8fbc (H) U Section 4a Vol 2 Cu347-1

sec04A.
book 1 ページ２０１１年１月２５日火曜日午後６時３５分
4A-1
TROUBLESHOOTING (2010.10~)
Page
BEFORE TROUBLESHOOTING......................... 4A-2
CONNECTOR HANDLING...................................... 4A-2
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ..................................................... 4A-2
TROUBLESHOOTING METHOD ........................ 4A-4
TO USE SST........................................................ 4A-5
DIAGNOSIS CODE LIST..................................... 4A-6
WHEN ERROR CODE IS DISPLAYED ............. 4A-22
WHEN NO ERROR CODE IS DISPLAYED..... 4A-193 4A
Note:
This chapter has been changed due to replacement of the Motor Driver from
October 2010 TIEM production.
Service Manual Change History
Description Page# Date

1 Added Service Manual Change History 2 8/31/12
2 Added SIB CC12-003 219 8/31/12
3 Added SIB CE11-001R 223- 11/15/2012
226
4 Added links to Table of Contents 1 2/15/13
5 Added SIB CE11-002 227 2/15/13
6 Added SIB CE11-003 228 2/15/13
7 Added SIB MA12-004 232 2/15/13
8 Added SIB CE14-005 246- 8/15/14
247
Page 1 of 1
Service Information Bulletins
1 SIB CC11-004 Tuning No.1 Explained 347-1 Chapter 3
2 SIB CC12-003 Pre-charge Circuit Eplanation (Error Codes 31-1 and 31-3) 347-1 Chapter 4a
3 SIB CC13-002 Unlocking H Mode and Speed Limiting 347-1 Chapter 3
4 SIB CC13-003 D-LIM and P-LIM Mode Options Set Explained 347-1 Chapter 3
5 SIB CC14-001 Brake and Stop Lamp Switch Adjustments 346 Chapter 2
6 SIB CE10-004R Voltage Conversion 347-1 Chapter 2
7 SIB CE10-007 Height Selector Information 347-1 Chapter 3
8 SIB CE10-008 Shock Sensor Information 347-1 Chapter 3
9 SIB CE11-001R Clamp Release Interlock (Mini Lever Units 347-1 Chapter 4 & 4a
10 SIB CE11-002 Horn Wires Breaking 347-1 Chapter 4 & 4a
11 SIB CE11-003 Clamp Release Interlock (Standard Lever Units) 347-1 Chapter 4 & 4a
12 SIB CE14-005 Special Grounding strap 347-1 Chapter 4 & 4a
13 SIB HS12-001 Revision to Pump Motor Class Rating 346 Chapter 5
14 SIB HS12-002 Oil Control Valve update to Chapter 16 346 Chapter 16
15 SIB HS13-003 Mini Lever Reducing Valve Pressure Checks 346 Chapter 16
16 SIB MA10-002 Tuning Modes Explained 347-1 Chapter 3
17 SIB MA10-003 Auto Speed Control Information 347-1 Chapter 3
18 SIB MA10-004 Touch Pad Information 347-1 Chapter 3
19 SIB MA10-006 AC Motor Controller Change 347-1 chapter 2
20 SIB MA11-001 Service Hint for Greasing Rear Axle Beam Pivot Pin 346 Chapter 0
21 SIB MA12-003 Lubrication of Horn Contact Rings 346 chapter 0
22 SIB MA12-004 R/M 347-1 Chapter 4A updates 347-1 Chapter 4a
23 SIB MA12-005 B-Type Option Explained 347-1 Chapter 3
24 SIB MA14-001 Hydraulic Pump Spline lubrication 346 Chapter 0
25 SIB RA13-002 Steering Troubleshooting Information 346 Chapter 9
26 SIB RA13-003 Priority Valve Operation 346 Chapter 9
27 SIB RA14-001 Rear Axle Hub Oil Sea 346 Chapter 8
27 SIB ST08-001 Recommended Special Service Tools Not inserted
28 SIB ST10-001 Measuring Parking Brake Force on Trucks 346 Chapter 10
Hotline Tech Tips

1 HTT-2010-06 Drive Motor Over Current Limit Checks
2 HTT-2010-07 Slow Travel Or Surging Hydraulics
3 HTT-2010-08 Display, Main CPU and Changing Voltage
4 HTT-2010-09 Measuring Parking Brake Force
5 HTT-2010-10 Important Service Information Bulletins
6 HTT-2010-11 Slow Attachment Speeds
7 HTT-2010-12 Travel Alarm
8 HTT-2011-01 Speed Limit Adjustment
9 HTT-2011-03 Slow Lowering With Standard Levers
10 HTT-2011-04 "H" Power Mode
11 HTT-2011-05 Adding Electrical Devices,
12 HTT-2011-06 Battery Option/Type selection
13 HTT-2011-08 Tuning Item 1 Explained
14 HTT-2011-09 Important Service Information Bulletins
15 HTT-2011-10 Controller Software Change
16 HTT-2011-11 Adding Forward Travel Alarm
17 HTT-2011-12 C1-2 Error Codes
18 HTT-2012-01 Relief Valve Structure, Using DVOM to Check Voltage Drop
sec04A.book 2 ページ２０１１年１月２５日火曜日午後６時３５分
4A-2
BEFORE TROUBLESHOOTING
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.
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:
Continuity check
1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between corresponding terminals of
the connectors at both ends.
Standard:10 W or less
Note:
Measure while lightly shaking the wire harness 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.
4A-3
Short circuit check

1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between the corresponding connector
terminal and N1. Always inspect the connectors at both ends.
Standard: 1 MΩ or above
ǡ
Measure while lightly shaking the wire harness up and down

and sideways.
3. Measure the resistance between a terminal corresponding to

the connector terminal and N1. Always inspect the connectors
at both ends.
Standard: 1 MΩ or above
The wiring may short-circuit due to pinching by the body or

defective clamping.
4A
ǡ ǡ
Visual and contact pressure checks

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

connector and check the extracting force.
Defective contact may exist at a terminal where the extracting
force is less than that of other terminals.
Note:
Even if there is rust or foreign matter trapped at the terminal,
or the contact pressure between male and female terminals is
low, abnormal contact condition may be changed to normal by
disconnecting and reconnecting the connector. In that case,
repeat connector connection and disconnection several times.
If defect is perceived even once, terminal contact may be
defective.
Click here for information on

Special Grounding Strap to help
reduce static electricity issues.
4A-4
TROUBLESHOOTING METHOD
Inspection: Check of seat switch condition Defective portion
1. Turn off the key switch and disconnect the battery Repair or replacement
SDM: 0
plug.
2. Disconnect the CN43 connector, connect the battery Seat switch defect
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
[ANL] I/O TRAVELING 2/5
SDM: 1 To the next step depending on the result.
Inspection 1:
1. Turn off the key switch and disconnect the battery
plug. NG
Harness defect
2. Disconnect the CN103, CN0104 and CN43
connectors and check the harnesses for their
continuities.
OK
Main controller defect
Explanation of Frames
1. Disconnect the battery plug, disconnect the CN43
connector, and visually check inside the connector
and the caulked portion of its wire for defects.
A single frame indicates measurement with a tester or an
(Refer to BEFORE TROUBLESHOOTING.)
ordinary step.
2. Connect the CN43 connector, connect the battery
plug, and then turn on the key switch without sitting in
the seat.
Inspection: Check of seat switch condition

A double frame indicates inspection by an analyzer
Check the value of SDM, using the Analyzer menu.
function.
Test item.
4A-5
TO USE SST
Use SSTs for quick, accurate electrical troubleshooting on the 8FBCU series.
Correct check will fail if the connection method is wrong. Since boards may be damaged by incorrect connection,
careful operation is necessary.
SST No. SST name remarks

-
09230-13240-71 Main controller check harness
(for power source check)
C8-1, 2
09240-13241-71 AC drive check harness
E8-1, 2
09230-13700-71 CN76 short harness 61-1, 2
C2-2
C4-1 to 6
C5-1 to 6
C8-1, 2
CN7 IC check pin E2-2

09232-13130-71 Check harness E8-1, 2
Each short harness FB-1, 2
4A
62-1, 2
71-1 to 3
72-1 to 4
G5-1 to 6
CN97 harness
09238-13130-71 68-1 to 3
CN99 check harness
Caution:
Always disconnect the battery plug before SST connection and disconnection. If the battery plug is kept
connected, various boards may be damaged.
sec04A.book
DIAGNOSIS CODE LIST
4A-6
Indication : Information can be checked on the display when vehicle trouble occurs.
Memory : Use indication information that can be checked when the mask function DIAG MEMORY is used.
6 ページ
Indicator : Diagnostic mode

O/H
Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

O/H
DCR A0-1 Drive motor drive power circuit overheating abnormality Traveling stop.
lighting
２０１１年１月２５日
O/H Load handling stop.

PCR A0-2 Pump motor drive power circuit overheating abnormality
lighting Steering become stiff.
火曜日
Diagnostic
Unable to traveling and load handling
A1-1 A1-1 mode Main controller high voltage
Steering become stiff.
blinking
Diagnostic
A1-2 A1-2 mode Drive motor drive circuit high voltage Traveling stop.
午後６時３５分
blinking
Diagnostic
Load handling stop.
A1-4 A1-4 mode Pump motor drive circuit high voltage
Steering become stiff
blinking
O/H Drive motor output restricted.
C/R A2-1 Main controller circuit board overheating abnormality
lighting Unable to load handling
Diagnostic
Traveling and load handling stop.
A3-1 A3-1 mode Battery connection incorrect
blinking
Diagnostic
OPSS function invalidity
A5-1 A5-1 mode Seat switch GND short abnormality
Parking brake reminder alarm partially disable.
blinking
Diagnostic
A6-3 A6-3 mode Tilt switch GND short abnormality Tilt stop.
blinking
Diagnostic Traveling stop.
A8-1 A8-1 mode F1 fuse abnormality (Open) Load handling stop.
blinking Steering become stiff.
Diagnostic
Traveling stop.
A8-2 A8-2 mode F6 fuse abnormality (Open)
Load handling stop.
blinking
Diagnostic
A9-2 A9-2 mode F7 fuse abnormality (Open) Load handling stop.
blinking
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Diagnostic
Drive motor output restricted.
AA-1 AA-1 mode Main controller temperature sensor abnormality
Load handling stop.
7 ページ
blinking
Diagnostic
Cooling fan stop.
AB-1 AB-1 mode Cooling fan drive circuit abnormality
blinking
AC-1 AC-1 mode Semiconductor switch abnormality Load handling stop.
２０１１年１月２５日
Diagnostic
AD-1 AD-1 mode Drive motor driver → Main controller communication abnormality
火曜日
blinking Traveling stop.

Diagnostic Knob position correcting stop.
Drive motor driver → Main controller communication abnormality (on
AD-2 AD-2 mode
start up)
blinking
Diagnostic
AD-5 AD-5 mode Pump motor driver → Main controller communication abnormality
blinking Load handling stop.
Diagnostic Steering become stiff.
Pump motor driver → Main controller communication abnormality (on
AD-6 AD-6 mode
start up)
blinking
Diagnostic
AF-1 AF-1 mode Main controller CPU error
blinking
Diagnostic
blinking Unable to traveling and load handling
blinking
Diagnostic
blinking
4A-7
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4A-8
Diagnostic
8 ページ
blinking
Diagnostic
blinking
Some control operations not stable.
Diagnostic
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
C0-2 C0-2 mode Drive motor power-circuit short
blinking
Diagnostic
C1-1 C1-1 mode Drive motor current sensor neutral voltage error. Traveling stop.
blinking
Diagnostic
C1-2 C1-2 mode Drive motor current sensor over current.
blinking
O/H
DM C2-1 Drive motor overheating abnormality.
lighting
Diagnostic
C2-2 C2-2 mode Drive motor temperature sensor abnormality.
blinking Drive motor output restricted.
Diagnostic
C3-1 C3-1 mode Drive motor power circuit temperature sensor abnormality.
blinking
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Diagnostic
C4-1 C4-1 mode Accelerator sensor POT1 open.
9 ページ
blinking
Diagnostic
C4-2 C4-2 mode Accelerator sensor POT2 open.
blinking
Display only
Diagnostic
C4-3 C4-3 mode Accelerator sensor POT1 VCC short.
blinking
２０１１年１月２５日
Diagnostic
C4-4 C4-4 mode Accelerator sensor POT2 VCC short.
火曜日
blinking
Diagnostic
C4-5 C4-5 mode Accelerator sensor offset abnormality. Traveling stop.
blinking
Diagnostic
C4-6 C4-6 mode Accelerator sensor matching value error. Drive motor output restricted.
blinking
Diagnostic
C8-1 C8-1 mode Drive motor speed sensor open.
blinking
Traveling stop.
Diagnostic
C8-2 C8-2 mode Drive motor speed sensor short.
blinking
CB-1 CB-1 mode MB contactor open. Load handling stop.
Diagnostic
CB-2 CB-2 mode MB contactor short. Display only
blinking
Diagnostic
CB-3 CB-3 mode MB contactor drive circuit open.
blinking
CB-4 CB-4 mode MB contactor drive circuit short. Load handling stop.
Diagnostic
CB-5 CB-5 mode MB contactor drive circuit short.
blinking
4A-9
sec04A.book
O/H
4A-10
C/P CB-6 MB contactor panel overheating abnormality.
lighting
10 ページ
Diagnostic Pump motor output restricted.

CB-7 CB-7 mode MB contactor panel temperature sensor abnormality.
blinking
Diagnostic
CC-1 CC-1 mode Drive motor drive CPU error.
blinking
Traveling stop.
Diagnostic
２０１１年１月２５日
CC-4 CC-4 mode Drive motor drive CPU error.

blinking
火曜日
Diagnostic
CC-6 CC-6 mode Drive motor drive CPU error. Display only
blinking
Diagnostic
E0-2 E0-2 mode Pump motor drive power circuit abnormality.
blinking
Diagnostic
Unable to load handling.
E1-1 E1-1 mode Pump motor current sensor neutral voltage error.
blinking
Diagnostic
E1-2 E1-2 mode Pump motor current sensor over current.
blinking
O/H
PM E2-1 Pump motor overheating abnormality.
lighting
Diagnostic
E2-2 E2-2 mode Pump motor temperature sensor abnormality.
Pump motor output restricted.
blinking
Diagnostic
E3-1 E3-1 mode Pump motor drive power circuit temperature sensor abnormality.
blinking
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Diagnostic
E8-1 E8-1 mode Pump motor speed sensor open.
blinking
11 ページ
Diagnostic
E8-2 E8-2 mode Pump motor speed sensor short.
blinking Unable to load handling.
EC-1 EC-1 mode Pump motor drive CPU error.
blinking
２０１１年１月２５日
Diagnostic
EC-4 EC-4 mode Pump motor drive CPU error.
火曜日
blinking
Diagnostic
EC-6 EC-6 mode Pump motor drive CPU error. Display only
blinking
Diagnostic
EE-1 EE-1 mode Display → Main controller communication error. Settings cannot be changed by display operation.
blinking
Diagnostic
EE-2 EE-2 mode Display → Main controller communication error. Unable to display operation
blinking
Diagnostic
F1-1 F1-1 mode Main controller → Display communication error.
blinking Vehicle settings cannot be changed by display
Diagnostic operation.
F1-2 F1-2 mode Main controller → Display communication error.
blinking
Diagnostic
F4-1 F4-1 mode Display CPU error.
blinking Traveling and load handling cannot be performed
Diagnostic simultaneously.
F4-2 F4-2 mode Display CPU error. Disable the traveling control function.
blinking W/ PIN Code Entry System:
Diagnostic PIN code entry system disable.
blinking
Diagnostic
F4-4 F4-4 mode Display CPU error. Display only
blinking
4A-11
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Diagnostic
4A-12
F4-5 F4-5 mode Display CPU error. Display function not stable.
blinking
12 ページ
Diagnostic
blinking
Diagnostic
F4-7 F4-7 mode Display CPU error. Some control operations not stable.
blinking
２０１１年１月２５日
Diagnostic
火曜日
blinking
Diagnostic
FF-1 FF-1 mode D7V power supply circuit over current. Display turns OFF.
blinking
Diagnostic
Knob position correcting stop.

FF-2 FF-2 mode SSTR+ power supply circuit over current.
blinking
Diagnostic
31-1 31-1 mode Declining of actibvating voltage for Drive motor drive circuit. Travelling stop.
blinking
Diagnostic
Load handling stop.
31-3 31-3 mode Declining of actibvating voltage for Pump motor drive circuit.
blinking
Diagnostic
32-1 32-1 mode Drive motor driver ID abnormality.
blinking
Display only.
Diagnostic
32-3 32-3 mode Pump motor driver ID abnormality.
blinking
Diagnostic
33-1 33-1 mode Main controller → Drive motor driver CAN communication abnormality. Travelling stop.
blinking
Diagnostic
Load handling stop.
33-3 33-3 mode Main controller → Pump motor driver CAN communication abnormality.
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Diagnostic
52-1 52-1 mode Yaw late sensor open.
blinking
13 ページ
Diagnostic
52-2 52-2 mode Yaw late sensor short. Swing lock disable.
blinking
Diagnostic
52-3 52-3 mode Yaw late sensor neutral voltage error.
blinking
２０１１年１月２５日
Diagnostic
54-1 54-1 mode Swing lock solenoid open.
火曜日
blinking
Diagnostic
54-2 54-2 mode Swing lock solenoid short. Swing lock failed.
blinking
Diagnostic
54-3 54-3 mode Swing lock solenoid drive circuit abnormality.

blinking
Diagnostic
54-4 54-4 mode Swing lock solenoid abnormality. Partial limitation of rear wheel swing control function.
blinking
Diagnostic
61-1 61-1 mode Load sensor open.
blinking Partial limitation of mast control function.
Partial limitation of traveling control function.
Diagnostic Partial limitation of OPSS function.
61-2 61-2 mode Load sensor short.
blinking
4A-13
sec04A.book
Diagnostic
4A-14
62-1 62-1 mode Tilt angle sensor open.
blinking
14 ページ
Diagnostic
62-2 62-2 mode Tilt angle sensor short.
blinking
Diagnostic
63-1 63-1 mode Tilt switch forward/backward simultaneous operation short. Partial limitation of mast control function.
blinking
２０１１年１月２５日
Diagnostic
63-2 63-2 mode Tilt switch forward position short.
火曜日
blinking
Diagnostic
63-3 63-3 mode Tilt switch backward position short.
blinking
Diagnostic
64-1 64-1 mode Lift lock solenoid open. Lift lower may stop.
blinking
Diagnostic
64-2 64-2 mode Lift lock solenoid short. Lift lower may stop.
blinking
(Conventional lever)
Diagnostic
Lift lower may operate while OPS is operating.
64-3 64-3 mode Lift lock solenoid drive circuit abnormality.
(Mini lever/Joystick lever)
blinking
Lift lower may not operate.
Diagnostic
Lift lower may operate while OPS is operating.
64-4 64-4 mode Lift lock solenoid its continuity.
blinking
Lift lower may not operate.
Diagnostic
65-1 65-1 mode Tilt control solenoid open. Tilt forward may stop.
blinking
Diagnostic
65-2 65-2 mode Tilt control solenoid short. Tilt forward may stop.
blinking
Diagnostic
Tilt forward may operate while OPS is operating.
65-3 65-3 mode Tilt control solenoid drive circuit abnormality.
blinking
Tilt forward may not operate.
sec04A.book
Diagnostic
Tilt forward may operate while OPS is operating.
65-4 65-4 mode Tilt control solenoid its continuity.
15 ページ
blinking
Tilt forward may not operate.
Diagnostic
66-1 66-1 mode Outside matching value range for tilt angle sensor. Partial limitation of mast control function.
blinking
Partial limitation of mast control function.
Diagnostic
Partial limitation of traveling control function.
67-1 67-1 mode Lifting height switch abnormality.
２０１１年１月２５日
Height selector disable.

blinking
Partial limitation of OPSS function.
火曜日
Diagnostic
68-1 68-1 mode Lifting height sensor open.
blinking
Diagnostic
Height selector disable.
68-2 68-2 mode Lifting height sensor short.
Lift speed limited.

blinking
Diagnostic
68-3 68-3 mode Lifting height sensor abnormality.
blinking
Diagnostic
71-1 71-1 mode Tire angle sensor open.
blinking
Diagnostic
71-2 71-2 mode Tire angle sensor short.
blinking
Diagnostic
72-1 72-1 mode Steering angle sensor SS1 open.
blinking Knob position correcting stop.
72-2 72-2 mode Steering angle sensor SS2 open.
blinking
Diagnostic
72-3 72-3 mode Steering angle sensor SSC open. Knob position correcting stop.
blinking
Diagnostic
72-4 72-4 mode Steering angle sensor power circuit open.
blinking
4A-15
sec04A.book
Diagnostic
4A-16
73-1 73-1 mode Knob position synchronizer solenoid open.
blinking
16 ページ
Diagnostic
73-2 73-2 mode Knob position synchronizer solenoid short.
blinking
Diagnostic
73-3 73-3 mode Knob position synchronizer solenoid power circuit abnormality. Knob position correcting stop.
blinking
２０１１年１月２５日
Diagnostic
73-4 73-4 mode Knob position synchronizer solenoid abnormality.
火曜日
blinking
Diagnostic
74-1 74-1 mode Outside matching value range for tire angle error.
blinking
Diagnostic
H1-1 H1-1 mode Lift lever potentiometer open.

blinking
Diagnostic
H1-2 H1-2 mode Lift lever potentiometer short. Lift stop.
blinking
Diagnostic
H1-3 H1-3 mode Lift lever potentiometer output abnormality.
blinking
Diagnostic
Lift stop. (Conventional lever)
H1-4 H1-4 mode Lift lever potentiometer neutral error.
Load handling stop. (Mini lever/Joystick lever)
blinking
Diagnostic
H1-5 H1-5 mode Lift lever potentiometer matching value error. Lift stop.
blinking
Diagnostic
H2-1 H2-1 mode Tilt lever potentiometer open.
blinking
Diagnostic
H2-2 H2-2 mode Tilt lever potentiometer short. Tilt stop.
blinking
Diagnostic
H2-3 H2-3 mode Tilt lever potentiometer output abnormality.
blinking
sec04A.book
Diagnostic
H2-4 H2-4 mode Tilt lever potentiometer neutral error. Load handling stop.
blinking
17 ページ
Diagnostic
H2-5 H2-5 mode Tilt lever potentiometer matching value error. Tilt stop.
blinking
Diagnostic
H3-1 H3-1 mode Attachment 1 lever potentiometer open.
blinking
２０１１年１月２５日
Diagnostic
H3-2 H3-2 mode Attachment 1 lever potentiometer short. Attachment 1 stop.
火曜日
blinking
Diagnostic
H3-3 H3-3 mode Attachment 1 lever potentiometer output abnormality.
blinking
Diagnostic
Attachment 1 stop. (Conventional lever)

H3-4 H3-4 mode Attachment 1 lever potentiometer neutral error.
blinking
Diagnostic
H3-5 H3-5 mode Attachment 1 lever potentiometer matching value error. Attachment 1 stop.
blinking
Diagnostic
H4-1 H4-1 mode Attachment 2 lever potentiometer open.
blinking
Diagnostic
H4-2 H4-2 mode Attachment 2 lever potentiometer short. Attachment 2 stop.
blinking
Diagnostic
H4-3 H4-3 mode Attachment 2 lever potentiometer output abnormality.
blinking
Diagnostic
Attachment 2 stop. (Conventional lever)
H4-4 H4-4 mode Attachment 2 lever potentiometer neutral error.
blinking
Diagnostic
H4-5 H4-5 mode Attachment 2 lever potentiometer matching value error. Attachment 2 stop.
blinking
4A-17
sec04A.book
Diagnostic
4A-18
H5-1 H5-1 mode Lift proportional solenoid open. (PULL)
blinking
18 ページ
Upward lift stop.

Diagnostic
H5-2 H5-2 mode Lift proportional solenoid short. (PULL)
blinking
Diagnostic
H5-3 H5-3 mode Lift proportional solenoid open. (PUSH)
blinking
２０１１年１月２５日
Downward lift stop.

