8FBH10, 14, 15, 18, 20, 25 8FBJ35

8FB10, 14, 15, 18, 20, 25, 30

8FB10, 14, 15, 18, 20, 25, 30
8FBH10, 14, 15, 18, 20, 25
8FBJ35

2
TROUBLESHOOTING
2Pub. No. CE210

Pub. No. CE210 Pub. No. CE210

 FOREWORD
This Manual (Volume 2) contains electrical wiring diagrams, diagnosis
and service procedures of electrical controller and display of the TOYOTA
ELECTRICAL POWERED FORKLIFT 8FB10 to 30 series and 8FBJ35.

For maintenance, specifications and repair procedure for the chassis,

body, material handling system and display please refer to Volume 1
(Pub. No. CE209) issued simultaneously.

Please use these manuals for providing quick, correct servicing of the
corresponding forklift models.

This manual deals with the above models as of January, 2017. Please
understand that disagreement can take place between the descriptions in
the manual and actual vehicles due to change in design and
specifications. Any change or modifications thereafter will be informed by
Toyota Industrial Equipment Parts & Service News.

(Reference)
Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 8FB10 - J35

NEW MODEL FEATURES (Pub. No. PE204)

TOYOTA INDUSTRIAL EQUIPMENT 8FB10 - J35

REPAIR MANUAL VOL.1 (Pub. No. CE209)
 i

Table of Contents
1 ELECTRICAL TROUBLESHOOTING ...................................................... 2
2 APPENDIX ............................................................................................ 509
1-2 1 ELECTRICAL TROUBLESHOOTING

1 ELECTRICAL TROUBLESHOOTING
1.1 SST............................................................................................................ 2
1.2 BEFORE TROUBLESHOOTING............................................................... 3
1.3 DIAGNOSIS CODE LIST........................................................................... 5
1.4 WHEN ERROR CODES ARE DISPLAYED ............................................ 17
1.5 NO ERROR CODE IS DISPLAYED ...................................................... 467

1.1 SST
In the electrical troubleshooting of 8FB series, an SST is used for accurate and instant inspection.
Incorrect connection will fail in correct check. Since boards may be damaged by incorrect connection, careful
operation is necessary.
No. Title
Short harness
09230-13700-71
(CN91)
Short harness
SST2: (For CN6, CN19, CN26, CN55, CN56, CN68, CN79, CN86, CN91, CN96,
09232-13130-71 CN97, CN101, CN110, CN115, CN119, CN120, CN121, CN122, CN123,
CN129, CN137, CN163, CN260)
SST8: Check harness
09238-13130-71 (CN124)
SST15: Check harness
09236-13900-71 (CN92, CN93, CN99)
09240-13241-71 Harness for Motor Driver (for voltage measurement)

TruckCom is used for troubleshooting telematics installed vehicles (OPT).

The following SST are for TruckCom.
For details on how to operate TruckCom, refer to TruckCom Instruction Manual.
No. Title
09250-82110-71 Castor USB
09561-12640-71 PC-CAN cable

CAUTION
Be sure to disconnect the battery plug before installing and removing each SST.
If the battery plug is kept connected, board damage may result.
1 ELECTRICAL TROUBLESHOOTING 1-3

1.2 BEFORE TROUBLESHOOTING 1

1.2.1 CONNECTOR HANDLING

1. Always disconnect the battery plug before connecting
and disconnecting each connectors and terminals.
2. When disconnecting the connectors, make sure to
pull it out with the connector unlocked and by holding
the main unit; not by pulling the harness.
When connecting, make sure to push it in until it is
locked.

3. When using a tester probe on the connector, always

use the tester rod by touching the connector from the
rear side of the connector (from the harness side).
4. For those connectors that cannot be inserted from the
rear side, such as the water resistant connectors,
carefully touch the connector with the test probe, so
that the connector’s terminals will not be deformed.
5. Do not touch the terminals of the connectors directly
with your hands.
6. When touching electrically charged connectors with
the tester probes, extra caution should be taken so
that the two tester probes will not touch one another.

1.2.2 WIRE HARNESS AND CONNECTOR INSPECTION

PROCEDURE
When a trouble occurs, inspect the relative connectors of the circuit and the wire harnesses using the follow-
ing procedure.

Continuity check
1. Disconnect the connectors at the both ends of the
harness.
2. Measure resistance between the terminals of the con-
nectors at each ends.
Standard: 10 Ω or less
NOTICE! :
▪ Measure the terminals by lightly rocking the
harness up and down, and from right to left.
▪ In case of a wire disconnection, it is rare that
the disconnection occurs at the mid point of
the vehicle’s wiring: most of the time, it oc-
curs at the connector area. Inspect the con-
nectors carefully, especially at the sensor
area.
1-4 1 ELECTRICAL TROUBLESHOOTING

Short Circuit Check

1. Disconnect the connectors at the both ends of the
harness.
2. Measure resistance between the terminals of the con-
nector and the frame. Always inspect connectors at
both sides.
Standard: 1M Ω or more
NOTICE! :
▪ Measure the terminals by lightly rocking the
harness up and down, and from right to left.

3. Measure resistance between the terminals of the con-

nector and another terminal of the same connector.
Always inspect connectors at both sides.
Standard: 1M Ω or more
NOTICE! :
▪ Shortages could happen by wirings being
jammed by the body or by a clamp failure.

Visual and Terminal Contact Inspection

1. Disconnect the connectors at the both ends of the
harness.
2. Perform a visual inspection to check whether there
are no rusting on the connector terminals and jam-
ming of foreign materials.
3. Inspect to see whether there are no loosening or
damages at the wire caulking, and whether the wire
will not be disconnected by lightly pulling the wire har-
ness from the connector.

4. Inspect the drawing force by preparing a same male

connector and inserting it into the female connector.
Terminals that have less drawing force compared to
other terminals could have a contact failure.
NOTICE! :
▪ If the connector has rusting, jamming of for-
eign materials or lowering of contact pressure
between the male and the female terminals,
disconnection of the connector could change
the connection condition and could result as
“no failure.” In this case, repeat the discon-
nection and connection of the connector sev-
eral times, and if there is even one failure,
there could be a possibility of a contact fail-
ure.
1 ELECTRICAL TROUBLESHOOTING 1-5

1.3 DIAGNOSIS CODE LIST 1

Display : Diagnostic codes shown on the display when an error occurs
Memory : Diagnostic codes recorded in the main controller when an error occurs
This can be viewed in the diagnosis memory function.
Indicators : Spanner

O/H (Overheat warning)

BT O/H (Battery fluid temperature warning)

○ UP LED (Charger operation panel completion LED)

