13
Record the result
Go to step 13
Record the result
STEP13
Confirm the STEP10, 11, 12
Judgment
Result Procedure
Defect for inspection item of less than 15V (Drive motor
Any voltage : less than 15V
driver LH, Drive motor driver RH, Pump motor driver)
Main controller defect
If the symptom persists after replacement of the main con-
All voltage : 15V or more All error occurs troller, there should be any other problems, so replace all of
the drive motor driver LH, drive motor driver RH, and pump
motor driver.
All voltage : 15V or more At least one error Defect for inspection item of the occured error (Drive motor
is not displayed driver LH, Drive motor driver RH, Pump motor driver)
Error Code: AD-3

Failure mode: Drive motor driver RH to Main controller : communication abnormality 3
CAUTION
• If AD-1 or AD-2 occurs at same time, perform troubleshooting for AD-2 first.
Probable cause
Related portion
CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1

Judgment
Result Procedure
Error Code: AD-4

Failure mode: Drive motor driver RH to Main controller : communication abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN111-17 (145, CAN1H)
CN111-16 (146, CAN1L)
Pump motor
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
Judgment
Result Procedure
STEP2
nector and the caulked portion of its wire for defects. (Refer to
BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
AD-3 or AD-4 error occurs. Go to step 3
STEP3
Inspection :
Confirm the identification of drive motor driver RH
Reconnect the battery plug and turn on the key switch. Confirm
the occured error.
Check with disconnecting the drive motor driver LH and pump
motor driver to confirm if drive motor driver RH isn't operated as
drive motor driver LH or pump motor driver.
Judgment
Result Procedure
"AD-2 error does not occur and AD-6 error
occurs" or "AD-2 error occurs and AD-6 er- Go to step 4
ror does not occur".
STEP4
IInspection : Harness
Disconnect the CN110 connectors and check the harnesses.

CN110 Perform this check with the battery plug and the CN110 con-
1 2 3 4 5 6 7 8
nectors disconnected, and visually check inside the connector
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
and the caulked portion of its wire for defects.
CN110-7(150) to CN110-23 Continuity
CN110-6 to N2(N2) No continuity
Judgment
Result Procedure
NG Harness defect
OK Drive motor driver RH defect
STEP5
Disconnect the CN103, CN110 connectors and check the har-
nesses.
CN103
CN110
1 2 3 4 5 6 connectors disconnected, and visually check inside the con-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
nector and the caulked portion of its wire for defects.
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
Error Code: AD-5

Failure mode: Pump motor driver to Main controller : communication abnormality 3
CAUTION
Probable cause
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L)
Pump motor
driver
Main controller CN111-6 (152, SETP1)
CN103-5 (N2, N2) CN111-23 (152, SETP-)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1

Judgment
Result Procedure
Error Code: AD-6

Failure mode: Pump motor driver to Main controller : communication abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L)
Drive motor
CN109-6 driver LH
NC
NC
CN103-5 (N2, N2) CN109-23
NC
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2) CN110-8 (42, KYSAT)
CN110-17 (145, CAN1H)
CN110-16 (146, CAN1L)
Drive motor
CN110-6 driver RH
NC
CN110-7 (150, SETDR1)
CN110-23 (150, SETDR-)
CN111-8 (42, KYSAT)

CN111-17 (145, CAN1H)
CN111-16 (146, CAN1L)
Pump motor
CN111-7
NC
CN111-23 (152, SETP-)
STEP1
Judgment
Result Procedure
STEP2
nector and the caulked portion of its wire for defects. (Refer to
Judgment
Result Procedure
AD-5 or AD-6 error occurs. Go to step 3
STEP3
Inspection :
Confirm the identification of pump motor driver
Turn off the key switch and disconnect the battery plug. Discon-
nect the CN109 and CN110 connector.
Reconnect the battery plug and turn on the key switch. Confirm
the occured error.
Check with disconnecting the drive motor driver LH and RH to
confirm if pump motor driver isn't operated as drive motor driver
LH or RH.
Judgment
Result Procedure
"AD-2 error does not occur and AD-4 error
occurs" or "AD-2 error occurs and AD-4 er- Go to step 4
ror does not occur".
AD-2 and AD-4 error occur Go to step 5
STEP4
Disconnect the CN111 connectors and check the harness.

CN111 Perform this check with the battery plug and the CN111 con-
1 2 3 4 5 6 7 8
nectors disconnected, and visually check inside the connector
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
CN111-7 to N2(N2) No continuity
Judgment
Result Procedure
NG Harness defect
OK Pump motor driver defect
STEP5
nesses.
CN103
CN111
1 2 3 4 5 6 connectors disconnected, and visually check inside the con-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
16 17 18 19 20 21 22 23
Judgment
Result Procedure
NG Harness defect
Error Code: AF-1

Failure mode: Main controller CPU error 3
CAUTION
• If AF-1 occurs, the Main controller is defective, so replace it.
Probable cause
Related portion
Main controller
Error Code: AF-2

Failure mode: Main controller CPU error
CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-3

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-4

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-5

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-6

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-7

CAUTION
Probable cause
Related portion
Main controller
Error Code: AF-8

CAUTION
Probable cause
Related portion
Main controller
Error Code: C0-2

Failure mode: Drive motor driver LH power-circuit abnormality 3
CAUTION
• If CB-3 occurs at same time, perform troubleshooting for CB-3 first.
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before starting troubleshooting.
Probable cause
▪ Drive motor cable tightening is defective
▪ Drive motor LH defect
▪ Drive motor cable defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off the key switch and disconnect the battery plug, visually
check the fastened and caulked portions of the motor cables for
defects. Refer to BEFORE TROUBLESHOOTING
Connect the drive motor cables, connect the battery plug, and
then turn on the key switch.
Operate the direction lever with forward or backward, and check
for errors.
Judgment
Result Procedure
Go to step 2
C0-2 error occurs.
Record the occured error code.
C0-2 error does not occur. Drive motor cable tightening is defective
STEP2
Return the direction lever neutral, turn off the key switch, and
Disconnect the three motor cables from the drive motor driver
LH and insulate the terminals of the cables disconnected.
Connect the battery plug and turn on the key switch to check if
C0-2 error occurs.
Judgment
Result Procedure
C0-2 error does not occur. Go to step 3
C0-2 error occurs. Drive motor driver LH defect
STEP3
Inspection : Drive motor cable
Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection
Check each drive motor cable for its continuity and short.
nect the three motor cables, visually check each terminal and
the caulked portion and coating of each cable for defects, and
then check the P7, P8 and P9 cables.

Both ends of P7 cable Continuity
P7 cable and P8 cable No continuity
Judgment
Result Procedure
OK (E0-2 does not occur at the same time
Go to step 4
on STEP1)
OK (E0-2 occurs at the same time on
Go to step 5
STEP1)
NG Drive motor cable defect
STEP4
Inspection : Drive motor driver
Replace the drive motor driver LH with the pump motor driver.
for errors. (Ignore the error codes 32-1 and 32-3.)
Judgment
Result Procedure
C0-2 error occurs. Drive motor LH defect 3
E0-2 error occurs. The motor driver that is drive motor driver LH before replace-
ment is defect.
STEP5
Inspection : Drive motor
Check the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
OK Drive motor driver LH defect
Error Code: C0-4

Failure mode: Drive motor driver RH power-circuit abnormality
CAUTION
Probable cause
▪ Drive motor cable tightening is defective
▪ Drive motor RH defect
▪ Drive motor cable defect
Related portion
P71
U
Drive motor P81

V Drive motor RH
driver RH
P91
W
STEP1
check the fastened and caulked portions of the motor cables for
defects. Refer to BEFORE TROUBLESHOOTING
for errors.
Judgment
Result Procedure
Go to step 2
C0-4 error occurs.
C0-4 error does not occur. Drive motor cable tightening is defective
STEP2
Disconnect the three motor cables from the drive motor driver
RH and insulate the terminals of the cables disconnected.
Connect the battery plug and turn on the key switch to check if
C0-4 error occurs. 3
Judgment
Result Procedure
C0-4 error occurs. Drive motor driver RH defect
STEP3
Inspection : Drive motor cable
Disconnect the motor cables from both the motor and the motor
driver.
Drive motor cable inspection

Judgment
Result Procedure
Go to step 4
on STEP1)
Go to step 5
STEP1)
NG Drive motor cable defect
STEP4
Replace the drive motor driver RH with the pump motor driver.
Judgment
Result Procedure
C0-4 error occurs. Drive motor RH defect
E0-2 error occurs. The motor driver that is drive motor driver RH before replace-
ment is defect.
STEP5
Inspection : Drive motor
Check the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C1-1

Failure mode: Drive motor driver LH current sensor neutral voltage error 3
CAUTION
• If C1-1 occurs, the drive motor driver LH is defective, so replace it.
Probable cause
Related portion
Current sensor
Error Code: C1-2

Failure mode: Drive motor driver LH current sensor over current abnormality
CAUTION
• If C8-1 or C8-2 occurs at same time C1-2, perform troubleshooting for C8-1 or C8-2 first.
Probable cause
▪ Drive motor LH cable tightening is defective
▪ Drive motor LH defect
▪ Drive motor LH cable defect
▪ Drive motor LH rotation sensor defect
Related portion
P7
U
Drive motor P8
V Drive motor LH
driver LH
P9
W
STEP1
Turn off / on the key switch, and check if C0-2 error occurs.
Judgment
Result Procedure
C0-2 error occurs. Perform troubleshooting for C0-2
STEP2
check the assembled and caulked portions of the motor cables
for defects. (Refer to BEFORE TROUBLESHOOTING)
Sit in the seat and perform a direction lever operation (forward
or backward), checking for errors with pushing the accelerator
pedal.
Judgment
Result Procedure
C1-2 error does not occur. Drive motor LH cable tightening is defective 3
Go to step 3
C1-2 error occurs.
Record the occurs errored code.
STEP3
Inspection : Drive motor cable LH
Inspect with disconnecting drive motor cable (drive side and
motor side).
Judgment
Result Procedure
Go to step 4
on STEP2)
Go to step 5
STEP2)
NG Drive motor LH cable defect
STEP4
pedal. (Ignore the error codes 32-1 and 32-3.)
Judgment
Result Procedure
C1-2 error occurs. Drive motor LH defect
E1-2 error occurs. The motor driver that is drive motor driver LH before replace-
ment is defect.
STEP5
Inspection : Drive motor LH
Turn off the key switch and disconnect the battery plug, and in-
spect the drive motor.
Judgment
Result Procedure
NG Drive motor LH defect
Error Code: C1-3

Failure mode: Drive motor driver RH current sensor neutral voltage error 3
CAUTION
• If C1-3 occurs, the drive motor driver RH is defective, so replace it.
Probable cause
Related portion
Current sensor
Error Code: C1-4

Failure mode: Drive motor driver RH current sensor over current abnormality
CAUTION
• If C8-3 or C8-4 occurs at same time C1-4, perform troubleshooting for C8-3 or C8-4 first.
Probable cause
▪ Drive motor RH cable tightening is defective
▪ Drive motor RH defect
▪ Drive motor RH cable defect
▪ Drive motor RH rotation sensor defect
Related portion
P71
U
Drive motor P81

V Drive motor RH
driver RH
P91
W
STEP1
Turn off / on the key switch, and check if C0-4 error occurs.
Judgment
Result Procedure
C0-4 error occurs. Perform troubleshooting for C0-4
STEP2
check the assembled and caulked portions of the motor cables
for defects. (Refer to BEFORE TROUBLESHOOTING)
pedal.
Judgment
Result Procedure
C1-4 error does not occur. Drive motor RH cable tightening is defective 3
Go to step 3
C1-4 error occurs.
STEP3
Inspection : Drive motor cable RH
Inspect with disconnecting drive motor cable (drive side and
motor side).
Judgment
Result Procedure
Go to step 4
on STEP2)
Go to step 5
STEP2)
NG Drive motor RH cable defect
STEP4
pedal. (Ignore the error codes 32-2 and 32-3.)
Judgment
Result Procedure
C1-4 error occurs. Drive motor RH defect
E1-2 error occurs. The motor driver that is drive motor driver RH before replace-
ment is defect.
STEP5
Inspection : Drive motor RH
Turn off the key switch and disconnect the battery plug, and in-
spect the drive motor.
Judgment
Result Procedure
NG Drive motor RH defect
Error Code: C2-1

Failure mode: Drive motor overheating abnormality 3
CAUTION
Probable cause
Related portion
CN109-9 (86, STDML+) CN121-2

Drive motor driver Temperature sensor
LH (Drive motor LH)
CN109-10 (87, STDML) CN121-1
CN110-9 (84, STDMR+) CN52-2

RH (Drive motor RH)
CN110-10 (85, STDMR) CN52-1
STEP1
Inspection :
Reconfirm the displayed error.
Judgment
Result Procedure
"DM" occurs. Go to step 2
After falling temperature of drive motor, "DM" is disappeared
"DM" does not occur. and the truck can be operated as usual. It is estimated that
the continuously running in overloaded condition cause this
error. So check the usage condition of the truck and hold
STEP2
Inspection :
Confirm the temperature of the drive motor and Reconfirm the
error
･Temperature of drive motor LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDM
Record the temperature of the drive motor.
occurs.
Judgment
Result Procedure
"DM" occurs. Go to step 3
After falling temperature of drive motor, "DM" is disappeared
"DM" does not occur. and the truck can be operated as usual. It is estimated that
STEP3
Inspection :
Reconfirm the temperature of drive motor
･Temperature of drive motor LH/RH

[ANL] I/O TEMP/VOLT 1/6 TDM
Check the temperature of drive motor and compare to the re-

corded value.
Judgment
Result Procedure
Go to step 2
more.
Temperature of drive motor LH has not
C2-2 Perform troubleshooting from STEP2.
lowered by 5°C or more.
Temperature of drive motor RH has not
C2-3 Perform troubleshooting from STEP2.
lowered by 5°C or more.
Error Code: C2-2

Failure mode: Drive motor LH temperature sensor (open/short) abnormality 3
Probable cause
▪ Drive motor LH temperature sensor defect
▪ Drive motor LH temperature sensor harness defect
Related portion
CN109-9 (86, STDML+) CN121-2

LH (Drive motor LH)
CN109-10 (87, STDML) CN121-1
STEP1
Disconnect the battery plug, and visually check inside the
CN121 connector and the caulked portion of its wire for defects.
Judgment
Result Procedure
C2-2 error occurs. Go to step 2
C2-2 error does not occur. Connector contact defect
STEP2
Inspection :
Temperature sensor individual inspection
Disconnect the CN121 connector, and perform the temperature
sensor individual inspection.
CN121
2 1

Carry out temperature sensor individual inspection.
Measure the temperature sensor resistance between CN121-2
and CN121-1 (sensor side of CN121)
Standard: Approx. 245 Ω to 600 kΩ
* The resistance is changed with depending on temperature. So

refer to the below table about rough standard value.
Temperature
sensor resist-
Temperature ance (between
CN121-2 and
CN121-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor LH temperature sensor defect
STEP3
harnesses.
CN109 CN121 Perform this check with the battery plug and the CN109, and
1 2 3 4 5 6 7 8 CN121 connectors disconnected, and visually check inside the
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
connector and the caulked portion of its wire for defects with
disconnecting SST.
*1 : It is OK to connect CN121-1 to CN121-2 through SST2

(09232-13130-71) and check if there is continuity between
CN109-9 and CN109-10.
No continu-
CN121-1 to CN121-2
ity
Judgment
Result Procedure
NG Drive motor LH temperature sensor harness defect
Error Code: C2-3

Failure mode: Drive motor RH temperature sensor (open/short) abnormality 3
Probable cause
▪ Drive motor RH temperature sensor defect
▪ Drive motor RH temperature sensor harness defect
Related portion
CN110-9 (84, STDMR+) CN52-2

RH (Drive motor RH)
CN110-10 (85, STDMR) CN52-1
STEP1
Disconnect the battery plug, and visually check inside the CN52
connector and the caulked portion of its wire for defects. Refer
to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
STEP2
Inspection :
Temperature sensor individual inspection
Disconnect the CN52 connector, and perform the temperature
sensor individual inspection.
CN52 and CN52-1 (sensor side of CN52)
2 1
Standard: Approx. 245 to 600 kΩ

Temperature
sensor resist-
CN52-2 and
CN52-1)
80°C Approx. 1.75 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Drive motor RH temperature sensor defect
STEP3
harnesses.
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
disconnecting SST.

CN110-9 and CN110-10.
No continu-
CN52-1 to CN52-2
ity
Judgment
Result Procedure
NG Drive motor RH temperature sensor harness defect
Error Code: C3-1

Failure mode: Drive motor driver LH power-circuit temperature sensor (open/short) 3
abnormality
CAUTION
• If C3-1 occurs, the drive motor driver LH is defective, so replace it.
Probable cause
Related portion
Temperature sensor
Error Code: C3-2

Failure mode: Drive motor driver RH power-circuit temperature sensor (open/short)
abnormality
CAUTION
• If C3-2 occurs, the drive motor driver RH is defective, so replace it.
Probable cause
Related portion
Temperature sensor
Error Code: C4-1

Failure mode: Accelerator potentiometer POT1 open abnormality 3
CAUTION
• Be sure to do the matching after reassembly if performed the removing and inspection of acceler-
ator potentiometer
Probable cause
▪ Harness defect
▪ Accelerator sensor defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN101-22 (50, VRA-) CN26-6 Accelerator
Main controller CN101-26 (55, VRA2+) CN26-1 sensor
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
ING)
Judgment
Result Procedure
STEP2
Inspection : Accelerator sensor
Disconnect the CN26 connector and check the accelerator

sensor resistance.

Inspect accelerator sensor resistance.
CN26 Turn off the key switch and disconnect the battery plug, discon-
nect the CN26 connector, visually check each terminal and the
6 5 4 3 2 1 caulked portion and coating of each cable for defects. (Refer to
And check the following both ends of connector resistance for

sensor. Then confirm the changing value with operating the por-
tion of sensor.
CN26-4(52) to CN26-6(50)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to step 3
STEP3
Disconnect the CN101, CN102, CN26 connectors and check

continuity of the harness.
CN101
Inspect for continuity of the harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN26 CN102, and CN26 connectors disconnected, and visually check
inside the connector and the caulked portion of its wire for de-
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1 : It is OK to connect CN26-5 to CN26-4 through SST2
CN101-27 and CN102-30.
CN101-27(53) to CN26-5 Continuity *1
Judgment
Result Procedure
NG Harness defect 3
Error Code: C4-2

Failure mode: Accelerator potentiometer POT2 open abnormality
CAUTION
ator potentiometer
Probable cause
▪ Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
ING)
Judgment
Result Procedure
STEP2

sensor resistance.

3

tion of sensor.
CN26-3(54) to CN26-2(51)
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN101-26 and CN102-32.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-3

Failure mode: Accelerator potentiometer POT1VCC short circuit abnormality 3
CAUTION
ator potentiometer
Probable cause
▪ Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
ING)
Judgment
Result Procedure
STEP2

sensor resistance.


tion of sensor.
CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

CN101-22 and CN102-30.
Judgment
Result Procedure
NG Harness defect 3
Error Code: C4-4

Failure mode: Accelerator potentiometer POT2VCC short circuit abnormality
CAUTION
ator potentiometer
Probable cause
▪ Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
ING)
Judgment
Result Procedure
STEP2

sensor resistance.

3

tion of sensor.
CN26-3(54) to CN26-2(51)
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-32 and CN102-32.
Judgment
Result Procedure
NG Harness defect
Error Code: C4-5

Failure mode: Accelerator potentiometer offset abnormality
CAUTION
ator potentiometer
Probable cause
▪ Harness defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
ING)
Judgment
Result Procedure
STEP2

sensor resistance.

3

tion of sensor.
CN26-4(52) to CN26-6(50)
CN26-3(54) to CN26-2(51)
CN26-5(53) to CN26-6(50) 1.8 to 3.5 kΩ
CN26-1(55) to CN26-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 It is OK to connect the following portion by using SST2
CN101 and CN102.
Portions to connect SST2 / Continuity check point
*1 : CN26-5 to CN26-4 / CN101-27 to CN102-30
*2 : CN26-6 to CN26-3 / CN101-22 to CN102-30
*3 : CN26-1 to CN26-3 / CN101-26 to CN102-32
*4 : CN26-2 to CN26-3 / CN101-32 to CN102-32

Judgment
Result Procedure
NG Harness defect
Error Code: C4-6

Failure mode: Accelerator potentiometer matching value abnormality 3
CAUTION
• If C4-1,2,3,4,5 occurs, give priority to troubleshooting for C4-1,2,3,4,5.
ator potentiometer
Probable cause
▪ Accelerator potentiometer matching defect
▪ Accelerator potentiometer assembly defect
Related portion
CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2
STEP1
Perform the accelerator potentiometer matching.
(Refer to page MATCHING [page 130]. )
Judgment
Result Procedure
NG matching Go to step 2
OK matching Go to step 3
STEP2
Check the accelerator potentiometer voltage.
Accelerator sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRA

Check if the voltage of accelerator is within the standard range

of the below table when accelerator is not operated and during
maximum pressing of accelerator.
Position of accelerator pedal sensor 1 sensor 2
When accelerator is not oper- 0.40V to
0.65V to 2.31V
ated 1.24V
During maximum pressing of 2.00V to
2.42V to 4.79V
accelerator 4.79V
Judgment
Result Procedure
Within standard range Main controller defect
Go to step 3
Outside standard range Accelerator potentiometer assembly defect
Perform the matching after reassemble.
STEP3
Turn off key switch and disconnect the battery plug. Connect
the battery plug again after 30 seconds and turn on the key
switch.
Judgment
Result Procedure
C4-6 error occurs. Main controller defect
Accelerator potentiometer matching defect
C4-6 error does not occur.
Use as it is.
Error Code: C5-1

Failure mode: Brake potentiometer POT1 open abnormality 3
CAUTION
• Be sure to do the matching after reassembly if performed the removing and inspection of brake po-
tentiometer
Probable cause
▪ Harness defect
▪ Brake potentiometer defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
Main controller CN101-33 (74, VRB2+) CN6-1 potentiometer
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
After disconnection the CN6 connector, check the inside of con-
nector and the caulked portion of wire whether it has defect or
not by visual confirm. (Refer to BEFORE TROUBLESHOOT-
ING)
Judgment
Result Procedure
STEP2
Inspection : Brake potentiometer
Disconnect the CN6 connector and check the brake poten-

tiometer resistance.