Diagnostic
H5-4 H5-4 mode Lift proportional solenoid short. (PUSH)
火曜日
blinking
Diagnostic
H5-5 H5-5 mode Lift proportional solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H5-6 H5-6 mode Lift proportional solenoid (PULL/PUSH) abnormality.

blinking
Diagnostic
H6-1 H6-1 mode Tilt backward solenoid open.
blinking
Backward tilt stop.
Diagnostic
H6-2 H6-2 mode Tilt backward solenoid short.
blinking
Diagnostic
H6-3 H6-3 mode Tilt forward solenoid open.
blinking
Forward tilt stop.
Diagnostic
H6-4 H6-4 mode Tilt forward solenoid short.
blinking
Diagnostic
H6-5 H6-5 mode Tilt solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H6-6 H6-6 mode Tilt forward/backward solenoid abnormality.
blinking
sec04A.book
Diagnostic
H7-1 H7-1 mode Attachment 1 PULL solenoid open.
blinking
19 ページ
Diagnostic
H7-2 H7-2 mode Attachment 1 PULL solenoid short.
blinking
Attachment 1 stop.
Diagnostic
H7-3 H7-3 mode Attachment 1 PUSH solenoid open.
blinking
２０１１年１月２５日
Diagnostic
H7-4 H7-4 mode Attachment 1 PUSH solenoid short.
火曜日
blinking
Diagnostic
H7-5 H7-5 mode Attachment 1 (PULL/PUSH) solenoid power circuit abnormality.
blinking
Load handling stop.
Diagnostic
H7-6 H7-6 mode Attachment 1 PULL/PUSH solenoid abnormality.

blinking
Diagnostic
H8-1 H8-1 mode Attachment 2 PULL solenoid open.
blinking
Diagnostic
H8-2 H8-2 mode Attachment 2 PULL solenoid short.
blinking
Attachment 2 stop.
Diagnostic
H8-3 H8-3 mode Attachment 2 PUSH solenoid open.
blinking
Diagnostic
H8-4 H8-4 mode Attachment 2 PUSH solenoid short.
blinking
4A-19
sec04A.book
Diagnostic
4A-20
H8-5 H8-5 mode Attachment 2 (PULL/PUSH) solenoid power circuit abnormality.
blinking
20 ページ
Diagnostic
H8-6 H8-6 mode Attachment 2 PULL/PUSH solenoid abnormality.
blinking
Diagnostic
HB-1 HB-1 mode Proportional solenoid power supply circuit (RY1) open. Load handling stop.
blinking
２０１１年１月２５日
Diagnostic
HB-2 HB-2 mode Proportional solenoid power supply circuit short.
火曜日
blinking
Diagnostic
HB-3 HB-3 mode Proportional solenoid power supply circuit over current.
blinking
Diagnostic
Lift upward or tilt backward may operate while OPS is

HC-1 HC-1 mode Unload solenoid open.
operating.
blinking
Diagnostic
HC-2 HC-2 mode Unload solenoid short.
operating.
blinking
Diagnostic
HC-3 HC-3 mode Unload solenoid drive circuit abnormality. Loading operations other than lower may not operate.
blinking
Diagnostic
HC-4 HC-4 mode Unload solenoid abnormality.
operating.
blinking
sec04A.book
Diagnostic
G5-1 G5-1 mode Shock sensor 1 open.
blinking
21 ページ
Diagnostic
G5-2 G5-2 mode Shock sensor 1 short.
blinking
Diagnostic
G5-3 G5-3 mode Shock sensor 1 neutral voltage error.
blinking
２０１１年１月２５日
Shock sensor disabled.

Diagnostic
G5-4 G5-4 mode Shock sensor 2 open.
火曜日
blinking
Diagnostic
G5-5 G5-5 mode Shock sensor 2 short.
blinking
Diagnostic
G5-6 G5-6 mode Shock sensor 2 neutral voltage error.

blinking
4A-21
4A-22
WHEN ERROR CODE IS DISPLAYED

z Error Code A0-1 (Drive motor power-circuit overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2
Drive motor drive circuit

N1
Temperature-sensor
Probable cause:
(1) The power cable and motor cable tightening is defective. (5) Cooling fan defect
(2) Connector contact defect (6) Overheating (continuous overload operation)
(3) Harness defect (7) Drive motor drive circuit defect
(4) Cooling fan clogging (8) Main controller defect
If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Disconnect the battery plug, and confirm whether is in the conclusion part of the power cable motor cable
loosen.
Do not leave the vehicle standing in a hot place.
Error code A0-1
Operate check of three cooling fans, Please apply the

cooling fan compulsorily by using Active Test. The fans
do not rotate.
[ANL]ACTIVE TEST 2/3 FAN 1
FAN OFF → ON
The fans rotate.
Inspection: Temperature check

Turn on the key switch and check the value of TDMDH
using the Analyzer menu.
[ANL] I/O TEMP/VOLT 2/4
Record the value of

TDMDH.
2
4A-23
Turn off the key switch and leave the vehicle standing
for a while (about 15 minutes).
The TDMDH temperature is 78°C or more for both
cooling fans 1 and 2 and it has lowered by 5°C or more
compared to the TDMDH temperature previously
checked.
Turn on the key switch and check the value of TDMDH

The TDMDH temperature is
TDMDH: 78°C or more and it has not
Less than lowered by 5°C or more compared
78°C to the TDMDH temperature
previously checked.
Drive motor drive circuit defect

Check the following and take necessary action, and the device as it is.
* Whether exhaust vent is blocked by paper etc.
* Whether operation was performed under overload conditions
Jp
Inspection 1: Harness check

1. Turn off the key switch and disconnect the battery plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN112, CN113 and CN114
connectors and check the harnesses for their continuities.
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN112, CN113 and CN114 connectors. Either
3. Connect the battery plug and turn on the key switch. 48V type: Excluding approx. 48V
4. Forcibly turn on the cooling fans, using Active Test. 36V type: Excluding approx. 36V
[ANL]ACTIVE TEST 2/3 Main controller defect
FAN OFF → ON
5. Check each connector for its voltage at the Fan ON.
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
48V type: Approx. 48V
Inspection:
The fans do
2. Connect the CN112 and disconnect the CN113 and CN114.
not rotate.
3. Turn on the key switch and connect the battery plug.
Cooling fan 1 defect
4. Forcibly turn on the cooling fans, using Active Test.
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
5. Operation check of cooling fan 1.
The fans rotate.
3
4A-24
Jp
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.
Inspection:
2. Connect the CN114 and disconnect the CN112 and CN113. The fans do
3. Turn on the key switch and connect the battery plug. not rotate.
FAN OFF → ON
The fans rotate.
Connector contact defect

Check each harness for its continuity.
Perform this check with the battery plug and the CN101, CN102, CN112, CN113 and CN114 connectors
disconnected, and visually check inside the connector and the caulked portion of its wire for defects.
Note:Perform this check with SST disconnected.
Portions to be checked Standard

CN101-3 to CN112-1 Continuity
CN101-4 to P1 Continuity
CN101-3 to CN102-1 No continuity
4A-25
z Error Code A0-2 (Pump motor power-circuit overheating abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2
Pump motor drive circuit

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

do not rotate.
[ANL]ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.

Turn on the key switch and check the value of TPMDH
Record the value of

TPMDH.
2
4A-26
The TPMDH temperature is 78°C or more for both
compared to the TPMDH temperature previously
checked.

The TPMDH temperature is
TPMDH:
78°C or more and it has not
Less than
lowered by 5°C or more compared
78°C
to the TPMDH temperature
previously checked.
Pump motor drive circuit defect

Jp

Harness defect
OK
Inspection:
1. Turn off the key switch and disconnect the battery plug. Either
2. Disconnect the CN112, CN113 and CN114 connectors. 48V type: Excluding approx. 48V
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
1. Turn off the key switch and disconnect the battery plug. The fans do
2. Connect the CN112 and disconnect the CN113 and CN114. not rotate.
FAN OFF → ON
The fans rotate.
3
4A-27
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
The fans do
not rotate.
FAN OFF → ON
The fans rotate.


4A-28
z Error Code A1-1 (Main controller high voltage)

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6 (19, VBMBSL)
Main
controller
CN102-4 (19, VBMBSL)
Probable cause:
(1) Battery defect (4) Battery plug defect
(2) MB contactor defect (5) Battery overvoltage
(3) F7 fuse open (6) The battery plug was disconnected during traveling.
(After the key switch is turned on and off,
A9-2 will be displayed.)
Error code A1-1
* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
A1-1
An error
occurs.
Turn off and back on the key switch. Inspection: Check of VBMBSL voltage
Check the VBMBSL voltage, using the Analyzer menu.
A1-1 No error occurs [ANL] I/O TEMP/VOLT 3/4
VBMBSL: Less than 65 V VBMBSL: More than 65 V
Inspection: Check of battery voltage

1. Turn off the key switch and disconnect the
battery plug.
2. Measure the voltage between both ends of the
battery plug with a circuit tester.
Inspection: Check of F7 fuse Approx. 48 V 65 V or more
battery plug. Main controller defect Replace the battery.
2. Remove the F7 fuse and measure the
resistance between its both ends with a circuit NG (∞ Ω)
F7 fuse open
tester.
OK (0 Ω)
Was the battery plug disconnected during YES Do not disconnect the battery plug during traveling except
traveling? in case of an emergency.
NO
Check the battery plug.

Check the battery electrolyte.
4A-29
z Error Code A1-2 (Drive motor drive circuit high voltage)

Related portion
MB
P1 F1 P4
Drive motor
drive circuit
Probable cause:
(2) MB contactor defect (5) Drive motor drive circuit defect
If CB-1 is also displayed, perform troubleshooting with priority given to CB-1.

If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.
Error code A1-2
A1-2
error
Turn the key switch from OFF to ON to check for occurs.
Inspection:
errors. (Check of voltage of drive motor drive circuit)
A1-2 error does not Check the value of VDMD, using the Analyzer menu.
occur [ANL] I/O TEMP/VOLT 4/4
VDMD: Less than 65 V VDMD: 65 V or more
Inspection 1: (Check the battery voltage.)

battery plug.
Inspection 2: (Check of F1 fuse) Less than 65 V 65 V or more
battery plug. Drive motor drive circuit defect Battery defect
F1 fuse open
tester.
OK (0 Ω)
NO
* Check the battery plug.

* Check the battery electrolyte.
4A-30
z Error Code A1-4 (Pump motor drive circuit high voltage)

Related portion
MB
P1 F1 P4
Pump motor
drive circuit
Probable cause:
(2) MB contactor defect (5) Pump motor drive circuit defect

If A1-1 is also displayed, perform troubleshooting with priority given to A1-1.
Error code A1-4
A1-4
error
Turn the key switch from OFF to ON to check for occurs.
Inspection:
errors. (Check of voltage of pump motor drive circuit)
A1-4 error does not Check the value of VDMD, using the Analyzer menu.
occur [ANL] I/O TEMP/VOLT 4/4
VDMD: Less than 65 V VDMD: 65 V or more
Inspection 1: (Check the battery voltage.)

battery plug.
Inspection 2: (Check of F1 fuse) Less than 65 V 65 V or more
battery plug. Pump motor drive circuit defect Battery defect
F1 fuse open
tester.
OK (0 Ω)
NO
* Check the battery plug.

* Check the battery electrolyte.
4A-31
z Error Code A2-1 (Main controller overheating abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
(1) The ambient temperature around the Main controller is high. (3) Temperature sensor defect (Main controller defect)
(2) Overheating (continuous overload operation)

Error code A2-1

Turn on the key switch and check the value of TMCB

Record the value of
TMCB.
The TMCB temperature is 79°C or more and it has
lowered by 5°C or more compared to the TMCB
temperature previously checked.
Turn on the key switch and check the value of TMCB

The TMCB temperature is 79°C or more and it has not lowered by 5°C
TMCB: Less than 79°C
or more compared to the TMCB temperature previously checked.
(The problem seems to be caused by continuous overload operation. So check how the vehicle was operated.)
4A-32
z Error Code A2-2 (Drive motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-1

do not rotate.
[ANL] ACTIVE TEST 2/3 1
FAN OFF → ON
The fans rotate.

Turn on the key switch and check the value of TDMDB

Record the value of
TDMDB.
2
4A-33
The TDMDB temperature is 73°C or more for both
compared to the TDMDB temperature previously
checked.

The TDMDB temperature is
TDMDB: 73°C or more and it has not
73°C to the TDMDB temperature
previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4A-34
Jp
Inspection:
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4A-35
z Error Code A2-3 (Pump motor drive circuit board overheating abnormality)
Related portion
CN101-3 (97,FAN+) CN112-1

Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
F5 CN101-4
P1
(41,VBBT) CN113-1
Main Cooling fan 2
CN102-2 (99,FNDC2) CN113-2
controller
CN114-1
Cooling fan 3
CN114-2

N1
Temperature-sensor
Probable cause:

loosen.
Error code A0-2

The fans
cooling fan compulsorily by using Active Test.
do not rotate.
1
FAN OFF → ON
The fans rotate.

[ANL] I/O TEMP/VOLT2/4

Record the value of
TDMDB.
2
4A-36
The TDMDB temperature is 73°C or more for both
compared to the TDMDB temperature previously
checked.

The TDMDB temperature is
TDMDB: 73°C or more and it has not
73°C to the TDMDB temperature
previously checked.

Jp

Harness defect
OK
Inspection:
FAN OFF → ON
CN112-1 ⇔ CN112-2
CN113-1 ⇔ CN113-2
CN114-1 ⇔ CN114-2
Both
Inspection:
FAN OFF → ON
The fans rotate.
3
4A-37
Jp
Inspection:
4. Forcibly turn on the cooling fans, using Active Test
FAN OFF → ON
The fans rotate.
Inspection:
FAN OFF → ON
The fans rotate.


4A-38
z Error Code A3-1 (Battery connection incorrect )

Related portion
F5
P1 CN130-4 CN104-1(41, B48V)
Main
controller
Battery
N1
Probable cause:
(1) Set voltage defect.
(2) The voltage in the B48V line after the F5 fuse is above the set voltage.
(3) Main controller defect.
Error code A3-1
Turn off the key switch and disconnect the battery plug.
A3-1 error does not occur. Plug contact defect or incorrect
Then, connect the battery plug correctly, turn back on
connection of battery
the key switch to check for errors.
A3-1 error occurs.
Inspection 1: Check of the set voltage

NG
Set voltage defect
[OPT] 36V YES/NO
OK
48V type: Less than 65V

Inspection: Check of battery voltage 36V type: Less than 48V
48V type: 65V or more

36V type: 48V or more
A
4A-39
48V type: Less than 65 V

Check of battery voltage 36V type: Less than 48 V
P1[+]←→N1[-]
48V type:65 V or more

36V type:48 V or more
Check the battery, and replace it with a regular battery if necessary.
Inspection 1: Check of set voltage
Check [OPT] 1.OPTIONSET 36V setting.

(See page 3-58)
Vehicle specification Standard

36V type YES
48V type NO
4A-40
z Error Code A5-1 (Seat switch GND short abnormality)

Related portion
CN103-6 (51, LS-) CN92-1
Main
Seat switch
controller
CN104-18 (67, SDM) CN92-2
Probable cause:
(1) Connector contact defect (3) Harness defect
(2) Seat switch defect (4) Main controller defect
Error code A5-1

plug, and then turn on the key switch without sitting in
the seat.

SDM: 0
Check the value of SDM, using the Analyzer menu.
SDM: 1

plug. SDM: 0
Seat switch defect
2. Disconnect the CN92 connector, connect the battery
plug, and turn on the key switch.
3. Check the value of SDM, using the Analyzer menu.
SDM: 1
Inspection 1:
1. Turn off the key switch and disconnect the battery NG
plug. Harness defect
2. Disconnect the CN103, CN104 and CN92 connectors
and check the harnesses for their continuities.
OK

4A-41
Inspection 1: Check each harness for its continuity.

Before this check, turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and
CN92 connectors, visually check inside each connector and the caulked portion of each wire for defects.

4A-42
z Error Code A6-3 (Tilt lever switch abnormality)

Related portion
Tilt lever switch

CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
controller CN103-6 (51,LS-) CN9-2
CN9-4
Probable cause:
(1) The battery plug is connected while the tilt lever is being operated.
(2) Connector contact defect
(3) Tilt lever switch defect
(4) Tilt lever switch installation portion defect.
(5) Tilt lever switch harness defect
(6) Main controller defect
The A6-3 error may occur if the battery plug is connected while the tilt lever is being operated.
Error code A6-3

A6-3 error does not
occur.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
plug, and turn on the key switch to see if an error
occurs.
A6-3 error occurs.

A6-3 error
1. Disconnect the CN9connector. does not occur. • Tilt lever switch defect
2. Connect the battery plug and turn on the key switch.
• Tilt lever switch installation portion defect.
Check the error code.
A6-3 error occurs.

NG
2. Disconnect the CN102 and CN103 connectors and
check the harnesses for their continuities.
OK

4A-43

Perform this check with the battery plug and the CN9, CN102and CN103 connectors disconnected, visually
check inside each connector and the caulked portion of each wire for defects.

4A-44
z Error Code A8-1, -2 (F1 and F6 fuse abnormality (Open))

Related portion
MB F1 P4
P3
Battery CN104-2 (44, VBMB)

CN130-5
F6
Drive motor Main

drive circuit controller
Pump motor drive

circuit
Probable cause:
(1) Cable or connector contact defect
(2) Improper installation of F1 or F6 fuse
(3) F1 or F6 fuse open
(4) F6 fuse holder defect
(5) Harness or cable defect
4A-45
Error code A8-1
* 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.
plug, and visually check the following terminals for
loose bolts: drive motor drive circuit positive terminal,
pump motor drive circuit positive terminal, contactor
panel P4 terminal, drive motor drive circuit negative
terminal, pump motor drive circuit negative terminal A8-1 error does not occur.
and contactor panel N1 terminal. Caution: Before Improper fastening of terminals
starting the job, measure the voltage between
positive terminal and GND; if there is any voltage,
insert a resistor at approx. 100Ω between + and GND
to discharge the capacitor.
2. Connect the battery plug and turn on the key switch
to check for errors.
A8-1 error occurs.
48V type:
All motor drive circuits
Inspection: Check of supply voltages to drive motor
Approx. 48 V
drive circuit and pump motor drive circuit. Drive motor drive circuit defect
1. Measure the voltage between the positive and Pump motor drive circuit defect
36V type:
negative terminals of each drive circuit.
All motor drive circuits
Approx. 36 V
0V
Inspection: Check of installation of F1 fuse

plug. A8-1 error does not occur.
F1 fuse installation defect
2. Visually check if the F1 fuse is installed properly.
3. Connect the power cable, connect the battery plug,
and then turn on the key switch.
A8-1 error occurs.
Inspection: Check of F1 fuse

1. Turn off the key switch and disconnect the battery NG (∞ Ω)
plug. F1 fuse open
2. Remove the F1 fuse and measure the resistance
between its both ends with a circuit tester.
OK (0 Ω)
Motor drive circuit defect (*)
Motor drive circuit defect (*)

Turn off the key switch and disconnect the battery plug, remove the cupper bar for connection to the motor drive
circuit positive terminal.
Measure the resistance between the positive and negative terminals of the motor drive circuit.
When using an analog tester
Positive terminal: [-] probe
Negative terminal: [+] probe
}
Motor drivers are defective if their resistance measured is 10 Ω or less.
4A-46
Error code A8-2
* If CB-1, CB-3 or CB-5 occurs, Perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
1. Before this check, disconnect the battery plug,
disconnect the CN130 connector, and visually check
inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE A8-2 error does not occur.
TROUBLESHOOTING.)
plug, and then turn on the key switch to check for
errors.
A8-2 error occurs.

A8-2 error occurs.
Inspection: Check of VBMBSL voltage

VBMBSL: Less than 25 V
Identify the causes of CB1 to CB5.
Check the value of VBMBSL, using the Analyzer menu.
VBMBSL: More than 25 V

1. Turn off the key switch and disconnect the battery NG (∞ Ω)
plug. F6 fuse open
OK (0 Ω)
Inspection: Check of F6 fuse holder

NG (∞ Ω)
plug.
F6 fuse holder defect
2. Disconnect the CN130 connector and measure the
terminals (CN130-5 and P3 terminal), on the F6 fuse
side with the F6 fuse installed in the fuse holder.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN104, CN130 connector and P3
terminal and check the harnesses for their
continuities.
OK

4A-47

Perform this check with the battery plug and the CN130, CN104 connectors and P3 terminal disconnected,
visually check inside each connector and the caulked portion of each wire for defects.
Note:Tighten the P3 terminal surely.

CN130-5 (fuse side) to P3 terminal Continuity
CN104-2 to N1 No continuity
CN130-5 (fuse side) to N1 No continuity
4A-48
z Error Code A9-2 (F7 fuse abnormality (Open))

Related portion
F7 P3
CN102-3 (19, VBMBSL) CN130-6
Main
controller
Probable cause:
(1) Connector contact defect (5) F7 fuse holder defect
(2) MB contactor defect (6) Harness defect
(3) F7 fuse installation defect (7) Main controller defect
(4) F7 fuse open
Error code A9-2
* If CB-1, CB-3 or CB-5 occurs, perform troubleshooting with priority given to CB-1, CB-3 or CB-5.
1. Before this check, disconnect the battery plug,
disconnect the CN130 connector, and visually check
inside the connector and the caulked portion of its
wire for defects. (Refer to BEFORE A9-2 error does not occur.
TROUBLESHOOTING.)
errors.
A9-2 error occurs.

A9-2 error occurs.
Inspection: Check of VBMB voltage

VBMB: Less than 25 V
Identify the causes of CB1 to CB5.
Check the value of VBMB, using the Analyzer menu.
VBMB: 25 V or more
A
4A-49

NG (∞ Ω)
plug. F7 fuse open
OK (0 Ω)
Inspection: Check of F7 fuse holder

plug. NG (∞ Ω)
terminals (CN130-6 and P3), on the F6 and F7 fuse
box side with the F7 fuse installed in the fuse box.
OK (0 Ω)

plug. NG
Harness defect
2. Disconnect the CN102, CN130 connectors and P3
terminal, and check the harnesses for their
continuities.
OK

Perform this check with the battery plug and the CN130, CN102 connectors and P3 terminal disconnected.

CN130-6 (fuse side) to P3 terminal Continuity
CN130-6 (fuse side) to N1 No continuity
4A-50
z Error Code AA-1 (Main controller temperature sensor abnormality)

Related portion
Main controller
Temperature sensor
TH101
Probable cause:
Error code AA-1
* If AA-1 is displayed, the Main controller is defective, so replace it.

4A-51
z Error Code AA-2 (Drive motor drive board temperature sensor abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-2
* If AA-2 is displayed, the drive motor drive circuit is defective, so replace it.
4A-52
z Error Code AA-4 (Pump motor drive board temperature sensor

abnormality)
Related portion
Temperature sensor
Probable cause:
Error code AA-4
* If AA-4 is displayed, the pump motor drive circuit is defective, so replace it.
4A-53
z Error Code AB-1 (Cooling fan drive circuit abnormality)

Related portion
CN101-3 (97,FAN+) CN112-1
Cooling fan 1
CN102-1 (98,FNDC1) CN112-2
CN113-1
Main
controller
Cooling fan 2
CN102-2 (99,FNDC1) CN113-2
CN114-1
Cooling fan 3
CN114-2
Probable cause:
(2) Cooling fan defect
(3) Harness defect
Error code AB-1

plug, disconnect the CN112, CN113 and CN114
connectors, and visually check inside the connector
2. Connect the CN112, CN113 and CN114 connectors, All cooling fans rotate.
connect the battery plug, turn on the key switch,
forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the
three cooling fans rotate.
[ANL]ACTIVE TEST 2/3
FAN OFF → ON
One of the cooling fans stops.
Inspection: Check of cooling fan 1

plug, disconnect the CN112, CN113 and CN114
connectors, and then connect the battery plug and
turn on the key switch. AB-1 error occurs.
B
2. Forcibly turn on the power to the cooling fans, using
Active Test in the Analyzer menu, and check the error
code after two minutes.
FAN OFF → ON
AB-1 error does not occurs.
A
4A-54

plug, connect the CN112 connector, disconnect the
CN113 and CN114 connectors, and then connect the
battery plug and turn on the key switch. Stop cooling fan 1.
Active Test in the Analyzer menu, and check if
cooling fan 1 rotates.
FAN OFF → ON Check the cooling fan 2
Cooling fan 1 rotates. sequentially.

CN112 and CN114 connectors, and then connect the Stop cooling fan 2.
battery plug and turn on the key switch. Cooling fan 2 defect
FAN OFF → ON Check the cooling fan 3
Cooling fan 2 rotates. sequentially.

CN112 and CN113 connectors, and then connect the
battery plug and turn on the key switch. Stop cooling fan 3.
FAN OFF → ON
Cooling fan 3 rotates.