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Drive motor driver main
O/H Drive motor
DCR A0-1 circuit temperature ab- Traveling disabled page 18
turned on driver
normal rise
Pump motor driver main Material handling disabled,
O/H Pump motor
PCR A0-2 circuit temperature ab- the steering becomes page 22
turned on driver
normal rise heavy
Traveling and material
Spanner Main controller high
A1-1 A1-1 Main controller handling disabled, the page 26
blinks voltage
steering becomes heavy
Spanner Drive motor Drive motor driver high
A1-2 A1-2 Traveling disabled page 28
blinks driver voltage
Material handling disabled,
Spanner Pump motor Pump motor driver high
A1-4 A1-4 the steering becomes page 30
blinks driver voltage
heavy
Main controller board
O/H
C/R A2-1 Main controller temperature abnormal Travel slowly page 32
turned on
rise
Drive motor driver board
O/H Drive motor
DCR A2-2 temperature abnormal Traveling disabled page 34
turned on driver
rise
Pump motor driver board Material handling disabled,
O/H Pump motor
PCR A2-3 temperature abnormal the steering becomes page 38
turned on driver
rise heavy
Traveling and material
Spanner Battery improper connec-
A3-1 A3-1 Main controller handling disabled, the page 42
blinks tion
steering becomes heavy
Traveling and material
Spanner Battery improper connec-
A3-2 A3-2 Main controller handling disabled, the page 43
blinks tion (incorrect voltage)
steering becomes heavy
OPS function disabled,
auto power off function dis-
Spanner Seat switch short circuit abled
A5-1 A5-1 Main controller page 44
blinks abnormality Parking brake non-pulling
warning disabled while key
is on
Spanner Tilt switch short circuit
A6-3 A6-3 Main controller Tilt disabled page 46
blinks abnormality
Traveling and material
Spanner
A8-1 A8-1 Main controller F1 fuse open abnormality handling disabled, the page 48
blinks
steering becomes heavy
Spanner Travel/load handling dis-
A8-2 A8-2 Main controller F6 fuse open abnormality page 51
blinks abled
Spanner F7 fuse / solenoid power
A9-2 A9-2 Main controller Load handling disabled page 54
blinks line open abnormality
1-6 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Main controller board
Spanner temperature sensor
AA-1 AA-1 Main controller Travel slowly page 57
blinks open/VCC short circuit
abnormality
Drive motor driver board
Reduced maximum travel-
Spanner Drive motor temperature sensor
AA-2 AA-2 ing speed, acceleration be- page 58
blinks driver open/VCC short circuit
comes slow
abnormality
Pump motor driver board
Spanner Pump motor temperature sensor Load lifting speed restric-
AA-4 AA-4 page 59
blinks driver open/VCC short circuit tion
abnormality
Spanner Travel slowly, cooling fan
AB-1 AB-1 Main controller Cooling fan overcurrent page 60
blinks disabled
Cooling fan open/short
Spanner Travel slowly, cooling fan
AB-2 AB-2 Main controller circuit abnormality (80V page 65
blinks disabled
vehicle)
Traveling and material
Spanner Motor driver power sup-
AC-1 AC-1 Main controller handling disabled, the page 68
blinks ply abnormality
steering becomes heavy
Drive motor driver to Traveling disabled,
Spanner
AD-1 AD-1 Main controller main controller commu- knob position correction page 70
blinks
nication abnormality disabled
Drive motor driver to Traveling disabled,
Spanner
AD-2 AD-2 Main controller main controller commu- knob position correction page 71
blinks
nication abnormality disabled
Pump motor driver to Material handling disabled,
Spanner
AD-5 AD-5 Main controller main controller commu- the steering becomes page 77
blinks
nication abnormality heavy
Pump motor driver to Material handling disabled,
Spanner
AD-6 AD-6 Main controller main controller commu- the steering becomes page 78
blinks
nication abnormality heavy
Traveling and material
Spanner Main controller CPU ab-
AF-1 AF-1 Main controller handling disabled, the page 81
blinks normality
steering becomes heavy
Traveling and material
Spanner Main controller CPU ab-
AF-2 AF-2 Main controller handling disabled, the page 81
blinks normality
steering becomes heavy
Traveling and material
Spanner Main controller CPU ab-
AF-3 AF-3 Main controller handling disabled, the page 81
blinks normality
steering becomes heavy
Traveling and material
Spanner Main controller CPU ab-
AF-4 AF-4 Main controller handling disabled, the page 81
blinks normality
steering becomes heavy
Spanner Main controller CPU ab- Various control operations
AF-5 AF-5 Main controller page 81
blinks normality not stable
Spanner Main controller CPU ab- Various control operations
AF-6 AF-6 Main controller page 81
blinks normality not stable
Spanner Main controller CPU ab- Various control operations
AF-7 AF-7 Main controller page 81
blinks normality not stable
Spanner Main controller CPU ab- Various control operations
AF-8 AF-8 Main controller page 81
blinks normality not stable
Spanner Drive motor Drive motor driver main
C0-2 C0-2 Traveling disabled page 82
blinks driver circuit abnormality
1 ELECTRICAL TROUBLESHOOTING 1-7

Dis- Mem Indicat- Detection Reference

play ory ors ECU
Failure mode Phenomenon on vehicle
pages 1
Drive motor driver current
Spanner Drive motor
C1-1 C1-1 sensor neutral abnormal- Traveling disabled page 90
blinks driver
ity
Drive motor driver current
Spanner Drive motor
C1-2 C1-2 sensor overcurrent ab- Traveling disabled page 91
blinks driver
normality
Reduced maximum travel-
O/H Drive motor Drive motor temperature
DM C2-1 ing speed, acceleration be- page 94
turned on driver abnormal rise
comes slow
Drive motor temperature Reduced maximum travel-
Spanner Drive motor
C2-2 C2-2 sensor open/short circuit ing speed, acceleration be- page 96
blinks driver
abnormality comes slow
Drive motor driver main
circuit temperature Reduced maximum travel-
Spanner Drive motor
C3-1 C3-1 sensor ing speed, acceleration be- page 98
blinks driver
open/short circuit abnor- comes slow
mality
Accelerator poten-
Spanner Error display only, normal
C4-1 C4-1 Main controller tiometer page 99
blinks operation is possible
POT1 open abnormality
Accelerator poten-
Spanner Error display only, normal
C4-2 C4-2 Main controller tiometer page 101
blinks operation is possible
POT2 open abnormality
Accelerator poten-
Spanner tiometer Error display only, normal
C4-3 C4-3 Main controller page 103
blinks POT1 VCC short circuit operation is possible
abnormality
Accelerator poten-
Spanner tiometer Error display only, normal
C4-4 C4-4 Main controller page 105
blinks POT2 VCC short circuit operation is possible
abnormality
Accelerator poten-
Spanner
C4-5 C4-5 Main controller tiometer offset abnormal- Traveling disabled page 107
blinks
ity
Accelerator play becomes
Accelerator poten-
Spanner excessive, maximum trav-
C4-6 C4-6 Main controller tiometer matching value page 110
blinks eling speed cannot be
abnormality
reached
Spanner Brake potentiometer Error display only, normal
C5-1 C5-1 Main controller page 112
blinks POT1 open error operation is possible
Spanner Brake potentiometer Error display only, normal
C5-2 C5-2 Main controller page 114
blinks POT2 open abnormality operation is possible
Brake potentiometer
Spanner Error display only, normal
C5-3 C5-3 Main controller POT2 VCC short circuit page 116
blinks operation is possible
abnormality
Brake potentiometer
Spanner Error display only, normal
C5-4 C5-4 Main controller POT2 VCC short circuit page 118
blinks operation is possible
abnormality
Reduced maximum travel-
Spanner Brake potentiometer off-
C5-5 C5-5 Main controller ing speed, acceleration be- page 120
blinks set abnormality
comes slow
Brake potentiometer
Spanner
C5-6 C5-6 Main controller matching value abnor- Traveling disabled page 123
blinks
mality
Spanner Drive motor Drive motor rpm sensor
C8-1 C8-1 Traveling disabled page 125
blinks driver open abnormality
1-8 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Spanner Drive motor Drive motor rpm sensor
C8-2 C8-2 Traveling disabled page 129
blinks driver short circuit abnormality
Spanner Tilt angle sensor open Slope assist function dis-
C9-1 C9-1 Main controller page 133
blinks abnormality abled
Spanner Tilt angle sensor short Slope assist function dis-
C9-2 C9-2 Main controller page 135
blinks abnormality abled
Spanner Tilt angle sensor match- Slope assist function dis-
C9-3 C9-3 Main controller page 137
blinks ing value abnormality abled
Traveling and material
Spanner MB contactor open ab-
CB-1 CB-1 Main controller handling disabled, the page 139
blinks normality
steering becomes heavy
Spanner MB contactor short circuit Error display only, normal
CB-2 CB-2 Main controller page 144
blinks abnormality operation is possible
Traveling and material
Spanner MB contactor coil side
CB-3 CB-3 Main controller handling disabled, the page 148
blinks open abnormality
steering becomes heavy
Traveling and material
Spanner MB contactor drive circuit
CB-4 CB-4 Main controller handling disabled, the page 151
blinks abnormality
steering becomes heavy
Traveling and material
Spanner MB contactor coil side
CB-5 CB-5 Main controller handling disabled, the page 154
blinks short circuit abnormality
steering becomes heavy
Spanner Drive motor Drive motor driver CPU
CC-1 CC-1 Traveling disabled page 157
blinks driver abnormality
Spanner Drive motor Drive motor driver CPU
CC-2 CC-2 Traveling disabled page 157
blinks driver abnormality
Spanner Drive motor Drive motor driver CPU
CC-3 CC-3 Stop traveling page 157
blinks driver abnormality
Spanner Drive motor Drive motor driver CPU
CC-4 CC-4 Traveling disabled page 157
blinks driver abnormality
Spanner Drive motor Drive motor driver CPU Error display only, normal
CC-6 CC-6 page 157
blinks driver abnormality operation is possible
Material handling disabled,
Spanner Pump motor Pump motor driver main
E0-2 E0-2 the steering becomes page 158
blinks driver circuit abnormality
heavy
Pump motor driver cur- Material handling disabled,
Spanner Pump motor
E1-1 E1-1 rent sensor neutral ab- the steering becomes page 165
blinks driver
normality heavy
Pump motor driver cur- Material handling disabled,
Spanner Pump motor
E1-2 E1-2 rent sensor overcurrent the steering becomes page 166
blinks driver
abnormality heavy
O/H Pump motor Pump motor temperature Load lifting speed restric-
PM E2-1 page 169
turned on driver abnormal rise tion
Pump motor temperature
Spanner Pump motor Load lifting speed restric-
E2-2 E2-2 sensor open/short circuit page 171
blinks driver tion
abnormality
Pump motor driver main
Spanner Pump motor circuit temperature Load lifting speed restric-
E3-1 E3-1 page 173
blinks driver sensor open/short circuit tion
abnormality
Material handling disabled,
Spanner Pump motor Pump motor rpm sensor
E8-1 E8-1 the steering becomes page 174
blinks driver open abnormality
heavy
1 ELECTRICAL TROUBLESHOOTING 1-9