Inspect brake potentiometer resistance.

potentiometer. Then confirm the changing value with operating
the portion of potentiometer.
CN6-4(71) to CN6-6(50)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
Judgment
Result Procedure
NG Brake potentiometer defect
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-34 and CN102-33.
Judgment
Result Procedure
NG Harness defect
Result Procedure
3
Error Code: C5-2

Failure mode: Brake potentiometer POT2 open abnormality
CAUTION
tentiometer
Probable cause
▪ Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
ING)
Judgment
Result Procedure
STEP2


3

CN6-3(73) to CN6-2(51)
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-33 and CN102-25.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-3

Failure mode: Brake potentiometer POT1VCC short circuit abnormality 3
CAUTION
• If C5-5 occurs at same time, perform troubleshooting for C5-5 first.
tentiometer
Probable cause
▪ Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
ING)
Judgment
Result Procedure
STEP2


CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-22 and CN102-33.
Judgment
Result Procedure
NG Harness defect 3
Error Code: C5-4

Failure mode: Brake potentiometer POT2VCC short circuit abnormality
CAUTION
tentiometer
Probable cause
▪ Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
ING)
Judgment
Result Procedure
STEP2


3

CN6-3(73) to CN6-2(51)
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN101-32 and CN102-25.
Judgment
Result Procedure
NG Harness defect
Error Code: C5-5

Failure mode: Brake potentiometer offset abnormality
CAUTION
tentiometer
Probable cause
▪ Harness defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
ING)
Judgment
Result Procedure
STEP2

CN6
6 5 4 3 2 1
3

caulked portion and coating of each cable for defects. (Refer to

CN6-4(71) to CN6-6(50)
CN6-3(73) to CN6-2(51)
CN6-5(72) to CN6-6(50) 1.8 to 3.5 kΩ
CN6-1(74) to CN6-2(51) 1.8 to 3.5 kΩ
Judgment
Result Procedure
OK Go to step 3
STEP3

CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN102 1 2 3 4 5 6
fects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 It is OK to connect the following portion by using SST2
CN101 and CN102.
Portions to connect SST2 / Continuity check point
*1 : CN6-5 to CN6-4 / CN101-34 to CN102-33
*2 : CN6-6 to CN6-4 / CN101-22 to CN102-33
*3 : CN6-1 to CN6-3 / CN101-33 to CN102-25
*4 : CN6-2 to CN6-3 / CN101-32 to CN102-25

Judgment
Result Procedure
NG Harness defect
Error Code: C5-6

Failure mode: Brake potentiometer matching value abnormality 3
CAUTION
• If C5-1,2,3,4,5 occurs, give priority to troubleshooting for C5-1,2,3,4,5.
tentiometer
Probable cause
▪ Brake potentiometer matching value defect
▪ Brake potentiometer assembly defect
Related portion
CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
CN101-22 (50, VRA-) CN6-6 Brake
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2
STEP1
Perform matching the brake potentiometer.
(Refer to page MATCHING [page 130].)
Judgment
Result Procedure
STEP2
Check the brake potentiometer voltage.
Brake sensor 1/2 voltage
[ANL] I/O TRAVELING 1/5 VRB

Confirm the range is within the value of following table with

brake operated and the different is 0.45V or more compared to
matching voltage with brake released.
Brake pedal height sensor 1 sensor 2
0.50V to
When released the brake 0.79V to 2.88V
1.79V
When start point of the brake 1.60V to
2.00V to 4.79V
activation 4.09V
Judgment
Result Procedure
Within standard range Main controller defect
Go to step 3
Outside standard range Brake potentiometer assembly defect
STEP3
switch.
Judgment
Result Procedure
C5-6 error occurs. Main controller defect
Brake potentiometer matching value defect
C5-6 error does not occur.
Use as it is.
Error Code: C8-1

Failure mode: Drive motor LH rotation sensor open abnormality 3
CAUTION
Probable cause
▪ Drive motor LH rotation sensor 1/2 harness defect
▪ Drive motor LH rotation sensor 1 defect
▪ Drive motor LH rotation sensor 1/2 defect
Related portion
CN109-15 (78, SSDL+) CN202-1 CN122-2

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1
Disconnect the battery plug, and visually check inside the con-
nector between CN109, CN122, CN123 and CN202 and the
caulked portion of its wire for defects. Refer to BEFORE
TROUBLESHOOTING
Judgment
Result Procedure
STEP2

CN109 CN122 CN123 Perform this check with the battery plug and the CN109, CN122
1 2 3 4 5 6 7 8 and CN123 connectors disconnected, and visually check inside
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
*1 : It is OK to connect CN122-1 to CN122-2 (CN109 side)

through SST2 (09232-13130-71) and check if there is continuity
between CN109-15 and CN109-14.
Measurement terminals Standard: Remarks
No continu-
CN109-15 to CN109-13
ity
No continu-
CN109-15 to CN109-14
ity
No continu-
CN109-13 to CN109-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor LH rotation sensor 1/2 harness defect
NG Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3
Connect the CN109 connector, then connect the battery plug
and turn on the key switch with disconnecting CN122 and
CN123 connector.
Measure the voltage between CN122-2 and N1, and between
CN123-2 and N1.
CN122 CN123
1 2 1 2 3
Judgment
Result Procedure
12 ~ 16V Go to step 4
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection :
Check the error code
Connect between CN122-1 and CN122-2, and between
CN123-1 and CN123-2 by using SST2 with connecting CN109
and disconnecting CN122, CN123.
CN122 CN123
1 2 1 2
the error occurs.
Judgment
Result Procedure
C8-2 error occurs Go to step 5
C8-1 error occurs, or error does not occur Drive motor driver LH defect
STEP5
Disconnect the SST2, and measure the resistance between
CN122-1 (CN109 side) and N1, and between CN123-2 (CN109
side) and N1 with connecting CN109 and disconnecting CN122,
CN123.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx. 100 Ω Go to step 6
Either resistance is not Approx. 100 Ω Drive motor driver LH defect
STEP6
Inspection : Drive motor LH rotation sensor
Reconnect the CN122 and CN123 connector.
Connect the battery plug and turn on the key switch to occurs
C8-1 error.
･Drive motor LH rotation sensor : sensor 1 / sensor 2

[ANL] I/O TRAVELING 5/5 SSDL
Judgment
Result Procedure
Drive motor LH rotation sensor 1 voltage :
0.3 or less
Drive motor LH rotation sensor 1 defect
0.4 to 1.9
0.4 to 1.9
0.3 or less
0.3 or less
Drive motor LH rotation sensor 1/2 defect
0.3 or less
Error Code: C8-2

Failure mode: Drive motor LH rotation sensor short abnormality 3
CAUTION
Probable cause
▪ Drive motor LH rotation sensor 1/2 harness defect
▪ Drive motor LH rotation sensor 1/2 defect
Related portion
CN109-15 (78, SSDL+) CN202-1 CN122-2

CN203-5 CN202-2 Drive motor LH
P4
+ rotation
CN109-14 (79, SSDL1) CN122-1 sensor 1
Drive motor
driver LH CN123-2
N1 Drive motor LH
- rotation
CN109-13 (80, SSDL2) CN123-1 sensor 2
STEP1
TROUBLESHOOTING
Judgment
Result Procedure
STEP2

CN109 CN122 CN123 Perform this check with the battery plug and the CN109, CN122
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

No continu-
CN109-15 to CN109-13
ity
No continu-
CN109-15 to CN109-14
ity
No continu-
CN109-13 to CN109-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor LH rotation sensor 1/2 harness defect
NG Harness defect between CN109 and CN122, between CN109
and CN123.
STEP3
CN123 connector.
CN123-2 and N1.
CN122 CN123
1 2 1 2 3
Judgment
Result Procedure
Other than 12 to 16V Drive motor driver LH defect
STEP4
Inspection :
CN123 connector. And check the occured error.
Judgment
Result Procedure
C8-2 error occurs, or error does not occur Drive motor driver LH defect
STEP5
Measure the resistance between CN122-1 (CN109 side) and
N1, and between CN123-2 (CN109 side) and N1 with connect-
ing CN109 and disconnecting CN122, CN123.
CN122 CN123
1 2 1 2
Judgment
Result Procedure
Both resistance is Approx.100 Ω Go to step 6
Either resistance is not Approx.100 Ω Drive motor driver LH defect
STEP6
Inspection : Drive motor LH rotation sensor
C8-1 error.
･Drive motor LH rotation sensor : sensor 1 / sensor 2

[ANL] I/O TRAVELING 5/5 SSDL
Judgment
Result Procedure
2.0 or more
0.4 to 1.9
0.4 to 1.9
2.0 or more
2.0 or more
Drive motor LH rotation sensor 1/2 defect
2.0 or more
Error Code: C8-3

Failure mode: Drive motor RH rotation sensor open abnormality 3
CAUTION
Probable cause
▪ Drive motor RH rotation sensor 1/2 harness defect
▪ Drive motor RH rotation sensor 1 defect
▪ Drive motor RH rotation sensor 1/2 defect
Related portion
CN110-15 (75, SSDR+) CN202-3 CN53-2

CN203-3 CN202-4 Drive motor RH
P4
+ rotarion
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotarion
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1
TROUBLESHOOTING
Judgment
Result Procedure
STEP2
Disconnect the CN110, CN53 and CN54 connectors and check
the harnesses.

CN110 CN53 CN54 Perform this check with the battery plug and the CN110, CN53,
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

CN110-15 and CN110-14.
CN110-15 and CN110-13.
No continu-
CN110-15 to CN110-13
ity
No continu-
CN110-15 to CN110-14
ity
No continu-
CN110-13 to CN110-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor RH rotation sensor 1/2 harness defect
NG Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3
and turn on the key switch with disconnecting CN53 and CN54
connector.
CN54-2 and N1.
CN53 CN54
1 2 1 2 3
Judgment
Result Procedure
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection :
Connect between CN53-1 and CN53-2, and between CN54-1
and CN54-2 by using SST2 with connecting CN110 and discon-
necting CN53, CN54.
the error occurs.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
C8-3 error occurs, or error does not occur Drive motor driver RH defect
STEP5
Disconnect the SST2, and measure the resistance between
CN53-1 (CN110 side) and N1, and between CN54-1 (CN110
side) and N1 with connecting CN110 and disconnecting CN53,
CN54.
CN53 CN54
1 2 1 2
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection : Drive motor RH rotation sensor
C8-3 error.
･Drive motor RH rotation sensor : sensor 1 / sensor 2

[ANL] I/O TRAVELING 5/5 SSDR
Judgment
Result Procedure
Drive motor RH rotation sensor 1 voltage :
0.3 or less
Drive motor RH rotation sensor 1 defect
0.4 to 1.9
0.4 to 1.9
0.3 or less
0.3 or less
Drive motor RH rotation sensor 1/2 defect
0.3 or less
Error Code: C8-4

Failure mode: Drive motor RH rotation sensor short abnormality 3
CAUTION
Probable cause
▪ Drive motor RH rotation sensor 1/2 harness defect
▪ Drive motor RH rotation sensor 1/2 defect
Related portion
CN110-15 (75, SSDR+) CN202-3 CN53-2

CN203-3 CN202-4 Drive motor RH
P4
+ rotarion
CN110-14 (76, SSDR1) CN53-1 sensor 1
Drive motor
driver RH CN54-2
N1 Drive motor RH
- rotarion
CN110-13 (77, SSDR2) CN54-1 sensor 2
STEP1
TROUBLESHOOTING
Judgment
Result Procedure
STEP2
Disconnect the CN110, CN53 and CN54 connectors and check
the harnesses.

CN110 CN53 CN54 Perform this check with the battery plug and the CN110, CN53,
1 2 1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23

CN110-15 and CN110-14.
CN110-15 and CN110-13.
No continu-
CN110-15 to CN110-13
ity
No continu-
CN110-15 to CN110-14
ity
No continu-
CN110-13 to CN110-14
ity
Judgment
Result Procedure
OK Go to step 3
Drive motor RH rotation sensor 1/2 harness defect
NG Harness between CN110 and CN53, between CN110 and CN54
defect
STEP3
connector.
CN54-2 and N1.
CN53 CN54
1 2 1 2 3
Judgment
Result Procedure
12 to 16V Go to step 4
Other than 12 to 16V Drive motor driver RH defect
STEP4
Inspection :
connector. And check the occured error.
Judgment
Result Procedure
C8-4 error occurs, or error does not occur Drive motor driver RH defect
STEP5
Measure the resistance between CN53-1 (CN110 side) and N1,
and between CN54-1 (CN110 side) and N1 with connecting
CN110 and disconnecting CN53, CN54.
Judgment
Result Procedure
Either resistance is not Approx.100 Ω Drive motor driver RH defect
STEP6
Inspection : Drive motor RH rotation sensor
C8-3 error.
･Drive motor RH rotation sensor : sensor 1 / sensor 2

[ANL] I/O TRAVELING 5/5 SSDR
Judgment
Result Procedure
2.0 or more
0.4 to 1.9
0.4 to 1.9
2.0 or more
2.0 or more
Drive motor RH rotation sensor 1/2 defect
2.0 or more
Error Code: CB-1

Failure mode: MB contactor open abnormality 3
CAUTION
• If CB-3 or CB-5 occurs, perform troubleshooting for that first.
Probable cause
▪ MB contactor defect
▪ Harness defect
▪ F6 fuse defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-2 (1, CBAT+) CN104-3 (1, CBAT+)
STEP1
After disconnection the F5, F6 fuse, check the inside of con-

ING)
Connect the F5, F6 fuse, connect the battery plug.

Judgment
Result Procedure
CB-1 error occurs. Go to step 2
CB-1 error does not occur. Connector contact defect
STEP2
Check the operation of MB contactor :
Check if MB contactor can be operated when turn on the key

switch.
Judgment
Result Procedure
OK Go to step 4
NG Go to step 3
STEP3
Check the contact of MB contactor :
Turn off the key switch and disconnect the battery plug, then
visually check contact of MB contactor (contamination, freeze
and so on)
Judgment
Result Procedure
OK Perform troubleshooting for CB-3.
MB contactor defect
NG
Use as it is.after repairing NG items.
STEP4
F6 fuse.
Judgment
Result Procedure
0Ω Go to step 5
F6 fuse defect
∞Ω
STEP5
Connect the F6 fuse, and disconnect the connector of fuse box.

Measure the resistance for both ends of F6 fuse box.
Judgment
Result Procedure
0Ω Go to step 6 3
STEP6
Disconnect the CN102 and CN104 connectors and F6 fuse and

check the harnesses for their continuities.
CN102 CN104
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17
20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25 Perform this check with the battery plug and the CN102 and
28 29 30 31 32 33 34 35 26 27 28 29 30 31 CN104 connectors and F6 fuse disconnected, and visually
check inside the connector and the caulked portion of its wire
CN250 for defects.
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 CN102-4(19) to P3 Continuity
CN250-52 (fuse side) to P3 Continuity
CN250-52 (fuse side) to N1 No continuity
Judgment
Result Procedure
OK Go to step 7
NG Harness defect
STEP7
Voltage inspection
After connecting the connector, connect the battery plug, and

Measure the both ends of voltage for the contactor (contact
side).
Refer to the following figure, and measure the both ends of
voltage for the contactor (contact side).
Standard UL-EE specification
P2
P3 P2
P3
P4
P4
P1
P1
Judgment
Result Procedure
30 V or more MB contactor defect
Less than 30 V Main controller defect
Error Code: CB-2

Failure mode: MB contactor short abnormality 3
CAUTION
• If AD-5, AD-6, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1, EC-2 or EC-3 occurs at same time CB-2, perform
troubleshooting for AD-5, AD-6, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1, EC-2 or EC-3 first.
• If CB-2 error occurs, electric charge remains in the pump motor and drive motor driver after the bat-
tery plug is disconnected, so measure the voltage between P4 and N1 and start operation after it has
lowered below 3 V.
Probable cause
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1
Turn off the key switch, disconnect the battery plug, then recon-
nect battery plug and turn on the key switch, and wait 5
seconds or more.
Turn off the key switch and 5 seconds or more after that, check
if error occurs.
Judgment
Result Procedure
CB-2 error does not occur. No abnormality. Use truck as it is.
STEP2
Check if the MB contactor opens when turn off the key switch.
Judgment
Result Procedure
The contactor opens Go to step 3
The contactor does not open. Go to step 4
STEP3
Inspection :
Voltage inspection
the battery plug again and turn on the key switch.
Turn off the key switch and 5 seconds or more after that, meas-
ure the voltage between P4 and N1.
Judgment
Result Procedure
Less than 15 V Main controller defect
15V or more Pump motor driver defect
STEP4
Inspection : MB contactor
Measure the voltage between P4 and N1 of the contactor to see
that it is 3 V or less.
Visually check the conditions of the contacts of the MB con-
tactor.
Judgment
Result Procedure
The contactor does not open. MB contactor defect
The contactor opens Perform troubleshooting for CB-3.
Error Code: CB-3

Failure mode: MB contactor (coil side) open abnormality 3
Probable cause
▪ Harness defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

ING)
Judgment
Result Procedure
STEP2
Inspection : MB contactor coil
Disconnect the CN136 connector, and measure th resistance of

MB contactor coil.
Check the resistance of MB contactor coil.
CN136 STD spec.：15 to
1
30 Ω (Approx. 20
2 3 Ω：20 °C), EE
CN136-1 to CN136-2
spec.：20 to 45 Ω
(Approx. 28 Ω：
20 °C)
Judgment
Result Procedure
OK Go to step 3
NG MB contactor defect
STEP3

nesses.
CN104
CN136
1 2 3 4 5 6 7 connectors disconnected, and visually check inside the con-
1
8 9 10 11 12 13 14 15 16 17
2 3
18 19 20 21 22 23 24 25
26 27 28 29 30 31 Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect
Error Code: CB-4

Failure mode: MB contactor drive circuit abnormality 3
Probable cause
▪ Harness defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

ING)
Judgment
Result Procedure
STEP2

MB contactor coil.
1
30 Ω (Approx. 20
2 3 Ω：20 °C), EE
CN136-1 to CN136-2
spec.：20 to 45 Ω
(Approx. 28 Ω：
20 °C)
Judgment
Result Procedure
OK Go to step 3
STEP3

nesses.
CN136 Perform this check with the battery plug and the CN104,CN136
1
2 3 nector and the caulked portion of its wire for defects.
CN136-1(2) to P1 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: CB-5

Failure mode: MB contactor (coil side) short abnormality 3
Probable cause
▪ Harness defect
Related portion
MB
P1 P3 F1 P4
N1 F6
CN250-51 CN250-52 (44) CN104-2 (44, VBMB)
Main
F5 controller
CN250-49 CN250-50 (41) CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN136-1 (2, CBAT-) CN104-9 (2, CBAT-)

MB
STEP1

ING)
Judgment
Result Procedure
STEP2

MB contactor coil.
1
30 Ω (Approx. 20
2 3 Ω：20 °C), EE
CN136-1 to CN136-2
spec.：20 to 45 Ω
(Approx. 28 Ω：
20 °C)
Judgment
Result Procedure
OK Go to step 3
STEP3

nesses.
CN104
CN136
1
8 9 10 11 12 13 14 15 16 17
2 3
18 19 20 21 22 23 24 25
26 27 28 29 30 31 Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect
Error Code: CC-1

Failure mode: Drive motor driver LH CPU abnormality 3
CAUTION
• If CC-1 occurs, the drive motor driver LH is defective, so replace it.
Probable cause
Related portion

Error Code: CC-2

Failure mode: Drive motor driver LH CPU abnormality
CAUTION
Probable cause
Related portion

Error Code: CC-3

CAUTION
Probable cause
Related portion

Error Code: CC-4

Failure mode: Drive motor driver LH CPU abnormality
CAUTION
Probable cause
Related portion

Error Code: CC-6

CAUTION
Probable cause
Related portion

Error Code: CD-1

Failure mode: Drive motor driver RH CPU abnormality
CAUTION
• If CD-1 occurs, the drive motor driver RH is defective, so replace it.
Probable cause
Related portion

Error Code: CD-2

Failure mode: Drive motor driver RH CPU abnormality 3
CAUTION
Probable cause
Related portion

Error Code: CD-3

CAUTION
Probable cause
Related portion

Error Code: CD-4

Failure mode: Drive motor driver RH CPU abnormality 3
CAUTION
Probable cause
Related portion

Error Code: CD-6

CAUTION
Probable cause
Related portion

Error Code: E0-2

Failure mode: Pump motor driver power-circuit abnormality 3
CAUTION
• If E0-2 error occurs, electric charge remains in the pump motor and drive motor driver after the bat-
lowered below 3 V.
Probable cause
▪ Pump motor cable tightening is defective
▪ Pump motor defect
▪ Pump motor cable defect
Related portion
P14
U
Pump motor P15

V Pump motor
driver
P16
W
STEP1
check the fastened and caulked portions of the pump motor
cables for defects. Refer to BEFORE TROUBLESHOOTING
Connect the pump motor cables, connect the battery plug, and
for errors.
Judgment
Result Procedure
Go to step 2
E0-2 error occurs.
E0-2 error does not occur. Pump motor cable tightening is defective
STEP2
Disconnect the three motor cables from the pump motor driver
and insulate the terminals of the cables disconnected.
if occur error E0-2.
Judgment
Result Procedure
E0-2 error does not occur. Go to step 3
E0-2 error occurs. Pump motor driver defect
STEP3
Inspection : Pump motor cable
Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for its continuity and short.
nect the pump motor cables, visually check each terminal and

P14 cable to P15 cable No continuity
Judgment
Result Procedure
OK (C0-2 does not occur at the same time
Go to step 4
on STEP1)
OK (C0-2 occurs at the same time on
Go to step 5
STEP1)
NG Pump motor cable defect
STEP4
Replace the pump motor driver with the drive motor driver LH.

Judgment 3
Result Procedure
C0-2 error occurs. The motor driver that is pump motor driver before replace-
ment is defect.
E0-2 error occurs. Pump motor defect
STEP5
Inspection : Pump motor
Check the pump motor
Judgment
Result Procedure
NG Pump motor defect
Error Code: E1-1

Failure mode: Pump motor driver current sensor neutral voltage error
CAUTION
• If E1-1 occurs, the pump motor driver circuit is defective, so replace it.
Probable cause
Related portion
Pump motor driver
Current sensor
Error Code: E1-2

Failure mode: Pump motor driver current sensor over current error 3
CAUTION
lowered below 3 V.
Probable cause
▪ Pump motor cable tightening is defective
▪ Pump motor defect
▪ Pump motor cable defect
Related portion
P14
U
Pump motor P15

V Pump motor
driver
P16
W
STEP1
Turn on / off the key switch, and operate the direction lever with
forward or backward, and check if occurs E0-2 error.
Judgment
Result Procedure
E0-2 error does not occur. Go to step 2
E0-2 error occurs. Perform troubleshooting for E0-2.
STEP2
check the assembled and caulked portions of the pump motor
cables for defects. Refer to BEFORE TROUBLESHOOTING
Connect the pump motor cables, connect the battery plug, and
for errors.
Judgment
Result Procedure
Go to step 3
E1-2 error occurs.
E1-2 error does not occur. Pump motor cable tightening is defective
STEP3
Inspection : Pump motor cable
Disconnect the pump motor cables from both the motor and the
motor driver.
Pump motor cable inspection
Check each pump motor cable for its continuity and short.
nect the pump motor cables, visually check each terminal and
Judgment
Result Procedure
OK (C1-2 does not occur at the same time
Go to step 4
on STEP2)
OK (C1-2 occurs at the same time on
Go to step 5
STEP2)
NG Pump motor cable defect
STEP4
Replace the pump motor driver with the drive motor driver LH.
Judgment
Result Procedure
Pump motor driver defect 3
C1-2 error occurs. The motor driver that is pump motor driver before replace-
ment is defect.
E1-2 error occurs. Pump motor defect
STEP5
Inspection : Pump motor
Check the pump motor
Judgment
Result Procedure
NG Pump motor defect
Error Code: E2-1

Failure mode: Pump motor overheating abnormality
CAUTION
Probable cause
Related portion
CN111-9 (88, STPM+) CN55-2

Pump motor driver Temperature sensor
(Pump motor)
CN111-10 (89, STPM) CN55-1
STEP1
Inspection :
Reconfirm the displayed error.
Judgment
Result Procedure
"PM" occurs. Go to step 2
After falling temperature of pump motor, "PM" is disappeared
"PM" does not occur. and the truck can be operated as usual. It is estimated that
STEP2
Inspection :
Confirm the temperature of the pump motor and Reconfirm the
error
･Pump motor temperature

[ANL] I/O TEMP/VOLT 3/6 TPM
Record the temperature of the pump motor.

occured.
3
Judgment
Result Procedure
"PM" occurs. Go to step 3
After falling temperature of pump motor, "PM" is disappeared
"PM" does not occur. and the truck can be operated as usual. It is estimated that
STEP3
Inspection :
Reconfirm the temperature of pump motor
･Pump motor temperature

[ANL] I/O TEMP/VOLT 3/6 TPM
Judgment
Result Procedure
It has not lowered by 5°C or more. E2-2 Perform troubleshooting from STEP2.
Error Code: E2-2

Failure mode: Pump motor temperature sensor (open/short) abnormality
Probable cause
▪ Pump motor temperature sensor defect
▪ Pump motor temperature sensor harness defect
Related portion
CN111-9 (88, STPM+) CN55-2

Pump motor driver Temperature sensor
(Pump motor)
CN111-10 (89, STPM) CN55-1
STEP1
nector between CN55 and the caulked portion of its wire for de-
fects. Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
E2-2 error occurs. Go to step 2
E2-2 error does not occur. Connector contact defect
STEP2
Inspection :
Pump motor temperature sensor individual inspection
Disconnect the CN55 connector, and perform the sensor indi-
vidual inspection.
CN55
2 1


and CN55-2 (sensor side of CN55)
Standard: Approx. 245 Ω to 600 kΩ 3

Temperature
sensor resist-
CN55-2 and
CN55-1)
20 °C Approx. 13 kΩ
80 °C Approx. 1.75 kΩ
100 °C Approx. 1 kΩ
Judgment
Result Procedure
OK Go to step 3
NG Pump motor temperature sensor defect
STEP3
harnesses.
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
disconnecting SST.