4A-55

plug. NG
Harness defect
2. Disconnect the CN101, CN102, CN113 and CN114
continuities.
OK

Perform this check with the battery plug and the CN101, CN102, CN113 and CN114 connectors disconnected,

4A-56
z Error Code AC-1 (Semiconductor switch abnormality)

Related portion
MB
P2
P1 F5
CN104-1 (41,B48V)
CN101-4 (41,VBBT)
Main
N1 CN143-2
controller
Pump motor drive CN111-8 (KYSAT)
Pre-charge unit
circuit
CN143-1
Drive motor CN110-8 (KYSAT)
drive circuit
CN103-4 (42,KYSAT)
Probable cause:
(1) Drive motor drive circuit harness defect
(2) Pump motor drive circuit harness defect
(3) Drive motor drive circuit defect
(4) Pump motor drive circuit defect
(6) Pre-charge unit defect
4A-57
Error code AC-1
Inspection: Harness check

plug. NG
Harness defect
2. Disconnect the CN103, CN110, CN111 and CN143
continuities.
OK
Remove the F1 fuse.
Inspection: Check of Main controller

Connect the CN103 connector, connect the battery AC-1 error occurs.
errors.
AC-1 error does not occur.
Inspection: Check of pre-charge unit

Connect the CN103, CN143 connectors, connect the AC-1 error occurs.
Pre-charge unit defect
battery plug and then turn on the key switch to check
the errors.
Inspection: Check of pump motor drive circuit

Connect the CN103, CN143 and CN111 connectors, AC-1 error occurs.
connect the battery plug, and then turn on the key
switch to check for errors.
Inspection: Check of drive motor drive circuit

Disconnect CN111, connect CN110, connect the battery
errors.
Check pump motor drive circuit

Defect in sections where AC-1 error occurs during
drive motor drive circuit check

Perform this check with the battery plug and the CN103, CN111 and CN110 connectors disconnected, visually

4A-58
z Error Code AD-1, -2, -5, -6 (Main controller (CAN) communication

abnormality)
Related portion
CN143-1 CN143-2
CN103-4 (KYSAT) Pre- CN110-8
charge
CN103-11 (CAN1H) CN110-17
CN103-12 (CAN1L) CN110-10
Main CN103-3 (DGND) CN110-2 Drive motor

controller drive circuit
CN103-5 (N2,N2)
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
CN111-8
CN111-17
CN111-10
CN111-2 Pump motor

drive circuit
CN111-12
CN111-11
Probable cause:
(1) Wrong motor driver type
(3) Harness defect
(4) Motor drive circuit defect
* If AC-1 occurs, perform troubleshooting with priority given to AC-1.

4A-59
Error code AD-1, -2, -5, -6
Detach the battery plugs and check that an 8FBCU Motor driver other than
motor driver is installed. Especially if the motor driver 8FBCU installed
Wrong motor driver type
has just been replaced, check that a different model
motor driver hasn’t been installed.
8FBCU motor
driver installed
plug and visually check inside the CN110 and
CN111connectors and the caulked portions of their
wires for defects. (Refer to BEFORE AD-1, AD-2,
TROUBLESHOOTING.) AD-5, AD-6
2. Connect all the connectors, connect the battery plug, None of these error codes
and then turn on the key switch to check for errors. are displayed.
Especially if a motor drive circuit was replaced
immediately before the error occurred, check if the
connector is connected correctly.
AD-2 or AD-6 is displayed.
(*1: Record the error that has occurred.)
plug. NG
Harness defect
2. Disconnect the CN103, CN104, CN110, CN111 and
CN143 connectors and check the harnesses for their
continuities.
OK
Check of battery voltage

1. Turn off the key switch, and then connect the CN103,
CN104 and CN143 connectors. At that time, leave Less than 15 V
the CN110 and CN111 connectors disconnected.
2. Turn on the key switch and measure the voltage
between CN110-8 and N2.
15 V or more
Motor drive circuit defect
Error that was recorded in *1

AD-2: Drive motor drive circuit defect
AD-6: Pump motor drive circuit defect
4A-60

disconnected, visually check inside each connector and the caulked portion of each wire for defects.
Portions to be checked Standard Point

CN103-4 to CN143-1 Continuity AD-1, 2, 5, 6
CN143-2 to CN110-8 Continuity AD-1, 2
CN110-8 to CN110-17 No continuity AD-1, 2
4A-61
z Error Code AF-1, -2, -3, -4, -5, -6, -7, -8 (CPU error)
Related portion
Main controller
Probable cause:
Error code AF-1, -2, -3, -4, -5, -6, -7, -8
* If AF is displayed, the Main controller is defective, so replace it.

4A-62
z Error Code C0-2 (Drive motor power-circuit short)

Related portion
P7
U
Drive P8
V Drive motor
motor
drive
circuit P9
W
Probable cause:
(1) Drive motor defect (3) Drive motor drive circuit defect
(2) Motor cable defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

* Before starting troubleshooting, jack up the vehicle until the front tires leave the ground, and place square logs or
the like under the vehicle to support the vehicle.
1. Turn off the key switch and disconnect the battery plug and visually
C0-2 error
check the fastened or caulked portions of the motor cables for
does not occur.
defects. (Refer to BEFORE TROUBLESHOOTING.) Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and then turn on the
key switch to check for errors.
C0-2 error occurs.
Inspection: (Check of motor drive circuits)
1. Turn off the key switch and disconnect the battery plug. C0-2 error
2. Disconnect the three motor cables from the drive circuit and occurs.
insulate the terminals of the cables disconnected.
4. Check if the C0-2 error occurs.
C0-2 error does not occur.
Inspection 1: (Check of motor cables)
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
3. Check the motor cables for its continuity.
OK
Inspection: (Check of motor drive circuit) *1
1. Replace the drive motor drive circuit with the drive pump drive C0-2 error
circuit or the pump motor drive circuit. occurs.
Drive motor defect
3. Check the error code that is displayed. (Ignore the error codes 32-1,
32-3.)
E0-2 error
occurs.
(Note: Drive circuit that is originally the drive motor drive circuit before replacement)
4A-63
*1 If the error codes C0-2, C0-4 and E0-2 are displayed all at once, perform the following
checks without checking the motor drive circuits.
Inspection: (Motor check)

NG
1. Turn off the key switch and disconnect the battery plug. Drive motor defect
2. Check the Drive motor. (See page 5-5)
OK
Inspection 1: Continuity check of motor cables

Check the cables for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect the three motor cables, visually check each
terminal and the caulked portion 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
4A-64
z Error Code C1-1 (Drive motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code C1-1
* If C1-1 is displayed, the drive motor drive circuit is defective, so replace it.
4A-65
z Error Code C1-2 (Drive motor current sensor over current)

Related portion
P7
U
Drive
motor V P8 Drive
drive motor
circuit
P9
W
Probable cause:
(1) Drive motor defect
* If C8-1, 2 is also displayed, perform troubleshooting with priority given to C8-1, 2.

Turn the key switch from OFF to ON, to check for C0-2 error occurs.
Proceed to identify the cause of C0-2.
errors.
C0-2 No error occurs.

plug and visually check the fastened or caulked C1-2
portions of the motor cables for defects. (Refer to No error occurs.
Improper fastening of motor cable
BEFORE TROUBLESHOOTING.)
2. Connect the cables, connect the battery plug, and
then turn on the key switch to check for errors.
C1-2 error occurs.

plug. NG
Drive motor cable defect
2. Disconnect the motors cables from both the motor
and the motor drive circuit.
OK
Inspection 2: (Check motor drive circuit)*1

plug.
C1-2 error occurs.
2. Replace the drive motor drive circuit with the pump Drive motor defect
motor drive circuit.
3. Connect the battery plug, and turn on the key switch.
4. Check the error code. (Disregard 32-1 & 32-3)
E1-2 error occurs.

4A-66
*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
motor drive circuits.
Drive motor defect
plug.
2. Check the drive motor.
OK

Refer to BEFORE TROUBLESHOOTING.

4A-67
z Error Code C2-1 (Drive motor temperature sensor abnormality)

Related portion
CN110-23 (86, STDM+) CN50-2
Drive motor Drive motor

drive circuit Temperature
CN110-22 (87, STDM) CN50-1 sensor
Probable cause:
Overheating (continuous overload operation)

Error code C2-1

Turn on the key switch.
Record the value of TDM.
Turn off the key switch and leave the vehicle standing The TDM temperature is 110° C or more for both the
for a while (about 30 minutes). drive motor temperature sensor and it has lowered by 5°
C or more compared to the TDM temperature previously
checked.
TDM: The TDM temperature is 110° C The TDM (R) temperature is 110° C or
less or more and it has not lowered more and it has not lowered by 5° C or
than by 5° C or more compared to the more compared to the TDM
110° C TDM temperature previously temperature previously checked.
checked.
4A-68
z Error Code C2-2 (Drive motor temperature sensor abnormality)

Click here for updated troubleshooting information from MA12-004
Related portion
CN110-23 (86, STDM+) CN50-2
Drive motor Drive motor

CN110-22 (87, STDM) CN50-1 sensor
Probable cause:
(1) Connector contact defect (3) Drive motor temperature sensor harness defect
(2) Drive motor temperature sensor defect (4) Drive motor drive circuit defect
Error code C2-2

plug and visually check inside the CN50 connector
C2-2 error
and the caulked portions of their wires for defects.
does not occur.
(Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
errors.
C2-2 error occurs.
Inspection 1: (Check of temperature sensor unit)

NG
plug. Temperature sensor defect
2. Disconnect the CN50 connector and check the
temperature sensor as a single unit.
OK
Inspection 2: (Harness check)

NG
OK

4A-69
Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN50-2 and CN50-1)
Standard value: Approx. 245 Ω and 600 kΩ
* Resistance change (It is a standard as for the following value).
Resistance
Temperature
(CN50-2⇔CN50-1)
20° C Approx. 13 kΩ
80° C Approx. 1.75 kΩ
100° C Approx. 1 kΩ
Inspection 2: Harness continuity/shorts

Turn off the key switch and disconnect the battery plug, disconnect the CN110 and CN50 connectors, and

CN110-23 to CN50-2 Continuity *1
*1: Connect CN50-1 and CN50-2 on the harness side through 09232-13130-71 and check if there is continuity
between CN110-23 and CN110-22.
4A-70
z Error Code C3-1 (Drive motor power circuit temperature sensor

abnormality)
Related portion
Temperature sensor
TH101
Probable cause:
Error code C3-1
* If C3-1 is displayed, the drive motor is defective, so replace it.

4A-71
z Error Code C4-1, -2, -3, -4, -5, -6 (Accelerator sensor abnormality)
Related portion
CN101-27 (53, VRA1+) CN29-5
CN102-30 (52, VRA1) CN29-4
CN101-22 (50, VRA-) CN29-6

Main Accelerator
controller CN101-26 (55, VRA2+) CN29-1 sensor
CN102-32 (54, VRA2) CN29-3
CN101-32 (51, POT-) CN29-2
Probable cause:
(1) Connector contact defect (4) Main controller defect
(2) Accelerator sensor defect (5) Accelerator fully open/fully closed matching error
(3) Accelerator sensor harness defect
Error code C4-1, -2, -3, -4, -5

plug, and visually check if the accelerator senor is
installed correctly, and also check inside the CN29
connector and the caulked portion of its wire for C4-1, -2, -3, -4, -5
defects. (Refer to BEFORE TROUBLESHOOTING.) No error occurs. Improper installation of acceleration sensor
2. Connect the CN29 connector, connect the battery Connector contact defect
plug, turn on the key switch, and depress and release
the accelerator pedal to check if an error occurs. (No
error code must be displayed when the accelerator is
operated.)*
C4-1, -2, -3, -4 or -5
error occurs.
Inspection 1: Check of accelerator sensor
NG
plug. Accelerator sensor defect
resistance of the accelerator sensor.
OK

NG
OK
* No error code must be displayed when the accelerator is operated.

4A-72
Error code C4-6
After the completion of matching,

Inspection 3: Matching
C4-6 error does not occur.
Perform matching between the fully closed and fully Use the device as it is.
open states of the accelerator.

C4-6 error occurs.
Inspection 1: Check the accelerator sensor as a single unit.

Perform this check with the battery plug and CN29 disconnected and CN101 and CN102 connected.
(1) Measuring the resistance of the accelerator sensor
Standard (on sensor side):
CN29-5 to CN29-6 1.8 to 3.5 kΩ
CN29-1 to CN29-2 (Open state)
(2) Measuring the resistance of the accelerator sensor output circuit

Standard (on sensor side):
CN29-4 to CN29-6 The resistance must increase as the
CN29-3 to CN29-2 potentiometer is rotated.

Perform this check with the battery plug, CN29, CN101 and CN102 disconnected.
{ : Items to be checked
C4
1 2 3 4 5 6
CN101-27 to CN29-5 Continuity { − − − { − *1
CN102-30 to CN29-4 Continuity { − − − − − *1
CN101-22 to CN29-6 Continuity − − { − { − *3
CN101-26 to CN29-1 Continuity − { − − { − *2
CN102-32 to CN29-3 Continuity − { − − − − *2
CN101-32 to CN29-2 Continuity − − − { { − *4
CN29-5 to CN29-6 No continuity { − − − − −
CN29-5 to CN29-2 No continuity { − − − − −
CN29-4 to CN29-6 No continuity { − − − { −
CN29-4 to CN29-2 No continuity { − − − { −
CN29-4 to CN29-5 No continuity − − { − { −
CN29-4 to CN29-1 No continuity − − { − { −
CN29-1 to CN29-6 No continuity − { − − − −
CN29-1 to CN29-2 No continuity − { − − − −
CN29-3 to CN29-6 No continuity − { − − { −
CN29-3 to CN29-2 No continuity − { − − { −
CN29-3 to CN29-5 No continuity − − − { { −
CN29-3 to CN29-1 No continuity − − − { { −
CN102-30 to CN102-32 No continuity − − − − { −
4A-73
Inspection 3: Perform matching.

(See page 3-62)
sec04A.fm 74 ページ２０１１年２月１日火曜日午前１０時１２分
4A-74
z Error Code C8-1 (Drive motor speed (rotation) sensor open)

Related portion
CN110-6 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-4 (79, SSD1) CN155-2 CN51-1
Drive motor
drive circuit CN155-5 CN52-2
N1
- Rotation
sensor 2
CN110-3 (80, SSD2) CN155-3 CN52-1
Probable cause:
(1) Connector contact defect (4) Rotation sensor 2 defect
(2) Rotation sensor harness defect (5) Drive motor drive circuit defect
(3) Rotation sensor 1 defect
1. Turn off the key switch and disconnect the battery plug and visually check
inside the CN155 connector and the caulked portions of their wires for
No error occurs.
defects. (Refer to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN155 connector, connect the battery plug, and then turn on the
An error occurs.
Between
CN110 and CN155
2. Disconnect the CN110 and CN155 connectors and check the harnesses for
Harness defect
their continuities.
OK
Other than
2. Disconnect the CN155 connector.
9 to 13 V
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive
5. Measure the voltage between CN110-6 and N1 on the SST side.
9 to 13 V
Inspection: (Check of error code)
C8-1 error
occurs.
3. Connect CN155-3 to CN155-5, and CN155-1 to CN155-2 on the wire harness
side through 09232-13130-71 in order to short them.
5. Check the error code that appears.
C8-2 error occurs. Drive motor drive circuit defect
1
4A-75

2. Disconnect 09232-13130-71 from the CN155 connector (on the wire harness At least one of the
side). resistances is not
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive approx. 100 Ω. Drive motor drive
motor drive circuit. circuit defect
4. Measure the resistance between CN155-2 and N1 and that between CN155-3
and N1.
Both the resistances are approx. 100 Ω.
Between
CN155 and CN51
or between
2. Disconnect the CN155, CN51 and CN52 connectors and check the harnesses
CN155 and CN52
for their continuities.
Harness defect
OK
Inspection: (Check of rotation sensor)

2. Connect the CN155, CN51 and CN52 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-1.
4. Check the value of SSD, using the Analyzer menu.
SSD: 0.3 or less/0.4 to 1.9 SSD: 0.4 to 1.9/0.3 or less SSD: 0.3 or less/0.3 or less
Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Turn off the key switch and disconnect the battery plug, disconnect CN110 and CN155, visually check inside
each connector and the caulked portion of each wire for defects and then check the CN110 and CN155
harnesses.

*1: Connect CN155-2 to CN155-1 on the CN110 side through 09232-13130-71 and check if there is continuity
between CN110-6 to CN110-4.
4A-76

Turn off the key switch and disconnect the battery plug, disconnect CN155, CN51 and CN52, visually check
inside each connector and the caulked portion of each wire for defects and then check the CN155 and CN51
harnesses and the CN155 to CN52 harnesses. (Refer to BEFORE TROUBLESHOOTING.)

*3: Connect CN51-1 to CN51-2 on the harness side through 09232-13130-71 and check if there is continuity
4A-77
z Error Code C8-2 (Drive motor speed (rotation) sensor short)

Click here for updated troubleshooting information from MA12-004
Related portion
CN110-6 (78, SSD+) CN155-1 CN51-2

P41
Rotation
+
sensor 1
CN110-4 (79, SSD1) CN155-2 CN51-1
Drive motor
drive circuit CN155-5 CN52-2
N1
- Rotation
sensor 2
CN110-3 (80, SSD2) CN155-3 CN52-1
Probable cause:
(1) Connector contact defect (4) Rotation sensor 2 defect
(2) Rotation sensor harness defect (5) Drive motor drive circuit defect
(3) Rotation sensor 1 defect
1. Disconnect the battery plug and visually check inside the CN155 connector
and the caulked portions of their wires for defects. (Refer to BEFORE
No error occurs.
TROUBLESHOOTING.) Connector contact defect
2. Connect the CN155 connector, connect the battery plug, and then turn on the
An error occurs.
Between
CN110 and CN155
2. Disconnect the CN110 and CN155 connectors and check the harnesses for
Harness defect
their continuities.
OK
9 to 13 V
Other than
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive
9 to 13 V
Inspection: (Check of error code) C8-2 error
1. Turn off the key switch and disconnect the battery plug. occurs.
C8-1 error occurs. Drive motor drive circuit defect
1
4A-78

2. Disconnect 09232-13130-71 from the CN155 connector (on the wire harness At least one of the
side). resistances
3. Insert 09240-13241-71 in the CN110 connector and connect it to the drive is not approx. 100 Ω. Drive motor drive
motor drive circuit. circuit defect
4. Measure the resistance between CN155-2 and N1 and that between CN155-3
and N1.
Both the resistances are approx. 100 Ω.
Between
CN155 and CN51
or between
2. Disconnect the CN155, CN51 and CN52 connectors and check the harnesses
CN155 and CN52
for their continuities.
Harness defect
OK
Inspection: (Check of rotation sensor)

2. Connect the CN155, CN51 and CN52 connectors.
3. Connect the battery plug and turn on the key switch to display the error code
C8-2.
4. Check the value of SSD, using the Analyzer menu.
SSD: 2.0 or more/0.4 to 1.9 SSD: 0.4 to 1.9/2.0 or more SSD: 2.0 or more/2.0 or more
Rotation sensor 1 Rotation sensor 2 Rotation sensor 1 and 2

defect defect defect

Turn off the key switch and disconnect the battery plug, disconnect CN110 and CN155, visually check inside
each connector and the caulked portion of each wire for defects and then check the CN110 and CN155
harnesses.

4A-79

Turn off the key switch and disconnect the battery plug, disconnect CN155, CN51 and CN52, visually check
inside each connector and the caulked portion of each wire for defects and then check the CN155 and CN51
harnesses and the CN155 to CN52 harnesses. (Refer to BEFORE TROUBLESHOOTING.)

4A-80
z Error Code CB-1,-2,-3,-4,-5 (MB contactor abnormality)

Related portion
MB
P1 P3 F1 P4
F7
CN130-6 CN102-3 (19, VBMBSL)
F6
CN130-5 CN104-2 (44, VBMB)
Main
F5 controller
CN130-4 CN104-1 (41, B48V)
CN101-4 (41, VBBT)
CN130-1 CN104-9 (2, CBAT-)

MB
contactor CN130-2 CN104-3 (1, CBAT+)
Probable cause:
(2) MB contactor defect
(3) Harness defect
(4) Fuse defect
4A-81
Error code CB-1
CB-1
Disconnect and then connect the battery plug again, and turn on the No error occurs
Check the state of the battery.
key switch to see if an error occurs.
CB-1
An error occurs.
No actuation
Check if the MB contactor actuation sound is heard when the key sound
Identify the cause of CB-3.
switch is turned on.
Actuation sound
Inspection: Check of F6, F7 fuse

1. Turn off the key switch and disconnect the battery plug. ∞Ω F6 fuse defect
2. Remove the F6 and F7 fuses and measure the resistance between F7 fuse defect
their both ends with a circuit tester.
0Ω
Inspection: Check of F6 and F7 fuse holders

1. Install the F6 and F7 fuses and disconnect the CN130 connector
∞Ω F6 fuse holder defect
from the fuse holder.
2. Measure the resistance between P3 and CN130-5 and that
between P3 and CN130-6 (fuse holder side).
0Ω
Inspection 1: Harness check NG

Harness defect
Disconnect the CN130, CN102, CN104 connectors and P3 terminal.
OK
Inspection: Check of voltage

1. Connect all the connectors, connect the battery plug, and then turn
on the key switch.
2. Measure the voltage between both ends on the contact side of the
contactor. (Refer to the figure)
30 V or more
MB contactor defect
P1
P3
Less than 30 V

4A-82
Error code CB-2
If the error codes AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, EC-1, -2, -3 and -4 are displayed all at once, perform
troubleshooting with priority given to AD-5 and -6, E1-1 and -2, E0-2, E8-1 and -2, and EC-1, -2, -3 and -4.
If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
disconnected, so measure the voltage between P4 and N1 and start operation after it has lowered below 3 V.
Use the device as it is.

Disconnect and then connect the battery plug again, turn on the key CB-2
(There are cases where the
switch and wait for 5 seconds. After that, turn off the key switch and No error occurs.
residual charge cannot be
wait for 5 seconds. Then back on the key switch to see if an error
discharged for reasons of
occurs.
another error.)
CB-2 error occurs.
The contactor
opens.
Check if the MB contactor opens when the key switch is turned off. A
The contactor does not open.
Inspection: Check of MB contactor

The contactor does
not open.
2. Measure the voltage between P4 and N1 of the contactor to see MB contactor defect
that it is 3 V or less.
3. Visually check the conditions of the contacts of the MB contactor.
The contactor opens.
Identify the cause of CB-3.
Inspection: Check of voltage

1. Disconnect and then connect the battery plug again, turn on the
Less than 15 V
key switch. Main controller defect
2. Turn off the key switch and 5 seconds or more after that, measure
the voltage between P4 and N1 of the contactor.
15 V or more

4A-83
Error code CB-3, -5
1. Disconnect the battery plug and visually check inside the CN130
CB-3, -5
connector and the caulked portions of their wires for defects. (Refer
No error occurs.
to BEFORE TROUBLESHOOTING.) Connector contact defect
2. Connect the CN130 connector, connect the battery plug, and then
turn on the key switch to check for errors.
CB-3 or CB-5
An error occurs.
Inspection: Check of MB contactor coil
NG
2. Disconnect the CN130 connector and measure the resistance of MB contactor defect
the MB contactor coil (resistance between CN130-1 and CN130-2).
Standard value: Approx. 28 Ω: 20°C
OK

NG
Disconnect the CN104 and CN130 connectors and check the Harness defect
harnesses for their continuities.
OK

4A-84
Error code CB-4
Disconnect the battery plug and visually check inside the CN130
connector and the caulked portions of their wires for defects. (Refer to
Inspection: Check of MB contactor coil

2. Disconnect the CN130 connector and measure the resistance of
the MB contactor coil (resistance between CN130-1 and CN130-2).
Standard value: Approx. 28 Ω: 20°C

Disconnect the CN104 and CN130 connectors and check the
Defective portion: Portion where a problem was found during a check of the MB contactor coil or harness.

Perform this check with the battery plug and the CN130, CN102, CN104 connectors and P3 terminal

CN130-6 to CN102-3 Continuity CB-1
CN130-6 (fuse side) to P3 terminal Continuity CB-1
CN130-5 (fuse side) to P3 terminal Continuity CB-1
CN130-5 (fuse side) to N1 No continuity CB-1
CN130-5 to N1 No continuity CB-1
CN130-6 (fuse side) to N1 No continuity CB-1

Before this check, disconnect the battery plug, disconnect the CN104 and CN130 connectors,

CN130-1 to CN136-2 No continuity CB-4, 5
CN130-1 to P1 No continuity CB-4
CN130-1 to P4 No continuity CB-4
4A-85
z Error Code CB-6 (MB contactor panel overheating abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
Temperature- CN131-2 CN101-18 (308,STCB) Main
sensor controller
Probable cause:
If CB-2, 4 or 5 is also displayed, perform troubleshooting with priority given to CB-2, 4 or 5.

Take adequate care when testing, as the parts may be hot.
4A-86
Error code CB-6

Record the value of TCMB
The TCMB temperature is 130°C or more
and it has lowered by 5°C or more
compared to the TCMB temperature
previously checked.