Dis- Mem Indicat- Detection Reference

play ory ors ECU
Failure mode Phenomenon on vehicle
pages 1
Material handling disabled,
Spanner Pump motor Pump motor rpm sensor
E8-2 E8-2 the steering becomes page 177
blinks driver short circuit abnormality
heavy
Material handling disabled,
Spanner Pump motor Pump motor driver CPU
EC-1 EC-1 the steering becomes page 180
blinks driver abnormality
heavy
Material handling disabled,
Spanner Pump motor Pump motor driver CPU
EC-2 EC-2 the steering becomes page 180
blinks driver abnormality
heavy
Material handling disabled,
Spanner Pump motor Pump motor driver CPU
EC-3 EC-3 the steering becomes page 180
blinks driver abnormality
heavy
Material handling disabled,
Spanner Pump motor Pump motor driver CPU
EC-4 EC-4 the steering becomes page 180
blinks driver abnormality
heavy
Spanner Pump motor Pump motor driver CPU Error display only, normal
EC-6 EC-6 page 180
blinks driver abnormality operation is possible
Spanner CAN bridge communica-
ED-1 ED-1 Main controller Cannot authenticate page 181
blinks tion disruption
CAN bridge controller /
Spanner CAN bridge operation management
ED-4 ED-4 Cannot authenticate page 186
blinks controller system communication
disruption
Display to main controller
Spanner Display
EE-1 EE-1 Main controller communication abnor- page 189
blinks Function partially disabled
mality
Display to main controller
Spanner Display
EE-2 EE-2 Main controller communication abnor- page 189
blinks Function partially disabled
mality
Main controller to display
Spanner Display
F1-1 F1-1 Display communication abnor- page 190
blinks Function partially disabled
mality
Main controller to display
Spanner Display
F1-2 F1-2 Display communication abnor- page 191
blinks Function partially disabled
mality
Travel load handling simul-
taneous operation disabled
Spanner
F4-1 F4-1 Display Display CPU abnormality Cannot authenticate for page 193
blinks
PIN code entry specifica-
tion
Travel load handling simul-
taneous operation disabled
Spanner
F4-2 F4-2 Display Display CPU abnormality Cannot authenticate for page 193
blinks
PIN code entry specifica-
tion
Travel load handling simul-
taneous operation disabled
Spanner
F4-3 F4-3 Display Display CPU abnormality Cannot authenticate for page 193
blinks
PIN code entry specifica-
tion
Spanner
F4-4 F4-4 Display Display CPU abnormality Error display only page 193
blinks
Spanner
F4-5 F4-5 Display Display CPU abnormality Display function not stable page 193
blinks
Spanner Various control operations
F4-6 F4-6 Display Display CPU abnormality page 193
blinks not stable
1-10 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Spanner Various control operations
F4-7 F4-7 Display Display CPU abnormality page 193
blinks not stable
Spanner Various control operations
F4-8 F4-8 Display Display CPU abnormality page 193
blinks not stable
Sensor for Battery Fluid Battery protection function
Spanner Temperature vehicle con- disabled
F5-1 F5-1 Display page 194
blinks nection harness open ab- Battery Data Log Function
normality partially disabled
Sensor for Battery Tem- Battery protection function
Spanner perature vehicle connec- disabled
F5-2 F5-2 Display page 197
blinks tion harness short circuit Battery Data Log Function
abnormality partially disabled
Battery protection function
Sensor for Battery Fluid
Spanner disabled
F5-3 F5-3 Display Temperature open abnor- page 201
blinks Battery Data Log Function
mality
partially disabled
Battery protection function
Battery fluid temperature
Spanner disabled
F5-4 F5-4 Display sensor temperature ab- page 203
blinks Battery Data Log Function
normality
partially disabled
UP LED On-vehicle charger char-
blinks ging failure (total timer
F6-1 F6-1 Display Charging disabled page 205
Spanner activation) (1 - 2 ton
blinks vehicles)
UP LED On-vehicle charger char-
blinks ging failure (safety timer
F6-1 F6-1 Display Charging disabled page 213
Spanner activation) (3 ton
blinks vehicles)
UP LED
blinks On-truck charger trans-
F6-2 F6-2 Display former overheat (1 - 2 ton Charging disabled page 216
Spanner vehicles)
blinks
UP LED
blinks On-truck charger trans-
F6-2 F6-2 Display former overheat (3 ton Charging disabled page 222
Spanner vehicles)
blinks
UP LED
blinks On-truck charger char-
F6-3 F6-3 Display ging failure (safety timer Charging disabled page 228
Spanner activation)
blinks
UP LED
blinks On-truck charger char-
F6-4 F6-4 Display Charging disabled page 236
Spanner ging disabled
blinks
UP LED
blinks On-truck charger char-
F6-5 F6-5 Main controller Charging disabled page 239
Spanner ging current abnormality
blinks
UP LED
blinks On-truck charger char-
F6-6 F6-6 Display Charging disabled page 246
Spanner ging voltage abnormality
blinks
1 ELECTRICAL TROUBLESHOOTING 1-11