CN111-9 and CN111-10.
No continu-
CN55-1 to CN55-2
ity
Judgment
Result Procedure
NG Pump motor temperature sensor harness defect
Error Code: E3-1

Failure mode: Pump motor driver power-circuit temperature sensor (open/short)
abnormality
CAUTION
• If E3-1 occurs, the pump motor driver circuit is defective, so replace it.
Probable cause
Related portion
Pump motor driver
Temperature sensor
Error Code: E8-1

Failure mode: Pump motor rotation sensor open abnormality 3
CAUTION
lowered below 3 V.
Probable cause
▪ Pump motor rotation sensor harness defect
▪ Pump motor rotation sensor defect
Related portion
P4
+
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1
nector between CN56 and CN111 and the caulked portion of its
wire for defects. Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
STEP2
harnesses.

1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
disconnecting SST.

CN111-15 and CN111-14.
No continu-
CN111-15 to CN111-14
ity
Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3
and turn on the key switch with disconnecting CN56 connector.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection :
Connect between CM56-1 and CN56-2 on the CN111 side by
using SST2 with disconnecting CN56 connector.
the error occurs.
CN56 3
1 2
Judgment
Result Procedure
E8-1 error occurs, or error does not occur. Pump motor driver defect
STEP5
Disconnecting SST2, and measure the resistance between
CN56-1 (CN111 side) and N2 with disconnecting CN56 con-
nector.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: E8-2

Failure mode: Pump motor rotation sensor short abnormality
CAUTION
lowered below 3 V.
Probable cause
▪ Pump motor rotation sensor harness defect
▪ Pump motor rotation sensor defect
Related portion
P4
+
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor

driver rotation sensor
CN111-14 (82, SSP1) CN56-1
N1
-
STEP1
wire for defects. Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
STEP2
harnesses.

3
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
disconnecting SST.

CN111-15 and CN111-14.
No continu-
CN111-15 to CN111-14
ity
Judgment
Result Procedure
OK Go to step 3
NG Pump motor rotation sensor harness defect
STEP3
and turn on the key switch with disconnecting CN56 connector.
Measure the voltage between CN56-2 (CN111 side) and N2.
CN56
1 2
Judgment
Result Procedure
Other than 12 to 16V Pump motor driver defect
STEP4
Inspection :
Connect the battery plug and turn on the key switch with dis-
connecting CN56 connector. And check the occured error.
Judgment
Result Procedure
E8-2 error occurs, or error does not occur. Pump motor driver defect
STEP5
Measure the resistance between CN56-1 (CN111 side) and N2
with disconnecting CN56 connector.
CN56
1 2
Judgment
Result Procedure
Approx. 100 Ω Pump motor rotation sensor defect
Outside Approx. 100 Ω Pump motor driver defect
Error Code: EC-1

Failure mode: Pump motor driver CPU abnormality 3
CAUTION
• If EC-1 occurs, the pump motor driver circuit is defective, so replace it.
Probable cause
Related portion
Pump motor driver

Error Code: EC-2

Failure mode: Pump motor driver CPU abnormality
CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC-3

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC-4

Failure mode: Pump motor driver CPU abnormality
CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EC-6

CAUTION
Probable cause
Related portion
Pump motor driver

Error Code: EE-1

Failure mode: Communication line abnormality : Display to main controller
CAUTION
• In case of confirming the memory of EE-1 at display, communication for display is recovered, so use
as it is.
Probable cause
▪ Display defect
Related portion
CN103-11 (145, CAN1H) CN70-16
Main controller Display

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:
Check if error F1-1 or F1-2 is occurring at display.
Judgment
Result Procedure
Under occurrence To troubleshooting for F1-1, F1-2
No occurrence Display or main controller defect
Error Code: EE-2

Failure mode: Communication line abnormality : Display to main controller 3
CAUTION
• In case of confirming the memory of EE-2 at display, communication for display is recovered, so use
as it is.
Probable cause
▪ Display defect
Related portion
CN103-11 (145, CAN1H) CN70-16

CN103-12 (146, CAN1L) CN70-15
STEP1
Confirming error occurrence:
Check if error F1-1 or F1-2 is occurring at display.
Judgment
Result Procedure
Under occurrence To troubleshooting for F1-1, F1-2
No occurrence Display or main controller defect
Error Code: F1-1

Failure mode: Communication line abnormality between main controller and display
Probable cause
Related portion
CN103-3 (14, DGND) CN70-4

CN103-14 (16, D7V) CN70-5
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15
STEP1
Inspection: Reconfirm the error
wire for defects. (Refer to BEFORE TROUBLESHOOTING)

turn key switch ON to confirm error.
Judgment
Result Procedure
F1-1 or F1-2 occurs Perform troubleshooting for F1-2.
Connector contact defect
F1-1 and F1-2 does not occur
Use truck as it is.
Error Code: F1-2

Failure mode: Communication line abnormality between main controller and display 3
Probable cause
▪ Harness defect
▪ Display defect
Related portion
CN103-3 (14, DGND) CN70-4

CN103-14 (16, D7V) CN70-5
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15
CN103-5 CN103-4
(N2, N2) (42, KYSAT)
CN109-8
CN109-17 Drive motor
driver LH
CN109-16
CN110-8
CN110-17 Drive motor
driver RH
CN110-16
CN111-8
CN111-17 Pump motor
driver
CN111-16
STEP1
nector CN103 and CN70 and the caulked portion of its wire for
defects. (Refer to BEFORE TROUBLESHOOTING)
Judgment
Result Procedure
F1-2 error occurs. Go to step 2
F1-2 error does not occur. Connector contact defect
STEP2
harnesses.
CN70
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35


Continuity (Ap-
CN103-11 to CN70-16
prox. 0Ω)
Continuity (Ap-
CN103-12 to CN70-15
prox. 0Ω)
No continuity (Ex-
CN70-15 to CN70-16
cept 0Ω)
No continuity (Ex-
CN70-15 to CN70-4
cept 0Ω)
No continuity (Ex-
CN70-15 to CN70-5
cept 0Ω)
No continuity (Ex-
CN70-16 to CN70-4
cept 0Ω)
No continuity (Ex-
CN70-16 to CN70-5
cept 0Ω)
No continuity (Ex-
CN103-11 to CN103-4
cept 0Ω)
No continuity (Ex-
CN103-12 to CN103-5
cept 0Ω)
No continuity (Ex-
CN103-11 to CN103-4
cept 0Ω)
No continuity (Ex-
CN103-12 to CN103-5
cept 0Ω)
Judgment
Result Procedure
NG Harness defect
OK Go to step 3
STEP3
After connecting CN70 and CN103 connector, connect the bat- 3
tery plug and turn on the key switch, and check the operation to
drive and material handling .
Judgment
Result Procedure
Display defect
The traveling and load handling operation If the symptom persists after replacement of the display,
can be performed. there should be any other problems, so replace the main con-
troller.
The traveling and load handling operation If the symptom persists after replacement of the main con-
cannot be performed. troller, there should be any other problems, so replace the
display.
Error Code: F4-1

Failure mode: Display CPU defect
CAUTION
• If F4-1 occurs, the display is defective, so replace it.
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-2

Failure mode: Display CPU defect 3
CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-3

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-4

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-5

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-6

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-7

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: F4-8

CAUTION
Probable cause
▪ Display defect
Related portion
Display
Error Code: FB-1

Failure mode: Battery current sensor neutral voltage error
CAUTION
• If the symptom persists after replacement of the current sensor, there should be any other prob-
lems, so replace the Main controller.
Probable cause
▪ Harness defect
▪ Battery current sensor defect
Related portion
Contactor panel
CN104-10 (303, CSBAT+) CN138-1
Main CN102-24 (304, CSBAT) CN138-3

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
or not by visual confirm. Refer to BEFORE TROUBLESHOOT-
ING
Judgment
Result Procedure
FB-1 error occurs. Go to step 2
FB-1 error does not occur. Connector contact defect
STEP2
CN102
Check the harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 3
28 29 30 31 32 33 34 35
CN138 and CN138 connectors disconnected, and visually check inside
1 2 3
CN104 (Note : Inspect in the state of disconnecting SST)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 *1 : Connect CN138-1 and CN138-3 on the harness side

18 19 20 21 22 23 24 25
through SST2 and check if there is continuity between
26 27 28 29 30 31
CN104-10 and CN102-24.
*2 : Connect CN138-2 and CN138-3 on the harness side
CN102-24 and CN102-35.
CN104-10(303) to
Continuity *1
CN138-1(303)
CN102-24(304) to
Continuity *1
CN138-3(304)
CN102-35(305) to
Continuity *2
CN138-2(305)
CN138-1(303) to No continu-
CN138-2(305) ity
CN138-1(303) ity
CN138-2(305) ity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Inspection : Battery current sensor
Check the value of battery current sensor using the Analyzer
menu.
[ANL] I/O OTHERS 1/1 CSBAT
Judgment
Result Procedure
Approx. 0.00 Go to step 4
Except 0.00 Main controller defect
STEP4
Disconnect CN138 and connect CN138-1 to CN138-3 on the
harness side through SST2.
menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FB-2

Failure mode: Battery current sensor overcurrent 3
Probable cause
▪ Harness defect
▪ Battery current sensor defect
Related portion
Contactor panel
CN104-10 (303, CSBAT+) CN138-1
Main CN102-24 (304, CSBAT) CN138-3

controller Battery current sensor
CN102-35 (305, CSBAT-) CN138-2
STEP1
ING)
Judgment
Result Procedure
FB-2 error occurs. Go to step 2
FB-2 error does not occur. Connector contact defect
STEP2
CN102
Check the harness.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
CN138 and CN138 connectors disconnected, and visually check inside
1 2 3
CN104 (Note : Inspect in the state of disconnecting SST)
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 *1 : Connect CN138-1 and CN138-3 on the harness side

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-10 and CN102-24.
*2 : Connect CN138-2 and CN138-3 on the harness side
CN102-24 and CN102-35.
CN104-10(303) to
Continuity *1
CN138-1(303)
CN102-24(304) to
Continuity *1
CN138-3(304)
CN102-35(305) to
Continuity *2
CN138-2(305)
CN138-2(305) ity
CN138-1(303) ity
CN138-2(305) ity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
menu.
Judgment
Result Procedure
Approx. 0.00 Go to step 4
STEP4
Disconnect CN138 and connect CN138-1 to CN138-3 on the
harness side through SST2. 3
menu.
CN138
1 2 3
Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Error Code: FF-1

Failure mode: Power supply circuit for display over current
CAUTION
• When FF-1 error occurs, error codes can't be checked on the display. Perform inspection and repair
while conducting troubleshooting at where no error is detected.
Probable cause
▪ Display defect
▪ Harness defect
Related portion
CN103-14 (16, D7V) CN70-5
CN103-3 (14, DGND) CN70-4
STEP1
Turn off the key switch and disconnect the battery plug. Check
the inside of connector CN103, CN70 and the caulked portion
of wire whether it has defect or not by visual confirm. (Refer to
turn on the key switch to confirm the display.
Judgment
Result Procedure
Screen is displayed and FF-1 error does
Connector contact defect
not occur.
Screen isn't displayed. Go to step 2
STEP2
Perform inspection and repair while conducting troubleshooting
at when no error code is displayed.
Troubleshooting at WHEN NO ERROR CODE IS DISPLAYED.

[Classification of Control], errors related to power source and
[Phenomenon occurs on vehicle] are not indicated on the dis-
play while the vehicle runs.
Error Code: FF-2

Failure mode: Steering sensor power-supply circuit over current 3
Probable cause
▪ Steering sensor defect
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1
Main controller Steering sensor
CN103-6 (51, LS-) CN19-2
STEP1
nector CN19 and the caulked portion of its wire for defects.

turn on the key switch to confirm the display.
Judgment
Result Procedure
FF-2 error occurs. Go to step 2
FF-2 error does not occur. Connector contact defect
STEP2
Inspection :
Steering sensor power supply inspection.
Measure the votage between the CN19-1 and CN19-2 connect-
ors on the harness side.

Inspect the steering sensor power supply.
1 2
3 4 5 6 caulked portion and coating of each cable for defects. (Refer to
CN19-1 (311) to CN19-2 (51) Approx. 15V
Judgment
Result Procedure
NG Go to step 3
OK Steering sensor defect
STEP3
harnesses.
CN103
CN19 Perform this check with the battery plug and the CN19 and
1 2 3 4 5 6
1 2
CN103 connectors disconnected, and visually check inside the
7 8 9 10 11 12 13 14 15 16
3 4 5 6 connector and the caulked portion of its wire for defects.
17 18 19 20 21 22 23 24 25 26 27
CN19-1 (311) to CN19-2 (51) No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 32-1

Failure mode: Drive motor driver (LH) : controller ID abnormality 3
CAUTION
• When a driver as using a pump motor driver or drive motor driver (RH) is installed as derive motor
driver (LH) on the vehicle, the 32-1 error always occurs. But it is not abnormality.
• If AD-3, AD-4 or AD-5 AD-6 occurs, perform troubleshooting for that first.
Probable cause
▪ Drive motor driver (LH) defect
Related portion
CN109-6 CN110-6
NC NC
Drive motor CN109-7 Drive motor CN110-7 (150, SETDR1)
driver LH NC driver RH
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1
After disconnection the CN109, CN110, CN111 connector,
check the inside of connector and the caulked portion of wire
whether it has defect or not by visual confirm. (Refer to BE-
FORE TROUBLESHOOTING)
Connect the CN109, CN110, CN111 connector, connect the
battery plug.

Judgment
Result Procedure
32-1 error occurs. Drive motor driver (LH) defect
32-1 error does not occur. Connector contact defect
Error Code: 32-2

Failure mode: Drive motor driver (RH) : controller ID abnormality 3
CAUTION
• When a new motor driver or a driver as using a pump motor driver or drive motor driver (LH) is in-
stalled as derive motor driver (RH) on the vehicle, the 32-2 error always occurs. But it is not abnor-
mality.
• If AD-1, AD-2 or AD-5, AD-6 occurs, perform troubleshooting for that first.
Probable cause
▪ Drive motor driver (RH) defect
Related portion
CN109-6 CN110-6
NC NC
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1
battery plug.

Judgment
Result Procedure
32-2 error occurs. Drive motor driver (RH) defect
Error Code: 32-3

Failure mode: Pump motor driver : controller ID abnormality 3
CAUTION
• When a new motor driver or a driver as using drive motor driver (LH) or (RH) is installed as pump
motor driver on the vehicle, the 32-1 error always occurs. But it is not abnormality.
• If AD-1, AD-2 or AD-3, AD-4 occurs, perform troubleshooting for that first.
Probable cause
Related portion
CN109-6 CN110-6
NC NC
CN109-23 CN110-23 (150, SETDR-)
NC
CN111-6 (152, SETP1)
Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)
STEP1
battery plug.

Judgment
Result Procedure
32-3 error occurs. Pump motor driver defect
Error Code: 33-1

Failure mode: Main controller to Drive motor driver (LH) : communication abnormality 3
CAUTION
• If AD-1 or AD-2 occurs, perform troubleshooting for AD-1 or AD-2 first.
Probable cause
▪ Harness defect
▪ Drive motor driver (LH) defect
Related portion
CN103-4 (42, KYSAT) CN109-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN109-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN109-16 (146, CAN1L) LH
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
After disconnection the CN103, CN104 and CN109 connector,
Connect the CN103, CN104 and CN109 connector, connect the
battery plug.

Especially if the drive motor driver (LH) has just been replaced,
check if the connector is connected correctly.
Judgment
Result Procedure
33-1 error occurs. Go to step 2
STEP2

CN103
CN109
1 2 3 4 5 6 CN104, CN109 connectors disconnected, and visually check in-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
side the connector and the caulked portion of its wire for de-
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 fects.
CN103-4(42) to CN103-5(N2) No continuity
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Turn off the key switch, and after connecting CN103, CN104,
CN109 connector, turn on the key switch.
Judgment
Result Procedure
STEP4
Inspection : Motor driver
the error occurs.
(Ignore the error codes 32-1 and 32-3.)
Judgment
Result Procedure 3
Drive motor driver (LH) defect
33-3 error occurs. The motor driver that is drive motor driver (LH) before re-
placement is defect.
33-1 error occurs. Main controller defect
Error Code: 33-2

Failure mode: Main controller to Drive motor driver (RH) : communication abnormality
CAUTION
Probable cause
▪ Harness defect
▪ Drive motor driver (RH) defect
Related portion
CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L) Drive motor
CN110-7 (150, SETDR1) driver RH
Main controller CN110-23 (150, SETDR-)
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
battery plug.

Especially if the drive motor driver (RH) has just been replaced,
Judgment
Result Procedure
STEP2
3

CN103
CN110
1 2 3 4 5 6 CN104, CN110 connectors disconnected, and visually check in-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 fects.
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Judgment
Result Procedure
STEP4
the error occurs.
Judgment
Result Procedure
Drive motor driver (RH) defect
33-3 error occurs. The motor driver that is drive motor driver (RH) before re-
placement is defect.
Error Code: 33-3

Failure mode: Main controller to Pump motor driver : communication abnormality 3
CAUTION
Probable cause
▪ Harness defect
Related portion
CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H) Pump motor
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L) driver
Main controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
STEP1
battery plug.

Especially if the pump motor driver has just been replaced,
Judgment
Result Procedure
STEP2
Inspect harness :

and check the harnesses for their continuities.
CN109
CN103
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
1 2 3 4 5 6
CN104, CN109, CN111 connectors disconnected, and visually
7 8 9 10 11 12 13 14 15 16
CN111 check inside the connector and the caulked portion of its wire
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8
for defects.
9 10 11 12 13 14 15
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
Judgment
Result Procedure
STEP4
the error occurs.
Judgment
Result Procedure 3
33-1 error occurs. The motor driver that is pump motor driver before replace-
ment is defect.
Error Code: 61-1

Failure mode: Load sensor open abnormality
Probable cause
▪ Harness defect
▪ Load sensor defect
Related portion
CN104-12 (58, SPLF+) CN91-1
Main controller CN103-29 (59, SPLF) CN91-2

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1
ING)
Judgment
Result Procedure
STEP2
Inspection : Load sensor
Disconnect the CN91 connector and connect CN91-1 to

CN91-2 on the harness side through SST (09230-13700-71).
error.
CN91
1 3
2
Judgment
Result Procedure
61-2 error occurs. Load sensor defect
61-2 error does not occur. Go to step 3
STEP3
Disconnect the CN91, CN101, CN103, CN104 connectors and

CN101 CN103
1 2 3 4 5 6 7 1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN91, CN101,
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN103, CN104 connectors disconnected, and visually check in-
CN104 CN91 fects.

8 9 10 11 12 13 14 15 16 17 2 Portion to be inspected Standard:
18 19 20 21 22 23 24 25
26 27 28 29 30 31 3 CN104-12(58) to CN91-1(58) Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 61-2

Failure mode: Load sensor short abnormality
Probable cause
▪ Load sensor defect
▪ Harness defect
Related portion
CN104-12 (58, SPLF+) CN91-1
Main controller CN103-29 (59, SPLF) CN91-2

Load sensor
CN101-32 (51, POT-) CN91-3
STEP1
ING)
Judgment
Result Procedure
STEP2
Inspection : Load sensor

Judgment
Result Procedure 3
61-1 error occurs. Load sensor defect
STEP3

CN101 CN91
Perform this check with the battery plug and the CN91, CN101,
1 2 3 4 5 6 7 1
CN103, CN104connectors disconnected, and visually check in-
8 9 10 11 12 13 14 15 16 17
2 side the connector and the caulked portion of its wire for de-
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 3
fects.
Judgment
Result Procedure
NG Harness defect
Error Code: 62-1

Failure mode: Tilt angle sensor open abnormality
Probable cause
▪ Tilt angle sensor defect
▪ Harness defect
Related portion
CN101-20 (57, VRTA+) CN86-1
Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor
CN101-32 (51, POT-) CN86-3
STEP1
ING)
Judgment
Result Procedure
STEP2
Inspection : Tilt angle sensor

CN86-2 on the harness side through SST2 (09232-13130-71).
error.
CN86
1 2 3
3
Judgment
Result Procedure
62-2 error occurs. Tilt angle sensor defect
STEP3

nesses for their continuities.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN101, CN103
CN86
28 29 30 31 32 33 34
1 2 3 nector and the caulked portion of its wire for defects.
CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
* : It is OK to connect CN86-1 to CN86-2 through SST2
28 29 30 31 32 33 34 35 (09232-13130-71) and check if there is continuity between
CN101-20 and CN102-17.
CN101-20(57) to CN86-1(57) * Continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 62-2

Failure mode: Tilt angle sensor short abnormality
Probable cause
▪ Tilt angle sensor defect
▪ Harness defect
Related portion
CN101-20 (57, VRTA+) CN86-1
Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor
CN101-32 (51, POT-) CN86-3
STEP1
ING)
Judgment
Result Procedure
STEP2
Inspection : Tilt angle sensor
error.
Judgment
Result Procedure
62-1 error does not occur. Go to step 3 3
62-1 error occurs. Tilt angle sensor defect
STEP3

harnesses for their continuities.
CN101 [Inspection procedure and standard]
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Perform this check with the battery plug and the CN86, CN101-
CN86 connectors disconnected, and visually check inside the con-
CN103
1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 * : It is OK to connect CN86-2 to CN86-3 through SST2
28 29 30 31 32 33 34 35 (09232-13130-71) and check if there is continuity between
CN103-17 and CN101-32.
Judgment
Result Procedure
NG Harness defect
Error Code: 63-1

Failure mode: Tilt switch forward / backward tilt switch simultaneously short
abnormality
Probable cause
▪ Harness defect
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
ING)
Judgment
Result Procedure
A6-3 error does not occur. Go to step 2
A6-3 error occurs. To troubleshooting for A6-3
STEP2
Inspection : Tilt lever switch
Operate the tilt lever in either direction to confirm 63-1 error.
Judgment
Result Procedure
The forward and backward tilt lever switches turned ON at the
63-1 error does not occur. same time in the past. (Check and adjustment of each switch
installation)
STEP3
3

main harnesses for their continuities.
CN89
Perform this check with the battery plug and the CN89 and
1 2
connector and the caulked portion of its wire for defects.
3 4
Judgment
Result Procedure
Tilt lever switch installation defect.
OK
Tilt lever switch defect
NG Harness defect
Error Code: 63-2

Failure mode: Tilt switch forward tilt switch continuously short abnormality
Probable cause
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
ING)
Judgment
Result Procedure
STEP2
Check the status of the switches when the tilt lever is operated
in forward direction and returned to center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTF

Judgment
Result Procedure
“0” occurs after operation repeated many Detect the error for operating in forward direction over 2 3
times. minutes. Use as it is.
It may be “1” occurs after operation re- Tilt lever switch installation defect.
peated several times. Tilt lever switch defect
Error Code: 63-3

Failure mode: Tilt switch backward tilt switch continuously short abnormality
Probable cause
Related portion
Tilt lever switch
CN102-23 (61, VRT1) CN89-1

CN102-22 (62, VRT2) CN89-3
Main
CN89-2
STEP1
ING)
Judgment
Result Procedure
STEP2
Check the status of the switches when the tilt lever is operated
in backward direction and returned to center repetitively.
[ANL] I/O M.HANDLING 6/8 SWTR

Judgment
Result Procedure
“0” occurs after operation repeated several Detect the error for operating in backward direction over 2 3
times. minutes. Use as it is.
It may be “1” occurs after operation re- Tilt lever switch installation defect.
peated several times. Tilt lever switch defect
Error Code: 64-1

Failure mode: Lift lock solenoid open abnormality
CAUTION
• If 64-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 64-3.
• If A9-2 occurs at same time, perform troubleshooting for A9-2 first.
• In case of mini lever spec. , replace CN88-6 with CN88-5.
Probable cause
▪ Lift lock solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
1 . Turn off the key switch and disconnect the battery plug.
Check the inside of connector CN88 and the caulked portion of
wire whether it has defect or not by visual confirm. (Refer to BE-
2 . After connecting CN88, connect the battery plug and turn on

the key switch to confirm error.
Judgment
Result Procedure
64-4 error occurs. Perform troubleshooting for 64-4.
STEP2
Apply the lift solenoid compulsorily by using Active Test and
check if an error occurs.
3
LIFT LWR SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Lift lock solenoid individual inspection
2 . Disconnect the CN88 connector, and check the resistance of

lift lock solenoid.
Check the resistance of lift lock solenoid.
CN88
4 3 2 1 nect the CN88 connector, visually check each terminal and the
8 7 6 5
CN88-2 to CN88-6 Approx. 10 Ω
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Disconnect the CN101, CN102, CN103, CN104 and CN88 con-
nector, then check the harness.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN101,
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN104, CN88 connectors disconnected, and
visually check inside the connector and the caulked portion of
CN103 CN88 its wire for defects. Refer to BEFORE TROUBLESHOOTING
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: Connect the CN88 connector and measure the resistance
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 between CN101-1(3)and CN102-16(4). And it is OK if this res-
28 29 30 31 32 33 34 35
istance is approx.10 Ω.