The TCMB temperature is 130°C or more and it has not
TCMB:
lowered by 5°C or more compared to the TCMB temperature
less than130°C
previously checked.
Proceed to identify the cause of CB-7
Turn off the key switch and disconnect the battery plug,
and check the terminals for loose bolts in the contactor
panel (See the “CONTACTOR PANEL ASSY
:REASSEMBLY”). NG Terminal bolt tightening defect.
Disconnect the CN131 connector, and visually check Connector contact defect
inside the connector and the caulked portion of its wire
for defects.
OK
Check the following and take necessary action, and the

device as it is.
(The problem seems to be caused by continuous
overload operation. So check how the vehicle was
operated.)
4A-87
z Error Code CB-7 (MB contacter Temperature-sensor abnormality)

Related portion
CN131-1 CN103-7 (307,STCB+)

MB contactor
Temperature- CN131-2 CN101-18 (308,STCB) Main
sensor controller
Probable cause:
(2) MB contacter Temperature-sensor defect
(3) MB contacter Temperature-sensor harness defect
Error code CB-7

plug, disconnect the CN131connector, and visually
check inside the connector and the caulked portion of CB-7 error does
its wire for defects. not occur
errors.
E0-2 error does not occur
Inspection 1:(Check of temperature-sensor as a single
unit)
Temperature-sensor defect
plug.
2. Disconnect the CN131and check the temperature-
sensor as a single unit.
E1-2 error occur
plug. NG
Harness defect
2. Disconnect the CN101, CN103 and CN131
continuities.
OK
Inspection 1: Check of temperature-sensor as a single unit

Check item
Temperature-sensor resistance (on sensor side:CN131-2 and CN131-1)
Standard value: Approx. 12kΩ: at 20°C (5kΩ ~ 28kΩ at 0 to 40°C)
4A-88

Turn off the key switch and disconnect the battery plug, disconnect the CN101, CN103 and CN131 connectors,
and visually check inside each connector and the caulked portion of each wire for defects.

CN131-1 ~ CN103-7 Continuity *1
CN131-2 ~ CN101-18 Continuity *1
CN103-7 ~ CN101-18 No continuity
*1: Connect CN103-71 and CN101-18 on the harness side through 09232-13130-71 and check if there is
continuity between CN131-1 and CN131-2.
4A-89
z Error Code CC-1, -4, -6 (CPU error)

Click here for updated troubleshooting information from SIB MA12-004
Related portion
Drive motor
drive circuit
Probable cause:
Error code CC-1, -4, -6
* If CC is displayed, the drive motor drive circuit is defective, so replace it.

4A-90
z Error Code E0-2 (Pump motor drive power circuit short)

Related portion
P14
P4 U
+
Pump
motor P15
Pump
V
drive motor
circuit
N2 P16
- W
Probable cause:
(1) Pump motor drive circuit defect (3) Pump motor drive circuit defect
* If CB-3 is also displayed, perform troubleshooting with priority given to CB-3.

* If this error occurs, electric charge remains in the motor drive circuit for a while after the battery plug is
1. Disconnect the battery plug and visually check the fastened or

E0-2 error
caulked portions of the motor cables for defects. (Refer to BEFORE
does not occur.
TROUBLESHOOTING.) Improper fastening of motor cable
2. Connect the cables, connect the battery plug, and then turn on the
E0-2 error occurs.
1. Turn off the key switch and disconnect the battery plug. E0-2 error
2. Disconnect the three motor cables from the drive circuit and occurs.
insulate the terminals of the cables disconnected.
4. Check if the E0-2 error occurs.
E0-2 error does not occur.
NG
2. Disconnect the motors cables from both the motor and the motor Motor cable defect
drive circuit.
OK
Inspection: (Check of motor drive circuit) *1
E0-2 error
2. Replace the pump motor drive circuit with the drive motor drive
occurs.
circuit. Pump motor defect
4. Check the error code that is displayed. (Ignore the error codes 32-1,
32-2 and 32-3.)
C0-2 error
occurs.
4A-91
*1 If the error codes C0-2 and E0-2 are displayed all at once, perform the following checks without checking the motor drive
circuits.

NG
1. Turn off the key switch and disconnect the battery plug. Pump motor drive circuit defect
2. Check the pump motor. (See page 5-14)
OK


4A-92
z Error Code E1-1 (Pump motor current sensor neutral voltage error)
Related portion
Current sensor
Probable cause:
Error code E1-1
* If E1-1 is displayed, the pump motor drive circuit is defective, so replace it.
4A-93
z Error Code E1-2 (Pump motor current sensor over current)

Related portion
P4 P14
+ U
Pump
motor P15 Pump
V
N2 drive motor
- circuit P16
W
Probable cause:
(1) Pump motor defect
(2) Pump motor cable defect
disconnected, so measure the voltage between P4 and N2 and start operation after it has lowered below
3V.
Error code E1-2
Turn the key switch from OFF to ON to check for E0-2 E0-2 error occur
Proceed to identify the cause of E0-2
error.
E0-2 error does not occur
Turn off the key switch and disconnect the battery plug
and visually check the fastened or caulked portions of
E1-2 error
the motor cables for defects. (Refer to BEFORE
does not occur
TROUBLESHOOTING) Improper fastening of motor cable
After installing the cables, connect the battery plug and
turn the key switch ON. Sit in the seat and perform a
load handling operation (lift or tilt), checking for errors.
E1-2 error occur

plug. NG
Motor cable defect
2. Disconnect the motor cables from both the motor and
3. Check motor cables for its continuity.
OK
1
4A-94
Inspection: (Check of motor drive circuit)*1

1. Replace the pump motor drive circuit with the drive
motor drive circuit. E1-2 error occur
Pump motor defect
3. Check the error code that is displayed. (Ignore the
error codes 32-1 and 32-2)
C1-2 error occur

(Note: Drive circuit that is originally the drive motor drive
circuit before replacement)
*1 If the error codes C1-2 and E1-2 are displayed all at once, perform the following checks without checking the
Pump motor defect
plug.
2. Check the pump motor. (See page 5-14)
OK

(Refer to BEFORE TROUBLESHOOTING)

4A-95
z Error Code E2-1 (Pump motor temperature sensor increase abnormality)

Related portion
CN111-23 (88, STPM+) CN41-2
Pump motor Pump motor

CN111-22 (89, STPM) CN41-1 sensor
Probable cause:

Error code E2-1

Turn on the key switch and check the value of TPM
Record the value of TPM.
The TPM temperature is 101°C or more and it has
lowered by 5°C or more compared to the TPM
Turn on the key switch and check the value of TPM

TPM: The TPM temperature is 101°C or
Less than more and it has not lowered by 5°C or
101°C more compared to the TPM
Proceed to identify the cause of E2-2.
4A-96
z Error Code E2-2 (Pump motor temperature sensor abnormality)

Click here for updated troubleshooting information from SIB MA12-004
Related portion
CN111-23 (88, STPM+) CN41-2
Pump motor Pump motor

CN111-22 (89, STPM) CN41-1 sensor
Probable cause:
(2) Pump motor temperature sensor defect
(3) Pump motor temperature sensor harness defect
Error code E2-2

plug and visually check inside the CN41 connector
E2-2 error
and the caulked portions of their wires for defects.
does not occurs.
(Refer to BEFORE TROUBLESHOOTING) Connector contact defect
errors.
E2-2 error occurs.
Inspection 1: (Check of temperature sensor unit)

NG
plug. Temperature sensor defect
2. Disconnect the CN41 connector and check the
temperature sensor as a single unit.
OK

NG
OK

4A-97
Inspection 1: Check of temperature sensor as a single unit

Check item
Temperature sensor resistance (on sensor side: CN41-2 and CN41-1)
Standard value Approx. 245 Ω and 600 kΩ
* Resistance changes (It is a standard as for the following value).
Resistance
Temperature
(CN41-2⇔CN41-1)
20°C Approx. 13 kΩ
80°C Approx. 1.75 kΩ
100°C Approx. 1 kΩ

Turn off the key switch and disconnect the battery plug and the CN111 and CN41 connectors and with SST

4A-98
z Error Code E3-1 (Pump motor drive power circuit temperature sensor
abnormality)
Related portion
Pump motor
drive circuit
Temperature sensor
Probable cause:
Error code E3-1
* If E3-1 is displayed, the pump motor drive circuit is defective, so replace it.
4A-99
z Error Code E8-1 (Pump motor speed (rotation) sensor open)

Related portion
P4 CN111-6 (81, SSP+) CN42-2

+
Pump motor Rotation
drive circuit sensor
N2 CN111-4 (82, SSP1) CN42-1
-
Probable cause:
(1) Connector contact defect (3) Rotation sensor defect
(2) Rotation sensor harness defect (4) Pump motor drive circuit defect
1. Disconnect the battery plug and visually check inside the CN42 connector and the
No error
caulked portions of their wires for defects. (Refer to BEFORE
occurs.
TROUBLESHOOTING) Connector contact defect
2. Connect the CN42 connector, connect the battery plug, and then turn on the key
An error occurs.
Harness defect
2. Disconnect the CN111 and CN42 connectors and check the harnesses for their
continuities.
OK
2. Disconnect the CN42 connector. Other than
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor 9 to 13 V Pump motor drive circuit
drive circuit. defect
9 to 13 V
2. Disconnect the CN42 connector. occur. Pump motor drive circuit
3. Using SST 09232-13130-71, connect the CN42-1 and CN42-2. defect
E8-2 error occurs.
Inspection: (Check of motor drive circuits) Other than
1. Turn off the key switch and disconnect the battery plug. Approx.
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). 100 Ω Pump motor drive circuit
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor defect
drive circuit.
4. Measure the resistance between CN111-4 and N2 on the SST side.
Approx. 100 Ω
Rotation sensor defect
4A-100

Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN42, and visually check inside
each connector and the caulked portion of each wire for defects and then check each harness.

sec04A.fm 101 ページ２０１１年１月２６日水曜日午後３時５３分
4A-101
z Error Code E8-2 (Pump motor speed (rotation) sensor short)

Click here for troubleshooting information from SIB MA12-004
Related portion
P4 CN111-6 (81, SSP+) CN42-2

+
Pump motor Rotation
drive circuit sensor
N2 CN111-4 (82, SSP1) CN42-1
-
Probable cause:
(1) Connector contact defect (3) Rotation sensor defect
(2) Rotation sensor harness defect (4) Pump motor drive circuit defect
1. Turn off the key switch and disconnect the battery plug and visually check inside
No error
the CN42 connector and the caulked portions of their wires for defects. (Refer to
occurs.
BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN42 connector, connect the battery plug, and then turn on the key
An error occurs.
Harness defect
2. Disconnect the CN111 and CN42 connectors and check the harnesses for their
continuities.
OK
2. Disconnect the CN42 connector. Other than
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor 9 to 13 V Pump motor drive circuit
drive circuit. defect
9 to 13 V
2. Disconnect the CN42 connector. occurs. Pump motor drive circuit
3. Using SST 09232-13130-71, connect the CN42-1 and CN42-2. defect
E8-1 error occurs.
Inspection: (Check of motor drive circuits) Approx.
1. Turn off the key switch and disconnect the battery plug. 100 Ω
2. Disconnect 09232-13130-71 from the CN42 connector (on the wire harness side). Other than Pump motor drive circuit
3. Insert 09240-13241-71 in the CN111 connector and connect it to the pump motor defect
drive circuit.
4. Measure the resistance between CN111-4 and N2 on the SST side.
Approx. 100 Ω
Rotation sensor defect
4A-102

Turn off the key switch and disconnect the battery plug, disconnect CN111 and CN42, and visually check inside
each connector and the caulked portion of each wire for defects and then check each harness.

4A-103
z Error Code EC-1, -4, -6 (CPU error)

Related portion
Click here for troubleshooting information, in SIB MA12-004
Pump motor drive

circuit
Probable cause:
Error code EC-1, -4, -6
* If EC is displayed, the pump motor drive circuit is defective, so replace it.

4A-104
z Error Code EE-1, -2 (Display → Main controller communication error)

Related portion
CN103-3 (14, DGND) CN27-4
CN103-14 (16, D7V) CN27-5

Main
Display
controller CN103-11 (145, CAN1H) CN27-16
CN103-12 (146, CAN1L) CN27-15
Probable cause:
(2) Harness defect
(3) Display defect
Error code EE-1, 2
* Identify the cause of F1-1 or F1-2.

4A-105
z Error Code F1-1, -2 (Main controller → Display communication error)

Related portion
CN103-11 (145,CAN1H) CN27-16 (145, CAN1H)
Main
Multi-display
controller
CN103-12 (146,CAN1L) CN27-15 (146, CAN1L)
Probable cause:
(1) Connector contact defect (3) Main controller defect
(2) Harness defect (4) Display defect
Error code F1-1, F1-2
Turn off the key switch and disconnect the battery plug and visually
check inside CN103 to CN27 connectors and the caulked portion of
each wire for defects.
No error occurs.
(Refer to BEFORE TROUBLESHOOTING) Connector contact defect
Connect the connector, connect the battery plug and turn on the key
switch, and if an error occurs.
An error occurs. If the version of at least one motor drive circuit is

displayed
Inspection 1:
Check the version information on the I/O monitor.
If the version of a motor drive
circuit is not displayed:
Inspection 2:
NG Harness (between CN103 and
CN27) defect
OK
Display defect (*1)
*1 If the symptom persists after replacement of the display, there should be any other problems, so replace the Main controller.
Inspection 2: Check harnesses for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN27 and CN103 connectors and check
the harnesses for their continuities.

CN103-11 to CN27-16 Continuity (Approx. 0 Ω)
CN103-12 to CN27-15 Continuity (Approx. 0 Ω)
CN27-15 to CN27-16 No continuity (Not 0 Ω)
4A-106
z Error Code F4-1,-2,-3,-4,-5,-6,-7,-8 (Display CPU error)

Related portion
Multi-display
Probable cause:
Display defect
Error code F4-1, -2, -3, -4, -5, -6, -7, -8
* If F4 is displayed, the display is defective, so replace it.

4A-107
z Error Code FF-1, -2 (Power supply circuit over current)

Related portion
CN103-14 (16,D7V) CN27-5
DISPLAY
CN103-3 (14, DGND) CN27-4
Main
controller CN103-13 (311, SSTR+) CN3-1
Steering-wheel
angle sensor
CN103-6 (51, LS-) CN3-2
Probable cause:
(2) Display or steering angle sensor defect
(3) Harness defect
Error code FF-1
1. Turn off the key switch and disconnect the battery plug, disconnect
the CN27 connector and visually check inside the connector and the A screen is displayed.
caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
2. Connect the connector, connect the battery plug, and then turn on
the key switch to see if a screen is displayed.
No screen is displayed.
Inspection: Check of display

2. Disconnect the CN27. Approx. 7 V
3. Connect the battery plug and turn on the key switch. Display defect
4. Measurement of voltage
Measure the voltage between the CN27-5 and CN27-4 connectors
on the harness side.
0V

NG
Harness defect
2. Disconnect the CN103 connector and check the harnesses for their
continuities.
OK

4A-108

Disconnect the battery plug, disconnect the CN27 and CN103 connectors, and visually check inside each
connector and the caulked portion of each wire for defects.

Error code FF-2
1. Disconnect the battery plug, disconnect the CN3 connector, and

visually check inside the connector and the caulked portion of its FF-2 error does not occur.
wire for defects. (Refer to BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN3 connector, connect the battery plug, and then turn
on the key switch to check for errors.
FF-2 error occurs.
Inspection: Check of steering angle sensor

2. Disconnect the CN3. Approx. 15 V
3. Connect the battery plug and turn on the key switch. Steering angle sensor defect
4. Measurement of voltage
Measure the voltage between the CN3-1 and CN3-2 connectors on
the harness side.
0V

NG
Harness defect
2. Disconnect the CN103 connector and check the harnesses for their
continuities.
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN3 and CN103 connectors, and visually

4A-109
z Error code 31-1 Declining of activating voltage for Drive motor drive circuit
Click here for SIB explaining
Related portion this fault code
MB
P1 P3 P4 +
Drive motor
F1 CN110-8 drive circuit
F6
CN143-2
N1 RCP
Pre-charge CN103-4 (42, KYSAT)
CN143-5 unit CN143-1
Main
CN104-2 (44, VBMB) controller
CN104-1 (41, B48V)

F5
CN101-4 (41, VBBT)
Probable cause:
(1) Battery defect
(2) RCP resistance defect
(3) F1 fuse defect
(4) F5 fuse defect
(5) F6 fuse defect
(9) Wire-harness defect
4A-110
Error code 31-1
Disconnect the battery plug, connector CN143, CN103

and CN110 and visually check inside the connector and
the caulked portion of its wire for defect (Refer to No error
BEFORE TROUBLESHOOTING). occurs
And visually check the Drive motor drive circuit plus,
P1, P3, P4 whether the terminal is loosened or not.
Connect the connectors and battery plug, then turn on
the key switch to check for error.
error occurs
1.Turn off the key switch and disconnect the battery
NG
plug.
1
2. Disconnect the CN103, CN104 and the plus terminal
of Drive motor drive circuit and check the harness.
OK
Inspection: (Check of Input voltage for Motor drive
circuit)
plug.
More than 20 V
2. Connect the CN103, CN104 and the plus terminal of Drive motor driver circuit defect
Drive motor drive circuit.
3. Connect battery plug and turn on the key switch.
4. Measure the voltage between the plus terminal of
Drive motor driver and N1.
Less than 20 V
Inspection: Voltage check of B48 V
plug. More than 20 V
2. Disconnect the CN104.
4. Measure the voltage between the CN104-1and N1.
Less than 20 V
Inspection: F5 fuse
∞Ω
plug. F5 fuse defect
0Ω
Inspection: Check battery voltage More than 20 V Harness defect between the P1 and
P1[+] ← → N1[-] CN104-1
Less than 20 V
Battery defect
4A-111

NG
plug. Harness defect between CN103 and CN143
2. Disconnnect the CN103, CN143 and check the
harness.
OK
Inspection: F1 fuse
∞Ω
0Ω

plug. No continuity Harness defect between P3 and plus
2. Connect the CN103, CN104 and install the F1 fuse. terminal of the Motor driver
3. Check the continuity between the Plus terminal of
Drive motor driver and P3.
Continuity
Inspection 3: (Pre-charge unit)

NG
plug. Pre-charge unit defect
2. Disconnect the CN143 and check the Pre-charge
unit.
OK
Inspection: F6 fuse check

∞Ω
0Ω
RCP defect, Harness defect between

CN143-5 and P3.
4A-112

Check each harness for its continuity
Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of Drive
motor driver, and visually check inside each connector and caulked portion. Then check the continuity between
the CN103 and plus terminal of Drive motor driver.
After inspection, plus terminal of Drive motor driver should be surely tightened.

CN103-4[+] to Plus terminal of Motor driver[-] ∞Ω
CN103-4[-] to Plus terminal of motor driver [+] Approx. 70 Ω (10 Ω range)
※ [+], [-]: In case of analogue tester

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside
each connector and caulked portion. Then check the harness between CN103 and CN143.

Inspection 3: Pre-charge unit check

Check the Pre-charge unit
Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each
connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity.

CN143-1[+] to CN143-5[-] ∞Ω
CN143-1[-] to CN143-5[+] Approx. 50 Ω (10 Ω range)
4A-113
z Error code 31-3 Declining of activating voltage for Pump motor drive circuit
Click here for SIB explaining Pre-
Related portion Charge Circuit
MB
P1 P3 P4 +
Pump motor
F1 drive circuit
CN110-8
F6
CN143-2
N1
RCP
Pre-charge CN103-4 (42, KYSAT)
CN143-5 unit CN143-1
Main
CN104-2 (44, VBMB) controller
CN104-1 (41, B48V)

F5
CN101-4 (41, VBBT)
Probable cause:
(1) Battery defect
(2) RCP resistance defect
(3) F1 fuse defect
(4) F5 fuse defect
(5) F6 fuse defect
(9) Wire-harness defect
4A-114
Error code 31-3
Disconnect the battery plug, connector CN143, CN103

and CN111 and visually check inside the connector and
the caulked portion of its wire for defect (Refer to
No error occurs
BEFORE TROUBLESHOOTING).
And visually check the Pump motor drive circuit plus,
P1, P3, P4 whether the terminal is loosened or not.
Connect the connectors and battery plug, then turn on
the key switch to check for error.
error occurs
NG
plug.
1
2. Disconnect the CN103, CN104 and the plus terminal
of Pump motor drive circuit and check the harness.
OK
Inspection: (Check of Input voltage for Motor drive
circuit)
plug.
More than 20 V
2. Connect the CN103, CN104 and the plus terminal of Pump motor driver circuit defect
Pump motor drive circuit.
3. Connect battery plug and turn on the key switch.
4. Measure the voltage between the plus terminal of
Pump motor driver and N1.
Less than 20 V
Inspection: Voltage check of B48 V
plug. More than 20 V
2. Disconnect the CN104.
4. Measure the voltage between the CN104-1and N1.
Less than 20 V
Inspection: F5 fuse
∞Ω
0Ω
Inspection: Check battery voltage More than 20 V Harness defect between the P1 and
P1[+] ← → N1[-] CN104-1
Less than 20 V
Battery defect
4A-115

NG
plug. Harness defect between CN103 and CN143
2. Disconnnect the CN103, CN143 and check the
harness.
OK
Inspection: F1 fuse
∞Ω
0Ω

plug. No continuity Harness defect between P3 and plus
2. Connect the CN103, CN104 and install the F1 fuse. terminal of the Motor driver
3. Check the continuity between the Plus terminal of
Pump motor driver and P3.
Continuity
Inspection 3: (Pre-charge unit)

NG
plug. Pre-charge unit defect
2. Disconnect the CN143 and check the Pre-charge
unit.
OK
Inspection: F6 fuse check

∞Ω
0Ω
RCP defect, Harness defect between

CN143-5 and P3.
4A-116

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104 and plus terminal of
Pump motor driver, and visually check inside each connector and caulked portion. Then check the continuity
between the CN103 and plus terminal of Pump motor driver.
After inspection, plus terminal of Pump motor driver should be surely tightened.

CN103-4[+] to Plus terminal of motor driver[-] ∞Ω
CN103-4[-] to Plus terminal of motor driver [+] Approx. 70 Ω (10 Ω range)

Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN143, and visually check inside
each connector and caulked portion. Then check the harness between CN103 and CN143.

Inspection 3: Pre-charge unit check

Check the Pre-charge unit
Turn off the key switch and disconnect the battery plug, disconnect the CN143, and visually check inside each
connector and caulked portion. Then check the harness between CN143-1 and CN143-5 its continuity.

CN143-1[+] to CN143-5[-] ∞Ω
CN143-1[-] to CN143-5[+] Approx. 50 Ω (10 Ω range)
4A-117
z Error Code 32-1 (Drive motor drive circuit EEPROM abnormality)

Related portion
Probable cause:
(2) Drive motor drive circuit harness defect
*: When a new motor drive circuit is installed on the vehicle, the 32-1 error always occurs (which does not mean that
the new drive circuit is defective).
Turn off and then back on the key switch.
If AD-5 or 6 is also displayed, perform troubleshooting with priority given to AD-5 or 6.
Error code 32-1

32-1
visually check inside the connector and the caulked portion of its
error does not occur. Drive motor drive circuit
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
connector contact defect
32-1
error occurs.
4A-118
z Error Code 32-3 (Pump motor drive circuit EEPROM abnormality)

Related portion
CN111-12 (152, 0STEP)
Pump motor drive circuit CN111-11 (152, STEP-)
Probable cause:
(2) Pump motor drive circuit harness defect
*: When a drive motor drive circuit is installed as a pump motor drive circuit, the 32-3 error always occurs (which does
not mean that the new drive motor drive circuit is defective).
Turn off and then back on the key switch.
If AD-1 or 2 is also displayed, perform troubleshooting with priority given to AD-1 or 2.
Error code 32-3

32-3
visually check inside the connector and the caulked portion of its
error does not occur. Pump motor drive circuit
wire for defects. (Refer to BEFORE TROUBLESHOOTING)
connector contact defect
32-3 error occurs.
4A-119
z Error code 33-1 Main controller → Drive motor driver CAN communication
abnormality
Related portion
CN103-4 (KYSAT) CN143-1 Pre-charge CN143-2 CN110-8

CN103-11 (CAN1H) unit CN110-17
Drive motor
CN103-12 (CAN1L) CN110-10
driver circuit
CN103-3 (DGND) CN110-2
Main
CN103-5 (N2,N2)
controller
CN104-4 (N2,N2)
CN104-5 (N2,N2)
CN104-6 (N2,N2)
Probable cause
(2) Harness defect
(3) Motor driver circuit defect
*If AD-1, 2 occurs, perform troubleshooting with priority given to AD-1, 2.
4A-120
Error code 33-1
Disconnect the battery plug, connector CN110, CN143 and visually

check inside the connector and the caulked portion of its wire for
defect (Refer to BEFORE TROUBLESHOOTING). 33-1 No error occurs
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the motor driver circuit, should be confirmed
the connection of each connector.
33-1
error occurs
NG
Harness defect
2. Disconnect the CN103, CN104, CN143, CN110 and check the
harness.
OK
Turn the key off and connect the CN103, CN143, CN104, CN110 then 33-1 No error occurs
turn the key on.
33-1
error occurs
Inspection: (Motor driver circuit) ∗1

1. Replacing the Drive motor driver and Pump motor driver. 33-1 No error occurs
2. Connect the battery plug and turn on the key switch. Main controller defect
3. Check the error code (The 32-1 and 32-3 can be ignored even if
displayed).
33-3
error occurs
Drive motor driver circuit defect
(note: this is Drive motor driver before repalcing)
4A-121

Check each harness for its continuity and short
Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104, CN143, CN110 and
visually check inside each connector and caulked portion. Then check the continuity and short of each harness
(Refer to BEFORE TROUBLESHOOTING).
Portion to be checked Standard

4A-122
z Error code 33-3 Main controller → Pump motor driver CAN communication
abnormality
Related portion
CN103-4 (KYSAT) CN143-1 Pre-charge CN143-2 CN111-8

CN103-11 (CAN1H) unit CN111-17
Pump motor
CN103-12 (CAN1L) CN111-10
driver circuit
CN103-3 (DGND) CN111-2
Main
CN103-5 (N2, N2)
controller
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause
(2) Harness defect
(3) Motor driver circuit defect
*If AD-5, 6 occurs, perform troubleshooting with priority given to AD-5, 6.
4A-123
Error code 33-3
Disconnect the battery plug, connector CN111, CN143 and visually

check inside the connector and the caulked portion of its wire for
33-3
defect (Refer to BEFORE TROUBLESHOOTING).
No error occurs
Connect the connectors and battery plug, then turn on the key switch Connector contact defect
to check for error.
Especially, after replacing the motor driver circuit, should be confirmed
the connection of each connector.
33-3
error occurs
Harness defect
2. Disconnect the CN103, CN104, CN143, CN110, CN111 and check
the harness.
OK
33-3
Turn the key off and connect the CN103, CN143, CN104, CN110, No error occurs
CN111 then turn the key on.
33-3
error occurs
Inspection: (Motor driver circuit) ∗1

33-3
1. Replacing the Drive motor driver and Pump motor driver.
No error occurs
2. Connect the battery plug and turn on the key switch. Main controller defect
3. Check the error code (The 32-1 and 32-3 can be ignored even if
displayed).
33-1
error occurs
Pump motor driver circuit defect
(Note: this is Pump motor driver before repalcing)
4A-124

Check each harness for its continuity and short
Turn off the key switch and disconnect the battery plug, disconnect the CN103, CN104, CN143, CN110, CN111
and visually check inside each connector and caulked portion. Then check the continuity and short of each
harness (Refer to BEFORE TROUBLESHOOTING).
Portion to be checked Standard

4A-125
z Error code 52-1,-2,-3 Yaw rate sensor abnornality

Related portion
CN104-13 (321,SYR+) CN34-1

CN103-27 (322,SYR) CN34-3
Main controller Yaw rate sensor
CN104-11 (323,SYR-) CN34-2
Probable cause:
(2) Yaw rate sensor harness defect
(3) Yaw rate sensor defect
Error code 52-1

visually check inside the connector and the caulked portion of its 52-1error does
wire for defects. (Refer to BEFORE TROUBLESHOOTING) not occur.
2. Connect the CN34 connector, connect the battery plug, turn on the
key switch, and then raise the lift from its lowermost to uppermost
position to see if an error occurs.
52-1error occurs
Inspection: Check of the yaw rate sensor

1. Turn off the key switch and disconnect the battery plug. 52-2error
2. Disconnect the CN34 connector and connect CN34-1 to CN34-2 on occurs.
Yaw rate sensor defect
the harness side through SST 09232-13130-71.
3. Connect the battery plug, and then turn on the key switch to check
for errors.
52-1error occurs

Harness defect
2. Disconnect the CN103 and CN104 connectors and check the
OK

4A-126
Error code 52-2, -3
the CN34 connector, and visually check inside the connector and 52-2,-3error
the caulked portion of its wire for defects. (Refer to BEFORE does not occur.
TROUBLESHOOTING)
2. Connect the CN34 connector, connect the battery plug and turn on
the key switch to check for errors.
52-2,-3error occurs
Inspection: Check of the yaw rate sensor.