Dis- Mem Indicat- Detection Reference

play ory ors ECU
Failure mode Phenomenon on vehicle
pages 1
UP LED
blinks On-truck charger char-
F7-1 F7-1 Display ging start failure (1-2 ton Charging disabled page 251
Spanner models)
blinks
UP LED On-truck charger char-
blinks ging start failure (Char-
F7-1 F7-1 Display Cannot charge page 260
Spanner ging start disabled) (3 ton
blinks models)
UP LED
blinks On-truck charger char-
F7-2 F7-2 Display Charging disabled page 268
Spanner ging over-voltage
blinks
UP LED
blinks On-truck charger over-
F7-3 F7-3 Display Charging disabled page 272
Spanner current abnormality
blinks
UP LED
blinks On-truck charger charge
F7-4 F7-4 Display current control abnormal- Charging disabled page 276
Spanner ity
blinks
UP LED
blinks On-truck charger magnet
F7-5 F7-5 Display Charging disabled page 280
Spanner abnormality
blinks
UP LED
blinks Drive /
On-truck charger driver
F7-6 F7-6 Pump Motor Charging disabled page 286
Spanner overcurrent
Driver
blinks
UP LED
blinks Drive / Connection error of on-
F7-7 F7-7 Pump Motor truck charger transformer Charging disabled page 292
Spanner Driver cable
blinks
Drive / On-truck charger charge
Spanner
F7-8 F7-8 Pump Motor current control abnormal- Charging output decrease page 294
blinks
Driver ity
UP LED On-truck charger char-
blinks ging completion failure
F8-1 F8-1 Display Charging will not finish page 298
Spanner (Charging completion dis-
blinks abled) (3 ton models)
Spanner On-truck charger system
F8-2 - Display Charging disabled page 303
blinks abnormality
Spanner CAN bridge CAN bridge controller
FA-1 FA-1 Cannot authenticate page 304
blinks controller CPU abnormality
Spanner CAN bridge CAN bridge controller
FA-2 FA-2 Cannot authenticate page 304
blinks controller CPU abnormality
Spanner CAN bridge CAN bridge controller
FA-3 FA-3 Cannot authenticate page 304
blinks controller CPU abnormality
1-12 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Power meter function dis-
abled, watt-hour meter
function disabled
Spanner Battery current sensor Battery Data Log Function
FB-1 FB-1 Main controller page 305
blinks neutral abnormality partially disabled
Tolerance of battery level
display after auxiliary
charge increases
Power meter function dis-
abled, watt-hour meter
function disabled
Spanner Battery current sensor Battery Data Log Function
FB-2 FB-2 Main controller page 308
blinks overcurrent partially disabled
Tolerance of battery level
display after auxiliary
charge increases
BT O/H
turned on Reduced traveling capabil-
Battery fluid temperature
- FC-1 Main controller ity, acceleration becomes page 311
Spanner overheat
slow
blinks
Spanner Display power supply cir-
FF-1 FF-1 Main controller Display turned off page 313
blinks cuit overcurrent
Steering becomes heavy
Spanner Steering sensor power
FF-2 FF-2 Main controller Knob position correction page 314
blinks supply circuit overcurrent
disabled
Spanner Drive motor Drive motor driver :con- Error display only, normal
32-1 32-1 page 316
blinks driver troller ID abnormality operation is possible
Spanner Pump motor Pump motor driver :con- Error display only, normal
32-3 32-3 page 317
blinks driver troller ID abnormality operation is possible
Main controller to Drive
Spanner Drive motor
33-1 33-1 motor driver : communic- Traveling disabled page 318
blinks driver
ation abnormality
Main controller to Pump Material handling disabled,
Spanner Pump motor
33-3 33-3 motor driver : communic- the steering becomes page 320
blinks driver
ation abnormality heavy
Spanner Yaw rate sensor open
52-1 52-1 Main controller Swing lock disabled page 322
blinks abnormality
Spanner Yaw rate sensor short
52-2 52-2 Main controller Swing lock disabled page 324
blinks abnormality
Spanner Yaw rate sensor neutral
52-3 52-3 Main controller Swing lock disabled page 326
blinks voltage abnormality
Spanner Swing solenoid open ab-
54-1 54-1 Main controller Swing lock is kept page 328
blinks normality
Spanner Swing solenoid short ab-
54-2 54-2 Main controller Swing lock is kept page 331
blinks normality
Spanner Swing solenoid drive cir-
54-3 54-3 Main controller Swing lock is kept page 334
blinks cuit abnormality
Spanner Swing solenoid open/
54-4 54-4 Main controller Swing lock is kept page 336
blinks short abnormality
Partial limitation of mast
control function
Limitation of travel control
Spanner Load sensor open abnor-
61-1 61-1 Main controller function page 340
blinks mality
Limitation of lift height and
load sensing steering
speed control
1 ELECTRICAL TROUBLESHOOTING 1-13

Dis- Mem Indicat- Detection Reference

play ory ors ECU
Failure mode Phenomenon on vehicle
pages 1
Partial limitation of mast
control function
Limitation of travel control
Spanner Load sensor short abnor-
61-2 61-2 Main controller function page 342
blinks mality
Limitation of lift height and
load sensing steering
speed control
Spanner Tilt angle sensor open Partial limitation of mast
62-1 62-1 Main controller page 344
blinks abnormality control function
Spanner Tilt angle sensor short Partial limitation of mast
62-2 62-2 Main controller page 346
blinks abnormality control function
Tilt switch forward/back-
Spanner Partial limitation of mast
63-1 63-1 Main controller ward tilt simultaneous page 348
blinks control function
short circuit abnormality
Tilt switch forward tilt
Spanner Partial limitation of mast
63-2 63-2 Main controller continuous short circuit page 350
blinks control function
abnormality
Tilt switch backward tilt
Spanner Partial limitation of mast
63-3 63-3 Main controller continuous short circuit page 351
blinks control function
abnormality
Spanner Lift lock solenoid open
64-1 64-1 Main controller Lift lowering disabled page 352
blinks abnormality
Spanner Lift lock solenoid short
64-2 64-2 Main controller Lift lowering disabled page 355
blinks abnormality
Lift lowering may be pos-
Spanner Lift lock solenoid driving
64-3 64-3 Main controller sible even during OPS page 358
blinks circuit abnormality
(standard lever)
Lift lowering may be pos-
Spanner Lift lock solenoid open/
64-4 64-4 Main controller sible even during OPS page 360
blinks short abnormality
(standard lever)
Spanner Tilt solenoid open abnor-
65-1 65-1 Main controller Front tilt disabled page 362
blinks mality
Spanner Tilt solenoid short abnor-
65-2 65-2 Main controller Front tilt disabled page 365
blinks mality
Lift lowering may be pos-
Spanner Tilt solenoid driving cir-
65-3 65-3 Main controller sible even during OPS page 368
blinks cuit abnormality
(standard lever)
Lift lowering may be pos-
Spanner Tilt solenoid open/short
65-4 65-4 Main controller sible even during OPS page 370
blinks abnormality
(standard lever)
Spanner Tilt matching value out of Partial limitation of mast
66-1 66-1 Main controller page 372
blinks range abnormality control function
Partial limitation of mast
control function
Limitation of travel control
Spanner Lifting height switch
67-1 67-1 Main controller function page 374
blinks open / short abnormality
Limitation of lift height and
load sensing steering
speed control
Spanner Lift height 800 mm switch
67-5 67-5 Main controller Travel slowly page 379
blinks short abnormality
Knob position correction
disabled
Spanner Tire angle sensor open
71-1 71-1 Main controller Limitation of lift height and page 381
blinks abnormality
load sensing steering
speed control function
1-14 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
Knob position correction
disabled
Spanner Tire angle sensor short
71-2 71-2 Main controller Limitation of lift height and page 383
blinks abnormality
load sensing steering
speed control function
Knob position correction
disabled
Spanner Tire angle sensor anchor-
71-3 71-3 Main controller Limitation of lift height and page 385
blinks ing abnormality
load sensing steering
speed control function
Knob position correction
Steering-wheel angle
Spanner disabled
72-1 72-1 Main controller sensor SS1 open abnor- page 387
blinks Steering becomes slightly
mality
heavy
Knob position correction
Steering-wheel angle
Spanner disabled
72-2 72-2 Main controller sensor SS2 open abnor- page 390
blinks Steering becomes slightly
mality
heavy
Steering-wheel angle
Spanner Knob position correction
72-3 72-3 Main controller sensor SSC open abnor- page 393
blinks disabled
mality
Knob position correction
Steering-wheel angle
Spanner disabled
72-4 72-4 Main controller sensor : sensor power page 396
blinks Steering becomes slightly
source open abnormality
heavy
Steering knob position
Spanner Knob position correction
73-1 73-1 Main controller synchronizer solenoid page 398
blinks disabled
open abnormality
Steering knob position
Spanner Knob position correction
73-2 73-2 Main controller synchronizer solenoid page 401
blinks disabled
short abnormality
Steering knob position
Spanner Knob position correction
73-3 73-3 Main controller synchronizer solenoid page 404
blinks disabled
power-circuit abnormality
Steering knob position
Spanner Knob position correction
73-4 73-4 Main controller synchronizer solenoid page 406
blinks disabled
(open / short) abnormality
Knob position correction
Tire angle matching: disabled
Spanner
74-1 74-1 Main controller matching value abnor- Limitation of lift height and page 408
blinks
mality load sensing steering
speed control function
Spanner Shock sensor 1 open ab-
G5-1 G5-1 Main controller Impact detection disabled page 410
blinks normality
Spanner Shock sensor 1 short ab-
G5-2 G5-2 Main controller Impact detection disabled page 412
blinks normality
Spanner Shock sensor 1 neutral
G5-3 G5-3 Main controller Impact detection disabled page 414
blinks voltage abnormality
Spanner Shock sensor 2 open ab-
G5-4 G5-4 Main controller Impact detection disabled page 416
blinks normality
Spanner Shock sensor 2 short ab-
G5-5 G5-5 Main controller Impact detection disabled page 418
blinks normality
Spanner Shock sensor 2 neutral
G5-6 G5-6 Main controller Impact detection disabled page 420
blinks voltage abnormality
Spanner Lift lever potentiometer Lift raising and lowering
H1-1 H1-1 Main controller page 422
blinks open abnormality disabled
1 ELECTRICAL TROUBLESHOOTING 1-15