CN101-1(3) to CN88-2(477) Continuously *1
CN102-16(4) to CN88-6 Continuously *1
Judgment
Result Procedure
NG Harness defect
Error Code: 64-2

Failure mode: Lift lock solenoid short abnormality 3
CAUTION
to 64-3.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the lift solenoid compulsorily by using Active Test and


LIFT LWR SOL：OFF to ON
Judgment
Result Procedure
STEP3
lift lock solenoid.
CN88
8 7 6 5
CN88-2(477) to A88-6(4) Approx. 10 Ω
Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to step 4
STEP4
Disconnect the CN101, CN102 and CN88 connector, then
check the harness.
CN102
CN88
1 2 3 4 5 6 7
1 2 3 4
CN102, CN88 connectors disconnected, and visually check in-
8 9 10 11 12 13 14 15 16 17 18 19 side the connector and the caulked portion of its wire for de-
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8 fects. Refer to BEFORE TROUBLESHOOTING
Judgment
Result Procedure
NG Harness defect 3
Error Code: 64-3

Failure mode: Lift lock solenoid drive circuit abnormality
CAUTION
Probable cause
▪ Harness defect
▪ F73 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Lift lock solenoid
lift lock solenoid.
CN88
8 7 6 5
CN88-2(477) to CN88-6(4) Approx. 10 Ω
Judgment
Result Procedure
Lift lock solenoid defect 3
NG
Go to step 2
OK Go to step 2
STEP2
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN88 Turn off the key switch and disconnect the battery plug, discon-
28 29 30 31 32 33 34
nect the CN101, CN102 and CN88 connector, visually check
1 2 3 4
each terminal and the caulked portion and coating of each
CN102 cable for defects. (Refer to BEFORE TROUBLESHOOTING)
5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 CN88-2(477) to CN88-6(4) No continuity
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN101-1(3) to CN102-16(4) No continuity
Judgment
Result Procedure
Harness defect
NG
Main controller defect Go to step 3
OK Main controller defect Go to step 3
STEP3
2 . After removing F73 fuse, measure the resistance for both
ends of F73 fuse.
Judgment
Result Procedure
F73 fuse defect
∞Ω Replace the F73 fuse with the defective portion in the former
step.
0Ω Replace the defective portion in the former step.
Error Code: 64-4

Failure mode: Lift lock solenoid (open / short) abnormality
CAUTION
to 64-3.
Probable cause
▪ F73 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F73
CN250-36 (477) CN250-35 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-2 (477) CN102-16 (4,SLLL-)
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
64-4 error occurs. Go to step 2 3
STEP2
Inspection : Check the mounting state of F73 fuse
2 . Check the mounting F73 fuse it has defect or not by visual

confirm.
3 . After connecting fuse, connect the battery plug and turn on

Judgment
Result Procedure
64-4 error does not occur. F73 fuse installation defect
STEP3
Inspection : F73 fuse indivisual inspection

ends of F73 fuse.
Judgment
Result Procedure
F73 fuse defect
∞Ω
0Ω Go to step 4
STEP4
Inspection : F73 fuse box
2 . Connect the F73 fuse, and disconnect the connector of F73

fuse box.
3 . Measure the resistance for both ends of F73 fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

lift lock solenoid.
CN88
8 7 6 5
CN88-2(477) to CN88-6(4) Approx. 10 Ω
Judgment
Result Procedure
Lift lock solenoid defect
NG If replacing the F73 fuse in the former step, perform the
STEP6.
OK Go to step 6
STEP6
Disconnect the CN101, CN102, CN103 and CN88 connector,
then check the harness.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN88 connectors disconnected, and visually
CN103 CN88 for defects. Refer to BEFORE TROUBLESHOOTING
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: In case of the OK in the former step, connect the CN88 con-
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 nector and measure the resistance between CN101-1(3)and
28 29 30 31 32 33 34 35
CN102-16(4). And it is OK if this resistance is approx.10 Ω.
CN88-2(477) to CN88-6(4) No continuity *1
Judgment
Result Procedure
NG Harness defect
Error Code: 65-1

Failure mode: Tilt solenoid open abnormality 3
CAUTION
to 65-3.
Probable cause
▪ Tilt solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the tilt solenoid compulsorily by using Active Test and


TILT SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Tilt solenoid individual inspection
tilt solenoid.
Check the resistance of tilt solenoid.
CN88
8 7 6 5
CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: Connect the CN88 connector and measure the resistance
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 between CN101-2 and CN102-19. And it is OK if this resistance
28 29 30 31 32 33 34 35
is approx.10 Ω.

CN101-2 (6) to CN88-3 (479) Continuity *
3
CN101-2 (6) to CN103-5 (N2) No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 65-2

Failure mode: Tilt solenoid short abnormality
CAUTION
to 65-3.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
65-4 error occurs . Perform troubleshooting for 65-4.
STEP2
Apply the tilt solenoid compulsorily by using Active Test and

check if if an error occurs.
[ANL] ACTIVE TEST 1/3 3

TILT SOL：OFF to ON
Judgment
Result Procedure
STEP3
tilt solenoid.
CN88
8 7 6 5
CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to step 4
STEP4
Disconnect theCN102 and CN88 connector, then check the har-
ness.
CN102
CN88
Perform this check with the battery plug and the CN102, CN88
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17 18 19 nector and the caulked portion of its wire for defects. Refer to
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
5 6 7 8 BEFORE TROUBLESHOOTING
CN102-19 (7) to P2 No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 65-3

Failure mode: Tilt solenoid drive circuit abnormality 3
CAUTION
Probable cause
▪ Harness defect
▪ F74 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Tilt solenoid
tilt solenoid.
CN88
8 7 6 5
CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Tilt solenoid defect
OK Go to step 2
STEP2
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 CN88 Perform this check with the battery plug and the CN101,
28 29 30 31 32 33 34
1 2 3 4
CN102 fects. Refer to BEFORE TROUBLESHOOTING
5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 CN88-3 (479) to CN88-7 (7) No continuity
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
NG
STEP3
ends of F74 fuse.
Judgment
Result Procedure
F74 fuse defect
step.
０Ω Replace the defective portion in the former step.
Error Code: 65-4

Failure mode: Tilt solenoid (open / short) abnormality 3
CAUTION
to 65-3.
Probable cause
▪ F74 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F74
CN250-38 (479) CN250-37 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-3 (479) CN102-19 (7,SLTFL-)
N1 Tilt forward
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
STEP3
ends of F74 fuse.
Judgment
Result Procedure
F74 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
2 . Measure the resistance for both ends of the connector for
F74 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
tilt solenoid.
3
CN88
4 3 2 1
8 7 6 5

CN88-3 (479) to CN88-7 (7) Approx. 10 Ω
Judgment
Result Procedure
STEP6.
OK Go to step 6
STEP6
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *: In case of the OK in the former step, connect the CN88 con-
5 6 7 8
17 18 19 20 21 22 23 24 25 26 27 nector and measure the resistance between CN101-2 and
28 29 30 31 32 33 34 35
CN102-19. And it is OK if this resistance is approx.10 Ω.
CN88-3 (479) to CN88-7 (7) No continuity *
Judgment
Result Procedure
NG Harness defect
Error Code: 66-1

Failure mode: Outside matching value range for tilt angle sensor 3
Probable cause
▪ Tilt sensor matching defect
Related portion
Main controller
STEP1
MATCHING :
Perform matching of the tilt horizontal angle and the forward tilt
angle. (Refer to "Matching" of Display section)
Judgment
Result Procedure
STEP2
Tilt sensor voltage inspection:
Check the tilt sensor voltage.
･Tilt sensor voltage inspection:
[ANL] I/O M.HANDRING 2/8 VRTA

Position of tilt angle Voltage
When horizontal position 1.27V to 3.99V
Judgment
Result Procedure
Go to step 3
Outside standard value Tilt sensor assembly defect.
After reassemble, perform matching and STEP3.
Within standard value Main controller defect
STEP3
Check the error :
After 30 seconds, reconnect the battery plug and turn on the
key switch.
Judgment
Result Procedure
Tilt sensor matching defect
66-1 error does not occur.
Use as it is.
Error Code: 67-1

Failure mode: Lifting height switch open / short abnormality 3
Probable cause
▪ Harness defect
▪ Lifting height switch defect
Related portion
CN90
CN104-22 (90, SH1) 3 3 CN92-2
Main controller CN103-24 (91, SH2-1) 2 2 CN92-3
CN103-6 (51, LS-) 1 1 CN92-1

Lifting height
switch
STEP1
Turn off the key switch and disconnect the battery plug at lift
lowermost position.
Disconnect the CN90, CN92 connectors, visually check inside
the connector of CN90 and CN92, and the caulked portion of its
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
Connect the CN90 and CN92 connector, connect the battery
plug.

Lifting height switch arm is released, check if an error occurs.
In case of being height switch in the truck, lifting height switch
arm is released, check if an error occurs.
Judgment
Result Procedure
STEP2
Turn off the key switch and disconnect the battery plug at keep-
ing the condition under the error occurs.
Disconnect the CN90 connectors and check the height switch

for their continuities.

Check the harness for continuity.
CN90 Perform this check with the battery plug and the CN90 connect-
ors disconnected, and visually check inside the connector and
3 2 1 the caulked portion of its wire for defects.
Give attention to the inspection contents. These are different

standard by the condition of height switch lever.
Portion to
Height switch lever condi-
be inspec- Standard
tion
ted
CN90-1(51)
Pushed (low height) to Continuity
CN90-2(90)
CN90-1(51)
Pushed (low height) to No continuity
CN90-3(91)
CN90-2(90)
CN90-3(91)
CN90-1(51)
Released (high height) to No continuity
CN90-2(90)
CN90-1(51)
Released (high height) to Continuity
CN90-3(91)
CN90-2(90)
CN90-3(91)
Judgment
Result Procedure
OK Go to step 3
NG Go to step 4
STEP3

CN103
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 3
17 18 19 20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN90, CN102,
28 29 30 31 32 33 34 35
CN90 CN103 and CN104 connectors disconnected, and visually
CN104 1 2 3 for defects.
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31 Portion to be inspected Standard
Judgment
Result Procedure
NG Harness defect
STEP4
Inspection : Lifting height switch
Turn off the key switch and disconnect the battery plug at keep-
ing the condition under the error occurs.
Disconnect the CN92 connectors and check the height switch

for their continuities.
Check the switch for continuity.
CN92 Perform this check with the battery plug and the CN92 connect-
ors disconnected, and visually check inside the connector and
3 2 1 the caulked portion of its wire for defects.
Give attention to the inspection contents. These are different

standard by the condition of height switch lever.
Portion to
Height switch lever condi-
be inspec- Standard
tion
ted
CN92-1(51)
Pushed (low height) to Continuity
CN92-2(90)
CN92-1(51)
CN92-3(91)
CN92-2(90)
CN92-3(91)
CN92-1(51)
CN92-2(90)
CN92-1(51)
Released (high height) to Continuity
CN92-3(91)
CN92-2(90)
CN92-3(91)
Judgment
Result Procedure
OK Harness defect
NG Lifting height switch defect
Error Code: 69-1

Failure mode: Backward lock solenoid open abnormality 3
CAUTION
to 69-3.
Probable cause
▪ Backward lock solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid compulsorily by using Active

Test and check if an error occurs.

TILT BWD SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Backward lock solenoid individual inspection
backward lock solenoid.
Check the resistance of backward lock solenoid.
CN88
8 7 6 5
CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
is approx.10 Ω.

3
Judgment
Result Procedure
NG Harness defect
Error Code: 69-2

Failure mode: Backward lock solenoid short abnormality
CAUTION
to 69-3.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Apply the backward lock solenoid compulsorily by using Active
Test and check if an error occurs.

TILT BWD SOL：OFF to ON
3
Judgment
Result Procedure
STEP3
CN88
8 7 6 5
CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
NG Backward lock solenoid defect
OK Go to step 4
STEP4
ness.
CN102
CN88
1 2 3 4 5 6 7
1 2 3 4
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: 69-3

Failure mode: Backward lock solenoid drive circuit abnormality 3
Probable cause
▪ Harness defect
▪ F75 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Backward lock solenoid indivisual inspection
CN88
8 7 6 5
CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Backward lock solenoid defect
OK Go to step 2
STEP2
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
NG
STEP3
ends of F75 fuse.
Judgment
Result Procedure
F75 fuse defect
step.
Error Code: 69-4

Failure mode: Backward lock solenoid (open / short) abnormality 3
CAUTION
to 69-3.
Probable cause
▪ F75 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F75
CN250-40 (480) CN250-39 (6) CN101-2 (6,SLTFB+)
Main
controller
CN88-8 (480) CN102-18 (8,SLTBL-)
N1 Backward
tilt lock
solenoid CN88-4 (8) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
STEP3
ends of F75 fuse.
Judgment
Result Procedure
F75 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
F75 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5

CN88 3
8 7 6 5
CN88-8 (480) to CN88-4 (8) Approx. 10 Ω
Judgment
Result Procedure
Backward lock solenoid defect
STEP6.
OK Go to step 6
STEP6
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: 71-1

Failure mode: Tire angle sensor open abnormality
Probable cause
▪ Tire angle sensor defect
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3
Main controller CN102-31 (317, VRTRA) CN97-2 Tire angle

sensor
CN102-26 (51, POT-) CN97-1
STEP1
Connector inspection
2 . Visually check inside the connector of CN97, and the
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
3 . After connecting the CN97 connector, connect the battery
plug and turn key switch ON to confirm error.
Judgment
Result Procedure
71-1 errors. Go to step 2
STEP2
Inspection : Tire angle sensor
2 . Disconnect the CN97 connector, and connect between
CN97-3 and CN97-2 with SST2.
3 . Reconnect the battery plug and turn on the key switch, and
check the error code.
CN97
1 2 3 3
Judgment
Result Procedure
71-2 error occurs. Tire angle sensor defect
STEP3
2 . Disconnect the CN101, CN102, and CN97 connector, and
inspect harness with SST disconnected.
CN101
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug and the
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN101, CN102 and CN97 connectors and with SST disconnec-
28 29 30 31 32 33 34 CN97 ted visually check inside each connector and the caulked por-
tion of each wire for defects.
1 2 3
1 2 3 4 5 6 7 Portion to be inspected Standard

8 9 10 11 12 13 14 15 16 17 18 19 CN101-23(316) to CN97-3(316) Continuity
20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
Error Code: 71-2

Failure mode: Tire angle sensor short abnormality
Probable cause
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
TROUBLESHOOTING)
plug and turn key switch ON to confirm error.
Judgment
Result Procedure
STEP2
2 . Disconnect the CN101, CN102 and CN97 connectors and
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN101, CN102 and CN97 connectors and visually check inside 3
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 CN97 each connector and the caulked portion of each wire for de-
fects.
1 2 3

8 9 10 11 12 13 14 15 16 17 18 19 CN97-2(317) to CN97-3(316) No continuity
20 21 22 23 24 25 26 27
Judgment
Result Procedure
OK Go to step 3
NG Harness defect
STEP3
2 . Disconnect the CN97 connector, then connect the CN101
and CN102 connectors.
3 . Reconnect the battery plug and turn on the key switch.
ON, and check the error code.
Judgment
Result Procedure
Error Code: 71-3

Failure mode: Tire angle sensor anchoring abnormality
Probable cause
▪ Harness defect
Related portion
CN101-23 (316, VRTRA+) CN97-3

sensor
CN102-26 (51, POT-) CN97-1
STEP1
TROUBLESHOOTING)
plug and turn on the key switch to confirm error with turning
steering wheel.
Judgment
Result Procedure
STEP2
and CN102 connectors.
Judgment
Result Procedure
STEP3
Tire angle sensor inspection

and CN102 connectors. Connect between CN97-3 and CN 97-2 3
for harness side with SST2 connected.
CN97
1 2 3
Judgment
Result Procedure
STEP4
2 . Disconnect the CN101, CN102 and CN97 connectors and
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN101, CN102 and CN97 connectors and visually check inside
28 29 30 31 32 33 34 CN97 each connector and the caulked portion of each wire for de-
fects.
1 2 3

8 9 10 11 12 13 14 15 16 17 18 19 CN101-23(316) to CN97-3(316) Continuity
20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
Error Code: 72-1

Failure mode: Steering-wheel angle sensor SS1 open abnormality
Probable cause
▪ Harness defect
▪ Steering angle sensor defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
Main controller CN104-31 (313, SSTR2) CN19-4
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
ING)
Turn on the key switch, and check if error occurs with turning
steering wheel.
Judgment
Result Procedure
STEP2
Inspection : Steering angle sensor
Check the condition of the sensor with operating steering

wheel.
[ANL] I/O STEERING 1/1 SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to step 3 3
1** (* represents either 0 or 1.) Go to step 5
STEP3
CN19
1 2
3 4 5 6


wheel.
Judgment
Result Procedure
1** (* represents either 0 or 1.) Steering angle sensor defect
STEP4

CN104
CN19 Perform this check with the battery plug and the CN19, CN101,
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
3 4 5 6 side the connector and the caulked portion of its wire for de-
18 19 20 21 22 23 24 25
26 27 28 29 30 31
fects.

Judgment
Result Procedure
NG Harness defect
STEP5

wheel.
Judgment
Result Procedure
STEP6

CN104
1 2 3 4 5 6 7
1 2
CN103 and CN104 connectors disconnected, and visually
8 9 10 11 12 13 14 15 16 17
3 4 5 6 check inside the connector and the caulked portion of its wire
18 19 20 21 22 23 24 25
26 27 28 29 30 31
for defects.

3
Judgment
Result Procedure
NG Harness defect
Error Code: 72-2

Failure mode: Steering-wheel angle sensor SS2 open abnormality
Probable cause
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
ING)
steering wheel.
Judgment
Result Procedure
STEP2

wheel.

Judgment
Result Procedure
STEP3
CN19
1 2
3 4 5 6


wheel.
Judgment
Result Procedure
STEP4

CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
fects.

Judgment
Result Procedure
NG Harness defect
STEP5

wheel.
Judgment
Result Procedure
STEP6

CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
for defects.

3
Judgment
Result Procedure
NG Harness defect
Error Code: 72-3

Failure mode: Steering-wheel angle sensor SSC open abnormality
Probable cause
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
ING)
steering wheel (over one revolution).
Judgment
Result Procedure
STEP2

wheel.

Judgment
Result Procedure
STEP3


wheel.
Judgment
Result Procedure
STEP4

CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31
fects.
Judgment
Result Procedure
NG Harness defect
STEP5

wheel.
Judgment
Result Procedure
STEP6
Disconnect the CN104 and CN19 connector and check the har-
nesses for their continuities.
CN104
1 2 3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16 17
3 4 5 6 ally check inside the connector and the caulked portion of its
18 19 20 21 22 23 24 25
26 27 28 29 30 31
wire for defects.
Judgment
Result Procedure
OK Main controller defect 3
NG Harness defect
Error Code: 72-4

Failure mode: Steering-wheel angle sensor : sensor power source open abnormality
CAUTION
• Turning the steering angle sensor without turning the steering wheel may cause error code 72-4 to
be set.
Probable cause
▪ Harness defect
Related portion
CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN102-10 (51, LS-) CN19-2
STEP1
ING)
Turn on the key switch, and turn the steering wheel to see if an
error occurs. (If the steering wheel cannot be turned easily, per-
form this check with the direction switch in the Forward or Re-
verse position.)
Judgment
Result Procedure
STEP2
Check of sensor supply voltage:

3
Check the supply voltage to the sensor.

CN19-1 to CN19-2
Judgment
Result Procedure
Approx. 0 V Go to step 3
Approx. 15V Go to step 4
STEP3

CN102
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Perform this check with the battery plug and the CN19, CN102,
CN19
28 29 30 31 32 33 34 35 CN103 and CN104 connectors disconnected, and visually
1 2
CN103 3 4 5 6
for defects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
Judgment
Result Procedure
NG Harness defect
STEP4
Reconnect the CN19 connector.
Perform troubleshooting for 72-1 (SSTR1).

Perform troubleshooting for 72-2 (SSTR2).
Error Code: 73-1

Failure mode: Steering knob position synchronizer solenoid open abnormality
CAUTION
to 73-3.
Probable cause
▪ Steering knob position synchronizer solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
Steering knob CN98-2 (485) CN102-14 (330,SLS-)
N1 position
syncohonizer CN98-1 (330) CN103-5 (N2, N2)
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)

Judgment
Result Procedure
73-4 error occurs. Perform troubleshooting for 73-4. 3
STEP2
Using Active Test, forcibly turn on the output of the steering

knob position synchronizer solenoid to see if an error occurs.