52-1error
occurs.
2. Disconnect the CN34 connector. Yaw rate sensor defect
3. Connect the battery plug, and then turn on the key switch to check
for errors.
52-2,-3error occurs

Harness defect
OK
Inspection 1,2: Check each harness for its continuity.
Turn off the key switch and disconnect the battery plug, disconnect CN34, CN103 and CN104 and perform the
check without connecting SST.

CN104-13 to CN34-1 Continuity 52-1 *1
CN104-11 to CN34-2 Continuity 52-2,-3 *2
CN34-1 to CN34-2 No continuity 52-1
CN34-1 to CN34-3 No continuity 52-2,-3
CN34-2 to CN34-3 No continuity 52-1,-3
4A-127
z Error Code 54-1,-2,-3,-4 (Swing lock solenoid abnormality)

Related portion
CN103-1 (327, SLSW+) CN43-1
CN103-2 (328, SLSW-) CN43-2
CN103-5 (N2, N2)

Main Swing lock
controller CN104-4 (N2, N2) solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Swing lock solenoid harness defect
(3) Swing lock solenoid defect
If the 54-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code 54-1
the CN43 connector, and visually check inside the connector and 54-1
the caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING)
turn on the key switch to see if an error occurs.
54-1 error occurs. 54-4
error occurs. Track down the
Check if the 54-4 error has also occurred.
cause of the 54-4 error.
54-4 error does not occur.
Inspection: Check of swing lock solenoid
2. Disconnect the CN43 connector and measure the resistance of the
swing lock solenoid
(Resistance between CN43-1 and CN43-2).
Standard value: 4 to 11 Ω (approx. 6 Ω at 20°C)

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
4A-128
Error code 54-2
TROUBLESHOOTING)
54-2 error occurs.
54-3
Check if the 54-3 error has also occurred. error occurs. Track down the
cause of the 54-3 error.
2. Disconnect the CN43 connector and measure the resistance of the NG
Swing lock solenoid defect
swing lock solenoid
OK
NG
harnesses for its continuities.
OK
Error code 54-3
Turn off the key switch and disconnect the battery plug, disconnect the
CN43 connector, and visually check inside the connector and the
TROUBLESHOOTING)

swing lock solenoid

Portion in which a problem was found during a check of the swing lock solenoid or its harness.
4A-129
Error code 54-4
the CN43 connector, and visually check inside the connector and
the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)
turn on the key switch.
Forcibly turn off the output of the swing lock solenoid, using Active 54-4
Test, to see if an error occurs. error does not occur.
[ANL] ACTIVE TEST 1/3 SWING SOL
54-4 error occurs.
Swing lock solenoid defect
swing lock solenoid
OK
NG
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN43, CN103 and CN104 connectors,

CN103-1 to CN43-1 Continuity 54-4 *
CN43-1 to CN43-2 No continuity 54-1,2,3,4
CN43-2 to P1 No continuity 54-1,2,3,4
* Connect the CN43 connector and measure the resistance between CN103-1 and CN103-2, to see if it falls
between 4 and 11 Ω (approx. 6 Ω at 20°C)
4A-130
z Error Code 61-1,-2 (Load sensor abnormality)

Related portion
CN104-12 (58, SPLF+) CN7-1
CN103-29 (59, SPLF) CN7-2

Main
Load sensor
controller
CN101-32 (51, POT-) CN7-3
Probable cause:
(2) Load sensor defect
(3) Load sensor harness defect
Error code 61-1
the CN7 connector, and visually check inside the connector and the 61-1
caulked portion of its wire for defects. (Refer to BEFORE error does not occur.
TROUBLESHOOTING)
61-1 error occurs.
Inspection: Check of load sensor
1. Turn off the key switch and disconnect the battery plug. 61-2
2. Disconnect the CN7 connector and connect CN7-1 to CN7-2 on the error occurs.
Load sensor defect
harness side through SST09230-13700-71.
61-1 error occurs.
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check
the harnesses for its continuities.
OK
4A-131
Error code 61-2
61-2 error occurs.
Inspection: Check of load sensor
61-1
error occurs.
2. Disconnect the CN7 connector. Lord sensor defect
61-2 error occurs.
Harness defect
OK
Inspection 1, 2: Check each harness for its continuity.

Turn off the key switch and disconnect the battery plug, disconnect the CN7, CN101, CN103 and CN104
connectors, and with SST disconnected, visually check inside each connector and the caulked portion of each
wire for defects.

*1: Connect CN7-1 and CN7-2 on the harness side through 09230-13700-71 and check
if there is continuity between CN104-12 and CN103-29.
*2: Connect CN7-2 and CN7-3 on the harness side through 09230-13700-71 and check
if there is continuity between CN103-29 and CN101-32.
4A-132
z Error Code 62-1,-2 (Tilt angle sensor abnormality)

Related portion
CN101-20 (57, VRTA+) CN26-1
CN103-17 (56, VRTA) CN26-2

Main Tilt angle
controller sensor
CN101-32 (51, POT-) CN26-3
Probable cause:
(2) Tilt angle sensor defect
(3) Tilt angle sensor harness defect
Error code 62-1
TROUBLESHOOTING)
62-1 error occurs.
Inspection: Check of tilt angle sensor
2. Disconnect the CN26 connector and connect CN26-1 and CN26-2 error occurs.
Tilt angle sensor defect
on the harness side through 09232-13130-71.
62-1 error occurs.
Harness defect
OK
4A-133
Error code 62-2
62-2 error occurs.
Inspection: Check of tilt angle sensor
62-1
error occurs.
2. Disconnect the CN26 connector. Tilt angle sensor defect
62-2 error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN86, CN101, and CN103 connectors,
and with SST disconnected, visually check inside each connector and the caulked portion of each wire for
defects.

between CN101-20 and CN103-17
4A-134
z Error Code 63-1,-2,-3 (Tilt switch abnormality)

Related portion
Tilt switch
CN102-23 (61,SWTR) CN9-3
CN102-22 (62,SWTF) CN9-1

Main
controller CN103-6 (51,LS-) CN9-2
CN9-4
Probable cause:
(2) Tilt switch adjustment defect.
(3) Tilt switch defect
(4) Tilt switch harness defect
Error code 63-1, -2, -3
the CN9 connector, and visually check inside the connector and the A6-3
caulked portion of its wire for defects. error occurs. Track down the cause of the
(Refer to BEFORE TROUBLESHOOTING) A6-3 error.
2. Connect the CN9 connector, connect the battery plug, and turn on
the key switch to see if an error occurs.
A6-3 error does not occur.
63-1
• Tilt switch defect
error occurs.
Operate the tilt lever and check the error code. • Tilt switch installation portion
defect.
[ANL] I/O M.HANDLING 6/8
Use the analyzer to check the values for the SWTF (forward tilt switch) Either switch
and SWTR (backward tilt switch). displaying “1”
Check the status of the switches when the tilt lever is operated in
either direction and returned to center.
Both switches displaying “0” after
OK
operation repeated several times
Stored in diagnosis memory
Memory 63-1 Memory 63-2, 63-3

The forward and backward tilt The tilt lever has been turned ON
lever switches turned ON at the for two minutes or more in the
same time in the past. past.(Normal)
(Check and adjustment of each
switch installation)
4A-135
z Error Code 64-1,-2,-3,-4 (Lift lower lock solenoid abnormality)

Related portion
CN101-1 (3, SOLLU+) CN8-1
CN102-16 (4, SLLL-) CN8-2
CN103-5 (N2, N2)

Main Lift lock
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Lift lock solenoid harness defect
(3) Lift lock solenoid defect
Error code 64-1
caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 64-4 error.
No error occurs.
64-1
error does not occur.
Lower the lift to see if an error occurs. Connector contact defect
64-1 error occurs.

Inspection: Check of lift lock solenoid
2. Disconnect the connector CN8 and measure the resistance of the
lift lock solenoid

2. Disconnect the CN101, CN102, CN103 and CN104 connectors and
Portion where a problem was found during a check of the lift lock solenoid or its harness.
4A-136
Error code 64-2
caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
No error occurs. 64-2
64-2 error occurs.

2. Disconnect the connector CN8 and measure the resistance of the NG
Lift lock solenoid defect
lift lock solenoid
OK
Harness defect
OK
Error code 64-3
TROUBLESHOOTING)

lift lock solenoid

Portion where a problem was found during a check of the lift lock solenoid or its harness.
4A-137
Error code 64-4
TROUBLESHOOTING)
64-4 error occurs.
Lift lock solenoid defect
lift lock solenoid
OK
Harness defect
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN8, CN101, CN102, CN103 and CN104
connectors, and

* Connect the CN8 connector and measure the resistance between CN101-1 and CN102-16 to see if it falls
4A-138
z Error Code 65-1,-2,-3,-4 (Tilt control solenoid abnormality)

Related portion
CN101-2 (6, SLTFB+) CN14-1
CN102-19 (7, SLTFL-) CN14-2
CN103-5 (N2, N2)

Main
Tilt solenoid
controller CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(2) Tilt control solenoid defect
(3) Tilt control solenoid harness defect
Error code 65-1
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
Tilt the mast forward to check again if an error occurs. Connector contact defect
65-1 error occurs.

Inspection: Check of tilt control solenoid
tilt control solenoid

Portion where a problem was found during a check of the tilt control solenoid or its harness.
4A-139
Error code 65-2
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of the
TROUBLESHOOTING) 65-3
Tilt the mast forward to check again if an error occurs. Connector contact defect
65-2 error occurs.

Tilt control solenoid defect
OK
Harness defect
OK
Error code 65-3
TROUBLESHOOTING)


Portion where a problem was found during a check of the tilt control solenoid or its harness.
4A-140
Error code 65-4
the caulked portion of its wire for defects. (Refer to BEFORE error not occur.
TROUBLESHOOTING)
65-4 error occurs.
Tilt control solenoid defect
OK
Harness defect
OK

CN104 connectors, and

4A-141
z Error Code 66-1 (Outside matching value range for tilt angle error)
Related portion
Main
controller
Probable cause:
(1) The tilt horizontal angle matching value is outside the specified matching range.
(2) The forward tilt angle matching value is outside the specified matching range.
(3) The load sensor matching value is outside the specified matching range.
Matching After the completion of matching,

Perform matching of the tilt horizontal angle, the forward tilt angle, and 66-1error does not occur.
the load sensor. Use the device as it is.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION / MACHING
After the completion of
matching,
66-1 error occurs.
4A-142
z Error Code 67-1 (Lifting height switch open)

Related portion
V mast, mast height: ~H2500
CN102-10 (51, LS-)

Main CN104-22 (90, SH1)
controller
CN103-24 (91, SH2-1)
N.C.
Others:
Lifting height
CN102-10 (51, LS-) CN96-1 switch
CN104-22 (90, SH1) CN96-2

Main
controller
CN103-24 (91, SH2-1) CN96-3
Probable cause:
(1) Connector contact defect (3) Lifting height switch defect
(2) Harness defect (4) Main controller defect
Error code 67-1
67-1
key switch, and then raise the lift from its lowermost to uppermost
position to see if an error occurs.
67-1 error occurs.
Inspection: Check of lifting switch input value
Turn on the key switch and check the value of SH using the Analyzer SH: 000
1
menu.
SH: Other than 000
Inspection: Check of lifting switch input value
1. Lower the lift to its lowermost position.
SH: 000
3. Disconnect the CN96 connector. Lifting height switch defect
4. Turn on the key switch and check the value of SH using the
Analyzer menu.
SH: Other than 000
A
4A-143

Harness defect
OK
Is the lifting height switch equipped? NO

2
YES
Lifting height switch arm is released.

Inspection: Check of mast lifting height (High lifting height)
Visually check the state of the lifting switch when an error is detected. 3
Lifting height switch arm is held.

(Low lifting height)
Inspection: Check of the lifting height switch as a single unit.
1. Keep the conditions under which the error occurs.
NG
3. Disconnect the CN96. Lifting height switch defect
4. Check for continuity on the switch side.
OK
Harness defect
OK

NG
Disconnect the CN102, CN103 and CN104 connectors and check the Harness defect
OK
4A-144
Inspection: Check of the lifting height switch as a single unit.

1. Keep the conditions under which the error occurs.
NG
3. Disconnect the CN96 connector. Lifting height switch defect
4. Check for continuity on the switch side.
OK
NG
Disconnect the CN102,103 and CN104 connectors and check the Harness defect
OK

Perform this check with the battery plug and the CN96, CN102,CN103 and CN104 connectors disconnected.
Visually check inside each connector and the caulked portion of each wire for defects.


Perform this check with the CN102, CN103 and CN104 connectors disconnected.

4A-145
z Error Code 68-1,-2,-3 (Lifting height sensor abnormality)

Related portion
CN101-32 (51, POT-) CN97-1
CN101-24 (219, VRH+) CN97-2

Main Lifting height
controller sensor
CN103-28 (220, VRH) CN97-3
Probable cause:
(1) Lifting height sensor defect
(3) Lifting height sensor harness defect
Error code 68-1
68-1 error does not
occur.
turn on the key switch to check how the vehicle operates and if an
error occurs.
68-1 error occurs.
Inspection: Check of lifting height sensor as a single unit
2. Disconnect CN97 and connect CN97-2 to CN97-3 on the harness 68-2 error occurs.
Lifting height sensor defect
side through 09238-13130-71.
68-1 error occurs.
Inspection 1: Continuity and short check of harness
Harness defect
OK
4A-146
Error code 68-2
68-2
turn on the key switch to check how the vehicle operates and if an
error occurs.
68-2 error occurs.
Inspection: Check of lifting height sensor as a single unit
68-1 error occurs.
2. Disconnect the CN97 connector. Lifting height sensor defect
68-2 error occurs.
Harness defect
OK
Error code 68-3
Visual check of lifting height sensor

• Is the wire broken? NG
Lifting height sensor defect
• Is the wire wound around or pulled out of the reel correctly when the
lift is raised to or lowered from an elevated position?
OK
TROUBLESHOOTING)
turn on the key switch.
Inspection: Check of lifting height sensor input value

Raise the lift to an elevated position.
Change in VRH value:
Then, further raise the lift by 1 m from this position and check the
0.5 or more Normal
change in the value of VRH at that time.
(Connector contact defect)
Turn on the key switch and check the value of VRH using the Analyzer
menu.
Change in VRH value:
Less than 0.5
Harness defect
OK
4A-147

Turn off the key switch and disconnect the battery plug, disconnect CN97, CN101 and CN103 and perform the
check without connecting SST.

CN101-24 to CN97-2 Continuity 68-1, 3 *1
CN97-1 to CN97-3 No continuity 68-1, 3
4A-148
z Error Code 71-1,-2,-3 (Tire angle sensor abnormality)

Related portion
CN101-23 (316, VRTRA+) CN94-3
CN102-31 (317, VRTRA) CN94-2

Main Tire angle
controller sensor
CN102-26 (51, POT-) CN94-1
Probable cause:
(2) Tire angle sensor harness defect
(3) Tire angle sensor defect
(4) Tire angle sensor joint, rear axle link system defect
Error code 71-1
71-1
TROUBLESHOOTING) 71-1 error occurs.
turn on the key switch to check how the steering operates and if an
error occurs.
71-1 error occurs.
Inspection: Check of tire angle sensor
2. Disconnect the CN94connector and connect CN94-3 and CN94-2 error occurs.
Tire angle sensor defect
on the harness side.
3. Connect the battery plug and turn on the key switch to check the
error code.
71-1 error occurs.
Harness defect
2. Disconnect the battery plug and the CN101 and CN102 connectors
and check the harness for their continuities.
OK
4A-149
Error code 71-2, -3
71-2, 71-3
turn on the key switch to check how the steering operates and if an
error occurs.
71-2 or 71-3 error occurs.
Inspection: Check of tire angle sensor
71-1
1. Turn off the key switch and disconnect the battery plug. Tire angle sensor defect
error occurs.
2. Disconnect the CN94 connector. Tire angle sensor installation
3. Connect the battery plug and turn on the key switch to check the portion defect.
error code.
71-2 error occurs or
no error occurs.
Harness defect
OK

Turn off the key switch and disconnect the battery plug and the CN94, CN101 and CN102 connectors and with
SST disconnected visually check inside each connector and the caulked portion of each wire for defects.

CN94-1 to CN94-2 Continuity 71-1
4A-150
z Error Code 72-1,-2,-3,-4 (Steering-wheel angle sensor abnormality)

Related portion
CN103-13 (311, SSTR+) CN3-1
CN104-30 (312, SSTR1) CN3-3
Main CN104-31 (313, SSTR2) CN3-4 Steering

controller angle sensor
CN104-24 (314, SSTRC) CN3-5
CN102-10 (51, LS-) CN3-2
Probable cause:
(2) Steering angle sensor harness defect
(3) Steering angle sensor defect
The error code 72-4 may be displayed if only the tire angle sensor, but not the steering wheel, is rotated.
Error code 72-1
TROUBLESHOOTING)
key switch, and turn the steering wheel to see if an error occurs.
72-1 error occurs.
Inspection: Checking the state, turning the steering wheel
Turn on the key switch and check the value of SSTR using the SSTR: 1**
Analyzer menu. (* represents either 0 or 1.)
[ANL] I/O STEERING 1/1
SSTR: 0**
(* represents either 0 or 1.)
A
Turn off the key switch, disconnect the battery plug and disconnect the
CN3 connector. After that, connect CN3-2 to CN3-3 (on the main
harness side) through 09232-13130-71 to short them, and then
connect the battery plug and turn on the key switch.
B
4A-151
SSTR: 1**
Inspection: Checking the state, turning the steering wheel (* represents either 0
Turn on the key switch and check the value of SSTR using the or 1.) Steering angle sensor
Analyzer menu. defect
SSTR: 0**
Main harness defect
2. Disconnect the CN104 connectors and check the harnesses for
their continuities.
OK
Disconnect the CN104 connector and disconnect the CN3 connector.

Connect the battery plug and turn on the key switch.
SSTR: 0**
(* represents either 0
or 1.)
Turn on the key switch and check the value of SSTR using the Steering angle sensor defect
Analyzer menu.
SSTR: 1**
Main harness defect
their continuities.
OK
4A-152
Error code 72-2
TROUBLESHOOTING.)
72-2 error occurs
SSTR: *1*
Turn on the key switch and check the value of SSTR using the (* represents either 0
Analyzer menu. or 1.)
SSTR: *0* C
SSTR: *1*
(* represents either 0
or 1.)
Turn on the key switch and check the value of SSTR using the Steering angle sensor defect
Analyzer menu.
SSTR: *0*
Main harness defect
their continuities.
OK
Disconnect the CN104 connector and disconnect the CN3 connector.

SSTR: *0*
Turn on the key switch and check the value of SSTR using the or 1.) Steering angle sensor
Analyzer menu. defect
SSTR: *1*
Main harness defect
their continuities.
OK
4A-153
Error code 72-3
TROUBLESHOOTING)
72-3 error occurs.
Inspection: Checking the state, turning the steering wheel SSTR: **1
Turn on the key switch and check the value of SSTR using the (* represents either 0
Analyzer menu. or 1.)
SSTR: **0 E
SSTR: **1
Turn on the key switch and check the value of SSTR using the or 1.)
Steering angle sensor defect
Analyzer menu.
SSTR: **0
Main harness defect
their continuities.
OK
4A-154
Turn off the key switch and disconnect the CN104 connector and
disconnect the CN3 connector.
Inspection: Checking the state, turning the steering wheel SSTR: **0
Turn on the key switch and check the value of SSTR using the (* represents either 0 or 1.)
Analyzer menu. Steering angle sensor defect
SSTR: **1
Main harness defect
their continuities.
OK
Error code 72-4
the CN3 connector, and visually check inside the connector and the
caulked portion of its wire for defects. (Refer to BEFORE 72-4
TROUBLESHOOTING) error does not occur.
(If the steering wheel cannot be turned easily, perform this check
with the direction switch in the Forward or Reverse position.)
72-4 error occurs.
Inspection: Check of sensor supply voltage
1. Turn off the key switch and disconnect the battery plug. Approx. 15 V
4. Check the supply voltage to the sensor.
CN3-1 ⇔ CN3-2
Approx. 0 V
their continuities.
OK Main harness defect
Turn off the key switch, disconnect the battery plug, and then connect CN3.
Track down the cause of 72-1 (SSTR1).

Proceed to identify the cause of 72-2 (SSTR2).
4A-155

Turn off the key switch and disconnect the battery plug, disconnect CN3, CN102, CN103 and CN104 and
perform the check without connecting SST.

4A-156
z Error Code 73-1,-2,-3,-4 (Steering knob synchronizer solenoid abnormality)

Related portion
CN102-7 (329, SLS+) CN37-1
CN102-14 (330, SLS-) CN37-2
CN103-5 (N2, N2)

Main Steering knob
controller CN104-4 (N2, N2) synchronizer
solenoid
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Knob position compensation solenoid defect
(2) Knob position compensation solenoid harness defect (4) Main controller defect
Error code 73-1
1. Turn off the key switch and disconnect the battery plug,
disconnect the CN37 connector, and visually check inside the 73-4
connector and the caulked portion of its wire for defects. (Refer to error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) 73-4 error.
Connect the CN37 connector, connect the battery plug, and turn
on the key switch to see if an error occurs.
No error occurs.
73-1
Using Active Test, forcibly turn on the output of the knob position
compensation solenoid to see if an error occurs. Connector contact defect
[ANL] ACTIVE TEST 1/3 STEERING SOL
73-1 error occurs.

Inspection: Check of knob position compensation solenoid
2. Disconnect the connector CN37 and measure the resistance of
the knob position compensation solenoid

Disconnect the CN102, CN103 and CN104 connectors and check
Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
4A-157
Error code 73-2
the caulked portion of its wire for defects. (Refer to BEFORE error occurs. Track down the cause of
TROUBLESHOOTING) the 73-3 error.
Connect the CN37 connector, connect the battery plug, and turn on
No error occurs.
Using Active Test, forcibly turn on the output of the knob position
73-2
compensation solenoid to see if an error occurs. Connector contact
defect
[ANL] ACTIVE TEST 1/3 STEERING SOL
73-2 error occurs.