Dis- Mem Indicat- Detection Reference

play ory ors ECU
Failure mode Phenomenon on vehicle
pages 1
Spanner Lift lever potentiometer Lift raising and lowering
H1-2 H1-2 Main controller page 425
blinks short abnormality disabled
Lift lever potentiometer
Spanner Lift raising and lowering
H1-3 H1-3 Main controller sensor output deviation page 427
blinks disabled
abnormality
Spanner Lift lever potentiometer Lift raising and lowering
H1-4 H1-4 Main controller page 430
blinks neutral abnormality disabled (standard lever)
Lift lever potentiometer
Spanner Lift raising and lowering
H1-5 H1-5 Main controller matching value abnor- page 432
blinks disabled
mality
Attachment 1 lever po-
Spanner Attachment 1 operation dis-
H3-1 H3-1 Main controller tentiometer open abnor- page 434
blinks abled
mality
Attachment 1 lever po-
Spanner Attachment 1 operation dis-
H3-2 H3-2 Main controller tentiometer short abnor- page 436
blinks abled
mality
Attachment 1 lever po-
Spanner Attachment 1 operation dis-
H3-3 H3-3 Main controller tentiometer sensor output page 438
blinks abled
deviation abnormality
Attachment 1 lever po-
Spanner
H3-4 H3-4 Main controller tentiometer neutral ab- Load handling disabled page 441
blinks
normality
Attachment 1 lever po-
Spanner Attachment 1 operation dis-
H3-5 H3-5 Main controller tentiometer matching page 443
blinks abled
value abnormality
Attachment 2 lever po-
Spanner Attachment 2 operation dis-
H4-1 H4-1 Main controller tentiometer open abnor- page 445
blinks abled
mality
Attachment 2 lever po-
Spanner Attachment 2 operation dis-
H4-2 H4-2 Main controller tentiometer short abnor- page 447
blinks abled
mality
Attachment 2 lever po-
Spanner Attachment 2 operation dis-
H4-3 H4-3 Main controller tentiometer sensor output page 449
blinks abled
deviation abnormality
Attachment 2 lever po-
Spanner
H4-4 H4-4 Main controller tentiometer neutral ab- Load handling disabled page 452
blinks
normality
Attachment 2 lever po-
Spanner Attachment 2 operation dis-
H4-5 H4-5 Main controller tentiometer matching page 454
blinks abled
value abnormality
Lift raising and backward
Spanner Unload solenoid open ab-
HC-1 HC-1 Main controller tilt may be possible even page 456
blinks normality
during OPS
Lift raising and backward
Spanner Unload solenoid short ab-
HC-2 HC-2 Main controller tilt may be possible even page 459
blinks normality
during OPS
Load handling other than
Spanner Unload solenoid driving
HC-3 HC-3 Main controller lowering may not be pos- page 462
blinks circuit abnormality
sible
Lift raising and backward
Spanner Unload solenoid open/
HC-4 HC-4 Main controller tilt may be possible even page 464
blinks short abnormality
during OPS
COL Reduced maximum travel-
Drive motor Drive motor driver tem-
D - - ing speed, acceleration be- page 466
driver perature low
DCR comes slow
1-16 1 ELECTRICAL TROUBLESHOOTING

Dis- Mem Indicat- Detection Reference

Failure mode Phenomenon on vehicle
play ory ors ECU pages
COL Reduced maximum travel-
Pump motor Pump motor driver tem-
D - - ing speed, acceleration be- page 466
driver perature low
PCR comes slow
1 ELECTRICAL TROUBLESHOOTING 1-17

1.4 WHEN ERROR CODES ARE DISPLAYED 1

1-18 1 ELECTRICAL TROUBLESHOOTING

1.4.1 A0-1
Failure mode: Drive motor driver main circuit temperature abnormal rise

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting AB-1.
• Disconnect the battery plug and check that the power cable/motor cable connection is not loose.
• Do not leave the truck in places where it gets hot.

Probable cause
▪ Power cable/motor cable connection defect
▪ Connector connection defect
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
▪ Overheating (overload continuous use)
▪ Drive motor driver defect
▪ Main controller defect

Related part

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2
controller CN104-3 (1, CBAT+) CN113-1

CN112-2
Cooling fan 1
CN112-1

Drive motor driver

Temperature sensor

[Link] Step 1
1. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-19

[Link] Step 2
1
Error recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"DCR" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the drive motor driver falls, the "DCR"
"DCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 3
Temperature check and error recheck
1. Record the drive motor driver main circuit temperature.
[ANL] I/O TEMP/VOLT 1/5
TDMDH
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 15 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"DCR" display Go to Step 4
Overheating (overload continuous use)
If the temperature of the drive motor driver falls, the "DCR"
"DCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 4
Temperature recheck
1. Check the drive motor driver main circuit temperature and
compare it with the recorded value.
[ANL] I/O TEMP/VOLT 1/5
TDMDH

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 3
It did not rise by 5℃ or more. Drive motor driver defect
1-20 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check the rotation condition of the
fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Not turning Go to Step 6

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN113 con-
nectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the battery plug, disconnect the CN102, CN104,
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
CN112, and CN113 connectors, visually inspect whether
28 29 30 31 32 33 34 35 there is no problem with the inside of the connector and
the wire caulking, and then inspect the harness.
CN104 Refer to "BEFORE TROUBLESHOOTING."
CN113 Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN102-1 - CN112-2 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-1 - CN113-2 Continuity
CN104-3 - CN112-1 Continuity
CN104-3 - CN113-1 Continuity
CN102-1 - CN104-3 No continuity

Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-21

[Link] Step 7
1
Cooling fan inspection
1. Disconnect the battery plug, and then connect the CN102,
CN104, CN112, and CN113 connectors. Connect the bat-
tery plug and turn the key switch ON.
2. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after repla-
cing the cooling fan, replace the main controller, as there
could be other types of defect.
1-22 1 ELECTRICAL TROUBLESHOOTING

1.4.2 A0-2
Failure mode: Pump motor driver main circuit temperature abnormal rise

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting AB-1.
• Disconnect the battery plug and check that the power cable/motor cable connection is not loose.
• Do not leave the truck in places where it gets hot.