STEERING SOL：OFF to ON
Judgment
Result Procedure
STEP3
Inspection : Steering knob position synchronizer solenoid
Disconnect the CN98 connector, and check the resistance of

the steering knob position synchronizer solenoid.
Inspect the solenoid resistance.
CN98
nector disconnected, and visually check inside the connector
2 1
between 7 and 17
CN98-2(329) to CN98-1(329) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4

nectors and check the harnesses for their continuities.
CN102
1 2 3 4 5 6 7 CN102, CN103 and CN104 connectors disconnected, and visu-
1 2
8 9 10 11 12 13 14 15 16 17 18 19 ally check inside the connector and the caulked portion of its
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
wire for defects.
*: In case of the OK in the steering knob position synchronizer

solenoid, connect the CN98 connector and measure the resist-
ance between CN102-7 and CN102-14. And it is OK if this res-
istance is between 7 and 17 Ω (approx. 10 Ω at 20°C).
Judgment
Result Procedure
NG Harness defect
Error Code: 73-2

Failure mode: Steering knob position synchronizer solenoid short abnormality 3
CAUTION
to 73-3.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)
Judgment
Result Procedure
STEP2
Using Active Test, forcibly turn on the output of the steering

knob position synchronizer solenoid to see if an error occurs.

STEERING SOL：OFF to ON
Judgment
Result Procedure
STEP3

steering knob position synchronizer solenoid.
CN98
2 1
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to step 4
STEP4


3
CN98
1 2 check inside the connector and the caulked portion of its wire
for defects.
Judgment
Result Procedure
NG Harness defect
Error Code: 73-3

Failure mode: Steering knob position synchronizer solenoid power-circuit abnormality
Probable cause
▪ Harness defect
▪ F71 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

CN98
2 1
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
Go to step 2 3
NG
Steering knob position synchronizer solenoid defect
OK Go to step 2
STEP2

CN102
1 2
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
wire for defects.
Judgment
Result Procedure
NG Harness and main controller defect. Go to step 3
OK Main controller defect. Go to step 3
STEP3
After removing F71 fuse, measure the resistance for both ends
of F71 fuse.
Judgment
Result Procedure
F71 fuse defect
step.
Error Code: 73-4

Failure mode: Steering knob position synchronizer solenoid (open / short) abnormality
CAUTION
to 73-3.
Probable cause
▪ F71 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F71
CN250-32 (485) CN250-31 (329) CN102-7 (329,SLS+)
Main
controller
N1 position
solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
ING)

Judgment
Result Procedure
73-4 error occurs. Go to step 2 3
STEP2
Check fuse installation:
firm.
Judgment
Result Procedure
STEP3
After removing F71 fuse, measure the resistance for both ends
of F71 fuse.
Judgment
Result Procedure
F71 fuse defect
∞Ω
0Ω Go to step 4
STEP4
Connect the F71 fuse, and disconnect the connector of F71

fuse box.
Measure the resistance for both ends of the connector for F71
fuse box.
Judgment
Result Procedure
0Ω Go to step 5
STEP5

CN98
2 1
between 7 and 17
CN98-2(329) to CN98-1(330) Ω (approx. 10 Ω
at 20°C)
Judgment
Result Procedure
STEP6.
OK Go to step 6
STEP6

CN102
1 2
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
wire for defects.
*: Connect the CN98 connector and measure the resistance

between CN102-7 and CN102-14. And it is OK if this resistance
is between 7 and 17 Ω (approx. 10 Ω at 20°C).

3
CN102-7(329) to CN102-14(330) * No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: 74-1

Failure mode: Tire angle matching: matching value abnormality
CAUTION
• If 71-1,71-2,71-3 occurs, give priority to troubleshooting for 71-1,71-2,71-3. After that, perform the fol-
lowing.
Probable cause
▪ Tire angle matching defect
Related portion
Main controller
STEP1
MATCHING :
Perform tire angle matching. (Refer to "Matching" of Display

section)
Judgment
Result Procedure
STEP2
Tire angle sensor voltage inspection :
Check the tire angle sensor voltage.
[ANL] I/O STEERING 1/1 VRTRA

Tire angle position Voltage
When straight running condition 2.11V to 2.81V
Judgment
Result Procedure
Go to step 3 3
Outside standard value Tire angle sensor assembly defect. After reassemble, perform
matching and STEP3.
STEP3
Check the error :

key switch.
Judgment
Result Procedure
74-1 error does not occur. Tire angle matching defect
Error Code: G5-1

Failure mode: Shock sensor 1 open abnormality
Probable cause
▪ Shock sensor defect
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN103-30 (301,IPL1) CN129-2 (301) Shock sensor 1
CN101-32 (51,POT-) CN129-1 (51)
Main controller CN130-3 (300)

CN130-1 (51)
STEP1
Check the inside of connector CN129 and the caulked portion
2 . After connecting CN129, connect the battery plug and turn
on the key switch to confirm error.
Judgment
Result Procedure
G5-1 error does not occur. Connector contact defect
G5-1 error occurs. Go to step 2
STEP2
Inspection : Shock sensor 1
2 . Disconnect the CN129 connector and connect the CN129-3
to CN129-2 on the harness side through SST2
(09232-13130-71).
3 . Connect the battery plug and turn on the key switch to con-
firm the error code.
CN129
1 2 3 3
Judgment
Result Procedure
G5-2 error occurs. Shock sensor defect
STEP3
2 . Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
CN103
CN129
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 1 2 3
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

nect CN129, CN101 and CN103, and perform the check without
connecting SST2 (09232-13130-71).

CN103-30 and CN103-8.
Portions to be checked Standard
Judgment
Result Procedure
NG Harness defect
Error Code: G5-2

Failure mode: Shock sensor 1 short abnormally
Probable cause
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN101-32 (51,POT-) CN129-1 (51)

CN130-1 (51)
STEP1
Judgment
Result Procedure
STEP2
2 . Disconnect CN129.
Judgment
Result Procedure
STEP3
check the harness. 3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN129
CN103 1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

nect CN129, CN101 and CN103, and perform the check.

CN101-32 and CN103-30.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-3

Failure mode: Shock sensor 1 : neutral voltage error
Probable cause
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN101-32 (51,POT-) CN129-1 (51)

CN130-1 (51)
STEP1
on the key switch to confirm error (one minute later).
Judgment
Result Procedure
G5-3 error . Go to step 2
STEP2
Judgment
Result Procedure
G5-1 error does not occur. Go to step 3
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN129
CN103 1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35


CN101-32 and CN103-30.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-4

Failure mode: Shock sensor 2 open abnormality
Probable cause
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN101-32 (51,POT-) CN129-1 (51)

CN130-1 (51)
STEP1
Judgment
Result Procedure
STEP2
2 . Disconnect the CN130 connector and connect the CN130-3
to CN130-2 on the harness side through SST2
(09232-13130-71).
CN130
1 2 3 3
Judgment
Result Procedure
STEP3
check the harness.
CN103
CN130
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 1 2 3
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35

nect CN130, CN101 and CN103, and perform the check without
connecting SST2 (09232-13130-71).

CN103-19 and CN103-8.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-5

Failure mode: Shock sensor 2 short abnormally
Probable cause
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN101-32 (51,POT-) CN129-1 (51)

CN130-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN130
CN103 1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35


CN101-32 and CN103-19.
Judgment
Result Procedure
NG Harness defect
Error Code: G5-6

Failure mode: Shock sensor 2 : neutral voltage error
Probable cause
▪ Harness defect
Related portion
CN103-8 (300,IPL+) CN129-3 (300)

CN101-32 (51,POT-) CN129-1 (51)

CN130-1 (51)
STEP1
on the key switch to confirm error (one minute later).
Judgment
Result Procedure
G5-6 error occurs . Go to step 2
STEP2
Judgment
Result Procedure
G5-4 error does not occur. Go to step 3
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
CN130
CN103 1 2 3
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35


CN101-32 and CN103-19.
Judgment
Result Procedure
NG Harness defect
Error Code: H1-1

Failure mode: Lift lever potentiometer open abnormality
CAUTION
• Be sure to do the matching after reassembly if performed the removing and inspection of the lever.
• In case of mini lever spec. , replace CN115 with CN162.
Probable cause
▪ Harness defect
▪ Lift lever potentiometer defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
Main controller Lift lever
CN103-18 (21, VRL2) CN115-2 potentiometer
CN102-26 (51, POT-) CN115-1
STEP1

ING)
Turn on the key switch to check the error occurs.
Judgment
Result Procedure
H1-1 error does not occur. Connector contact defect
H1-1 error occurs. Go to step 2
STEP2
Inspection: Lift lever potentiometer
Connect between CN115-3 and CN 115-4 for harness side with
SST2 connected.
CN115
1 2 3 4
3
the error occurs.
Judgment
Result Procedure
H1-2 error does not occur. Go to step 4
STEP3
SST2 connected.
the error occurs.
CN115
1 2 3 4
Judgment
Result Procedure
H1-2 error occurs. Lift lever potentiometer defect
STEP4
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN115
28 29 30 31 32 33 34
CN103, and CN115 connectors disconnected, and visually
CN103 for defects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Portion to be inspected Standard:
Judgment
Result Procedure
NG Harness defect
Error Code: H1-2

Failure mode: Lift lever potentiometer short abnormality 3
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1

ING)
Judgment
Result Procedure
STEP2
the error occurs.
Judgment
Result Procedure
STEP3

CN102
1 2 3 4 5 6 7 CN103, and CN115 connectors disconnected, and visually
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 check inside the connector and the caulked portion of its wire
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
for defects.

Judgment
Result Procedure
NG Harness defect
Error Code: H1-3

Failure mode: Lift lever potentiometer : sensor output declination abnormality 3
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1

ING)
Judgment
Result Procedure
STEP2
Inspection : Lift lever potentiometer
the error occurs.
Judgment
Result Procedure
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
CN115 CN102, CN103 and CN115 connectors disconnected, and visu-
CN103 1 2 3 4 wire for defects.
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Portion to be inspected Standard:
Judgment
Result Procedure
NG Harness defect
STEP4
SST2 connected.
the error occurs.
3
CN115
1 2 3 4
Judgment
Result Procedure
STEP5
SST2 connected.
the error occurs.
CN115
1 2 3 4
Judgment
Result Procedure
Error Code: H1-4

Failure mode: Lift lever potentiometer neutral abnormality
CAUTION
• H1-4 error occurs if turn on the key switch or release the emergency stop button with operating lift
lever.
Probable cause
▪ Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
ING)
Judgment
Result Procedure
STEP2
Check if the lift lever potentiometer is installed correctly.
the error occurs.
Perform matching the lift lever potentiometer. (Refer to page

MATCHING [page 130].)
3
Judgment
Result Procedure
NG matching Lift lever potentiometer defect
OK matching Lift lever potentiometer assembly defect
Error Code: H1-5

Failure mode: Lift lever potentiometer matching value abnormality
CAUTION
• If H1-1,2,3,4 occurs, give priority to troubleshooting for H1-1,2,3,4.
Probable cause
▪ Lift lever potentiometer matching value defect
▪ Lift lever potentiometer assembly defect
Related portion
CN101-25 (28, VRL+) CN115-4

CN103-26 (20, VRL1) CN115-3
CN102-26 (51, POT-) CN115-1
STEP1
Perform matching the lift lever potentiometer.
(Refer to page MATCHING [page 130].)
Judgment
Result Procedure
STEP2
Check the lift lever potentiometer voltage.
Lift lever angle sensor (1/2) voltage

[ANL] I/O M. HANDLING 5/8 VRL

In case of uppermost / lowermost, be sure to confirm the range
is within the following table and the difference of the sensor
neutral matching voltage is over 0.79V.
Standard lever
Position of lift Mini lever spec.
spec.
lever
sensor 1 sensor 2 sensor 1 sensor 2
1.65 ~ 1.52 ~ 1.78 ~ 1.78 ~ 3
Neutral
2.87V 3.01V 2.75V 2.75V
When Uppermost 0.30 ~ 1.52 ~ 1.78 ~ 0.30 ~
position 2.87V 4.50V 4.50V 2.75V
When Lowermost 1.65 ~ 0.30 ~ 0.30 ~ 1.78 ~
position 4.50V 3.01V 2.75V 4.50V
Judgment
Result Procedure
Go to step 3
Outside standard value Lift lever potentiometer assembly defect
STEP3
switch.
Judgment
Result Procedure
Lift lever potentiometer matching value defect
H1-5 error does not occur.
Use as it is.
H1-5 error occurs. Main controller defect
Error Code: H2-1

Failure mode: Tilt lever potentiometer open abnormality
CAUTION
Probable cause
▪ Harness defect
▪ Tilt lever potentiometer defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
Main controller Tilt lever
CN102-22 (23, VRT2) CN163-2 (23) potentiometer
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection : Tilt lever potentiometer
2 . Replace CN163 with CN162 (connector of tilt lever poten-
tiometer and lift lever potentiometer).
H1-4, H2-4 can be ignored.

Judgment
Result Procedure
H2-1 error occurs. Go to step 3 3
H1-1 error occurs. Tilt lever potentiometer defect
STEP3
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 CN102, CN163 connectors disconnected, and visually check in-
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 * : It is OK "to connect CN163-3 to CN163-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-28 and CN102-23", and "to connect CN163-2 to
CN163-4 through SST2 (09232-13130-71) and check if there is
continuity between CN101-28 and CN102-22".
Portions to be checked Standard:
Judgment
Result Procedure
NG Harness defect
Error Code: H2-2

Failure mode: Tilt lever potentiometer short abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
STEP2
2 . Replace CN163 with CN162 (connector of tilt lever poten-
tiometer and left lever potentiometer).

Judgment
Result Procedure
STEP3
2 . Disconnect the CN102 and CN163 connector, then check
the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 connectors disconnected, and visually check inside the con-
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 * : It is OK to connect CN163-1 to CN163-4 through SST2

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-28.
Judgment
Result Procedure
NG Harness defect
Error Code: H2-3

Failure mode: Tilt lever potentiometer : sensor output declination abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1

ING)
Judgment
Result Procedure
STEP2
the error occurs.
Judgment
Result Procedure
H2-1 error does not occur. Go to step 3 3
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34 CN163 and CN163 connectors disconnected, and visually check inside
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 Portions to be checked Standard:
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
STEP4
SST2 connected.
the error occurs.
CN163
1 2 3 4
Judgment
Result Procedure
STEP5
Check the tilt lever potentiometer
SST2 connected.
the error occurs.
CN163
1 2 3 4
Judgment
Result Procedure
Error Code: H2-4

Failure mode: Tilt lever potentiometer neutral error abnormality 3
CAUTION
• H2-4 error occurs if turn on the key switch or release the emergency stop button with operating tilt
lever.
Probable cause
▪ Tilt lever potentiometer assembly defect
Related portion
CN101-28 (29, VRT+) CN163-4 (29)

CN102-23 (22, VRT1) CN163-3 (22)
CN102-26 (51, POT-) CN163-1 (51)
STEP1
Judgment
Result Procedure
H2-4error does not occur. Connector contact defect
STEP2
2 . Check if the tilt lever potentiometer is installed correctly.
4 . Perform matching the tilt lever potentiometer. (Refer to
"Matching" of Display section)
Judgment
Result Procedure
NG matching Tilt lever potentiometer defect
OK matching Tilt lever potentiometer assembly defect
Error Code: H2-5

Failure mode: Tilt lever potentiometer matching value abnormality 3
Probable cause
▪ Tilt lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING :
Perform matching of the tilt lever.

(Refer to "Matching" of Display section)
Judgment
Result Procedure
STEP2
Tilt lever potentiometer voltage inspection:
Check the tilt lever voltage.
･Tilt lever potentiometer voltage
[ANL] I/O M.HANDRING 6/8 VRT

Position of tilt lever sensor 1 sensor 2
1.78V to
When neutral position 1.78V to 2.75V
2.75V
Judgment
Result Procedure
Go to step 3
Outside standard value Tilt lever assembly defect After reassemble, perform match-
ing and STEP3.
STEP3
Check the error :
key switch.
Judgment
Result Procedure
Tilt lever potentiometer matching defect
Use as it is.
Error Code: H3-1

Failure mode: Attachment 1 lever potentiometer open abnormality 3
CAUTION
• In case of mini lever spec. , replace CN119 with CN164, and CN115 with CN162.
Probable cause
▪ Harness defect
▪ Attachment 1 lever potentiometer defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-21 (24, VRA11) CN119-3 (24) Attachment 1
Main controller lever
CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
Inspection : Attachment 1 lever potentiometer
2 . Replace CN119 with CN115 (connector of attachment lever
1 potentiometer and lift lever potentiometer).

Judgment
Result Procedure
H1-1 error occurs. Attachment 1 lever potentiometer defect
STEP3
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H3-2

Failure mode: Attachment 1 lever potentiometer short abnormality 3
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Judgment
Result Procedure
STEP3
the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-29.
Judgment
Result Procedure
NG Harness defect
Error Code: H3-3

Failure mode: Attachment 1 lever potentiometer : sensor output declination 3
abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1

ING)
Judgment
Result Procedure
STEP2
Inspection : Attachment 1 potentiometer
the error occurs.
Judgment
Result Procedure
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
STEP4
Inspection : Attachment 1 potentiometer
SST2 connected.
the error occurs.
CN119
1 2 3 4 3
Judgment
Result Procedure
STEP5
SST2 connected.
the error occurs.
CN119
1 2 3 4
Judgment
Result Procedure
Error Code: H3-4

Failure mode: Attachment 1 lever potentiometer neutral abnormality
CAUTION
• H3-4 error occurs if turn on the key switch or release the emergency stop button with operating at-
tachment 1 lever.
Probable cause
▪ Attachment 1 lever potentiometer assembly defect
Related portion
CN101-29 (30, VRAT1+) CN119-4 (30)

CN102-20 (25, VRA12) CN119-2 (25)
potentiometer
CN102-26 (51, POT-) CN119-1 (51)
STEP1
Judgment
Result Procedure
STEP2
2 . Check if the attachment 1 lever potentiometer is installed
correctly.
4 . Perform matching the attachment 1 lever potentiometer.
Judgment
Result Procedure
NG matching Attachment 1 lever potentiometer defect 3
OK matching Attachment 1 lever potentiometer assembly defect
Error Code: H3-5

Failure mode: Attachment 1 lever potentiometer matching value abnormality
Probable cause
▪ Attachment 1 lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING :
Perform matching the attachment 1 lever.

Judgment
Result Procedure
STEP2
Attachment 1 lever potentiometer voltage inspection :
Check the attachment 1 lever voltage.
Attachment 1 lever potentiometer voltage.
[ANL] I/O M.HANDRING 7/8 VRA1

Position of attachment 1
sensor 1 sensor 2
lever
When the neutral position 1.65V to
1.52V to 3.01V
(Standard lever spec.) 2.87V
When the neutral position (Mini 1.78V to
1.78V to 2.75V
lever spec.) 2.75V
Judgment
Result Procedure
Go to step 3 3
Outside standard value Attachment 1 lever assembly defect After reassemble, per-
form matching and STEP3.
STEP3
Check the error :
key switch.
Judgment
Result Procedure
Attachment 1 lever potentiometer matching defect
Use as it is.
Error Code: H4-1

Failure mode: Attachment 2 lever potentiometer open abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Judgment
Result Procedure
STEP3
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H4-2

Failure mode: Attachment 2 lever potentiometer short abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2

Judgment
Result Procedure
STEP3
the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-26 and CN101-30.
Judgment
Result Procedure
NG Harness defect
Error Code: H4-3

Failure mode: Attachment 2 lever potentiometer : sensor output declination
abnormality
CAUTION
Probable cause
▪ Harness defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1

ING)
Judgment
Result Procedure
STEP2
the error occurs.
3
Judgment
Result Procedure
STEP3
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
CN102 1 2 3 4
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
STEP4
SST2 connected.
the error occurs.
CN120
1 2 3 4
Judgment
Result Procedure
STEP5
SST2 connected.
the error occurs.
CN120
1 2 3 4
Judgment
Result Procedure
Error Code: H4-4

Failure mode: Attachment 2 lever potentiometer neutral abnormality 3
CAUTION
• H4-4 error occurs if turn on the key switch or release the emergency stop button with operating at-
tachment 2 lever.
Probable cause
▪ Attachment 2 lever potentiometer assembly defect
Related portion
CN101-30 (31, VRAT2+) CN120-4 (31)

CN102-28 (27, VRA22) CN120-2 (27)
potentiometer
CN102-26 (51, POT-) CN120-1 (51)
STEP1
Judgment
Result Procedure
STEP2
2 . Check if the attachment 2 lever potentiometer is installed
correctly.
4 . Perform matching the attachment 2 lever potentiometer.
Judgment
Result Procedure
NG matching Attachment 2 lever potentiometer defect
OK matching Attachment 2 lever potentiometer assembly defect
Error Code: H4-5

Failure mode: Attachment 2 lever potentiometer matching value abnormality 3
Probable cause
▪ Attachment 2 lever potentiometer matching defect
Related portion
Main controller
STEP1
MATCHING :
Perform matching the attachment 2 lever.

Judgment
Result Procedure
STEP2
Attachment 2 lever potentiometer voltage inspection :
Check the attachment 2 lever voltage.
Attachment 2 lever potentiometer voltage.
[ANL] I/O M.HANDRING 8/8 VRA2

Position of attachment 2
sensor 1 sensor 2
lever
When the neutral position 1.65V to
1.52V to 3.01V
(Standard lever spec.) 2.87V
When the neutral position (Mini 1.78V to
1.78V to 2.75V
lever spec.) 2.75V
Judgment
Result Procedure
Go to step 3
Outside standard value Attachment 2 lever assembly defect After reassemble, per-
form matching and STEP3.
STEP3
Check the error :
key switch.
Judgment
Result Procedure
Attachment 2 lever potentiometer matching defect
Use as it is.
Error Code: H5-1

Failure mode: Lift proportional valve solenoid open abnormality (lever pull side) 3
CAUTION
• If H5-5 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to H5-5.
• If HB-1 or HB-3 occurs at same time, perform troubleshooting for HB-1, HB-3 first.
Probable cause
▪ Lift proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
CN127-1 (19,VBMBSL) CN127-7 (17,SOLCOM) CN102-5 (17,SOLCOM)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

Lift PULL controller
solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
solenoid CN104-4 (N2, N2)
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Judgment
Result Procedure
H5-6 error occurs. Perform troubleshooting for H5-6.
STEP2
Operate the pull side of lift lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Lift proportional valve solenoid (PULL) individual in-
spection

lift proportional valve solenoid (PULL).
Check the resistance of lift proportional valve solenoid (PULL).
CN78
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

17 18 19 20 21 22 23 24 25 26 27 between CN101-5(9) and CN101-17(10). And it is OK if this res-
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H5-2

Failure mode: Lift proportional valve solenoid short abnormality (lever pull side)
CAUTION
to H5-5.
Probable cause
▪ Lift proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
1 . Turn off the key switch and disconnect the battery plug, dis-
connect the CN78 connector, visually check each terminal and
the caulked portion and coating of each cable for defects.
2 . After connecting the connector, connect the battery plug and

Judgment
Result Procedure
H5-6 error occurs. Perform troubleshooting for H5-6. 3
STEP2
Operate the pull side of lift lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Lift proportional valve solenoid (PULL) individual in-
spection
lift proportional valve solenoid (PULL).
Check the resistance of lift proportional valve solenoid (PULL).
CN78
8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
Disconnect the CN101 and CN78 connector, then check the
harness.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H5-3

Failure mode: Lift proportional valve solenoid open abnormality (lever push side) 3
CAUTION
to H5-5.
Probable cause
▪ Lift proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1

Judgment
Result Procedure
STEP2
Operate the push side of lift lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Lift proportional valve solenoid (PUSH) individual
inspection

lift proportional valve solenoid (PUSH).
Check the resistance of lift proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connector, and visually check inside each con-
nector and the caulked portion of each wire for defects. (Refer
8 7 6 5
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

17 18 19 20 21 22 23 24 25 26 27 between CN101-5(9) and CN101-16(11). And it is OK if this res-
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: H5-4

Failure mode: Lift proportional valve solenoid short abnormality (lever push side)
CAUTION
to H5-5.
Probable cause
▪ Lift proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
1 . Turn off the key switch and disconnect the battery plug, dis-
connect the CN87 connector, and visually check inside each
connector and the caulked portion of each wire for defects.
2 . After connecting the connector, connect the battery plug and

Judgment
Result Procedure
STEP2
Operate the push side of lift lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Lift proportional valve solenoid (PUSH) individual
inspection
lift proportional valve solenoid (PUSH).
Check the resistance of lift proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connector, and visually check inside each con-
8 7 6 5
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
NG Lift proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
Disconnect the CN101 and CN87 connector, then check the
harness.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H5-5

Failure mode: Lift proportional valve solenoid drive circuit abnormality 3
Probable cause
▪ Lift proportional valve solenoid defect
▪ Harness defect
▪ F76 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Lift proportional valve solenoid individual inspection
2 . Disconnect the CN78 and CN87 connector, and check the
resistance of lift proportional valve solenoid.
Check the resistance of lift proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78 and CN87 connector, visually check each ter-
minal and the caulked portion and coating of each cable for de-
8 7 6 5 8 7 6 5
fects. (Refer to BEFORE TROUBLESHOOTING)
CN78-5(481) to CN78-1(10) Approx. 8 Ω
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
Lift proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Disconnect the CN101, CN78 and CN87 connector, then check
the harness.
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87 BEFORE TROUBLESHOOTING
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
NG
OK
Go to step 3
STEP3
ends of F76 fuse.
Judgment
Result Procedure
F76 fuse defect
step.
Error Code: H5-6

Failure mode: Lift proportional valve solenoid (open / short) abnormality 3
CAUTION
to H5-5.
• If HB-1, HB-2, or HB-3 occurs at same time, perform troubleshooting for HB-1, HB-2, HB-3 first.
Probable cause
▪ F76 fuse defect
▪ Lift proportional valve solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
CN78-5 (481) CN101-17 (10,SLPL-) Main

solenoid
SLPL CN78-1 (10) CN101-16 (11,SLPS-)
CN87-5 (481) CN103-5 (N2, N2)

Lift PUSH
SLPS CN87-1 (11) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Check the inside of connector CN78 and CN87, and the
2 . After connecting CN78 and87, connect the battery plug and

Judgment
Result Procedure
STEP2

confirm.