Knob position
2. Disconnect CN37 and measure the resistance of the knob position NG
compensation solenoid
defect
OK
NG
OK
Error code 73-3
TROUBLESHOOTING)

2. Disconnect CN37 and measure the resistance of the knob position

Disconnect the CN102, CN103 and CN104 connectors and check the
Portion where a problem was found during a check of the knob position compensation solenoid or its harness.
4A-158
Error code 73-4
TROUBLESHOOTING)
Connect the CN37 connector, connect the battery plug, and turn on
73-4 error occurs.
2. Disconnect the connector CN37 and measure the resistance of the NG Knob position compensation
knob position compensation solenoid solenoid defect
OK
NG
OK

Turn off the key switch and disconnect the battery plug, disconnect the CN37, CN102, CN103 and CN104
connectors, Visually check inside each connector and the caulked portion of each wire for defects.

between 7 and 17 Ω (approx. 10 Ω at 20°C).
4A-159
z Error Code 74-1 (Outside matching value range for tire angle error)
Related portion
Steering knob synchronizer

solenoid
Probable cause:
Tire straight running matching value is outside the specified matching range.
If the 71-1, 71-2 or 71-3 error occurs, identify the cause of it first, and then perform the following.

matching, 74-1 error
Matching has been made
Perform tire straight running matching. Refer to MULTI-FUNCTION does not occur.
correctly.
DISPLAY / MUSK FUCTION / MACHING
74-1 error occurs.
4A-160
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer

abnormality-Conventional lever)
Related portion
CN101-25 (28, VRL+) CN47-4
CN103-26 (20, VRL1) CN47-3

Main Lift lever
controller CN103-18 (21, VRL2) CN47-2 potentiometer
CN102-26 (51, POT-) CN47-1
If the lever was removed for a check, be sure to perform matching after installing it.
The H1-4 error may occur if the key switch is turned on while the lift lever is being operated.
Probable cause:
(2) Lift lever potentiometer harness defect
(3) Lift lever potentiometer defect
Error code H1-1, -2, -3
the CN47 connector, and visually check inside the connector and H1-1, -2, -3 error does
the caulked portion of its wire for defects. (Refer to BEFORE not occur.
TROUBLESHOOTING)
H1-1, -2 or -3 error
One of these errors occurs.
H1-1 error occurs and
Inspection: Check of lift lever potentiometer
H1-2, H2-3 error does
not occur.
2. Disconnect the lift lever potentiometer connector (CN47). A
H1, -2 or -3 error
Harness defect
2. Disconnect the CN101,CN102 and CN103 connectors and check
OK

4A-161
H1-2 error Inspection: Check of lift lever potentiometer

does not 1. Turn off the key switch and disconnect the battery
occur. plug.
2. Connect the CN47-3 to CN47-4 on the harness side
through SST 09230-13700-71.
H1-2 error occurs.

plug.
H1-2 error occurs.
2. Disconnect the CN47 connector. Lift lever
3. Connect the CN47-2 to CN47-4 on the harness side potentiometer defect
through SST 09230-13700-71.
H1-2 error does not occur.

plug. NG
Harness defect
2. Disconnect the CN101,CN102 and CN103
continuities.
OK

4A-162
Error code H1-4
the CN47 connector, and visually check inside the connector and H1-4 error does not
the caulked portion of its wire for defects. (Refer to BEFORE occur.
TROUBLESHOOTING)
H1-4 error occurs.

2. Check if the lift lever potentiometer is installed correctly.
OK
3. Connect the battery plug and turn on the key switch. Incorrect installation
4. Perform matching of the lift lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY /MUSK FUCTION /
MACHING
NG
Lift lever potentiometer defect
Error code H1-5
Matching of the lift lever potentiometer After the completion of matching,

Refer to MULTI-FUNCTION DISPLAY / MUSK H1-5 error does not occur. Matching has been made correctly.
FUCTION / MACHING Use the device as it is.
matching, H1-5 error
occurs.

With the battery plug and the CN47, CN101, CN102 and CN103 connectors disconnected,
H1
1 2 3 4 5
CN101-25 to CN47-4 Continuity { − − − −
CN102-26 to CN47-1 Continuity − { − − −
CN47-2 to CN47-1 No continuity { − { − −
CN47-2 to CN47-4 No continuity − { { − −
CN47-2 to CN47-3 No continuity − − { − −
4A-163
z Error Code H1-1, -2, -3, -4, -5 (Lift lever potentiometer abnormality-Mini lever)
Related portion
CN101-25 (28, VRL+) CN79-4
CN103-26 (20, VRL1) CN79-3

Main Lift lever
controller CN103-18 (21, VRL2) CN79-2 potentiometer
CN102-26 (51, POT-) CN79-1
The H1-4 error may occur if the key switch is turned on while the lift lever is being operated.
Probable cause:
(2) Lift lever potentiometer harness defect
(3) Lift lever potentiometer defect
TROUBLESHOOTING)
1. Turn off the key switch and disconnect the battery plug. H2-1, -2 or -3 error One
2. Replace the lift lever potentiometer connector (CN79) with the tilt of these errors occurs.
lever potentiometer connector (CN80). H1-4, H2-4 can be
3. Connect the battery plug and turn on the key switch. ignored.
Harness defect
2. Disconnect the CN101,CN102 and CN103 connectors and check
OK

4A-164
Error code H1-4
TROUBLESHOOTING)
H1-4 error occurs.

2. Check if the lift lever potentiometer is installed correctly.
OK
4. Perform matching of the lift lever potentiometer.
MACHING
NG
Error code H1-5
Matching of the lift lever potentiometer After the completion of matching,

occurs.

H1
1 2 3 4 5
4A-165
z Error Code H2-1, -2, -3, -4, -5 (Tilt lever potentiometer abnormality)
Related portion
CN101-28 (29, VRT+) CN80-4
CN102-23 (22, VRT1) CN80-3

Main Tilt lever
controller CN102-22 (23, VRT2) CN80-2 potentiometer
CN102-26 (51, POT-) CN80-1
The H2-4 error may occur if the key switch is turned on while the tilt lever is being operated.
Probable cause:
(2) Tilt lever potentiometer harness defect
(3) Tilt lever potentiometer defect
the CN80 connector, and visually check inside the connector and H2-1, -2, -3
TROUBLESHOOTING)
Inspection: Check of tilt lever potentiometer H1-1, -2 or -3 error
1. Turn off the key switch and disconnect the battery plug. One of these errors
2. Replace the tilt lever potentiometer connector (CN80) with the lift occurs.
Tilt lever potentiometer defect
lever potentiometer connector (CN79). H1-4, H2-4
3. Connect the battery plug and turn on the key switch. can be ignored.
Harness defect
OK

4A-166
Error code H2-4
TROUBLESHOOTING)
H2-4 error occurs.
Inspection: Check of tilt lever potentiometer

2. Check if the tilt lever potentiometer is installed correctly.
OK
4. Perform matching of the tilt lever potentiometer.
MACHING
NG
Tilt lever potentiometer defect
Error code H2-5
Matching of the tilt lever potentiometer After the completion of matching,

Matching has been made
Refer to MULTI-FUNCTION DISPLAY / MUSK H2-5 error does not occur.
correctly.
FUCTION / MACHING
occurs.

H2
1 2 3 4 5
4A-167
z Error Code H3-1, -2, -3, -4, -5 (Attachment 1 lever potentiometer

abnormality)
Related portion
CN101-29 (30, VRAT1+) CN48-4
CN102-21 (24, VRA11) CN48-3

Main Attachment 1
controller CN102-20 (25, VRA12) CN48-2 lever
potentiometer
CN102-26 (51, POT-) CN48-1
The H3-4 error may occur if the key switch is turned on while the attachment 1 lever is being operated.
* The mini lever specification changes CN48 in CN81 and CN47 is changed into CN79.
Probable cause:
(1) Connector contact defect (3) Attachment 1 lever potentiometer defect
(2) Attachment 1 lever potentiometer harness defect (4) Main controller defect
TROUBLESHOOTING)
Inspection: Check of attachment 1 lever potentiometer H1-1, -2 or -3 error
2. Replace the attachment 1 lever potentiometer connector (CN48) occurs. Attachment 1 lever
with the lift lever potentiometer connector (CN47). H1-4, H3-4 can be potentiometer defect
Harness defect
OK

4A-168
Error code H3-4
• Attachment 1 operation stop. (Conventional Lever)

• Load handling stop. (Mini Lever/Joystick Lever)
TROUBLESHOOTING)
H3-4 error occurs.
Inspection: Check of attachment 1 lever potentiometer

2. Check if the attachment 1 lever potentiometer is installed correctly.
OK
4. Perform matching of the attachment 1 lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION /
MACHING
NG
Attachment 1 lever potentiometer defect
Error code H3-5

Matching of the attachment 1 lever potentiometer. Matching has been made
H3-5 error does not occur.
Refer to MULTI-FUNCTION DISPLAY / MUSK correctly.

occurs.

Perform this check with the battery plug and the CN48, CN101 and CN102 connectors disconnected,
H3
1 2 3 4 5
4A-169
z Error Code H4-1, -2, -3, -4, -5 (Attachment 2 lever potentiometer

abnormality) If truck is equipped with Clamp Release
Interlock feature, click here for calibration
Related portion information before following this
troubleshooting guide.
CN101-30 (31, VRAT2+) CN49-4
CN102-29 (26, VRA21) CN49-3

Main Attachment 2
controller CN102-28 (27, VRA22) CN49-2 lever
potentiometer
CN102-26 (51, POT-) CN49-1
The H4-4 error may occur if the key switch is turned on while the attachment 2 lever is being operated.
* The mini lever specification changes CN49 in CN82 and CN47 is changed into CN79.
Probable cause:
(1) Connector contact defect (3) Attachment 2 lever potentiometer defect
(2) Attachment 2 lever potentiometer harness defect (4) Main controller defect
TROUBLESHOOTING)
Inspection: Check of attachment 2 lever potentiometer H1-1, -2 or -3 error
2. Replace the attachment 2 lever potentiometer connector (CN49) occurs. Attachment 2 lever
with the lift lever potentiometer connector (CN47). H1-4, H4-4 can be potentiometer defect
Harness defect
OK

4A-170
Error code H4-4
• Attachment 2 operation stop. (Conventional Lever)

• Load handling stop. (Mini Lever/Joystick Lever)
TROUBLESHOOTING)
H4-4 error occurs.
Inspection: Check of attachment 2 lever potentiometer

2. Check if the attachment 2 lever potentiometer is installed correctly.
OK
4. Perform matching of the attachment 2 lever potentiometer.
Refer to MULTI-FUNCTION DISPLAY / MUSK FUCTION /
MACHING
NG
Attachment 2 lever potentiometer defect
Error code H4-5
Matching of the attachment 2 lever potentiometer. After the completion of matching,

occurs.

With the battery plug and the CN49, CN101 and CN102 connectors disconnected, visually check inside each
H4
1 2 3 4 5
4A-171
z Error Code H5-1, -2, -3, -4, -5, -6 (Lift PUSH/PULL solenoid abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-5

Lift push
CN101-16 (11, SLPS-) CN11-1 solenoid
CN10-5
Lift pull
CN101-17 (10, SLPL-) CN10-1 solenoid
Main
controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Lift pull solenoid harness defect
(2) Lift push solenoid harness defect (5) Lift pull solenoid defect
(3) Lift push solenoid defect (6) Main controller defect
If the H5-5 error occurs, disconnect the battery plug immediately and track down the cause of it.
Error code H5-1, -3
the CN10 and CN11 connectors, and visually check inside the
connector and the caulked portion of its wire for defects. (Refer to H5-6 error occurs. Track down the cause of the
BEFORE TROUBLESHOOTING) H5-6 error.
2. Connect the CN10 and CN11 connector, connect the battery plug,
and turn on the key switch to see if an error occurs.
No error occurs
Push and hold down the lift lever and pull and hold it up for more than not occur.
1 second each to check if an error occurs.
H5-1 or H5-3 error occurs.
Inspection: Check of lift solenoid

2. Disconnect the CN10 and CN11 connectors and measure the
resistance of the lift solenoid.
(CN10-5 to CN10-1, CN11-5 to CN11-1).

Portion where a problem was found during a check of the lift solenoid or its harness.
4A-172
Error code H5-2, -4
No error occurs.
Push and hold down the lift lever and pull and hold it up for more than not occur.

2. Disconnect the CN10 and CN11 connectors and measure the NG
Lift solenoid defect
(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK
Error code H5-5
CN10 and CN11 connectors, and visually check inside the connector
and the caulked portion of its wire for defects. (Refer to BEFORE
TROUBLESHOOTING)

(CN10-5 to CN10-1, CN11-5 to CN11-1).

Portion where a problem was found during a check of the lift solenoid or its harness.
4A-173
Error code H5-6
1. Turn off the key switch and disconnect the battery plug,
disconnect the CN10 and CN11 connectors, and visually check H5-6 error does not
inside the connector and the caulked portion of its wire for defects. occur.
H5-6 error occurs.
HB-2 error occurs. Track down the cause of the

Check if the HB-2 error has also occurred.
HB-2 error.
HB-2 error does not occur.

Lift solenoid defect
(CN10-5 to CN10-1, CN11-5 to CN11-1).
OK

Harness defect
OK

connectors, and visually check inside each connector and the caulked portion of each wire for defects.

CN101-5 to CN10-5 Continuity H5-6 *1
CN101-5 to CN104-4 No continuity H5-6
CN10-5 to CN10-1 No continuity H5-1, 2, 3, 4, 5, 6
CN10-1 to P1 No continuity H5-1, 2, 3, 4, 5, 6
*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-17
to see if it falls between 6 and 12 Ω (approx. 7 Ω at 20°C).
4A-174
z Error Code H6-1, -2, -3, -4, -5, -6 (Tilt PUSH/PULL solenoid abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-6

Tilt push
CN101-13 (34, STPS-) CN11-2 solenoid
CN10-6
Tilt pull
CN101-12 (33, STPL-) CN10-2 solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Tilt pull solenoid harness defect
(2) Tilt push solenoid harness defect (5) Tilt pull solenoid defect
(3) Tilt push solenoid defect (6) Main controller defect
Error code H6-1, -3
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur.
Inspection: Check of tilt proportional solenoid

resistance of the tilt solenoid.
(CN10-6 to CN10-2, CN11-6 to CN11-2).

Portion where a problem was found during a check of the tilt solenoid or its harness.
4A-175
Error code H6-2, -4
No error occurs.
Push and hold down the tilt lever and pull and hold it up for more than not occur. Connector contact defect

Tilt solenoid defect
(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK
Error code H6-5
TROUBLESHOOTING)

(CN10-6 to CN10-2, CN11-6 to CN11-2).

Portion where a problem was found during a check of the tilt solenoid or its harness.
4A-176
Error code H6-6
the CN10 and CN11 connectors, and visually check inside the H6-6 error does not
connector and the caulked portion of its wire for defects. (Refer to occur.
BEFORE TROUBLESHOOTING)
H6-6 error occurs.

HB-2 error.

Tilt solenoid defect
(CN10-6 to CN10-2, CN11-6 to CN11-2).
OK

Harness defect
OK


4A-177
z Error Code H7-1, -2, -3, -4, -5, -6 (Attachment 1 PUSH/PULL solenoid
abnormality)
Related portion
CN101-6 (32, SLTA1+) CN11-7

Attachment 1
CN101-11 (37, SA1PS-) CN11-3 push solenoid
CN10-7
Attachment 2
CN101-10 (36, SA1PL-) CN10-3 push solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Attachment 1 pull solenoid harness defect
(2) Attachment 1 push solenoid harness defect (5) Attachment 1 pull solenoid defect
(3) Attachment 1 push solenoid defect (6) Main controller defect
Error code H7-1, -3
No error occurs.
Push and hold down the attachment 1 lever and pull and hold it up for not occur.
more than 1 second each to check if an error occurs.
Inspection: Check of attachment 1 solenoid

2. Disconnect the CN10 and CN11 connectors.
Measure the resistance of attachment 1 solenoid
(CN10-7 to CN10-3, CN11-7 to CN11-3).

Portion where a problem was found during a check of the attachment 1 solenoid or its harness.
4A-178
Error code H7-2, -4
No error occurs.
Push and hold down the attachment 1 lever and pull and hold it up for not occur.

2. Disconnect the CN10 and CN11 connectors. NG Attachment 1
Measure the resistance of attachment 1 solenoid solenoid defect
(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK
Error code H7-5

(CN10-7 to CN10-3, CN11-7 to CN11-3).

4A-179
Error code H7-6
the CN10 and CN11 connectors, and visually check inside the H7-6 error does not
connector and the caulked portion of its wire for defects. (Refer to occur.
H7-6 error occurs.

HB-2 error.

(CN10-7 to CN10-3, CN11-7 to CN11-3).
OK

Harness defect
OK


4A-180
z Error Code H8-1, -2, -3, -4, -5, -6 (Attachment 2 PUSH/PULL solenoid
abnormality)
Related portion
CN101-5 (9, SLLA2+) CN11-8

Attachment 2
CN101-15 (40, SA2PS-) CN11-4 push solenoid
CN10-8
Attachment 2
CN101-14 (39, SA2PL-) CN10-4 pull solenoid
Main
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (4) Attachment 2 pull solenoid harness defect
(2) Attachment 2 push solenoid harness defect (5) Attachment 2 pull solenoid defect
(3) Attachment 2 push solenoid defect (6) Main controller defect
Error code H8-1, -3
Track down the
connector and the caulked portion of its wire for defects. (Refer to H8-6 error occurs.
cause of the H8-6
error.
No error occurs.
H8-1, H8-3
Push and hold down the attachment 2 lever and pull and hold it up for No error occurs Connector contact
more than 1 second each to check if an error occurs. defect
H8-1 or
H8-3 error occurs.
(CN10-8 to CN10-4, CN11-8 to CN11-4).

4A-181
Error code H8-2, -4
the CN10 and CN11 connectors, and visually check inside the H8-5
connector and the caulked portion of its wire for defects. (Refer to error occurs. Track down the cause of the
No error occurs.
H8-2, H8-4
Push and hold down the attachment 2 lever and pull and hold it up for error occurs

2. Disconnect the CN10 and CN11 connectors. NG
Attachment 2 solenoid defect
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK

Harness defect
OK
Error code H8-5
TROUBLESHOOTING)

(CN10-8 to CN10-4, CN11-8 to CN11-4).

4A-182
Error code H8-6
1. Turn off the key switch and disconnect the battery plug, disconnect the
CN10 and CN11 connectors, and visually check inside the connector H8-6
and the caulked portion of its wire for defects. (Refer to BEFORE No error occurs
TROUBLESHOOTING.)
2. Connect the CN10 and CN11 connector, connect the battery plug, and
H8-6 error occurs.
HB-2 error.
(CN10-8 to CN10-4, CN11-8 to CN11-4).
OK
Harness defect
2. Disconnect the CN101, CN103 and CN104 connectors and check the
OK


*1: Connect CN10 to the solenoid and measure the resistance between CN101-5 and CN101-14 to see if it falls
*2: Connect CN11 to the solenoid and measure the resistance between CN101-5 and CN101-15 to see if it falls
4A-183
z Error Code HB-1, -2, -3, (Solenoid power supply circuit over current)
Related portion
F7
CN130-6 (19, F7)
CN102-5 (17, SOLCOM) CN132-8 (17, SOLCOM)

CN102-6 (17, SOLCOM)
RY1
CN102-13 (335, RY1) CN132-4 (335, RY1) CN132-2 (97, FAN+)
CN101-3 (97, FAN+)
CN101-5 (9, SLLA2+) CN11-5

Lift PUSH
CN101-16 (11, SLPS-) CN11-1 solenoid
CN101-17 (10, SLPL-) CN10-5

Lift PULL
CN10-1 solenoid
CN101-6 (32, SLTA1+) CN11-6

Tilt PUSH
CN101-13 (34, STPS-) CN11-2 solenoid
CN101-12 (33, STPL-) CN10-6

Tilt PULL
Main
CN10-2 solenoid
controller
CN11-7
ATT1 PUSH
CN101-11 (37, SA1PS-) CN11-3 solenoid
CN101-10 (36, SA1PL-) CN10-7

ATT1 PULL
CN10-3 solenoid
CN11-8
ATT2 PUSH
CN101-15 (40, SA2PS-) CN11-4 solenoid
CN101-14 (39, SA2PL-) CN10-8

ATT2 PULL
CN103-5 (N2, N2) CN10-4 solenoid
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

4A-184
Probable cause:
(2) Harness defect
(3) RY1 defect
Error code HB-1
the CN132 connector, and visually check inside the connector and HB-1 error does not
TROUBLESHOOTING)
2. Connect the CN132 connector, connect the battery plug, and turn
HB-1 error occurs.

Harness defect
OK
Relay defect (*1)

*1 If the symptom persists after replacement of the relay, there should be any other problems,
so replace the Main controller.
Error code HB-2
the CN132, CN10 and CN11 connectors, and visually check inside HB-2 error does not
the connector and the caulked portion of its wire for defects. occur.
2. Connect the CN132, CN10 and CN11 connector, connect the
battery plug, and turn on the key switch to see if an error occurs.
HB-2 error occurs.

Harness defect
2. Disconnect the CN101, CN102, CN103, CN104, CN10 and CN11
OK

4A-185
Error code HB-3
the CN132 connector, and visually check inside the connector and HB-3 error does not
TROUBLESHOOTING)
2. Connect the CN132 connector, connect the battery plug, and turn
HB-3 error occurs.

Harness defect
OK
Inspection: Relay check

2. Disconnect the connector CN132, check the relay and measure its NG
Relay defect
resistance on the primary side
(resistance between CN132-4 and CN132-2).
OK

With the battery plug and the CN101, CN102, and CN132 connectors disconnected, visually check inside each

CN102-13 to CN132-4 Continuity HB-1
4A-186

With the battery plug and the CN101, CN102, CN103, CN104, CN10 and CN11 connectors disconnected,

CN102-5 to CN104-4 No continuity HB-2

Turn off the key switch and disconnect the battery plug, disconnect the CN102 and CN132 connectors, and

CN132-4 to P1 No continuity HB-3
CN132-4 to P4 No continuity HB-3
4A-187
z Error Code HC-1, -2, -3, -4, (Unload valve solenoid abnormality)
Related portion
CN101-1 (3, SOLLU+) CN13-1
CN102-17 (5, SLUL-) CN13-2
CN103-5 (N2, N2)

Main Unload valve
CN104-5 (N2, N2)
CN104-6 (N2, N2)
Probable cause:
(1) Connector contact defect (3) Unload valve solenoid defect
(2) Unload valve solenoid harness defect (4) Main controller defect
If the HC-3 error occurs, disconnect the battery plug immediately and track down the cause of it.
0
Error code HC-1
the caulked portion of its wire for defects. (Refer to BEFORE HC-4 error occurs. Track down the cause of the
TROUBLESHOOTING) HC-4 error.
No error occurs.
HC-1 error does not
Lower the lift to see if an error occurs. occur. Connector contact defect
HC-1 error occurs.
Inspection: Check of unload valve solenoid

unload valve solenoid

Portion where a problem was found during a check of the unload valve solenoid or its harness
4A-188
Error code HC-2
the caulked portion of its wire for defects. (Refer to BEFORE HC-3 error occurs. Track down the cause of the
TROUBLESHOOTING) HC-3 error.
No error occurs.
HC-2 error does not
occur.
HC-2 error occurs.

Unload valve solenoid defect
OK

Harness defect
OK
Error code HC-3
TROUBLESHOOTING)


Portion where a problem was found during a check of the unload valve solenoid or its harness
4A-189
Error code HC-4
the CN13 connector, and visually check inside the connector and HC-4 error does not
TROUBLESHOOTING)
HC-4 error occurs.

Unload valve solenoid defect
OK

Harness defect
OK

CN104 connectors, and visually check inside each connector and the caulked portion of each wire for defects.