Probable cause
▪ Power cable/motor cable connection defect
▪ Connector connection defect
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
▪ Overheating (overload continuous use)
▪ Pump motor driver defect
▪ Main controller defect

Related part

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2
controller CN104-3 (1, CBAT+) CN113-1

CN112-2
Cooling fan 1
CN112-1

Pump motor driver

Temperature sensor

[Link] Step 1
1. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-23

[Link] Step 2
1
Error recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"PCR" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the pump motor driver falls, the "PCR"
"PCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 3
Temperature check and error recheck
1. Record the pump motor driver main circuit temperature.
[ANL] I/O TEMP/VOLT 2/5
TPMDH
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 15 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"PCR" display Go to Step 4
Overheating (overload continuous use)
If the temperature of the pump motor driver falls, the "PCR"
"PCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 4
Temperature recheck
1. Check the pump motor driver main circuit temperature and
compare it with the recorded value.
[ANL] I/O TEMP/VOLT 2/5
TPMDH

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 3
It did not rise by 5℃ or more. Pump motor driver defect
1-24 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check the rotation condition of the
fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Not turning Go to Step 6

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN113 con-
nectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the battery plug, disconnect the CN102, CN104,
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
CN112, and CN113 connectors, visually inspect whether
28 29 30 31 32 33 34 35 there is no problem with the inside of the connector and
the wire caulking, and then inspect the harness.
CN104 Refer to "BEFORE TROUBLESHOOTING."
CN113 Measurement terminals Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN102-1 - CN112-2 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-1 - CN113-2 Continuity
CN104-3 - CN112-1 Continuity
CN104-3 - CN113-1 Continuity
CN102-1 - CN104-3 No continuity

Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-25

[Link] Step 7
1
Cooling fan inspection
1. Disconnect the battery plug, and then connect the CN102,
CN104, CN112, and CN113 connectors. Connect the bat-
tery plug and turn the key switch ON.
2. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after repla-
cing the cooling fan, replace the main controller, as there
could be other types of failure.
1-26 1 ELECTRICAL TROUBLESHOOTING

1.4.3 A1-1
Failure mode: Main controller high voltage

CAUTION
• If CB-1, CB-3, or CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3, or CB-5.

Probable cause
▪ Battery defect
▪ Battery fluid-level low
▪ Battery plug defect
▪ Battery voltage overvoltage
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19,VBMBSL)

F7
CN140-4 CN140-3 (19) CN102-4 (19,VBMBSL)
Main
controller

N1

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
then leave it for 2 minutes or more.
2. Reconnect the battery plug and turn the key switch ON to
check the error.

Judgment
Result Procedure
Error at A1-1 Go to Step 2
Error at A3-1 Perform A3-1 troubleshooting
No error at A1-1 and A3-1 Perform battery inspection
1 ELECTRICAL TROUBLESHOOTING 1-27

[Link] Step 2
1
Battery voltage inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Use the tester to measure the voltage at both ends of the
battery plug.

Judgment
Result Procedure
64V or more (48V vehicles), 109V or more
Perform battery inspection
(80V vehicles)
Less than 64V (48V vehicles), less than
Main controller defect
109V (80V vehicles)
1-28 1 ELECTRICAL TROUBLESHOOTING

1.4.4 A1-2
Failure mode: Drive motor driver high voltage

CAUTION
• If CB-1, CB-3, or CB-5 is displayed with A1-2 at the same time, give a higher priority to troubleshoot-
ing CB-1, CB-3, or CB-5.

Probable cause
▪ Battery defect
▪ Battery fluid-level low
▪ Battery plug defect
▪ Battery voltage overvoltage
▪ Drive motor driver defect

Related part

MB F1
P1 P4

Drive motor driver

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
then leave it for 2 minutes or more.
2. Reconnect the battery plug and turn the key switch ON to
check the error.

Judgment
Result Procedure
Error at A1-2 Go to Step 2
Error at A3-1 Perform A3-1 troubleshooting
No error at A1-2 and A3-1 Perform battery inspection
1 ELECTRICAL TROUBLESHOOTING 1-29

[Link] Step 2
1
Battery voltage inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Use the tester to measure the voltage at both ends of the
battery plug.

Judgment
Result Procedure
64V or more (48V vehicles), 107V or more
Perform battery inspection
(80V vehicles)
Less than 64V (48V vehicles), less than
Drive motor driver defect
107V (80V vehicles)
1-30 1 ELECTRICAL TROUBLESHOOTING

1.4.5 A1-4
Failure mode: Pump motor driver high voltage

CAUTION
• CB-1, CB-3, or CB-5 is displayed with A1-4 at the same time, give a higher priority to troubleshooting
CB-1, CB-3, or CB-5.

Probable cause
▪ Battery defect
▪ Battery fluid-level low
▪ Battery plug defect
▪ Battery voltage overvoltage
▪ Pump motor driver defect

Related part

MB F1
P1 P4

Pump motor driver

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
then leave it for 2 minutes or more.
2. Reconnect the battery plug and turn the key switch ON to
check the error.

Judgment
Result Procedure
Error at A1-4 Go to Step 2
Error at A3-1 Perform A3-1 troubleshooting
No error at A1-4 and A3-1 Perform battery inspection
1 ELECTRICAL TROUBLESHOOTING 1-31

[Link] Step 2
1
Battery voltage inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Use the tester to measure the voltage at both ends of the
battery plug.

Judgment
Result Procedure
64V or more (48V vehicles), 107V or more
Perform battery inspection
(80V vehicles)
Less than 64V (48V vehicles), less than
Pump motor driver defect
107V (80V vehicles)
1-32 1 ELECTRICAL TROUBLESHOOTING

1.4.6 A2-1
Failure mode: Main controller board temperature abnormal rise

CAUTION
• Do not leave the truck in places where it gets hot.

Probable cause
▪ Overheating (overload continuous use)
▪ Temperature sensor defect (main controller defect)

Related part

Main controller

Temperature sensor

[Link] Step 1
Error recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"C/R" display Go to Step 2
Overheating (overload continuous use)
If the temperature of the main controller falls, the "C/R" dis-
"C/R" not display play disappears, and you can use the truck as usual. Because
an error occurred due to a continuous use in an overloaded
condition, check the truck usage and avoid an overloaded
continuous use.
1 ELECTRICAL TROUBLESHOOTING 1-33

[Link] Step 2
1
Main controller board temperature check and error recheck
1. Record the main controller board temperature.
[ANL] I/O TEMP/VOLT 3/5
TMCB
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 30 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"C/R" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the main controller falls, the "C/R" dis-
"C/R" not display play disappears, and you can use the truck as usual. Because
an error occurred due to a continuous use in an overloaded
condition, check the truck usage and avoid an overloaded
continuous use.

[Link] Step 3
Main controller board temperature recheck
1. Check the main controller board temperature and compare
it with the recorded value.
[ANL] I/O TEMP/VOLT 3/5
TMCB

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 2
It did not rise by 5℃ or more. Temperature sensor defect (main controller defect)
1-34 1 ELECTRICAL TROUBLESHOOTING

1.4.7 A2-2
Failure mode: Drive motor driver board temperature abnormal rise

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting AB-1.
• Disconnect the battery plug and check that the power cable/motor cable connection is not loose.
• Do not leave the truck in places where it gets hot.