Judgment
Result Procedure
H5-6 error does not occur. F76 fuse installation defect
STEP3
Inspection : F76 fuse indivisual inspection

ends of F76 fuse.
Judgment
Result Procedure
F76 fuse defect
∞Ω
After replacing fuse, go to STEP5
0Ω Go to step 4
STEP4

fuse box.
3 . Measure the resistance for both ends of F76 fuse box.

Judgment
Result Procedure
∞Ω F76 fuse box defect 3
0Ω Go to step 5
STEP5
Inspection : Lift proportional valve solenoid individual inspection

resistance of lift proportional valve solenoid.
Check the resistance of lift proportional valve solenoid.
CN78 CN87
8 7 6 5 8 7 6 5
CN78-5(481) to CN78-1(10) Approx. 8 Ω
CN87-5(481) to CN87-1(11) Approx. 8 Ω
Judgment
Result Procedure
Lift proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
Disconnect the CN101, CN103 CN78 and CN87 connector,
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN103 for defects. Refer to BEFORE TROUBLESHOOTING
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1: In case of the OK in the former step, connect the CN78 con-
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 nector and measure the resistance between CN101-5(9)and
28 29 30 31 32 33 34 35
*2: In case of the OK in the former step, connect the CN87 con-
nector and measure the resistance between CN101-5(9)and

Judgment
Result Procedure
NG Harness defect
Error Code: H6-1

Failure mode: Tilt proportional valve solenoid open abnormality (lever pull side) 3
CAUTION
to H6-5.
Probable cause
▪ Tilt proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

Tilt PULL controller
solenoid CN78-2 (33) CN101-13 (34,STPS-)
CN87-6 (482) CN103-5 (N2, N2)

Tilt PUSH CN104-4 (N2, N2)
solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the pull side of tilt lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Tilt proportional valve solenoid (PULL) individual in-
spection
tilt proportional valve solenoid (PULL).
Check the resistance of tilt proportional valve solenoid (PULL).
CN78
8 7 6 5
CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
CN101-6 (32) to CN78-6 (482) Continuously *1
Judgment
Result Procedure
NG Harness defect
Error Code: H6-2

Failure mode: Tilt proportional valve solenoid short abnormality (lever pull side)
CAUTION
to H6-5.
Probable cause
▪ Tilt proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the pull side of tilt lever more than 1 second to check if
an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Tilt proportional valve solenoid (PULL) indivisual in-
spection
tilt proportional valve solenoid (PULL).
Check the resistance of tilt proportional valve solenoid (PULL).
CN78
8 7 6 5
CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
ness.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H6-3

Failure mode: Tilt proportional valve solenoid open abnormality (lever push side) 3
CAUTION
to H6-5.
Probable cause
▪ Tilt proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of tilt lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Tilt proportional valve solenoid (PUSH) individual
inspection
tilt proportional valve solenoid (PUSH).
Check the resistance of tilt proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connectors, and visually check inside each con-
8 7 6 5
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H6-4

Failure mode: Tilt proportional valve solenoid short abnormality (lever push side)
CAUTION
to H6-5.
Probable cause
▪ Tilt proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of tilt lever more than 1 second to check
if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Tilt proportional valve solenoid (PUSH) indivisual
inspection
tilt proportional valve solenoid (PUSH).
Check the resistance of tilt proportional valve solenoid (PUSH).
CN87
4 3 2 1 nect the CN87 connectors, and visually check inside each con-
8 7 6 5
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
NG Tilt proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
ness.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H6-5

Failure mode: Tilt proportional valve solenoid drive circuit abnormality 3
Probable cause
▪ Tilt proportional valve solenoid defect
▪ Harness defect
▪ F77 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Tilt proportional valve solenoid indivisual inspection
resistance of tilt proportional valve solenoid.
Check the resistance of tilt proportional valve solenoid.
CN78 CN87
8 7 6 5 8 7 6 5
CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
Tilt proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
Disconnect theCN101, CN78 and CN87 connector, then check
the harness.
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87 to BEFORE TROUBLESHOOTING
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
NG
OK
Go to step 3
STEP3
ends of F77 fuse.
Judgment
Result Procedure
F77 fuse defect
step.
Error Code: H6-6

Failure mode: Tilt proportional valve solenoid (open / short) abnormality 3
CAUTION
to H6-5.
Probable cause
▪ F77 fuse defect
▪ Tilt proportional valve solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482) CN101-12 (33,STPL-) Main

CN87-6 (482) CN103-5 (N2, N2)

solenoid CN87-2 (34) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Check the inside of connector CN78, CN87 and the caulked
portion of wire whether it has defect or not by visual confirm.
2 . After connecting CN78, CN87, connect the battery plug and
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
STEP3
ends of F77 fuse.
Judgment
Result Procedure
F77 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
F77 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection : Tilt proportional valve solenoid individual inspection
tilt proportional valve solenoid.
[Inspection procedure and standard] 3
Check the resistance of tilt proportional valve solenoid.
CN78 CN87
4 3 2 1 4 3 2 1 nect the CN78, CN87 connectors, and visually check inside
each connector and the caulked portion of each wire for de-
8 7 6 5 8 7 6 5
CN78-6 (482) to CN78-2 (33) Approx. 8 Ω
CN87-6 (482) to CN87-2 (34) Approx. 8 Ω
Judgment
Result Procedure
Tilt proportional valve solenoid defect
STEP6.
OK Go to step 6
STEP6
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 *1 : In case of the OK in the former step, connect the CN78
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8 connector and measure the resistance between CN101-6 and
28 29 30 31 32 33 34 35
*2 : In case of the OK in the former step, connect the CN87

connector and measure the resistance between CN101-6 and

CN78-6 (482) to CN78-2 (33) No continuity *1
Judgment
Result Procedure
NG Harness defect
Error Code: H7-1

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever pull 3
side)
CAUTION
to H7-5.
Probable cause
▪ Attachment 1 proportional valve solenoid (PULL) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

Attachment 1 controller
PULL
solenoid CN78-3 (36) CN101-11 (37,SA1PS-)
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the pull side of attachment 1 lever more than 1 second
to check if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Attachment 1 proportional valve solenoid (PULL) in-
dividual inspection
attachment 1 proportional valve solenoid (PULL).
Check the resistance of attachment 1 proportional valve solen-
oid (PULL).
CN78
4 3 2 1 Turn off the key switch and disconnect the battery plug, discon-
8 7 6 5
CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PULL) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H7-2

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever pull
side)
CAUTION
to H7-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
divisual inspection
oid (PULL).
CN78
8 7 6 5
CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
ness.

CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H7-3

Failure mode: Attachment 1 proportional valve solenoid open abnormality (lever push 3
side)
CAUTION
to H7-5.
Probable cause
▪ Attachment 1 proportional valve solenoid (PUSH) defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Operate the push side of attachment 1 lever more than 1
second to check if an error occurs.
Judgment
Result Procedure
STEP3
Inspection : Attachment 1 proportional valve solenoid (PUSH)
individual inspection
attachment 1 proportional valve solenoid (PUSH).
oid (PUSH).
CN87
nect the CN87 connectors, and visually check inside each con-
8 7 6 5
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
NG Attachment 1 proportional valve solenoid (PUSH) defect
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 3
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H7-4

Failure mode: Attachment 1 proportional valve solenoid short abnormality (lever push
side)
CAUTION
to H7-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
indivisual inspection
oid (PUSH).
CN87
8 7 6 5
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
ness.

CN101
CN87
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H7-5

Failure mode: Attachment 1 proportional valve solenoid drive circuit abnormality 3
Probable cause
▪ Attachment 1 proportional valve solenoid defect
▪ Harness defect
▪ F78 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Attachment 1 proportional valve solenoid indivisual
inspection
resistance of attachment 1 proportional valve solenoid.
oid.
CN78 CN87
4 3 2 1 4 3 2 1 Turn off the key switch and disconnect the battery plug, discon-
nect the CN78 and CN87 connector, visually check each ter-
8 7 6 5 8 7 6 5

CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
Attachment 1 proportional valve solenoid defect
NG
Go to step 2
OK Go to step 2
STEP2
the harness.
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
NG
OK
Go to step 3
STEP3
ends of F78 fuse.
Judgment
Result Procedure
F78 fuse defect
step.
Result Procedure
3
Error Code: H7-6

Failure mode: Attachment 1 proportional valve solenoid (open / short) abnormality
CAUTION
to H7-5.
Probable cause
▪ F78 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F78
CN250-46 (483) CN250-45 (32) CN101-6 (32,SLTA1+)
CN78-7 (483) CN101-10 (36,SA1PL-) Main

PULL
CN87-7 (483) CN103-5 (N2, N2)

Attachment 1
CN104-4 (N2, N2)
PUSH
solenoid CN87-3 (37) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
STEP3
ends of F78 fuse.
Judgment
Result Procedure
F78 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
F78 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection : Attachment 1 proportional valve solenoid individual
inspection
2 . Disconnect the CN78, CN87 connector, and check the res-
istance of attachment 1 proportional valve solenoid.

oid.
CN78 CN87
nect the CN78, CN87 connectors, and visually check inside
8 7 6 5 8 7 6 5
CN78-7 (483) to CN78-3 (36) Approx. 8 Ω
CN87-7 (483) to CN87-3 (37) Approx. 8 Ω
Judgment
Result Procedure
STEP6.
OK Go to step 6
STEP6
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87
1 2 3 4 5 6
1 2 3 4
28 29 30 31 32 33 34 35


3
Judgment
Result Procedure
NG Harness defect
Error Code: H8-1

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever pull
side)
CAUTION
to H8-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
dividual inspection
oid (PULL).
CN78
8 7 6 5
CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H8-2

Failure mode: Attachment 2 proportional valve solenoid short abnormality (lever pull 3
side)
CAUTION
to H8-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
divisual inspection
oid (PULL).
CN78
8 7 6 5
CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
ness.

CN101
CN78 3
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H8-3

Failure mode: Attachment 2 proportional valve solenoid open abnormality (lever push
side)
CAUTION
to H8-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
individual inspection
oid (PUSH).
CN87
8 7 6 5
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
5 6 7 8
1 2 3 4 5 6

28 29 30 31 32 33 34 35
is approx.8 Ω.
Judgment
Result Procedure
NG Harness defect
Error Code: H8-4

Failure mode: Attachment 2 proportional valve solenoid short abnormality (lever push 3
side)
CAUTION
to H8-5.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
Judgment
Result Procedure
STEP3
indivisual inspection
oid (PUSH).
CN87
8 7 6 5
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
OK Go to step 4
STEP4
ness.

CN101
CN87 3
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34
Judgment
Result Procedure
NG Harness defect
Error Code: H8-5

Failure mode: Attachment 2 proportional valve solenoid drive circuit abnormality
Probable cause
▪ Harness defect
▪ F79 fuse defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Attachment 2 proportional valve solenoid indivisual
inspection
resistance of attachment 2 proportional valve solenoid.
oid.
CN78 CN87
nect the CN78 and CN87 connector, visually check each ter-
8 7 6 5 8 7 6 5

CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
3
Judgment
Result Procedure
NG
Go to step 2
OK Go to step 2
STEP2
the harness.
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
Judgment
Result Procedure
Harness defect
NG
OK
Go to step 3
STEP3
ends of F79 fuse.
Judgment
Result Procedure
F79 fuse defect
step.
Result Procedure
Error Code: H8-6

Failure mode: Attachment 2 proportional valve solenoid (open / short) abnormality 3
CAUTION
to H8-5.
Probable cause
▪ F79 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19)
RY1
N1
F79
CN250-48 (484) CN250-47 (9) CN101-5 (9,SLLA2+)
CN78-8 (484) CN101-14 (39,SA2PL-) Main

PULL
CN87-8 (484) CN103-5 (N2, N2)

Attachment 2
CN104-4 (N2, N2)
PUSH
solenoid CN87-4 (40) CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
H8-6 error turn on the key switch. F79 fuse installation defect
STEP3
ends of F79 fuse.
Judgment
Result Procedure
F79 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
F79 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
Inspection : Attachment 2 proportional valve solenoid individual
inspection
2 . Disconnect the CN78, CN87 connector, and check the res-
istance of attachment 2 proportional valve solenoid.
3

oid.
CN78 CN87
nect the CN78, CN87 connectors, and visually check inside
8 7 6 5 8 7 6 5
CN78-8 (484) to CN78-4 (39) Approx. 8 Ω
CN87-8 (484) to CN87-4 (40) Approx. 8 Ω
Judgment
Result Procedure
STEP6.
OK Go to step 6
STEP6
CN101
CN78
1 2 3 4 5 6 7
1 2 3 4
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
5 6 7 8
28 29 30 31 32 33 34
CN87
1 2 3 4 5 6
1 2 3 4
28 29 30 31 32 33 34 35


Judgment
Result Procedure
NG Harness defect
Error Code: HB-1

Failure mode: Proportional valve solenoid power supply : RY1 contact open 3
abnormality
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
Lift PULL CN78-5 (481)
solenoid CN78-1 (10) CN101-17 (10,SLPL-)
SLPL CN101-16 (11,SLPS-)
Lift PUSH CN87-5 (481)
solenoid CN87-1 (11)
SLPS
F79
CN250-48 (484) CN250-47 (9)
Attachment 2 CN78-8 (484)
PULL CN78-4 (39) CN101-14 (39,SA2PL-) Main
solenoid CN101-15 (40,SA2PS-) controller
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
Attachment 1 CN78-7 (483) CN101-10 (36,SA1PL-)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
Attachment 1 CN87-7 (483) CN104-4 (N2, N2)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HB-1 error does not occur. Connector contact defect
HB-1 error occurs. Go to step 2
STEP2
2 . Disconnect the CN101, CN102, CN127 and CN137 con-
nector, then check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its wire
1 2 3 4 5 6 7 CN137 Portions to be checked Standard:

8 9 10 11 12 13 14 15 16 17 18 19
1 CN102-13 (335) to CN127-5 (335) Continuity
20 21 22 23 24 25 26 27
2 3
28 29 30 31 32 33 34 35 CN101-3 (97) to CN127-3 (97) Continuity
Judgment
Result Procedure
NG Harness defect
RY1 defect
OK If the symptom persists after replacement of the relay, there
should be any other problems, so replace the Main controller.
Error Code: HB-2

Failure mode: Proportional valve solenoid load-short abnormality 3
Probable cause
▪ Harness defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
Check the inside of connector CN127, CN78, CN87 and the
2 . After connecting CN127, CN78 and CN87, connect the bat-
tery plug and turn on the key switch to confirm error.
Judgment
Result Procedure
STEP2
2 . Disconnect the CN101, CN102, CN103, CN104, CN78 and
CN87 connector, then check the harness.
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 CN102, CN103, CN104, CN78, CN87 connectors disconnected,
and visually check inside the connector and the caulked portion
CN104 of its wire for defects. Refer to BEFORE TROUBLESHOOTING
1 2 3 4 5 6 7 Portions to be checked Standard

8 9 10 11 12 13 14 15 16 17 CN102-5 (17) to CN104-4 (N2) No continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-6 (17) to CN104-4 (N2) No continuity
Judgment
Result Procedure
NG Harness defect
Error Code: HB-3

Failure mode: Proportional valve solenoid power supply : RY1 over current 3
abnormality
Probable cause
▪ Harness defect
▪ RY1 defect
Related portion
MB
P1 CSB P2 P3 CN137-3 (19) F1 P4

RY1
CN127-3 (97,FAN+) CN127-5 (335,RY1-) CN102-13 (335,RY1)
CN101-3 (97,FAN+)
F76
CN250-42 (481) CN250-41 (9) CN101-5 (9,SLLA2+)
SLPS
F79
CN250-48 (484) CN250-47 (9)
PUSH CN87-4 (40)
solenoid
F77
CN250-44 (482) CN250-43 (32) CN101-6 (32,SLTA1+)
CN78-6 (482)
Tilt PULL
CN78-2 (33) CN101-12 (33,STPL-)
solenoid
CN101-13 (34,STPS-)
CN87-6 (482)
Tilt PUSH
CN87-2 (34)
solenoid
F78
CN250-46 (483) CN250-45 (32)
PULL CN78-3 (36) CN101-11 (37,SA1PS-)
PUSH CN87-3 (37) CN104-5 (N2, N2)
solenoid
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
the harness.
CN127
1 2 3 4 5 6 7 nector and the caulked portion of its wire for defects. Refer to
Judgment
Result Procedure
NG Harness defect
RY1 defect
OK If the symptom persists after replacement of the relay, there
should be any other problems, so replace the Main controller.
Error Code: HC-1

Failure mode: Unload solenoid open abnormality 3
CAUTION
• If HC-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to HC-3.
Probable cause
▪ Unload solenoid defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HC-4 error occurs. Perform troubleshooting for HC-4.
HC-4 error does not occur. Go to step 2
STEP2
Apply the unload solenoid compulsorily by using Active Test


UNLOAD SOL：OFF to ON
Judgment
Result Procedure
HC-1 error does not occur. Connector contact defect
HC-1 error occurs. Go to step 3
STEP3
Inspection: Unload solenoid individual inspection
unload solenoid.
Check the resistance of unload solenoid.
CN88
8 7 6 5
CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
NG Unload solenoid defect
OK Go to step 4
STEP4
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
is approx.10 Ω.

3
Judgment
Result Procedure
NG Harness defect
Error Code: HC-2

Failure mode: Unload solenoid short abnormality
CAUTION
to HC-3.
Probable cause
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
HC-4 error occurs. Perform troubleshooting for HC-4.
HC-4 error does not occur. Go to step 2
STEP2
Apply the unload solenoid compulsorily by using Active Test

UNLOAD SOL：OFF to ON
3
Judgment
Result Procedure
STEP3
unload solenoid.
CN88
8 7 6 5
CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
NG Unload solenoid defect
OK Go to step 4
STEP4
ness.
CN102
CN88
1 2 3 4
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: HC-3

Failure mode: Unload solenoid drive circuit abnormality 3
Probable cause
▪ Harness defect
▪ F72 fuse defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Inspection : Unload solenoid indivisual inspection
unload solenoid.
CN88
8 7 6 5
CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
Go to step 2
NG
Unload solenoid defect
OK Go to step 2
STEP2
check the harness.
CN101
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
28 29 30 31 32 33 34
1 2 3 4
5 6 7 8
20 21 22 23 24 25 26 27
Judgment
Result Procedure
Harness defect
NG
STEP3
ends of F72 fuse.
Judgment
Result Procedure
F72 fuse defect
step.
Error Code: HC-4

Failure mode: Unload solenoid (open / short) abnormality 3
CAUTION
to HC-3.
Probable cause
▪ F72 fuse defect
▪ Harness defect
Related portion
MB
P2 P3 CN137-3 (19) CN102-3 (19,VBMBSL)
CN102-4 (19,VBMBSL)
F72
CN250-34 (478) CN250-33 (3) CN101-1 (3,SOLLU+)
Main
controller
CN88-1 (478) CN102-17 (5,SLUL-)
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
STEP1
Judgment
Result Procedure
STEP2
confirm.
Judgment
Result Procedure
HC-4 error does not occur. F72 fuse installation defect
STEP3
ends of F72 fuse.
Judgment
Result Procedure
F72 fuse defect
∞Ω
０Ω Go to step 4
STEP4

fuse box.
F72 fuse box.
Judgment
Result Procedure
０Ω Go to step 5
STEP5
unload solenoid.

CN88 3
8 7 6 5
CN88-1 (478) to CN88-5 (5) Approx. 10 Ω
Judgment
Result Procedure
Unload solenoid defect
STEP6.
OK Go to step 6
STEP6
CN101 CN102
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 5 6
1 2 3 4
5 6 7 8
28 29 30 31 32 33 34 35
Judgment
Result Procedure
NG Harness defect
Error Code: SAFETY MONITOR

Failure mode: Drive motor driver low temperature
If caution indicator occurs, turn on the key switch, and leave 20
to 30 minutes at normal temperature (0 to 40 °C).
Error Code: SAFETY MONITOR

Failure mode: Pump motor driver low temperature
If caution indicator occurs, turn on the key switch, and leave 20
to 30 minutes at normal temperature (0 to 40 °C).
3.5 WHEN NO ERROR CODE IS DISPLAYED

Probable causes of problems for which no error code is displayed. 3
If an error code is displayed or the spanner indicator blinks, be sure to perform
checks with priority given to it.
Phenomena on the Failed portions and Action and remed-
Control systems How to check
vehicle failure modes ies
Emergency switch
main body (with ▪ Release the
Emergency switch) - emergency
: Switch is held switch.
down.
Check the battery
voltage.
Battery : Battery plug is dis- ▪ Charge the Bat-
: Low voltage connected. tery
Check the battery
voltage.
Key switch main
body ▪ Check the
: Open failure switch, and re-
Emergency switch place it if neces-
main body (with sary
Emergency switch) ▪ Check the har-
-
: Open failure ness and repair
Key switch harness or replace it if
Although the key
:Wire breakage, necessary.
switch or ten-key op-
eration is turned on, short circuit or leak- ▪ Replace the F5
power is not sup- age (harness, con- fuse.
Power-supply re- plied. nector or F5 fuse)
lated control (The multi-function Numeric keypad har- ▪ Check the har-
screen does not ap- ness (with PIN code ness and repair
pear, and the vehicle -
entry) or replace it if
does not move, : Open failure necessary.
either.)
Check the operation
of each switch.
: Check if a re-
sponse (lighting of
LED or sounding of
buzzer) is given only
to a particular
switch.
Numeric keypad If there are two
main body (with PIN types of switches: ▪ Replace the nu-
code entry) switch to which a re- meric keypad.
: Switch failure sponse is given and
switch to which no
response is given in
the combination of
(1, 2 and 3), (4, 5
and 6), (7, 8 and 9)
or (OFF, 0 and ON),
it is certain that there
is a defective switch.