CN101-1 to CN13-1 Continuity HC-4 *
CN102-17 to CN13-2 Continuity HC-4 *
CN101-1 to CN104-4 No continuity HC-4
CN102-17 to CN104-4 No continuity HC-4
CN13-2 to CN13-1 No continuity HC-1, 2, 3, 4
CN13-2 to P1 No continuity HC-1, 2, 3, 4
CN13-2 to P4 No continuity HC-1, 2, 3, 4
4A-190
z Error Code G5-1, -2, -3, -4, -5, -6 (Shock sensor abnormality)
Related portion
CN103-8 (300, IPL+) CN39-3
CN103-30 (301, IPL1) CN39-2

Shock sensor 1
CN101-32 (51, POT-) CN39-1
Main
controller CN40-3
CN103-19 (302, IPL2) CN40-2

Shock sensor 2
CN40-1
Probable cause:
(2) Shock sensor harness defect
(3) Shock sensor defect
Error code G5-1 or G5-4 (For G-5-4, read the numbers in brackets, which refer to the corresponding error code,
connector number, etc.)
the CN39 [CN40] connectors, and visually check inside the G5-1 [G5-4]
connector and the caulked portion of its wire for defects. (Refer to error does not occur.
BEFORE TROUBLESHOOTING) Connector contact defect
2. Connect the CN39 [CN40] connector, connect the battery plug, and
G5-1 [G5-4] error occurs.
Inspection: Check of shock sensor 1 [shock sensor 2]

1. Turn off the key switch and disconnect the battery plug. G5-2 [G5-5]
2. Disconnect the CN39 [CN40] connector and connect the CN39-3 to error occurs. Shock sensor 1
CN39-2 [CN40-3 to CN40-2] on the harness side through [shock sensor 2] defect
09232-13130-71.

NG
Harness defect
OK

4A-191

G5-1 [G5-4]
error occurs. Shock sensor 1
2. Disconnect the CN39 [CN40] connector.
[shock sensor 2] defect

Harness defect
OK
turn on the key switch to see if an error occurs. (after one minute)

G5-1 [G5-4]
error occurs. Shock sensor 1
2. Disconnect the CN39 [CN40] connector.
[shock sensor 2] defect
G5-1 [G5-4] error does not occur.

Harness defect
OK

4A-192

Turn off the key switch and disconnect the battery plug, disconnect CN39 [CN40], CN101 and CN103 and
perform the check without connecting SST.

CN103-8 to CN39-3 Continuity G5-1 *1
CN101-32 to CN39-1 Continuity G5-2, -3 *2
CN39-2 to CN39-1 No continuity G5-1
CN39-3 to CN39-2 No continuity G5-2, -3
CN101-32 to CN40-1 Continuity G5-5, -6 *4
CN40-3 to CN40-2 No continuity G5-5, -6
sec04A.book
WHEN NO ERROR CODE IS DISPLAYED
Probable causes of problems for which no error code is displayed
Note:
193 ページ
If an error code is displayed or the spanner light is on, be sure to perform checks with priority given to it.
Control
Phenomena that arise on the vehicle Failed portions and failure modes How to check Action and remedies
systems
Emergency switch main body (with
Emergency switch) – • Release the emergency switch.
: Switch is held down.
２０１１年１月２５日
Check the battery voltage.

Battery
: Battery plug is disconnected. • Charge the Battery
: Low voltage
火曜日
Check the battery voltage.

Key switch main body
: Open failure
Emergency switch main body (with • Check the switch, and replace it if
Emergency switch) necessary.
: Open failure – • Check the harness and repair or

Key switch harness replace it if necessary.
: Wire breakage, short circuit or • Replace the F5 fuse.
Although the key switch or ten-key leakage (harness, connector or F5
operation is turned on, power is not fuse)
Power-supply supplied. Numeric keypad harness (with PIN
related control (The multi-function screen does not • Check the harness and repair or
code entry) –
appear, and the vehicle does not replace it if necessary.
: Open failure
move, either.)
Check the operation of each switch.
: Check if a response (lighting of LED
or sounding of buzzer) is given only
to a particular switch.
Numeric keypad main body (with PIN If there are two types of switches:
code entry) switch to which a response is given • Replace the numeric keypad.
: Switch failure 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 display (with PIN code
Using the Administrator menu, check if • Register PIN using the Administrator
entry)
PIN has been registered. menu.
: PIN not registered
4A-193
Control
sec04A.book
systems
4A-194
Display power supply and ground
harness (with PIN code entry)
194 ページ
Although the key switch is turned on, : Wire breakage, short circuit,
• Check the harness and repair or
power is not supplied. leakage (harness or connector)
replace it if necessary.
(The multi-function screen does not Multi-function display (with PIN code –
• Replace the display.
appear, and the vehicle does not entry)
• Replace the main controller.
move, either.) : Internal failure
Main controller
Power-supply : Internal failure (D7V, DGND)
２０１１年１月２５日
related control
Display power supply or ground
harness
火曜日
: Wire breakage, short circuit, • Check the harness and repair or

The multi-function screen does not
leakage (harness or connector) replace it if necessary.
appear. –
Multi-function display • Replace the display.
(The vehicle runs normally.)
: Internal failure • Replace the main controller.
Main controller
: Internal failure
After the key switch was turned on, the
accelerator was not released or the
– Operate them correctly.
direction switch was not returned to
neutral.
Check the direction switch, using
Analyzer.
Direction switch main body
: Accelerator is fully closed. • Check the switch, and replace it if
: Open failure
Operate the direction switch to see if necessary.
Direction switch harness
it turns on and off normally. • Check the harness and repair or
: Wire breakage, short circuit
(The vehicle does not run if the replace it if necessary.
(harness or connector)
forward and reverse switches are
turned on simultaneously.)
The vehicle does not run.
Traveling Direction switch installation portions
(The drive motor does not rotate.)
(EZ pedal)
Check the operation of the direction • Repair or replace the part that does
: One of the installation portions is
switch (microswitch). not operate normally.
broken or damaged or does not
operate normally.
Accelerator sensor main body
: Internal failure Check the accelerator sensor voltage,
Accelerator sensor installation portion using Analyzer. • Check the sensor and replace it if
: The link or the installation portion is : Direction switch is in neutral. necessary.
broken or damaged. Fully open and close the drive to • Check the harness and repair or
Accelerator sensor harness check the change in voltage at that replace it if necessary.
: Wire breakage, short circuit, time.
leakage (harness or connector)
Control
sec04A.book
systems
Accelerator fully closed/fully open
Check the matching value on the
matching value • Perform matching again.
Matching screen.
195 ページ
: No agreement with the vehicle state

Check the brake switch voltage, using
Brake switch main body Analyzer.
• Check the switch and replace it if
: Open failure : Direction switch in neutral, drive
necessary.
Brake switch harness fully closed
: Wire breakage, short circuit, Fully open and close the brake
leakage (harness or connector) cylinder valve to check the change
２０１１年１月２５日
in voltage.
Check the seat switch, using Analyzer.
火曜日
Seat switch main body : Direction switch in neutral, drive • Check the seat and replace it if
: Open failure fully closed necessary.
Seat switch harness Check if the switch turns on and off • Check the harness and repair or
: Wire breakage (harness, connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Brake Check the brake and the drive motor.

• Check the brake, and repair or
: Dragging (internal failure) : With the battery plug disconnected,
Drive motor the parking brake released and the
The vehicle does not run. • Check the drive motor, and repair or
Traveling : Seizure or dragging of drive motor front wheels off the ground, rotate
(The drive motor does not rotate.) replace it if necessary.
(internal failure) each tire to see if it rotates smoothly.
Main body of drive motor rotation
sensor Check the voltage of the drive motor
: Internal failure rotation sensor, using Analyzer. • Check the drive motor rotation
Drive motor rotation sensor installation : Seated in seat, direction switch in sensor, and adjust or replace it if
portion forward position, brake released necessary.
: Gap improperly adjusted Operate the accelerator and check • Check the harness and repair or
Drive motor harness the change in the rotation sensor replace it if necessary.
: Wire breakage, short circuit, voltage.
Check the voltage of the drive motor
Drive motor drive circuit current sensor, using Analyzer.
: Internal failure : Seated in seat, direction switch in • Check the cable, and repair or
Motor cables forward position, brake released replace it if necessary.
: Wire breakage, short circuit or Operate the accelerator and check • Replace the drive motor drive circuit.
leakage (cable or terminal board) the change in the current sensor
voltage.
Main controller
– • Replace the main controller.
: Internal failure
4A-195
Control
sec04A.book
systems
4A-196
Pump motor rotation sensor main body
: Internal failure Check the voltage of the drive motor
• Check the pump motor rotation
196 ページ
Pump motor rotation sensor rotation sensor, using Analyzer.

sensor, and adjust or replace it if
installation portion : Seated in the seat
necessary.
: Gap improperly adjusted Operate the direction switch and
Pump motor harness check the change in the rotation
: Wire breakage, short circuit, sensor voltage.
Load handling cannot be performed
and the steering is heavy. Measure the voltage of the pump
２０１１年１月２５日

(The pump motor does not work for motor current sensor, using Analyzer. • Check the motor cables, and repair
: Internal failure
material handling operation, steering : Seated in the seat or replace them if necessary.
Motor cables
火曜日
operation and direction switch Operate the direction switch and • Replace the pump motor drive
: Wire breakage, short circuit or
operation.) check the change in the current circuit.
leakage (cable or terminal board)
sensor voltage.
Pump • Check the pump, and repair or
: Seizure replace it if necessary.
–
Pump motor • Check the pump motor, and repair or

: Seizure replace it if necessary.
Main controller
– • Replace the Main controller.
Load handling : Internal failure
and power Main body of load handling lever
steering potentiometer
: Internal failure Measure the voltage of the load
Only load handling cannot be Installation of load handling lever handling lever potentiometer, using
• Check the sensor and replace it if
performed. potentiometer Analyzer.
necessary.
(The pump motor operates normally : Installation portion is broken or : Leave the seat
during steering operation and direction damaged. Tilt the load handling lever forward
switch operation.) Load handling lever potentiometer and backward to check the change
harness in voltage.
: Wire breakage, short circuit,
Main body of tilt forward/backward
switch (Conventional lever)
: Internal failure
Check the tilt forward/backward
Only load handling cannot be Installation of tilt forward/backward
switch, using Analyzer. • Check the switch and replace it if
performed. switch
: Seated in the seat necessary.
(The pump motor operates normally : Installation portion is broken or
Operate the tilt lever forward to • Check the harness and repair or
during steering operation and direction damaged.
backward position to check the replace it if necessary.
switch operation.) Tilt forward/backward switch
switch turns on and off normally.
harness
Control
sec04A.book
systems
Seat switch main body • Check the seat and replace it if
: Load handling lever in neutral
: Open failure necessary.
197 ページ
Check if the switch turns on and off

Seat switch harness • Check the harness and repair or
normally, sitting in the seat or
: Wire breakage (harness, connector) replace it if necessary.
standing beside it.
Oil control valve (Conventional lever) • Check the oil control valve, and
Only load handling cannot be : Seizure of or leakage from unload repair or replace it if necessary.
performed. valve • Check the unload valve solenoid
–
(The pump motor operates normally Harness of unload valve solenoid and replace it if necessary.
２０１１年１月２５日
during steering operation and direction : Wire breakage, short circuit, • Check the harness and repair or
switch operation.) leakage (harness or connector) replace it if necessary.
火曜日
Pump • Check the pump, and repair or

: Leak replace it if necessary.
–
Load handling Priority valve • Check the priority valve, and repair
and power : Leak, seizure or replace it if necessary.
steering Main controller

: Internal failure
Only lowering is impossible. If a current flows, turn on the lowering
Lowering lock valve • Check the lowering lock valve, and
(Other load handling operations, lock solenoid using Active Test to
: Seizure (internal damage) repair or replace it if necessary.
including raising, are possible.) lower the fork.
Only forward tilting is impossible.
If a current flows, turn on the tilt control
(Other load handling operations, Tilt control valve • Check the tilt control valve, and
solenoid using Active Test to lower the
including backward tilting, are : Seizure (internal damage) repair or replace it if necessary.
fork.
possible.)
Check the direction switch, using
Direction switch • Check the switch, and replace it if
The steering is heavy. Analyzer.
: Open failure necessary.
(The pump motor operates normally : Accelerator is fully closed.
Direction switch harness • Check the harness and repair or
during material handling.) Operate the direction switch to see if
: Wire breakage (harness, connector) replace it if necessary.
it turns on and off normally.
4A-197
Control
sec04A.book
systems
4A-198
Main body of steering angle sensor
: Internal damage
Check the steering angle sensor, using • Check the sensor and replace it if
198 ページ
Installation of steering angle sensor

Analyzer. necessary.
: Cam or steering wheel is defective.
: Turn the steering wheel to check the • Check the harness and repair or
Steering angle sensor harness
input signal. replace it if necessary.
The steering is heavy. leakage (harness or connector)
(The pump motor operates normally Pump • Check the pump, and repair or
Load handling during material handling.) : Leak replace it if necessary.
２０１１年１月２５日
and power Priority valve • Check the priority valve, and repair
–
steering : Leak, seizure or replace it if necessary.
火曜日
PS valve • Check the PS valve, and repair or

: Leak, seizure replace it if necessary.
Main controller
– • Replace the Main controller.
: Internal failure
Display setting
Although ATT1 (ATT2) is operated, no : The serial number setting is not in Check the set value on the Option Set • Change the setting (see "MULTI
operation is performed. agreement with that of the vehicle. screen. FUNCTION DISPLAY")
(OCV WAY)
Backup buzzer main body
• Check the backup buzzer and
: Internal damage
Backup buzzer harness –
: Wire breakage, short circuit or leakage
(harness, connector or F5 fuse)
Auxiliary equipment relay main body
• Check the auxiliary equipment relay
: Open failure
The backup buzzer (option) does not and replace it if necessary.
Auxiliary equipment relay harness –
sound. • Check the harness and repair or
Auxiliary Backup relay main body (EZ pedal)
• Check the backup relay and replace
equipment : Open failure
it if necessary.
Backup relay harness –
: Wire breakage, short circuit.
Main controller (EZ pedal)
• Replace the Main controller.
: Internal failure
Backup buzzer main body
• Check the backup buzzer and
: Internal breakage
The backup buzzer (option) does not replace it if necessary.
Backup buzzer harness –
stop sounding. • Check the harness and repair or
: Short circuit, leakage (harness or
connector)
Control
sec04A.book
systems
: Short circuit
and replace it if necessary.
199 ページ

connector)
The backup buzzer (option) does not Backup relay main body (EZ pedal)
stop sounding. : Short circuit
it if necessary.
２０１１年１月２５日
connector)
火曜日

: Internal failure
Backup light main body
: Internal breakage, burnout of light • Check the backup light and replace
Auxiliary bulb it if necessary.
–
equipment Backup light harness • Check the harness and repair or
: Wire breakage, short circuit, replace it if necessary.

: Open failure
The backup light (option) does not go Auxiliary equipment relay harness –
on. : Short circuit, leakage (harness or
connector)
Backup relay main body (EZ pedal)
: Open failure
it if necessary.
connector)
: Internal failure
4A-199
Control
sec04A.book
systems
4A-200
Backup light main body
• Check the backup light and replace
: Internal breakage,
it if necessary.
200 ページ
Backup light harness –

: Short circuit
Auxiliary The backup light (option) does not go • Check the harness and repair or
２０１１年１月２５日
equipment out. replace it if necessary.

connector)
Backup relay main body (EZ pedal)
火曜日

: Short circuit
it if necessary.
connector)

: Internal failure
Display setting
: OPS operation notification buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
disabled screen. FUNCTION DISPLAY")
OPS operation warning does not (OPS BUZZER, SEAT BUZZER)
sound.
Check that the built-in buzzer sounds a
Display • If the buzzer does not sound,
short beep when the direction switch
: Built-in buzzer is broken. replace the display.
(microswitch) is pressed.
Display setting
: Return-to-neutral warning buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
Buzzer-related The traveling OPS return-to-neutral (OPS BUZZER)
control warning does not sound.
Display setting
: Return-to-neutral warning buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
The load handling OPS return-to- (OPS BUZZER)
neutral warning does not sound.
Control
sec04A.book
systems
Check the parking brake switch, using
Analyzer.
Parking brake switch main body
201 ページ
(The switch can also be checked by

: Short circuit • Check the switch, and adjust or
checking if the parking indicator on the
Installation of parking brake switch replace it if necessary.
display goes on and out.)
: Switch is held down. • Check the harness and repair or
: Direction switch is in neutral.
Parking brake switch harness replace it if necessary.
The parking brake lever release Operate the parking brake lever
: Short circuit (harness or connector)
reminder does not sound. lever to see if the switch turns on
and off normally.
２０１１年１月２５日

火曜日
Main controller
: Internal failure
Analyzer.
Parking brake switch main body

(The switch can also be checked by
: Open failure • Check the switch, and adjust or
Buzzer-related Installation of parking brake switch replace it if necessary.
When the vehicle runs with the parking display goes on and out.)
control : Switch is off. • Check the harness and repair or
brake lever released, the parking : Direction switch is in neutral.
brake release reminder sounds. Operate the parking brake lever to
: Wire breakage (harness, connector)
see if the switch turns on and off
normally.
Main controller
: Internal failure
Display setting
: Parking brake reminder buzzer Check the set value on the Option Set • Change the setting (see "MULTI-
(PKB BUZZER)
The parking brake lever reminder does Parking brake switch main body Analyzer.
not sound. (The switch can also be checked by
: Open failure • Check the switch, and adjust or
Installation of parking brake switch replace it if necessary.
display goes on and out.)
: Switch is off. • Check the harness and repair or
: Direction switch is in neutral.
Operate the parking brake lever to
see if the switch turns on and off
normally.
4A-201
Control
sec04A.book
systems
4A-202
Seat switch main body Check the seat switch, using Analyzer. • Check the seat and replace it if
: Short circuit : Check if the switch turns on and off necessary.
202 ページ
Seat switch harness normally, sitting in the seat or • Check the harness and repair or
: Short circuit (harness or connector) standing beside it. replace it if necessary.
The parking brake lever reminder does
not sound. Display • If the buzzer does not sound,
Main controller
２０１１年１月２５日
: Internal failure
Parking brake switch main body Check the parking brake switch, using
: Short circuit Analyzer. • Check the switch, and adjust or
火曜日
Buzzer-related
control Installation of parking brake switch : Direction switch is in neutral. replace it if necessary.
: Switch is held down. Operate the parking brake lever to • Check the harness and repair or
Parking brake switch harness see if the switch turns on and off replace it if necessary.
: Short circuit (harness or connector) normally.
Although the parking brake lever is

pulled up, the parking brake reminder
Seat switch main body : Direction switch in neutral, drive • Check the seat switch and replace it
does not stop sounding.
: Open failure fully closed if necessary.
Seat switch harness Check if the switch turns on and off • Check the harness and repair or
: Wire breakage (harness, connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
: Internal failure
Display setting
The height selector function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Height selector function disabled
screen does not appear. screen. FUNCTION DISPLAY")
(H-SELECTOR)
Check the lifting height switch, using
Lifting height switch main body Analyzer.
• Check the switch, and replace it if
: Low lifting height is always detected. : In NL
necessary.
Lifting switch harness Raise and lower the lift to its
Height selector • Check the harness and repair or
The lifting stop position cannot be set. : Wire breakage, short circuit uppermost and lowermost positions
(option) replace it if necessary.
(harness or connector) to see if the switch turns on and off
normally.
Main controller
: Internal failure
Display setting
No limit is placed on the maximum Check the set value on the lifting stop • Change the setting (see "MULTI-
: The maximum lifting height is not be
lifting height. position setting screen. FUNCTION DISPLAY")
set.
Control
sec04A.book
systems
Display setting
Check the set value on the lifting stop • Change the setting (see "MULTI-
: The automatic lifting stop position is
position setting screen. FUNCTION DISPLAY")
203 ページ
not set.
Height selector switch main body
: Open failure, short circuit
Mechanical detection unit of height Check the height selector switch,
Although the height selector switch is • Check the height selector switch,
selector switch using Analyzer.
pressed, the automatic lifting stop and adjust or replace it if necessary.
: Gap in detection unit is improperly : Vehicle stopped
position cannot be selected. • Check the harness and repair or
adjusted. Operate the height selector switch
２０１１年１月２５日
Height selector switch harness to see if it turns on and off normally.
: Wire breakage, short circuit
火曜日
Main controller
: Internal failure
If the loading conditions, the tilt angle
of the mast, etc at that time are
different from those when the lifting – –

height was set, the fork stop position
Height selector may not agree with the set position.
(option) Lifting height sensor main body
: Dragging or improper winding of wire Check the lifting sensor voltage, using
Installation of lifting height sensor Analyzer.
The fork stop position is far away from : Breakage of sensor installation : In NL
necessary.
the lifting height set position (100 mm portion, breakage of wire routing Raise and lower the lift to its
or more). portion uppermost (relief) and lowermost
Lifting height sensor harness positions to check the change in the
: Wire breakage, short circuit, voltage.
Change over time of lifting sensor
Check the set value on the lifting stop • Change the setting (see "MULTI-
detection unit
position setting screen. FUNCTION DISPLAY")
Main controller
: Internal failure
• Check the positional relationship
The automatic lifting stop position
The automatic lifting stop position among automatic lifting stop
cannot be selected if the maximum
cannot be selected, although it was set – position, maximum lifting height and
lifting height or the lifting height limit is
for sure. lifting height limit, and set them
set below it.
properly.
Display setting
Shock sensor The shock detection function setting Check the set value on the Option Set • Change the setting (see "MULTI-
: Shock detection function disabled
(option) screen does not appear. screen. FUNCTION DISPLAY")
(SHOCK SENSOR)
4A-203
Control
sec04A.book
systems
4A-204
Way in which the vehicle collides
: The degree of shock that the shock
204 ページ
sensor receives vary depending on

the way and direction in which the
– –
vehicle collides and the object with
which it collides. The shock sensor
does not necessarily detect all kinds
of shock.
Display setting
２０１１年１月２５日
• Change the setting (see "MULTI-

: A too large (improper) value is set –
Although shock is applied, the shock FUNCTION DISPLAY")
for shock detection.
detection alarm does not go on.
火曜日
Shock sensor main body

Check the voltages of shock sensors 1
: Sensitivity reduced
and 2, using Analyzer.
Installation of shock sensor • Check the sensor and replace it if
: Vehicle stopped 2.0 ± 0.21 V
: Improper installation (loosening), necessary.
Apply shock to each sensor to see if
interference • Check the harness and repair or
its voltage changes.
Shock sensor harness replace it if necessary.