Probable cause
▪ Power cable/motor cable connection defect
▪ Connector connection defect
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
▪ Overheating (overload continuous use)
▪ Drive motor driver defect
▪ Main controller defect

Related part

CN102-1 (98, FANDC1) CN113-2

Main Cooling fan 2
controller CN104-3 (1, CBAT+) CN113-1

CN112-2
Cooling fan 1
CN112-1

Drive motor driver

Temperature sensor Temperature sensor

(circuit board) (capacitor)

[Link] Step 1
1. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-35

[Link] Step 2
1
Error recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"DCR" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the drive motor driver falls, the "DCR"
"DCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 3
Temperature check and error recheck
1. Record the values of the drive motor driver board temperat-
ure and drive motor driver capacitor temperature.
[ANL] I/O TEMP/VOLT 1/5
TDMDB, TDMDC
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 30 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"DCR" display Go to Step 4
Overheating (overload continuous use)
If the temperature of the drive motor driver falls, the "DCR"
"DCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 4
Temperature recheck
1. Check the values of the drive motor driver board temperat-
ure and drive motor driver capacitor temperature and com-
pare them with the recorded values.
[ANL] I/O TEMP/VOLT 1/5
TDMDB, TDMDC

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 3
It did not rise by 5℃ or more. Drive motor driver defect
1-36 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check the rotation condition of the
fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Not turning Go to Step 6

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN113 con-
nectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the battery plug, disconnect the CN102, CN104,
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
CN112, and CN113 connectors, visually inspect whether
28 29 30 31 32 33 34 35 there is no problem with the inside of the connector and
the wire caulking, and then inspect the harness.
CN104 Refer to "BEFORE TROUBLESHOOTING."
CN113 Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN102-1 - CN112-2 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-1 - CN113-2 Continuity
CN104-3 - CN112-1 Continuity
CN104-3 - CN113-1 Continuity
CN102-1 - CN104-3 No continuity

Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-37

[Link] Step 7
1
Cooling fan inspection
1. Disconnect the battery plug, and then connect the CN102,
CN104, CN112, and CN113 connectors. Connect the bat-
tery plug and turn the key switch ON.
2. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after repla-
cing the cooling fan, replace the main controller, as there
could be other types of defect.
1-38 1 ELECTRICAL TROUBLESHOOTING

1.4.8 A2-3
Failure mode: Pump motor driver board temperature abnormal rise

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting AB-1.
• Disconnect the battery plug and check that the power cable/motor cable connection is not loose.
• Do not leave the truck in places where it gets hot.

Probable cause
▪ Power cable/motor cable connection defect
▪ Connector connection defect
▪ Harness defect
▪ Cooling fin/fan clogging
▪ Cooling fan abnormality
▪ Overheating (overload continuous use)
▪ Pump motor driver defect
▪ Main controller defect

Related part

CN102-1 (98, FANDC1) CN113-2

Cooling fan 2
Main
controller CN104-3 (1, CBAT+) CN113-1

CN112-2
Cooling fan 1
CN112-1

Pump motor driver

Temperature sensor Temperature sensor

(circuit board) (capacitor)

[Link] Step 1
1. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Not turning Go to Step 5
Turning Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-39

[Link] Step 2
1
Error recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"PCR" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the pump motor driver falls, the "PCR"
"PCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 3
Temperature check and error recheck
1. Record the values of the pump motor driver board temperat-
ure and pump motor driver capacitor temperature.
[ANL] I/O TEMP/VOLT 2/5
TPMDB, TPMDC
2. Turn the key switch OFF, leave the truck for a while (ap-
proximately 30 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"PCR" display Go to Step 4
Overheating (overload continuous use)
If the temperature of the pump motor driver falls, the "PCR"
"PCR" not display display disappears, and you can use the truck as usual. Be-
cause an error occurred due to a continuous use in an over-
loaded condition, check the truck usage and avoid an over-
loaded continuous use.

[Link] Step 4
Temperature recheck
1. Check the values of the pump motor driver board temperat-
ure and pump motor driver capacitor temperature and com-
pare them with the recorded values.
[ANL] I/O TEMP/VOLT 2/5
TPMDB, TPMDC

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 3
It did not rise by 5℃ or more. Pump motor driver defect
1-40 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check the rotation condition of the
fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Not turning Go to Step 6

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN113 con-
nectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the battery plug, disconnect the CN102, 104,
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
112, and CN113 connectors, visually inspect whether there
28 29 30 31 32 33 34 35 is no problem with the inside of the connector and the wire
caulking, and then inspect the harness.
CN104 Refer to "BEFORE TROUBLESHOOTING."
CN113 Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN102-1 - CN112-2 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-1 - CN113-2 Continuity
CN104-3 - CN112-1 Continuity
CN104-3 - CN113-1 Continuity
CN102-1 - CN104-3 No continuity

Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-41

[Link] Step 7
1
Cooling fan inspection
1. Disconnect the battery plug, and then connect the CN102,
CN104, CN112, and CN113 connectors.
2. Connect the battery plug and turn the key switch ON.
3. Forcibly turn ON the cooling fan by “ACTIVE TEST” and
check the rotation condition of the fan.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
Turning Connector connection defect
Cooling fan abnormality
Not turning If the fan does not rotate by “ACTIVE TEST” even after ex-
changing the cooling fan, exchange the main controller, as
there could be other types of failure.
1-42 1 ELECTRICAL TROUBLESHOOTING

1.4.9 A3-1
Failure mode: Battery improper connection

Probable cause
▪ Battery plug connection defect
▪ Battery improper connection
▪ Battery defect
▪ Main controller defect

Related part

48V: P1 Emergency switch

80V: P0 F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)
CN176-1 (41, SWE+) CN176-2 (41, SWE-)
Main
controller

Battery

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Reconnect the battery plug correctly and turn the key switch
ON.

Judgment
Result Procedure
Battery plug connection defect or battery improper connec-
No error at A3-1
tion
Error at A3-1 Go to Step 2

[Link] Step 2
Battery voltage inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Use the tester to measure the voltage at both ends of the
battery plug.

Judgment
Result Procedure
64V or more (48V vehicles), 109V or more
Perform battery inspection
(80V vehicles)
Less than 64V (48V vehicles), less than
Main controller defect
109V (80V vehicles)
1 ELECTRICAL TROUBLESHOOTING 1-43

1.4.10 A3-2 1
Failure mode: Battery improper connection

Probable cause
▪ Main controller installed incorrectly
▪ Main controller defect

Related part
48V
CN176-1 (41, SWE+) CN176-2 (41, SWE-)
P1 F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)
Emergency switch
CN101-4 (41, VBBT)
Main
controller

Battery

N1

80V
Emergency switch
P1 F6
CN176-1 (18, 80V+) CN176-3 (18, 80V-)
CN104-1 (18, B80V)
Main
controller
Battery F5
CN176-2 (41, 48V+) CN176-4 (41, 48V-)
CN101-4 (41, VBBT)
P0

N1

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Check the part number of the main controller.

Judgment
Result Procedure
Wrong part No. Main controller installed incorrectly
Correct part No. Main controller defect
1-44 1 ELECTRICAL TROUBLESHOOTING

1.4.11 A5-1
Failure mode: Seat switch short circuit abnormality

Probable cause
▪ Connector connection defect
▪ Seat switch defect
▪ Harness defect
▪ Main controller defect

Related part

CN102-10 (51, LS-) CN44-1

Main
Seat swtich
controller
CN104-18 (67, SDM) CN44-2

[Link] Step 1
Seat switch condition inspection
1. Turn the key switch OFF, disconnect the battery plug and
visually inspect the inside of the CN44 connector and the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON while the operator is off the
vehicle.
[ANL] I/O [Link] 1/8
SDM

Judgment
Result Procedure
Displays “0” Connector connection defect
Displays “1” Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-45

[Link] Step 2
1
Seat switch condition inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. After disconnecting the CN44 connector, connect the bat-
tery plug and turn the key switch ON.
[ANL] I/O [Link] 1/8
SDM

Judgment
Result Procedure
Displays “0” Seat switch defect
Displays “1” Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN44 connect-
ors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7
Turn the key switch off, disconnect the battery plug, disconnect
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
the CN102, CN104, and CN44 connectors, visually inspect
28 29 30 31 32 33 34 35 CN44 whether there is no problem with the inside of the connector
and the wire caulking, and then inspect the harness.
CN104
1 2 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 CN102-10 (51) - CN44-1 (51) Continuity

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-18 (67) - CN44-2 (67) Continuity
CN44-1 (51) - CN44-2 (67) No continuity

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-46 1 ELECTRICAL TROUBLESHOOTING

1.4.12 A6-3
Failure mode: Tilt switch short circuit abnormality

CAUTION
• Connect the battery plug while operating the tilt lever, and if an error is displayed by turning the key
switch ON, but the error display disappears by stopping the lever operation, it is normal.