Multi-function dis- Using the Adminis-
▪ Register PIN us-
play (with PIN code trator menu, check if
ing the Adminis-
entry) PIN has been re-
trator menu.
: PIN not registered gistered.
Display power sup-
Although the key ply and ground har-
switch or ten-key op- ness (with PIN code
eration is turned on, entry)
power is not sup- ▪ Check the har-
:Wire breakage,
Power-supply re- plied. ness and repair
short circuit, leakage
lated control (The multi-function (harness or con- or replace it if
screen does not ap- nector) necessary.
pear, and the vehicle -
▪ Replace the dis-
does not move, Multi-function dis-
play.
either.) play (with PIN code
entry) ▪ Replace the
: Internal failure main controller.
Main controller
: Internal failure
(D7V, DGND)
Display power sup-
ply and ground har-
ness ▪ Check the har-
:Wire breakage, ness and repair
The multi-function short circuit, leakage or replace it if
screen does not ap- (harness or con- necessary.
Power-supply re-
pear. nector) -
lated control ▪ Replace the dis-
(The vehicle runs
Multi-function display.
normally.)
play ▪ Replace the
Main controller
: Internal failure

Confirm the caution
*It is not abnormal- 3
indicator and warn-
ity. Warm-up func-
ing tone on the dis-
tion may be oper-
play
ated for several
seconds when turn
*Caution indicator is
on the key switch.
Warm-up operation displayed with warn-
with running cold ing tone and awake
Operate after disap-
protect function. to customers in case
peared the warning
of running the warm-
tone because travel-
up operation by
ing and handling
used for customer.
function can not be
(e.g. leave long time
operated under
under low temperat-
warm-up function.
ure)
After the key switch
was turned on, re-
lease the accelerator
and operate neutral
After the key switch
for the direction
was turned on, the
switch once, then
accelerator was not
operate traveling
released or the dir- -
function.
ection switch was
The vehicle does not not returned to neut- Traveling function
run (the drive motor ral. can not be operated
Traveling does not rotate) or after detecting the
can't run at slope accelerator released
suddenly. and neutral for the
direction switch.
Check the direction
switch, using Ana-
lyzer.
Direction switch : Accelerator is fully ▪ Check the
main body closed. switch, and re-
: Open failure Operate the direc- place it if neces-
Direction switch har- tion switch to see if it sary
ness turns on and off nor- ▪ Check the har-
:Wire breakage, mally. ness and repair
short circuit (harness (The vehicle does or replace it if
or connector) not run if the forward necessary.
and reverse
switches are turned
on simultaneously.)
Direction switch in-
stallation portions
(EZ pedal) ▪ Repair or re-
Check the operation
: One of the installa- place the part
of the direction
tion portions is that does not op-
switch (microswitch).
broken or damaged erate normally.
or does not operate
normally.

Accelerator sensor
main body
: Internal failure Check the acceler-
ator sensor ▪ Check the
Accelerator sensor
voltage,using Ana- sensor and re-
installation portion
lyzer. place it if neces-
: The link or the in-
: Direction switch is sary.
stallation portion is
in neutral.
broken or damaged.
Fully open and close ▪ Check the har-
Accelerator sensor the accelerator ness and repair
harness pedal to check the or replace it if
:Wire breakage, change in voltage at necessary.
short circuit, leakage that time.
(harness or con-
nector)
Accelerator fully
closed/fully open Check the matching
▪ Perform match-
matching value value on the Match-
ing again.
: No agreement with ing screen.
the vehicle state
Brake sensor main
body
: Internal failure
Check the brake ▪ Check the
Brake sensor install-
sensor voltage,using sensor and re-
ation portion: The
Analyzer. place it if neces-
link or the installa-
: Direction switch is sary.
tion portion is broken
in neutral.
The vehicle does not or damaged. Fully open and close ▪ Check the har-
run (the drive motor Brake sensor har- the brake pedal to ness and repair
Traveling does not rotate) or ness check the change in or replace it if
can't run at slope :Wire breakage, voltage at that time. necessary.
suddenly. short circuit, leakage
(harness or con-
nector)
Brake fully closed /
operational point Check the matching
▪ Perform match-
ing again.
the vehicle state
Tire angle sensor
main body
: Internal failure Check the sensor
voltage,using Ana- ▪ Check the
Tire angle sensor in-
lyzer. sensor and re-
stallation
: Direction switch is place it if neces-
: The installation
in neutral. sary.
portion is broken or
Fully close the ac-
damaged. ▪ Check the har-
celerator pedal and
Tire angle sensor operate steering ness and repair
harness wheel to check the or replace it if
(harness or con-
nector)
Tire angle sensor
straight running Check the matching
▪ Perform match-
ing again.
the vehicle state

Check the seat
switch, using Ana- 3
Seat switch main lyzer. ▪ Check the seat
body : Direction switch in and replace it if
: Open failure neutral, accelerator necessary.
Seat switch harness pedal fully closed ▪ Check the har-
:Wire breakage, Check if the switch ness and repair
(harness or con- turns on and off nor- or replace it if
nector) mally, sitting in the necessary.
The vehicle does not seat or standing be-
run (the drive motor side it.
Traveling does not rotate) or
can't run at slope Check the brake and
suddenly. the drive motor. ▪ Check the brake,
Brake :With the battery and repair or re-
: Dragging (internal plug disconnected,
place it if neces-
failure) the parking brake re- sary.
Drive motor leased and the front
▪ Check the drive
: Seizure or dragging wheels off the
ground, motor, and re-
of drive motor (in-
rotate each tire to pair or replace it
ternal failure)
see if it rotates if necessary.
smoothly.
Main body of drive
motor rotation
sensor Check the voltage of
: Internal failure the drive motor rota- ▪ Check the drive
Drive motor rotation tion sensor, using motor rotation
sensor installation Analyzer. sensor, and ad-
portion : Seated in seat, dir- just or replace it
: Gap improperly ad- ection switch in for- if necessary.
justed ward position, brake
released ▪ Check the har-
Drive motor harness Operate the acceler- ness and repair
:Wire breakage, ator and check the or replace it if
short circuit, leakage change in the rota- necessary.
The vehicle does not (harness or con- tion sensor voltage.
run (the drive motor nector)
Traveling does not rotate) or
can't run at slope
Check the voltage of
suddenly.
the drive motor cur-
Drive motor drive cir- rent sensor, using
▪ Check the cable
cuit Analyzer. and repair or re-
: Internal failure : Seated in seat, dir- place it if neces-
Motor cables ection switch in for- sary.
:Wire breakage, ward position, brake
▪ Replace the
short circuit or leak- released
Operate the acceler- drive motor drive
age (cable or ter-
ator and check the circuit.
minal board)
change in the cur-
rent sensor voltage.
Main controller ▪ Replace the
-

Confirm the caution
*It is not abnormal-
indicator and warn-
ity. Warm-up func-
ing tone on the dis-
tion may be oper-
play
ated for several
seconds when turn
*Caution indicator is
on the key switch.
Warm-up operation displayed with warn-
with running cold ing tone and awake
Operate after disap-
protect function. to customers in case
peared the warning
of running the warm-
tone because travel-
up operation by
ing and handling
used for customer.
function can not be
(e.g. leave long time
operated under
under low temperat-
warm-up function.
ure)
Main body of pump
motor rotation
sensor Check the voltage of
: Internal failure ▪ Check the pump
the pump motor ro- motor rotation
Pump motor rotation tation sensor, using sensor, and ad-
Load handling can-
sensor installation Analyzer. just or replace it
not be performed
portion : Seated in the seat if necessary.
and the steering is
: Gap improperly ad- Operate the direc-
heavy. ▪ Check the har-
justed tion switch and
(The pump motor ness and repair
Load handling and Pump motor harness check the change in
does not work for or replace it if
power steering :Wire breakage, the rotation sensor
material handling necessary.
short circuit, leakage voltage.
operation, steering
operation and direc- (harness or con-
tion switch opera- nector)
tion.) Check the voltage of
Pump motor drive the pump motor cur- ▪ Check the motor
circuit rent sensor, using cables, and re-
: Internal failure Analyzer. pair or replace
Motor cables : Seated in the seat them if neces-
:Wire breakage, Operate the direc- sary.
short circuit or leak- tion switch and ▪ Replace the
age (cable or ter- check the change in pump motor
minal board) the current sensor drive circuit.
voltage.
▪ Check the pump,
and repair or re-
Pump place it if neces-
: Seizure sary.
-
Pump motor ▪ Check the pump
: Seizure motor, and re-
pair or replace it
if necessary.
-

Main body of load
handling lever po- 3
tentiometer
: Internal failure
Measure the voltage
Installation of load ▪ Check the
of the load handling
handling lever po- sensor and re-
lever potentiometer,
tentiometer place it if neces-
using Analyzer.
: Installation portion sary.
: Leave the seat
is broken or dam-
Tilt the load handling ▪ Check the har-
aged.
lever forward and ness and repair
Load handling lever backward to check or replace it if
potentiometer har- the change in necessary.
ness voltage.
:Wire breakage,
(harness or con-
nector)
Main body of tilt for-
ward/backward
Only load handling switch (Conventional
cannot be per- lever)
formed. : Internal failure
Load handling and (The pump motor Check the tilt for-
Installation of tilt for- ▪ Check the
power steering operates normally ward/backward
ward/backward switch, and re-
during steering oper- switch (Conventional switch, using Ana-
ation and direction lever) lyzer. place it if neces-
switch operation.) : Leave the seat sary
: Installation portion
Operate the tilt lever ▪ Check the har-
is broken or dam-
forward to backward ness and repair
aged.
position to check the or replace it if
Tilt forward/back- switch turns on and necessary.
ward switch harness off normally.
(Conventional lever)
:Wire breakage,
(harness or con-
nector)
Check the seat
Seat switch main switch, using Ana- ▪ Check the seat
body lyzer. and replace it if
: Open failure : Load handling lever necessary.
in neutral
Seat switch harness Check if the switch ▪ Check the har-
:Wire breakage, turns on and off nor- ness and repair
(harness or con- mally, sitting in the or replace it if
nector) seat or standing be- necessary.
side it.

▪ Check the oil
control valve,
and repair or re-
Oil control valve place it if neces-
(Conventional lever) sary. Refer to re-
Only load handling : Seizure of or leak- pair manual
cannot be per- age from unload vol.1
formed. valve "TROUBLESHO
Load handling and (The pump motor OTING" of oil
Harness of unload -
power steering operates normally control valve.
valve solenoid (Con-
during steering oper- ventional lever) ▪ Check the un-
ation and direction :Wire breakage, load valve solen-
switch operation.) short circuit, leakage oid and replace
(harness or con- it if necessary.
nector) ▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the pump,
and repair or re-
place it if neces-
sary.
Only load handling
Pump ▪ Check the prior-
cannot be per-
: Leak ity valve, and re-
formed. - pair or replace it
Load handling and (The pump motor Priority valve
if necessary.
power steering operates normally : Leak, seizure
Refer to repair
during steering oper-
manual vol.1
ation and direction
"TROUBLESHO
switch operation.)
OTING" of oil
control valve.
-
Only lowering is im-
If a current flows, ▪ Check the lower-
possible.
Lowering lock valve turn on the lowering ing lock valve,
Load handling and (Other load handling
: Seizure (internal lock solenoid using and repair or re-
power steering operations,including
damage) Active Test to lower place it if neces-
raising, are pos-
the fork. sary.
sible.)
Only forward tilting is
If a current flows, ▪ Check the tilt for-
impossible. Tilt forward lock
turn on the tilt forward lock valve,
Load handling and (Other load handling valve:
ward lock solenoid and repair or re-
power steering operations,including Seizure (internal
using Active Test to place it if neces-
backward tilting, are damage)
forward the fork. sary.
possible.)
Only backward tilting
If a current flows, ▪ Check the back-
is impossible. Tilt backward lock
turn on the tilt backward lock valve,
Load handling and (Other load handling valve
ward lock solenoid and repair or re-
power steering operations,including : Seizure (internal
using Active Test to place it if neces-
forward tilting, are damage)
backward the fork. sary.
possible.)

Lifting height switch Check the lifting
main body height switch, using ▪ Check the 3
switch, and re-
: High lifting height is Analyzer.
: In NL place it if neces-
always detected.
Raise and lower the sary
Lifting switch har- lift to its uppermost ▪ Check the har-
ness and lowermost posi- ness and repair
:Wire breakage, tions to see if the or replace it if
short circuit (harness switch turns on and
necessary.
or connector) off normally.
Main body of tilt
angle sensor
: Internal damage
Check the tilt angle ▪ Check the
Tilt angle sensor in-
sensor voltage, us- sensor, and ad-
stallation
ing Analyzer. just or replace it
Load handling and Not activated lift limit : The link or the in-
: In NL if necessary.
power steering function stallation portion is
Tilt the mast to its
broken or damaged. ▪ Check the har-
forward and back-
Tilt angle sensor ward tilt limits to ness and repair
harness check the change in or replace it if
:Wire breakage, voltage. necessary.
(harness or con-
nector)
Display setting:
Lifting speed limita- Check the set value
tion disabled. on the Option Set ▪ Setting screen
(OPTION SET L UP- screen.
SPD LIM)
Display setting: Check the set value
: Tuning No.35 on the Tuning ▪ Setting screen
(TUNE GEN. 35) screen.
▪ Adjusting of set-
Delay of moving Display setting
ting
load handling Or the : The setting of OCV Check the OCV ac-
Adjust activation
Load handling and play of load handling activation current is tivation current value
current of turning
power steering lever is large until not in agreement on the Matching
after setting the
moving with that of the screen.
OCV activation
(Mini lever spec.) vehicle state.
current.

Check the direction ▪ Check the
Direction switch switch, using Ana- switch, and re-
: Open failure lyzer place it if neces-
.: Accelerator is fully sary
Direction switch har- closed.
ness Operate the direc- ▪ Check the har-
:Wire breakage (har- tions witch to see if it ness and repair
ness or connector) turns on and off nor- or replace it if
mally. necessary.
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Installation of steer- sensor and re-
Check the steering
ing angle sensor place it if neces-
angle sensor, using
: Cam or steering sary.
Analyzer.
wheel is defective.
: Turn the steering ▪ Check the har-
Steering angle wheel to check the ness and repair
sensor harness input signal. or replace it if
:Wire breakage, necessary.
The steering is (harness or con-
heavy. nector)
Load handling and (The pump motor ▪ Check the pump,
power steering operates normally and repair or re-
during material place it if neces-
handling.) sary.
▪ Check the prior-
ity valve, and re-
pair or replace it
if necessary.
Pump Refer to repair
: Leak manual vol.1
Priority valve "TROUBLESHO
-
: Leak, seizure OTING" of oil
PS valve control valve.
: Leak, seizure ▪ Check the PS
valve, and repair
or replace it if
necessary. Refer
to repair manual
vol.1
"TROUBLESHO
OTING" of steer-
ing.
-
Although ATT1
Display setting:
(ATT2) is operated,
The serial number
no operation is per- Check the set value
Load handling and setting is not in
formed. on the Option Set ▪ Setting screen
power steering agreement with that
(Pump motor is not screen.
of the vehicle.
rotated at ATT oper-
(OCV WAY)
ation)

Check the seat
switch, using Ana- ▪ Check the 3
Seat switch main lyzer. switch, and re-
body : Direction switch in place it if neces-
: Short failure neutral, accelerator sary
Neither traveling pedal fully closed
Seat switch harness Check if the switch ▪ Check the har-
OPS OPS nor load hand-
:Short circuit (har- turns on and off nor- ness and repair
ling OPS operates.
ness or connector) mally, sitting in the or replace it if
seat or standing be- necessary.
side it.
-
Drive motor drive cir- ▪ Replace the
cuit - drive motor drive
Only traveling OPS : Internal failure circuit.
OPS
does not operate.
-

▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the tilt for- sary. Refer to re-
: Seizure of or leak- ward lock valve, us- pair manual
age from tilt forward ing Active Test. vol.1
lock valve : Tilt forward solen- "TROUBLESHO
oid forcibly turned off OTING" of oil
Tilt forward solenoid (forward tilting control valve.
harness stopped)
:Short circuit, leak- ▪ Check the solen-
Tilt the fork forward
age (harness or con- oid and replace
to check the opera-
nector) it if necessary.
tion.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the tilt back- sary. Refer to re-
age from tilt back- ing Active Test. vol.1
ward lock valve : Tilt backward "TROUBLESHO
Only load handling
solenoid forcibly OTING" of oil
OPS OPS does not oper- Tilt backward solen-
turned off control valve.
ate. oid harness (backward tilting
:Short circuit, leak- ▪ Check the solen-
stopped) Tilt the fork
age (harness or con- oid and replace
backward to check
nector) it if necessary.
the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Oil control valve Check the lift lower sary. Refer to re-
: Seizure of or leak- lock valve, using pair manual
age from lift lower Active Test. vol.1
lock valve : Lift lower lock "TROUBLESHO
solenoid forcibly OTING" of oil
Lift lock solenoid
turned off control valve.
harness
:Short circuit, leak- (lifting stopped) ▪ Check the solen-
age (harness or con- Lower the lift to oid and replace
nector) check the operation. it if necessary.
▪ Check the har-
ness and repair
or replace it if
necessary.

▪ Check the oil
control valve, 3
and repair or re-
Oil control valve place it if neces-
(Conventional lever) sary. Refer to re-
: Seizure or leakage Check the unload pair manual
from unload valve valve, using Active vol.1
Test. "TROUBLESHO
Harness of unload : Unload solenoid OTING" of oil
Only load handling valve solenoid (Con- forcibly turned on
control valve.
OPS OPS does not oper- ventional lever) (lifting stopped)
ate. :Wire breakage, ▪ Check the solen-
Lower the lift to
short circuit, leakage check the operation. oid and replace
(harness or con- it if necessary.
nector) ▪ Check the har-
ness and repair
or replace it if
necessary.
-
Backup buzzer main
▪ Check the
body
backup buzzer
: Internal damage
and replace it if
Backup buzzer har- necessary.
ness -
▪ Check the har-
:Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
Auxiliary equipment ▪ Check the auxili-
relay main body ary equipment
: Open failure relay and re-
The backup buzzer Auxiliary equipment place it if neces-
and smart alarm relay harness - sary.
Auxiliary equipment does not sound. :Wire breakage, ▪ Check the har-
(EZ pedal, motion short circuit, leakage ness and repair
alarm spec.) (harness or con- or replace it if
nector) necessary.
Backup relay main
▪ Check the
body
backup relay
: Open failure
and replace it if
Backup relay har- necessary.
ness -
▪ Check the har-
:Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
-

Backup buzzer main ▪ Check the
body backup buzzer
: Internal damage and replace it if
Backup buzzer har- - necessary.
:Short circuit, leak- ness and repair
age (harness or con- or replace it if
nector) necessary.
▪ Check the auxili-
Auxiliary equipment
ary equipment
relay main body
relay and re-
The backup buzzer : Short circuit
place it if neces-
and smart alarm Auxiliary equipment - sary.
does not stop relay harness
Auxiliary equipment ▪ Check the har-
sounding. :Short circuit, leak-
ness and repair
(EZ pedal, motion age (harness or con-
or replace it if
alarm spec.) nector)
necessary.
Backup relay main ▪ Check the
body backup relay
: Short circuit and replace it if
-
nector) necessary.
-
Backup lamp or light
▪ Check the
main body
backup light and
: Open failure, light
replace it if ne-
bulb blow-out.
cessary.
Backup light harness -
▪ Check the har-
:Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
Auxiliary equipment ▪ Check the auxili-
relay main body ary equipment
: Open failure relay and re-
Auxiliary equipment place it if neces-
The backup light relay harness - sary.
Auxiliary equipment does not go on. :Wire breakage, ▪ Check the har-
(EZ pedal spec.) short circuit, leakage ness and repair
(harness or con- or replace it if
nector) necessary.
Backup relay main
▪ Check the
body
backup relay
: Open failure
and replace it if
ness -
▪ Check the har-
:Wire breakage,
ness and repair
or replace it if
(harness or con-
necessary.
nector)
-

Backup light or lamp ▪ Check the
main body backup light and 3
: Open failure replace it if ne-
Backup light harness - cessary.
:Wire breakage, ▪ Check the har-
short circuit, leakage ness and repair
(harness or con- or replace it if
nector) necessary.
▪ Check the auxili-
Auxiliary equipment
ary equipment
relay main body
relay and re-
: Short circuit
place it if neces-
The backup light Auxiliary equipment - sary.
does not stop go relay harness
Auxiliary equipment ▪ Check the har-
out. :Short circuit, leak-
ness and repair
(EZ pedal spec.) age (harness or con-
or replace it if
nector)
necessary.
Backup relay main ▪ Check the
body backup relay
: Short circuit and replace it if
-
nector) necessary.
-
Display setting
: OPS operation no-
Check the set value
tification buzzer dis-
on the Option Set ▪ Setting screen
OPS operation abled
screen.
warning does not (BUZZER SPEC,
Buzzer-related con- sound. SEAT BUZZER)
trol (Export spec. except Check that the built-
for OPS buzzer less in buzzer sounds a ▪ If the buzzer
spec.) Display
short beep when the does not sound,
: Built-in buzzer is
display switch (mi- replace the dis-
broken.
croswitch) is play.
pressed.
Display setting
: Return-to-neutral Check the set value
warning buzzer dis- on the Option Set ▪ Setting screen
abled (BUZZER screen.
The traveling OPS SPEC)
Buzzer-related con- return-to-neutral
trol warning does not Check that the built-
sound. in buzzer sounds a ▪ If the buzzer
Display
broken.
croswitch) is play.
pressed.