(Compare the voltages of sensors 1
and 2.)
Shock sensor
Main controller
(option) – • Replace the main controller.
: Internal failure
• Change the setting.
Display setting
(Set a value that corresponds to
: A too small (improper) value is set –
shock unlikely to be applied during
for shock detection.
normal operation.)
Shock sensor main body
: Internal damage (excessive
response)
Check the voltages of shock sensors 1
Installation of shock sensor
and 2, using Analyzer.
Although no shock is applied, the : Improper installation (loosening), • Check the sensor and replace it if
: Vehicle stopped 2.0 ± 0.21 V
shock detection alarm sets off. interference necessary.
Apply shock to each sensor to see if
Shock sensor harness • Check the harness and repair or
its voltage changes excessively.
: Wire breakage, short circuit, replace it if necessary.
(Compare the voltages of sensors 1
and 2.)
(Especially if there are half-broken
wires in the harness, shock may be
detected frequently.)
Main controller
: Internal failure
Control
sec04A.book
systems
• Change the setting.
One of the following matching
205 ページ
* If accelerator pedal fully closed and

operations is not performed.
fully open matching is finished by
• Tire straight running angle matching
simply performing fully closed
• Forward tilt limit angle matching
matching and fully open matching in
• Tilt horizontal angle matching
[Diagnostic mode indicator] this order, the setting will not be
• Tilt no-load matching Check the matching value on the
Although no error code is displayed, saved.
• Accelerator pedal fully closed Matching screen.
the diagnostic mode indicator is left on.
matching
２０１１年１月２５日
* If brake pedal fully closed and

• Accelerator pedal fully open
operating point matching is finished
matching
by simply performing fully closed
火曜日
• Mini-lever neutral voltage matching

matching and operating point
• Tire diameter data
matching in this order, the setting will
not be saved.
Tilt angle sensor main body
: Internal damage Check the tilt angle sensor voltage,

Multi-function Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
display : The link or the installation portion is : In NL replace it if necessary.
broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
[Tilt indicator] : Wire breakage, short circuit, change in voltage.
The correct tilt angle is not displayed. leakage (harness or connector)
Tilt angle sensor leveling matching
value • Perform matching again.
Matching screen.
No problem if the tilt angle is 0° under
A load is carried. –
no-load conditions.
When a load is carried, the position
where the fork stops when automatic
[Tilt indicator] fork leveling is finished does not
The tilt angle is not indicated as 0° always agree with the position of the
A load is carried. –
when the automatic fork leveling is fork when its tilt angle is indicated as
finished. 0° on the tilt indicator, so the tilt angle
may not be indicated as 0°, depending
on the load.
4A-205
Control
sec04A.book
systems
4A-206
• Check the tires and replace them if
Tire specification necessary.
–
206 ページ
: Type, diameter, tire pressure • Check the pressure of each tire and
repair tires if necessary.
Lock cylinder main body
: Leakage, incapable of locking • Check the lock cylinder, and repair
Check the lock cylinder, using Active
Installation of lock cylinder or replace it if necessary.
Test.
: Installation portion is damaged or • Check the swing solenoid and
: Forcibly turn on (unlocked) and off
broken. replace it if necessary.
２０１１年１月２５日
(locked) the swing solenoid to check

Swing solenoid harness • Check the harness and repair or
the state of the lock cylinder.
: Short circuit, leakage (harness or replace it if necessary.
火曜日
connector)
Check the load sensor voltage, using
Load sensor main body Analyzer.
: Internal damage : In NL
necessary.
Load sensor harness Raise and lower the lift to its
: Wire breakage, short circuit, uppermost (relief) and lowermost

leakage (harness or connector) positions to check the change in the
voltage.
The vehicle lacks stability during
traveling.
Swing lock Lifting height switch main body Analyzer.
(The swing mechanism does not lock • Check the switch, and replace it if
easily or at all during traveling.) necessary.
: Wire breakage, short circuit uppermost and lowermost positions
normally.
Yaw rate sensor main body Check the sensor voltage, using
: Internal failure Analyzer.
necessary.
Yaw rate sensor harness : Vehicle stopped
: Wire breakage, short circuit, Check the sensor voltage approx.
leakage (harness or connector) 2.5V.
sensor
: Internal failure
necessary.
Drive motor rotation sensor harness
– • Check the harness and repair or
• Replace the drive motor drive circuit.
: Internal failure
Main controller
: Internal failure
Control
sec04A.book
systems
• Check the lock cylinder, and repair
Lock cylinder main body Check the lock cylinder, using Active
or replace it if necessary.
: Seizure of lock cylinder Test.
207 ページ
• Check the solenoid and replace it if

Swing solenoid harness : Forcibly turn on (unlocked) and off
necessary.
: Wire breakage, short circuit, (locked) the swing solenoid to check
leakage (harness or connector) the state of the lock cylinder.
２０１１年１月２５日
necessary.
火曜日

voltage.
Lifting height switch main body
Analyzer.
: A high lifting height is always • Check the lifting height switch, and
: In NL
detected. replace it if necessary.
The swing mechanism always locks Raise and lower the lift to its
Lifting switch harness • Check the harness and repair or
Swing lock during traveling or load handling, uppermost and lowermost positions
: Wire breakage, short circuit replace it if necessary.
or it locks frequently. to see if the switch turns on and off
normally.
Yaw rate sensor main body Check the sensor voltage, using
: Internal failure Analyzer.
necessary.
Yaw rate sensor harness : Vehicle stopped
: Wire breakage, short circuit, Check the sensor voltage approx.
leakage (harness or connector) 2.5V.
sensor
: Internal failure
necessary.
Drive motor rotation sensor harness
– • Check the harness and repair or
• Replace the drive motor drive circuit.
: Internal failure
Main controller
: Internal failure
4A-207
Control
sec04A.book
systems
4A-208
208 ページ
Installation of tilt angle sensor using Analyzer. • Check the sensor, and adjust or
: The link or the installation portion is : In NL replace it if necessary.
: Wire breakage, short circuit, change in voltage.
２０１１年１月２５日

Matching screen.
火曜日
When tilted forward for leveling, the Main body of automatic fork leveling
fork does not stop automatically in a switch
Check the automatic fork leveling
horizontal position. : Open failure
switch, using Analyzer. • Check the switch, and replace it if
(The fork tilts to its forward tilt limit Mechanical detection unit of automatic
: Load handling lever in neutral necessary.
without stopping in a horizontal fork leveling switch
Operate the automatic fork leveling • Check the harness and repair or
position.) : Gap in detection unit is improperly

switch to see if it turns on and off replace it if necessary.
adjusted.
normally.
Automatic fork leveling switch harness
Tilt control : Wire breakage (harness, connector)
Oil control valve Check the tilt control valve, using • Check the oil control valve, and
: Seizure of or leakage from tilt Active Test. repair or replace it if necessary.
control valve : Tilt solenoid forcibly turned off • Check the solenoid and replace it if
Tilt solenoid harness (forward tilting stopped) necessary.
: Short circuit, leakage (harness or Tilt the fork forward to check the • Check the harness and repair or
connector) operation. replace it if necessary.
Main controller
: Internal failure
When the fork tilted forward for : The link or the installation portion is : In NL replace it if necessary.
leveling, it does not stop automatically broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
in a horizontal position. Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
(The fork does not stop in a horizontal : Wire breakage, short circuit, change in voltage.
position.) leakage (harness or connector)
Matching screen.
Control
sec04A.book
systems
209 ページ
necessary.
When the fork tilted forward for Load sensor harness Raise and lower the lift to its
leveling, it does not stop automatically : Wire breakage, short circuit, uppermost (relief) and lowermost
in a horizontal position. leakage (harness or connector) positions to check the change in the
(The fork does not stop in a horizontal voltage.
position.) Load sensor no-load matching value Check the matching value on the
• Perform matching again.
: No agreement with the vehicle state Matching screen.
２０１１年１月２５日
Main controller
: Internal failure
火曜日

Tilt control Check the matching value on the
Matching screen.
When tilted forward for leveling, the Check the load sensor voltage, using
fork does not stop automatically in a Load sensor main body Analyzer.
horizontal position. : Internal breakage : In NL
necessary.
(When tilted forward for leveling, the Load sensor harness Raise and lower the lift to its
fork stops where it is when the : Wire breakage, short circuit, uppermost (relief) and lowermost
automatic fork leveling switch is leakage (harness or connector) positions to check the change in the
pressed.) voltage.
Load sensor no-load matching value Check the matching value on the
• Perform matching again.
: No agreement with the vehicle state Matching screen.
Analyzer.
: A high lifting height is always • Check the switch, and replace it if
: In NL
detected. necessary.
Raise and lower the lift to its
uppermost and lowermost positions
to see if the switch turns on and off
normally.
Main controller
: Internal failure
4A-209
Control
sec04A.book
systems
4A-210
210 ページ
(Mini Lever / Joystick Lever) Tilt angle sensor leveling matching
２０１１年１月２５日
When the fork is tilted backward for Check the matching value on the
value • Perform matching again
leveling, it does not stop automatically Matching screen.
in a horizontal position.
火曜日
(The fork tilts to its backward tilt limit Main body of automatic fork leveling
without stopping in a horizontal switch
position.) : Open failure
Mechanical detection unit of automatic
fork leveling switch
: Gap in detection unit is improperly

adjusted.
normally.
Tilt control Main controller
: Internal failure
(Mini Lever / Joystick Lever)
When the fork is tilted backward for See "When the fork is tilted forward for
leveling, it does not stop automatically leveling, it does not stop automatically
– –
in a horizontal position. in a horizontal position (The fork does
(The fork does not stop in a horizontal not stop in a horizontal position.)"
position.)
(Mini Lever / Joystick Lever) : The link or the installation portion is : In NL replace it if necessary.
When the fork is tilted backward for broken or damaged. Tilt the mast to its forward and • Check the harness and repair or
leveling, it does not stop automatically Tilt angle sensor harness backward tilt limits to check the replace it if necessary.
in a horizontal position. : Wire breakage, short circuit, change in voltage.
(The fork stops where it is when the leakage (harness or connector)
automatic fork leveling switch is Tilt angle sensor leveling matching
pressed.) value • Perform matching again.
Matching screen.
Main controller
: Internal failure
Control
sec04A.book
systems
Main body of automatic fork leveling
switch
211 ページ
: Open failure
adjusted.
normally.
２０１１年１月２５日
Check the tilt control valve, using • Check the oil control valve, and
Oil control valve
Active Test. repair or replace it if necessary.
: Seizure of tilt control valve
火曜日
The mast backward tilting speed is not Tilt solenoid harness : Tilt solenoid forcibly turned on • Check the solenoid and replace it if
limited. (backward tilting speed limited) necessary.
Tilt the mast backward to check the • Check the harness and repair or
operation. replace it if necessary.

necessary.
Tilt control : Wire breakage, short circuit uppermost and lowermost positions
normally.
Main controller
: Internal failure
Main body of automatic fork leveling
switch
: Short circuit
adjusted.
The mast backward tilting speed is normally.
always slow. : Short circuit (harness or connector)
Tilt solenoid harness (backward tilting speed not limited) necessary.
: Short circuit, leakage (harness or Tilt the mast backward to check the • Check the harness and repair or
connector) operation. replace it if necessary.
4A-211
Control
sec04A.book
systems
4A-212
Analyzer.
212 ページ
: In NL
The mast backward tilting speed is Lifting switch harness • Check the harness and repair or
always slow. : Wire breakage, short circuit replace it if necessary.
normally.
Main controller
: Internal failure
２０１１年１月２５日
Display setting
Check the set value on the Option Set • Change the setting
: Forward tilting speed setting
火曜日
screen. (see "MULTI-FUNCTION DISPLAY")

(T F-SPD LIM)
Although the load is lifted high, the • Check the switch, and replace it if
Tilt control mast forward tilting speed is not necessary.
limited. • Check the harness and repair or

normally.
Main controller
: Internal failure
Analyzer.
: In NL
The mast forward tilting speed is Lifting switch harness • Check the harness and repair or
always slow. : Wire breakage, short circuit replace it if necessary.
normally.
Main controller
: Internal failure
Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
Knob position The knob is displaced from its normal damaged. fully closed • Check the harness and repair or
compensation position to a certain position. Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
control (10° or more from the straight running : Wire breakage, short circuit, the change in voltage.
(OPT) position) leakage (harness or connector)
Tire angle sensor straight running
angle matching value • Perform matching again.
Matching screen.
Control
sec04A.book
systems
: Internal damage
213 ページ

Check the knob position compensation
The knob is displaced from its normal valve, using Active Test.
２０１１年１月２５日
Knob position compensation valve • Check the knob position

position to a certain position. : Tire end
main body compensation valve, and repair or
(10° or more from the straight running Forcibly turn on (bypass) and off (no
: Leakage, seizure (internal damage) replace it if necessary.
火曜日
position) bypass) the knob position

Knob position compensation solenoid • Check the solenoid and replace it if
compensation solenoid to check
harness necessary.
how the steering system operates.
Forcibly ON ... Steering idles (light).
Forcibly OFF ... Steering does not
idles (heavy).
Knob position The road surface is inclined. – –

compensation Main controller
control : Internal failure
(OPT) Tire angle sensor main body
: Internal failure Check the sensor voltage, using
Installation of tire angle sensor Analyzer. • Check the sensor and replace it if
: Installation portion is broken or : Direction switch in neutral, drive necessary.
damaged. fully closed • Check the harness and repair or
Tire angle sensor harness Turn the steering wheel and check replace it if necessary.
: Wire breakage, short circuit, the change in voltage.
The knob is displaced from its normal leakage (harness or connector)
position. Tire angle sensor straight running
(The knob position is not constant angle matching value • Perform matching again.
Matching screen.
during straight running.) : No agreement with the vehicle state
: Internal damage
4A-213
Control
sec04A.book
systems
4A-214
Check the knob position compensation
valve, using Active Test.
Knob position compensation valve • Check the knob position
214 ページ
: Tire end
main body compensation valve, and repair or
Forcibly turn on (bypass) and off (no
: Leak, seizure replace it if necessary.
bypass) the knob position
Knob position compensation solenoid • Check the solenoid and replace it if
Knob position The knob is displaced from its normal compensation solenoid to check
harness necessary.
compensation position. how the steering system operates.
control (The knob position is not constant Forcibly ON ... Steering idles (light).
(OPT) during straight running.) Forcibly OFF ... Steering does not
２０１１年１月２５日
idles (heavy).
PS cylinder system link is defective. • Check the cylinder, and repair or
–
火曜日
: Eccentric pin or kingpin is defective replace it if necessary.

Main controller
: Internal failure
Seat switch main body : Direction switch in neutral, drive • Check the switch, and replace it if
: Short circuit fully closed necessary.

Neither traveling OPS nor load Seat switch harness Check if the switch turns on and off • Check the harness and repair or
handling OPS operates. : Short circuit (harness or connector) normally, sitting in the seat or replace it if necessary.
standing beside it.
Main controller
: Internal failure
– • Replace the drive motor drive circuit.
: Internal failure
Only traveling OPS does not operate.
Main controller
OPS : Internal failure
Tilt solenoid harness (forward tilting stopped) necessary.
: Short circuit, leakage (harness or Tilt the fork forward to check the • Check the harness and repair or
Only load handling OPS does not connector) operation. replace it if necessary.
operate. Oil control valve • Check the oil control valve, and
Check the lift lowering lock valve,
: Seizure of or leakage from lift repair or replace it if necessary.
using Active Test.
lowering lock valve • Check the solenoid and replace it if
: Lift lock solenoid forcibly turned off
Lift lock solenoid harness necessary.
(lift lock)
: Short circuit, leakage (harness or • Check the harness and repair or
Lower the lift to check the operation.
connector) replace it if necessary.
Control
sec04A.book
systems
• Check the oil control valve, and
Oil control valve (Conventional Lever)
repair or replace it if necessary.
: Seizure of or leakage from load
215 ページ
• Check the material handling

handling proportional valve
proportional valve solenoid, and
: Seizure of or leakage from unload
– replace it if necessary.
Only load handling OPS does not valve
OPS • Check the unload valve solenoid
operate. Harness of unload valve solenoid
２０１１年１月２５日
Main controller
: Internal failure
火曜日

necessary.

voltage.
Display setting
: The tire diameter data is not in Check the tire diameter data on the • Change the setting (see "MULTI-
agreement with the data on the Matching screen. FUNCTION DISPLAY")
Traveling Although no load is applied, the speed actual vehicle state.
control (option) is limited when the lift is raised high. • In traveling control, the attachment
weight and the mast weight are
treated as part of the load weight,
because they affect the longitudinal
stability of the vehicle. For a very
Heavy attachment, mast with a high
– heavy mast or an FSV or FV mast
lifting height
with a high lifting height, if its inner
middle mast is rather heavy, a limit
may sometimes be placed on the
speed even under no-load
conditions.
4A-215
Control
sec04A.book
systems
4A-216
When the lift is raised to its uppermost
position, the load sensor cannot
216 ページ
distinguish this situation from a

situation in which a heavy load is
carried, because, in that situation, a
relief pressure remains in the lift
Lift relief pressure detected. –
Although no load is applied, the speed cylinder pressure that the load sensor
is limited when the lift is raised high. senses.
After a lift relief, however, it becomes
２０１１年１月２５日
possible to perform operation because

the relief pressure is discharged when
the lift is lowered even a little.
火曜日
Main controller
: Internal failure
necessary.
Traveling replace it if necessary.
control (option) voltage.
necessary.
Although a load is carried, the speed is replace it if necessary.
not limited when the lift is raised high. normally.
Display setting
: Traveling control setting disabled
Check the set value on the Option Set • Change the setting (see "MULTI-
Load sensing speed restriction
screen. FUNCTION DISPLAY")
disabled
(ASC W/LOAD, MODE)
Display setting
actual vehicle state.
Main controller
: Internal failure
Control
sec04A.book
systems
Analyzer.
217 ページ
: In NL
Although the fork is not raised high, Raise and lower the lift to its
the speed is limited when a load is uppermost and lowermost positions
carried. to see if the switch turns on and off
normally.
Main controller
Traveling – • Replace the main controller.
: Internal failure
２０１１年１月２５日
control (option)
Display setting • Change the setting (see "MULTI-
Check the set value.
: Maximum speed limit is set very low. FUNCTION DISPLAY")
火曜日
Display setting
A limit is always placed on the speed
regardless of whether a load is carried
or not.
actual vehicle state.
Main controller
: Internal failure
4A-217
Control Circuit
CC12-003
August 31, 2012
8FBCU Pre-charge Circuit Explanation
SERVICE INFORMATION BULLETIN 8FBCU20-32, 8FBCHU25 (-9/2010)
Subject: 8FBCU Pre-charge Circuit Explanation (Error Codes 31-1 and 31-3) Page 1 of 3
MODEL APPLICATION:
8FBCU20-32, 8FBCHU25 (Produced after 9/2010)
REPAIR INFORMATION:
Circuit explanation:
• UICL= Unit In-rush Current Limit: This is a small printed board (black cover and sits in front of
the pump motor controller in the left lower compartment). Inside this box there are 3
thermistors (PTC’s) that are used for slowing in-rush currents.
• RCP=Resistor Current Protect: This is used to control voltage/current timing and is located
behind the controller air box (The wiring is viewable if the battery is removed and battery tray
lifted/removed on left side).
• Why do we need these items?
With the new Kollmorgen controller (much different than the Toyota controllers) they must
check the capacitor banks in each controller by time/voltage rise, so the controller requires a
trickle up effect and current flows through the PTC’s (UICL) and resistor (RCP) to P4 before
closing the MB contactor. If the capacitor banks (inside motor controllers) do not charge to 22
volts in less than 250ms then the motor controller sends an error code to our CPU by CAN
communication (MB never closes). The charge cycle prevents MOSFET’s from being damaged
in the controller if the capacitor circuit is open.
P3 and P4: Do Not connect any UICL=Unit In-rush Current Limit

electrical devices to this circuit.
RCP (Resistor Current Protect). RCP

is located on the air box back side.
Chassis Electrical
CE11-001R
May 13, 2011
Clamp Release Interlock (Mini
Lever Units)
7FBEU15-20, 7FBEHU18,
8FBCU20-32, 8FBCHU25,
SERVICE INFORMATION BULLETIN 8FGCU15-32 and 8FGU15-32
Subject: Clamp Release Interlock (Mini Lever Units) Page 1 of 4
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 8FGCU15-32 and 8FGU15-32
GENERAL INFORMATION:
Starting with units built in October 2010, new units with mini levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments must
have a second release method (2 moves to open the attachment) to prevent accidental opening. Please
refer to Product Bulletins 19-10 and 24-10.
Toyota Designed Circuit for ANSI B56.1
Factory Programmed
The function of the controller is to maintain the

Attachment 2 (ATT21 and ATT22) potentiometer
voltage at a neutral status until the additional switch
(Hall Effect type) on the mini lever is depressed.
System Components:
Clamp Release Interlock (CRI) Controller

• 7FBEU models it is located in the left
step in front of the battery (under the fan
box).
• 8FBCU models it is located behind the
hydraulic tank under the battery.
• 8FGCU and 8FGU models it is located
on the right frame near the transmission.
Clamp Release Controller connector

plug is numbered. Due to changes in
various models and options the color
code can change so it is preferred to
use the pin connection on each unit
and track back to the power supply
and mini lever potentiometer.
12 volt power supply is only used on

the electric trucks (7FBEU or
8FBCU) and is wired to P1 and
N1/N2. It is located near the Clamp
Release Controller.
System Components Continued:
Mini Lever
Potentiometer
Wiring.
680 Ohm Resistor
Calibration Instructions:
Note – Calibration only required when controller is replaced. See note on page 4.
1. Turn truck off.
2. Unplug power supply for CRI controller.
3. Unplug calibration jumper harness.
4. Turn truck on.
5. Plug power supply back in for CRI controller
6. After waiting 15 seconds, place calibration jumper back on harness.
7. Perform matching for lever that has CRI.
Note: After extended usage the variable resistor (level angle sensor ATT2) could encounter a
slight neutral voltage drift and error codes H4-3 and/or H4-4 could be logged. Before replacing
any parts, first recalibrate the CRI module (see page 3) then perform matching of the level
angle sensor (see page 3-68 in repair manual CU331).
Chassis Electrical
CE11-002
August 31, 2011
8FBCU Horn Wires Breaking
SERVICE INFORMATION BULLETIN 8FBCU20-32, 8FBCHU25
Subject: 8FBCU Horn Wires Breaking Page 1 of 1
MODEL APPLICATION:
8FBCU20-32, 8FBCHU25
Beginning with Serial Numbers:

8FBC(H)U20/25-60636
8FBCU30/32-60233
REPAIR INFORMATION:
Starting 11/12/2010 the main wiring harness was changed to lengthen the horn wires. For units built
prior to this change, here is the procedure to modify units in operation that may encounter this
condition:
Chassis Electrical
CE11-003
August 31, 2011
Clamp Release Interlock
(Standard Lever Units)
7FBE(H)U15-20, 8FBC(H)U20-
SERVICE INFORMATION BULLETIN 32, 7FBCU15-55, 8FG(C)U15-32,
7FGCU35-70 and 7FGU35-80
Subject: Clamp Release Interlock (Standard Lever Units) Page 1 of 4
MODEL APPLICATION:
7FBEU15-20, 7FBEHU18, 8FBCU20-32, 8FBCHU25, 7FBCU15-55
8FGCU15-32, 8FGU15-32, 7FGCU35-70 and 7FGU35-80
Starting with October 2010, new units with standard hydraulic levers may be equipped with a Clamp
Release Interlock Circuit. ANSI B56.1 states that all units with clamp attachment or roll attachments
must have a 2nd release method (2 moves to open the attachment) to prevent accidental opening.
Please refer to product bulletins 19-10 and 24-10.
Toyota Designed Circuit for ANSI B56.1

Switch and Wiring Installation
Clamp release switch

Switch assembly and wiring as routed
by the factory.
Wire routing through boot and lever

connects to relay circuit.
Solenoid and Hydraulic Hose Connections
Hose Connection at Oil Control Valve Hose to Attachment Spacer Plate
Bolts
Relay
Solenoids 12, 36 and

48 volts (Voltage
Specific).
Hose from Fitting

valve
This drawling is an example of an

8FBCU25 only. Most locations of the
solenoid and relay are close to the
Oil Control Valve (right side of
frame).
Power and Ground Wire Connections
This drawing is an example of the

panel connections for an 8FBCU25
and will be similar on all electric
products. For IC trucks, the
positive and negative sources are
connected directly to the battery.
Maintenance
MA12-004
May 31, 2012
8FBCU Repair Manual Updates
SERVICE INFORMATION BULLETIN Models 8FBCU20-32
Subject: 8FBCU Repair Manual Updates Page 1 of 14
MODEL APPLICATION:
8FBCU20-32
Please replace the following pages in your repair manual CU347-1.
Chassis Electrical
CE14-005
August 15, 2014
Special Grounding Strap
(30)/7FBCU15-32, 7FBCHU25,
SERVICE INFORMATION BULLETIN 8FBCU20-32
Subject: Special Grounding Strap Page 1 of 2
MODEL APPLICATION:
(30)/7FBCU15-32, 7FBCHU25, 8FBCU20-32
This special grounding strap can be added to the models mentioned above. This strap has
excellent conductance to reduce ESD (Electro Static Discharge) when using non marking tires.
Parts Required for One Unit
56184-21320-71 (2 PCS)
Install earth wire after setting
collars.
56401-21320-71
Mount using the rear
91551-80816 (2 PCS)
steer axle mounting
bolts.
56412-21320-71
56185-21320-71
Subject: Special Grounding Strap Page 2 of 2
If the grounding strap cannot be attached to the rear axle, use the alternate method below.

8fbc (H) U Section 4a Vol 2 Cu347-1

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8fbc (H) U Section 4a Vol 2 Cu347-1

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book 1 ページ ２０１１年１月２５日 火曜日 午後６時３５分

Description Page# Date

Hotline Tech Tips

3. Bring a tester probe into contact with a connector terminal from

WIRE HARNESS AND CONNECTOR

Short circuit check

Measure while lightly shaking the wire harness up and down

3. Measure the resistance between a terminal corresponding to

The wiring may short-circuit due to pinching by the body or

Visual and contact pressure checks

• Insert a male terminal same as that of the terminal to a female

Click here for information on

SDM: 1 To the next step depending on the result.

Main controller defect

Inspection: Check of seat switch condition

SST No. SST name remarks

CN7 IC check pin E2-2

Indicator : Diagnostic mode

Indication Memory Lamp Error mode Phenomenon on vehicle Remarks

O/H Load handling stop.

blinking Traveling stop.

Diagnostic Pump motor output restricted.

CC-4 CC-4 mode Drive motor drive CPU error.

Knob position correcting stop.

54-3 54-3 mode Swing lock solenoid drive circuit abnormality.

Height selector disable.

Lift speed limited.

H1-1 H1-1 mode Lift lever potentiometer open.

Attachment 1 stop. (Conventional lever)

Upward lift stop.

Downward lift stop.

H5-6 H5-6 mode Lift proportional solenoid (PULL/PUSH) abnormality.

H7-6 H7-6 mode Attachment 1 PULL/PUSH solenoid abnormality.

Lift upward or tilt backward may operate while OPS is

Shock sensor disabled.

G5-6 G5-6 mode Shock sensor 2 neutral voltage error.

WHEN ERROR CODE IS DISPLAYED

CN101-3 (97,FAN+) CN112-1

Drive motor drive circuit

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Operate check of three cooling fans, Please apply the

The fans rotate.

Inspection: Temperature check

[ANL] I/O TEMP/VOLT 2/4

Record the value of

[ANL] I/O TEMP/VOLT 2/4

Drive motor drive circuit defect

Inspection 1: Harness check

The fans rotate.

The fans rotate.

Connector contact defect

Inspection 1: Harness check

Portions to be checked Standard

z Error Code A0-2 (Pump motor power-circuit overheating abnormality)

CN101-3 (97,FAN+) CN112-1

Pump motor drive circuit

If AB-1 is also displayed, perform troubleshooting with priority given to AB-1.

Operate check of three cooling fans, Please apply the

The fans rotate.

Inspection: Temperature check

[ANL] I/O TEMP/VOLT 2/4

Record the value of

book 1 ページ２０１１年１月２５日火曜日午後６時３５分