Display setting
: Return-to-neutral Check the set value
The load handling warning buzzer dis- on the Option Set ▪ Setting screen
OPS return-to neut- abled (BUZZER screen.
ral warning does not SPEC)
Buzzer-related con- sound. (Export spec.
trol Check that the built-
except for OPS in buzzer sounds a ▪ If the buzzer
buzzer less spec.) Display
broken.
croswitch) is play.
pressed.
Check the parking
brake switch, using
Parking brake switch Analyzer.
main body (The switch can also
: Short circuit ▪ Check the
be checked by switch, and ad-
Installation of park- checking if the park- just or replace it
ing brake switch ing indicator on the if necessary.
: Switch is held display goes on and
down. out.) ▪ Check the har-
ness and repair
Parking brake switch :Direction switch is or replace it if
The parking brake harness in neutral.
Buzzer-related con- necessary.
trol
release reminder : Short circuit (har- Operate the parking
does not sound. ness or connector) brake to see if the
switch turns on and
off normally.
Check that the built-
in buzzer sounds a ▪ If the buzzer
Display
broken.
croswitch) is play.
pressed.
-
Check the parking
brake switch, using
: Open failure ▪ Check the
When the vehicle ing brake switch ing indicator on the
runs with the parking : Switch is off. if necessary.
display goes on and
Buzzer-related con- brake released, the ▪ Check the har-
trol parking brake re- Parking brake switch out.) ness and repair
harness :Direction switch is
lease reminder in neutral. or replace it if
sounds. : Wire breakage necessary.
(harness or con- Operate the parking
nector) brake to see if the
switch turns on and
off normally.
-

Display setting
: Parking brake re- Check the set value 3
minder buzzer dis- on the Option Set ▪ Setting screen
abled screen.
(PKB BUZZER)
Check the parking
brake switch, using
: Open failure ▪ Check the
ing brake switch ing indicator on the if necessary.
: Switch is off. display goes on and
▪ Check the har-
Parking brake switch out.) ness and repair
harness :Direction switch is
in neutral. or replace it if
: Wire breakage necessary.
(harness or con- Operate the parking
The parking brake brake to see if the
Buzzer-related connector)
reminder does not switch turns on and
trol
sound. off normally.
Check the seat ▪ Check the seat
Seat switch main switch, using Ana- and replace it if
body lyzer. necessary.
: Short failure : Check if the switch
▪ Check the har-
Seat switch harness turns on and off nor-
mally, sitting in the ness and repair
:Short circuit (har-
or replace it if
ness or connector) seat or standing be-
side it. necessary.
Check that the built-
in buzzer sounds a ▪ If the buzzer
Display
broken.
croswitch) is play.
pressed.
-
Parking brake switch
main body Check the parking ▪ Check the
: Short circuit brake switch, using switch, and ad-
Analyzer. just or replace it
Installation of park-
Although the parking : Direction switch is if necessary.
ing brake switch
brake is pushing, the in neutral.
Buzzer-related con- : Switch is on. ▪ Check the har-
parking brake re- Operate the parking
trol Parking brake switch brake to see if the ness and repair
minder does not
harness switch turns on and or replace it if
stop sounding.
: Short circuit (har- off normally. necessary.
ness or connector)
-
The shock detection Display setting
The shock detection Check the set value
function setting : Shock detection
function on the Option Set ▪ Setting screen
screen does not ap- function disabled
(OPT) screen.
pear. (SHOCK SENSOR)

Way in which the
vehicle collides
: The degree of
shock that the shock
sensor receives vary
depending on the
way and direction in
- -
which the vehicle
collides and the ob-
ject with which it col-
lides. The shock
sensor does not ne-
cessarily detect all
kinds of shock.
▪ Change the set-
ting.
Display setting (Set a value that
: A too large (im- corresponds to
Although shock is -
The shock detection proper) value is set shock unlikely to
applied, the shock
function for shock detection. be applied dur-
detection alarm does
(OPT) ing normal oper-
not go on.
ation.)
Shock sensor main
body Check the voltages
: Sensitivity reduced of shock sensors 1
Installation of shock and 2, using Ana- ▪ Check the
sensor lyzer. sensor and re-
: Improper installa- : Vehicle stopped place it if neces-
tion (loosening), in- 2.0 ± 0.21 V sary.
terference Apply shock to each ▪ Check the har-
Shock sensor har- sensor to see if its ness and repair
ness voltage changes. or replace it if
:Wire breakage, (Compare the necessary.
short circuit, leakage voltages of sensors
(harness or con- 1 and 2.)
nector)
-

▪ Change the set-
Display setting: A
ting.(Set a value 3
that corresponds
too small (improper)
- to shock unlikely
value is set for
to be applied
shock detection.
during normal
operation.)
Shock sensor main
body
: Internal damage
(excessive re-
sponse) Check the voltages
Although no shock is Installation of shock of shock sensors 1
sensor and 2, using Ana-
The shock detection applied, the shock ▪ Check the
detection alarm sets : Improper installa- lyzer. sensor and re-
function
off. tion (loosening), in- : Vehicle stopped place it if neces-
(OPT)
terference 2.0 ± 0.21 V sary.
Shock sensor har- Apply shock to each
sensor to see if its ▪ Check the har-
ness ness and repair
:Wire breakage, voltage does not
or replace it if
short circuit, leakage change excessively. necessary.
(harness or con- (Compare the
nector) voltages of sensors
(Especially if there 1 and 2.)
are half-broken
wires in the harness,
shock may be detec-
ted frequently.)
-

One of the following
matching operations
is not performed.
▪ Tire straight run-
ning angle
matching
▪ Setting screen
▪ Forward tilt limit
* If accelerator pedal
angle matching
fully closed and fully
▪ Tilt horizontal open matching is fin-
angle matching ished by simply per-
▪ Tilt no-load forming fully closed
matching matching and fully
open matching in
[Diagnostic mode in- ▪ Mast type data this order, the set-
dicator] matching
Check the matching ting will not be
Although no error ▪ Accelerator
Multifunction display value on the Match- saved.
code is displayed, pedal fully open ing screen.
the spanner indic- matching * If brake pedal fully
ator is left on. closed and operating
▪ Accelerator
pedal fully point matching is fin-
closed matching ished by simply per-
forming fully closed
▪ Brake pedal fully matching and oper-
open matching ating point matching
▪ Brake pedal fully in this order, the set-
closed matching ting will not be
saved.
▪ Each load hand-
ling lever: neut-
ral voltage
matching
▪ Tire diameter
data

Main body of tilt
angle sensor 3
: Internal damage
stallation
forward and back-
[Tilt indicator] :Wire breakage, voltage. necessary.
The correct tilt angle short circuit, leakage
is not displayed. (harness or con-
nector)
The tilt indicator cal- Tilt angle sensor ho-
culates as 0° when rizontal matching Check the matching
matching as hori- ▪ Perform match-
value value on the Match-
Multifunction display zontal angle for no : No agreement with ing screen. ing again.
load. At tilt most for- the vehicle state
ward / most back-
ward position, it may ▪ The tilt indicator
be jolt out of align- calculates as 0°
ment for the actual when matching
tilt angle. But it is as horizontal
normal. angle for no
load. So if load
is carried, have
the potential to
A load is carried. -
display the angle
of backward side
in spite of mak-
ing fork hori-
zontal level, be-
cause tire and
mast bend to for-
ward side.
▪ The automatic
tilt leveling func-
tion stops at the
position of the
backward side
corrected for the
load in consider-
ation for the
bend of tire and
[Tilt indicator] mast when a
The tilt angle is not load is carried.
Multifunction display indicated as 0° when A load is carried. - On the other
the automatic fork hand, tilt indic-
leveling is finished. ator calculates
as 0° when
matching as ho-
rizontal angle for
no load.
tilt angle may not
be indicated as
0° depending on
the load, but it is
normal.

▪ Check the tires
and replace
them if neces-
Tire specification sary
: Type, diameter, tire -
pressure ▪ Check the pres-
sure of each tire
and repair tires if
necessary.
Load sensor main Check the load
sensor voltage, us- ▪ Check the
body
ing Analyzer. sensor and re-
: Internal damage
Load sensor har- Raise and lower the sary.
ness lift to its uppermost ▪ Check the har-
:Wire breakage, (relief) and lower- ness and repair
short circuit, leakage most positions to
or replace it if
(harness or con- check the change in necessary.
nector) the voltage.
Load sensor no-load
Check the matching
matching value ▪ Perform match-
value on the Match-
: No agreement with ing again.
ing screen.
the vehicle state
The vehicle lacks Lifting height switch Check the lifting
stability during trav- main body height switch, using ▪ Check the
switch, and re-
eling. : Low lifting height is Analyzer.
Turn speed control (The speed limit : In NL place it if neces-
always detected.
does not activate Raise and lower the sary
easily or at all during Lifting switch har- lift to its uppermost ▪ Check the har-
turning.) ness and lowermost posi- ness and repair
necessary.
Tire angle sensor
main body
stallation
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.
the vehicle state

Main body of drive
motor rotation ▪ Check the 3
sensor sensor and re-
: Internal failure place it if neces-
Drive motor rotation sary.
sensor harness ▪ Check the har-
:Wire breakage, - ness and repair
The vehicle lacks short circuit, leakage or replace it if
stability during trav- (harness or con- necessary.
eling. nector) ▪ Replace the
Turn speed control (The speed limit Drive motor drive cir- drive motor drive
does not activate cuit circuit.
easily or at all during : Internal failure
turning.) Display setting
: The setting of tire
Check the matching
diameter data is not ▪ Correct the set-
value on the tire dia-
in agreement with ting
meter data screen.
that of the vehicle
state.
-

Main body of tilt
angle sensor
: Internal damage
stallation
forward and back-
(harness or con-
nector)
Tilt angle sensor ho-
rizontal matching Check the matching
▪ Perform match-
ing again.
the vehicle state
Main body of auto-
matic fork leveling
switch
Check the automatic
When tilted forward : Open failure ▪ Check the
fork leveling switch,
for leveling, the fork Mechanical detec- switch, and re-
using Analyzer.
does not stop auto- tion unit of automatic place it if neces-
: Load handling lever
matically in a hori- fork leveling switch sary
in neutral
Tilt control zontal position. : Gap in detection
Operate the auto- ▪ Check the har-
(The fork tilts to its unit is improperly ad-
matic fork leveling ness and repair
forward tilt limit justed.
switch to see if it or replace it if
without stopping in a Automatic fork level-
turns on and off nor- necessary.
horizontal position.) ing switch harness
mally.
:Wire breakage,
short circuit (harness
or connector)
▪ Check the oil
control valve,
and repair or re-
place it if neces-
Check the tilt control sary. Refer to re-
Oil control valve valve, using Active pair manual
: Seizure of or leak- Test. vol.1
age from tilt forward : Tilt forward solen- "TROUBLESHO
lock valve oid forcibly turned off OTING" of oil
Tilt solenoid harness (forward tilting control valve.
:Short circuit, leak- stopped)
▪ Check the solen-
age (harness or con- Tilt the fork forward oid and replace
nector) to check the opera-
it if necessary.
tion.
▪ Check the har-
ness and repair
or replace it if
necessary.
-

Main body of tilt
angle sensor 3
: Internal damage
stallation
forward and back-
(harness or con-
nector)
When the fork tilted
forward for leveling, Tilt angle sensor ho-
it does not stop rizontal matching Check the matching
▪ Perform match-
automatically in a value value on the Match-
Tilt control ing again.
horizontal position. : No agreement with ing screen.
(The fork does not the vehicle state
stop in a horizontal Load sensor main Check the load
position.) sensor voltage, us- ▪ Check the
body
: Internal damage
or replace it if
Load sensor no-load
Check the matching
value on the Match-
ing screen.
the vehicle state
-

Main body of tilt
angle sensor
: Internal damage
stallation
forward and back-
(harness or con-
nector)
Tilt angle sensor ho-
▪ Perform match-
ing again.
the vehicle state
forward for leveling, Load sensor main Check the load
it does not stop body
automatically in a : Internal damage
Tilt control : In NL place it if neces-
horizontal position. Load sensor har-
Raise and lower the sary.
(The fork does not ness
stop in a horizontal :Wire breakage, lift to its uppermost ▪ Check the har-
position.) (relief) and lower- ness and repair
or replace it if
Load sensor no-load
Check the matching
value on the Match-
ing screen.
the vehicle state
height switch, using ▪ Check the
main body
Analyzer. switch, and re-
: High lifting height is
always detected.
necessary.
-

Main body of tilt
angle sensor 3
: Internal damage
stallation
forward and back-
(harness or con-
nector)
When tilted back-
ward for leveling, the Tilt angle sensor ho-
fork does not stop rizontal matching Check the matching
▪ Perform match-
automatically in a value value on the Match-
ing again.
horizontal position. : No agreement with ing screen.
Tilt control
(The fork tilts to its the vehicle state
backward tilt limit Main body of auto-
without stopping in a matic fork leveling
horizontal position.) switch
(Mini lever spec.) : Open failure Check the automatic
fork leveling switch, ▪ Check the
Mechanical detec- sensor and re-
using Analyzer.
tion unit of automatic place it if neces-
fork leveling switch sary.
in neutral
: Gap in detection
unit is improperly ad-
justed.
Automatic fork level- turns on and off nor- necessary.
ing switch harness mally.
:Wire breakage,
short circuit (harness
or connector)
-
Refer to "When the
backward for level-
fork tilted forward for
ing, it does not stop
leveling, it does not
automatically in a
stop automatically in
Tilt control horizontal position. - -
a horizontal position.
(The fork does not
(The fork does not
stop in a horizontal
stop in a horizontal
position.)
position.)"
(Mini lever)

Main body of tilt
angle sensor
: Internal damage
stallation
When the fork tilted stallation portion is
backward for level- broken or damaged. ▪ Check the har-
forward and back-
ing, it does not stop Tilt angle sensor ward tilt limits to ness and repair
automatically in a harness check the change in or replace it if
Tilt control horizontal position. :Wire breakage, voltage. necessary.
(The fork does not short circuit, leakage
stop in a horizontal (harness or con-
position.) nector)
(Mini lever spec.) Tilt angle sensor ho-
▪ Perform match-
ing again.
the vehicle state
-
Main body of auto-
matic fork leveling
switch
: Open failure Check the automatic
fork leveling switch, ▪ Check the
Mechanical detec- sensor and re-
using Analyzer.
tion unit of automatic place it if neces-
fork leveling switch sary.
in neutral
: Gap in detection
unit is improperly ad-
justed.
The mast backward :Wire breakage,
Tilt control tilting speed is not short circuit (harness
limited. or connector)
main body
always detected.
necessary.
-

Main body of auto-
matic fork leveling 3
switch Check the automatic
: Short circuit fork leveling switch, ▪ Check the
Mechanical detec- using Analyzer. switch, and re-
tion unit of automatic : Load handling lever place it if neces-
fork leveling switch in neutral sary
: Gap in detection Operate the auto- ▪ Check the har-
unit is improperly ad- matic fork leveling ness and repair
justed. switch to see if it or replace it if
:Short circuit (har-
ness or connector)
▪ Check the oil
control valve,
and repair or re-
place it if neces-
OTING" of oil
Tilt forward solenoid oid forcibly turned off
( No backward tilting control valve.
harness
:Short circuit, leak- speed limit ) Tilt the ▪ Check the solen-
age (harness or con- fork backward to oid and replace
nector) check the operation. it if necessary.
▪ Check the har-
The mast backward ness and repair
Tilt control tilting speed is al- or replace it if
ways slow. necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
: Seizure or leakage ward lock valve, us- pair manual
from tilt backward ing Active Test. vol.1
lock valve : Tilt backward "TROUBLESHO
Tilt backward solen- solenoid forcibly OTING" of oil
oid harness turned on control valve.
:Wire breakage, ( No backward tilting
short circuit, leakage speed limit ) Tilt the oid and replace
(harness or con- fork backward to
it if necessary.
nector) check the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
main body
always detected.
necessary.
-

Display setting : For-
Check the set value
ward tilting speed
on the Option Set ▪ Setting screen
setting
screen.
(T F-SPD LIM)
main body
Although the load is : Low lifting height is Analyzer. switch, and re-
lifted high, the mast always detected. : In NL place it if neces-
Tilt control sary
forward tilting speed Raise and lower the
is not limited. Lifting switch har- lift to its uppermost ▪ Check the har-
short circuit (harness switch turns on and necessary.
-

main body height switch, using ▪ Check the 3
switch, and re-
: High lifting height is Analyzer.
always detected.
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
OTING" of oil
Tilt forward solenoid oid forcibly turned off
( No backward tilting control valve.
harness
:Short circuit, leak- speed limit ) Tilt the ▪ Check the solen-
age (harness or con- fork backward to oid and replace
The mast forward nector) check the operation. it if necessary.
Tilt control tilting speed is al- ▪ Check the har-
ways slow. ness and repair
or replace it if
necessary.
▪ Check the oil
control valve,
and repair or re-
place it if neces-
: Seizure or leakage ward lock valve, us- pair manual
from tilt backward ing Active Test. vol.1
lock valve : Tilt backward "TROUBLESHO
Tilt backward solen- solenoid forcibly OTING" of oil
oid harness turned on control valve.
:Wire breakage, ( No backward tilting
short circuit, leakage speed limit ) Tilt the oid and replace
(harness or con- fork backward to
it if necessary.
nector) check the operation.
▪ Check the har-
ness and repair
or replace it if
necessary.
-

Tire angle sensor
main body
stallation
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.
the vehicle state
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Check the steering
angle sensor, using
: Cam or steering sary.
Analyzer.
The knob is dis- wheel is defective.
: Turn the steering ▪ Check the har-
placed from its nor- Steering angle wheel to check the ness and repair
Knob position com- mal position to a cer- sensor harness input signal. or replace it if
pensation control tain position. :Wire breakage, necessary.
(OPT) (10° or more from short circuit, leakage
the straight running (harness or con-
position) nector)
Check the knob pos-
ition compensation
▪ Check the the
Knob position com- valve, using Active knob position
pensation valve Test.
: Tire end compensation
main body valve, and repair
: Leakage, seizure Forcibly turn on (by- or replace it if
(internal damage) pass) and off (no by-
pass) the knob posi- necessary.
Harness of knob po- tion compensation ▪ Check the solen-
sition compensation solenoid to check oid and replace
solenoid how the steering it if necessary.
:Wire breakage, system operates.
short circuit, leakage Forcibly ON ... ▪ Check the har-
(harness or con- ness and repair
Steering idles (light). or replace it if
nector) Forcibly OFF ... necessary.
Steering does not
idles (heavy).
If run on the road
surface inclined to
right and left, the
The road surface is
- knob position to run
inclined.
straight is different
from it at the hori-
zontal surface.
-

Tire angle sensor
main body 3
stallation
: The installation
in neutral. sary.
Fully close the ac-
celerator pedal and
(harness or con-
nector)
Tire angle sensor
▪ Perform match-
ing again.
the vehicle state
Main body of steer-
ing angle sensor
: Internal damage
▪ Check the
Check the steering
angle sensor, using
The knob is dis- : Cam or steering sary.
Analyzer.
placed from its nor- wheel is defective. : Turn the steering ▪ Check the har-
Knob position com-
mal position. Steering angle wheel to check the ness and repair
pensation control
(The knob position is sensor harness input signal. or replace it if
(OPT)
not constant during :Wire breakage, necessary.
straight running.) short circuit, leakage
(harness or con-
nector)
Check the knob pos-
ition compensation
▪ Check the the
Knob position com- valve, using Active knob position
pensation valve Test.
: Tire end compensation
main body valve, and repair
: Leakage, seizure Forcibly turn on (by- or replace it if
(internal damage) pass) and off (no by-
pass) the knob posi- necessary.
Harness of knob po- tion compensation ▪ Check the solen-
sition compensation solenoid to check oid and replace
solenoid how the steering it if necessary.
:Wire breakage, system operates.
short circuit, leakage Forcibly ON ... ▪ Check the har-
(harness or con- ness and repair
Steering idles (light). or replace it if
nector) Forcibly OFF ... necessary.
Steering does not
idles (heavy).
PS cylinder system ▪ Check the cylin-
link is defective. der, and repair
-
: Eccentric pin or or replace it if
kingpin is defective necessary.
-

body
: Internal damage
or replace it if
Display setting
Check the matching
meter data screen.
that of the vehicle
state.
▪ In traveling con-
trol, the attach-
ment weight and
the mast weight
are treated as
part of the load
weight, because
they affect the
longitudinal sta-
bility of the
Heavy attachment, vehicle. For a
mast with a high lift- - very heavy mast
ing height or an FSV or
QFV mast with a
Speed limit applies
high lifting
Traveling control at high lifting height
height, if its inner
(OPT) despite not being
middle mast is
loaded
rather heavy, a
limit may some-
times be placed
on the speed
even under no-
load conditions.
When the lift is
raised to its upper-
most position, the
load sensor cannot
distinguish this situ-
ation from a situation
in which a heavy
load is carried, be-
cause, in that situ-
ation, a relief pres-
Lift relief pressure sure remains in the
-
detected. lift cylinder pressure
that the load sensor
senses.
After a lift relief,
however, it becomes
possible to perform
operation because
the relief pressure is
discharged when the
lift is lowered even a
little.
-

body sensor voltage, us- ▪ Check the 3
: Internal damage
or replace it if
main body
: Low lifting height is
always detected.
Although a load is ness and lowermost posi- ness and repair
Traveling control carried, the speed is :Wire breakage, tions to see if the or replace it if
(OPT) not limited when the short circuit (harness switch turns on and necessary.
lift is raised high. or connector) off normally.
Display setting
: Traveling control
setting disabled Check the set value
Load sensing speed on the Option Set ▪ Setting screen
restriction disabled screen.
(ASC W/LOAD,
MODE)
Display setting
Check the matching
meter data screen.
that of the vehicle
state.
-
main body
switch, and re-
: Low lifting height is Analyzer.
always detected.
Speed limit applies Raise and lower the sary
Lifting switch har- lift to its uppermost
Traveling control when loaded despite ▪ Check the har-
ness and lowermost posi-
(OPT) being at a low lifting ness and repair
:Wire breakage, tions to see if the
height or replace it if
necessary.
-
Display setting
:Maximum speed Check the set value. ▪ Setting screen
limit is set very low.
A limit is always Display setting
placed on the speed : The setting of tire
Traveling control Check the matching
regardless of diameter data is not ▪ Correct the set-
(OPT) value on the tire dia-
whether a load is in agreement with ting
meter data screen.
carried or not. that of the vehicle
state.
-

8FBE RM CE206 Section 3 Troubleshooting Vol. 2 - Codigos

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8FBE RM CE206 Section 3 Troubleshooting Vol. 2 - Codigos

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3 TROUBLESHOOTING 3-159

3.1 BEFORE TROUBLESHOOTING

3.1.1 CONNECTOR HANDLING

3. Bring a tester probe into contact with a connector

3.1.2 WIRE HARNESS AND CONNECTOR INSPECTION

Short circuit check

3. Measure the resistance between a terminal corres-

Visual and contact pressure checks

▪ Insert a male terminal same as that of the ter-

3.3 DIAGNOSIS CODE LIST

Overheat warning (O/H)

3.4 WHEN ERROR CODE IS DISPLAYED

Error Code: A0-1

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2

Drive motor driver LH Drive motor driver RH

Temperature sensor Temperature sensor

[ANL] ACTIVE TEST 2/3

Turn on the key switch and check the error occurs.

･Drive motor driver power-circuit temperature LH/RH

Record the temperature of the drive motor driver power-circuit.

･Drive motor driver power-circuit temperature LH/RH

Check the drive motor driver power-circuit temperature and

[ANL] ACTIVE TEST 2/3

Portion to be inspected Standard:

Disconnect the battery plug, then connect the CN102, CN104,

[ANL] ACTIVE TEST 2/3

Error Code: A0-2

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2

Pump motor driver

[ANL] ACTIVE TEST 2/3

Turn on the key switch and check the error occurs.

[ANL] I/O TEMP/VOLT 3/6 TPMDH

Record the temperature of the pump motor driver power-circuit.

[ANL] I/O TEMP/VOLT 3/6 TPMDH

Check the pump motor driver power-circuit temperature and

[ANL] ACTIVE TEST 2/3

[ANL] ACTIVE TEST 2/3

Error Code: A1-1

Error Code: A1-2

Error Code: A1-3

Error Code: A1-4

Error Code: A2-1

Turn on the key switch and check the error occurs.

[ANL] I/O TEMP/VOLT 4/6 TMCB

Record the main controller board temperature.

[ANL] I/O TEMP/VOLT 4/6 TMCB

Check the main controller board temperature and compare to

Error Code: A2-2

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2

Drive motor driver LH Drive motor driver RH

Temperature sensor Temperature sensor Temperature sensor Temperature sensor

[ANL] ACTIVE TEST 2/3

Turn on the key switch and check the error occurs.

･Drive motor driver circuit board temperature LH/RH

Record the temperature of drive motor driver circuit board and

･Drive motor driver circuit board temperature LH/RH

Check the the temperature of drive motor driver circuit board

[ANL] ACTIVE TEST 2/3

[Inspection procedure and standard]

Disconnect the battery plug, then connect the CN102, CN104,