Probable cause
▪ Operate the tilt lever while the battery plug is connected
▪ Connector connection defect
▪ Tilt lever switch defect
▪ Tilt lever switch installation defect
▪ Harness defect
▪ Main controller defect

Related part

Tilt lever switch

CN102-23 (61, SWTF) CN89-1

CN102-22 (62, SWTR) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN89 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN89 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at A6-3 Connector connection defect
Error at A6-3 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-47

[Link] Step 2
1
Backward tilt switch inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN89 connector
3. Connect the battery plug and turn the key switch ON.
4. Check for errors.

Judgment
Result Procedure
Tilt lever switch defect
No error at A6-3
Tilt lever switch installation defect
Error at A6-3 Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN89 and CN102 connector.
3. Inspect for continuity and short circuiting of the harness.
Notes:
CN102 Disconnect the battery plug, disconnect the CN89 and
CN89 CN102 connector, visually inspect whether there is no
1 2 3 4 5 6 7 problem with the inside of the connector and the wire
8 9 10 11 12 13 14 15 16 17 18 19 1 2 caulking, and then inspect the harness.
20 21 22 23 24 25 26 27 3 4 Refer to "BEFORE TROUBLESHOOTING."
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN102-23 (61) - CN89-1 (61) Continuity
CN102-22 (62) - CN89-3 (62) Continuity
CN102-26 (51) - CN89-4 (51) Continuity
CN102-26 (51) - CN89-2 (51) Continuity
CN102-23 (61) - CN102-26 (51) No continuity
CN102-22 (62) - CN102-26 (51) No continuity
CN102-23 (61) - CN102-22 (62) No continuity

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-48 1 ELECTRICAL TROUBLESHOOTING

1.4.13 A8-1
Failure mode: F1 fuse open abnormality

CAUTION
• If CB-1, CB-3, CB-5, A8-2 (48V vehicle) or A9-2 (80V vehicle) is occurring, give a higher priority to
troubleshooting CB-1, CB-3, CB-5, A8-2 or A9-2.

Probable cause
▪ Terminal tightening defect
▪ Motor driver defect
▪ F1 fuse installation defect
▪ F1 fuse defect
▪ Cable defect

Related part
48V F6
CN140-2 CN140-1 (44)

MB F1 P4
P3

Battery CN104-2 (44, VBMB)

Main
controller
N1
Drive motor
drive circuit

Pump motor
drive circuit

80V F7
CN136-6 (19)

MB F1 P4
P3

Battery CN104-2 (19, VBMB)

Main
controller
N1
Drive motor
drive circuit

Pump motor
drive circuit
1 ELECTRICAL TROUBLESHOOTING 1-49

[Link] Step 1
1
Terminal tightening inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no loosening at the bolt
tightening section of each motor driver’s [+] terminal, [-] ter-
minal, P4 terminal, and N1 terminal.
3. Connect the battery plug and turn the key switch ON to
check for errors.

Judgment
Result Procedure
Error at A8-1 Go to Step 2
No error at A8-1 Terminal tightening defect

[Link] Step 2
Motor driver supply voltage check
1. Connect the battery plug and turn the key switch ON to
measure the voltage between [+] terminal and [-] terminal of
the drive motor driver.
Notes:
Turn the key switch OFF, disconnect the battery plug, and
then visually inspect whether there is no problem with the
copper bar for connecting the motor driver [+] terminal and
[-] terminal, such as raptures or cracks, and then perform
the inspection.

Judgment
Result Procedure
0V Go to Step 3
Approx. 48V (48V vehicles)
All motor drivers defect
Approx. 80V (80V vehicles)

[Link] Step 3
F1 fuse installation check
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with F1 fuse in-
stallation.
3. Connect the battery plug and turn the key switch ON to
check for errors.

Judgment
Result Procedure
Error at A8-1 Go to Step 4
No error at A8-1 F1 fuse installation defect
1-50 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
F1 fuse inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the F1 fuse and measure the resistance at both
ends of the F1 fuse.
Motor driver defect inspection *1
1. Turn the key switch OFF, disconnect the battery plug and
remove the copper bar for connecting the motor driver [+]
terminal.
2. Measure the resistance between [+] terminal and [-] ter-
minal of the motor driver.
3. For an analog type tester, use the black tester probe for [+]
terminal, and the red tester probe for [-] terminal.
4. Motor driver defect if the measured value is 10 [Ω] or less

Judgment
Result Procedure
0Ω Motor driver defect (*1)
F1 fuse defect
∞Ω Or motor driver defect (*1) or short circuit between P4 and N1
terminal.
1 ELECTRICAL TROUBLESHOOTING 1-51

1.4.14 A8-2 1
Failure mode: F6 fuse open abnormality

CAUTION
• If CB-1, CB-3 and CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3 and CB-5.

Probable cause
▪ Connector connection defect
▪ F6 fuse installation defect
▪ F6 fuse defect
▪ F6 fuse box defect
▪ Harness defect
▪ Main controller defect

Related part
48V F6
CN140-2 CN140-1 (44)

MB F1 P4
P3

Battery CN104-2 (44, VBMB)

Main
controller
N1 F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)
CN102-4 (19, VBMBSL)

80V F7
CN136-6 (19)

MB F1
P2 P4
P3
Battery

CN104-2 (19, VBMB)

Main
controller
N1 F6
CN104-1 (19, B80V)
1-52 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN104, CN140 (48V vehicles), CN136 (80V
vehicles) connector and visually inspect whether there is no
problem with the inside of the connector and the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN104, CN140 (48V vehicles), CN136 (80V
vehicles) connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
Go to Step 2 (48V vehicles)
Error at A8-2
Go to Step 3 (80V vehicles)
No error at A8-2 Connector connection defect

[Link] Step 2
VBMBSL voltage value inspection
1. Connect the battery plug and turn the key switch ON.
[ANL] I/O TEMP/VOLT 4/5
VBMBSL

Judgment
Result Procedure
25 [V] or more Go to Step 3
Less than 25 [V] Perform CB-1 troubleshooting

[Link] Step 3
Fuse installation inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with F6 fuse in-
stallation.
3. Connect the battery plug and turn the key switch ON.

Judgment
Result Procedure
Error at A8-2 Go to Step 4
No error at A8-2 F6 fuse installation defect

[Link] Step 4
Fuse inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the F6 fuse and measure the resistance at both
ends of the F6 fuse.
1 ELECTRICAL TROUBLESHOOTING 1-53

Judgment
1
Result Procedure
Go to Step 5 (48V vehicles)
0 [Ω]
Go to Step 6 (80V vehicles)
F6 fuse defect
∞ [Ω]
Replace the F6 fuse and Go to Step 6.

[Link] Step 5
Fuse box inspection
1. Install the F6 fuse and disconnect the connector of the F6
fuse box.
2. Measure the resistance at both ends on the connector side
of the F6 fuse box.

Judgment
Result Procedure
0 [Ω] Go to Step 6
∞ [Ω] F6 fuse box defect

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. If the connector of the F6 fuse box was disconnected in the
previous step, connect the connector.
3. Disconnect the CN104, CN140 (48V vehicle) and CN136
(80V vehicle) connectors.
4. Inspect for continuity and short circuiting of the harness.
CN140 Notes:
CN104 1 2 Turn the key switch off, disconnect the battery plug, dis-
3 4 connect the CN104, CN140 (48V vehicles), and CN136 (80V
1 2 3 4 5 6 7 (48V) vehicles) connectors, visually inspect whether there is no
8 9 10 11 12 13 14 15 16 17
CN136
problem with the inside of the connector and the wire
18 19 20 21 22 23 24 25
26 27 28 29 30 31
caulking, and then inspect the harness.
1 2 3 Refer to "BEFORE TROUBLESHOOTING."
4 5 6
(80V) Portion to be inspected (48V and 80V
Standard
vehicles)
CN104-2 (44) - CN140-1 (44) Continuity
CN140-2 (44, fuse side) - P3 Continuity
CN104-2 (44) - N1 No continuity
CN140-2 (44) - N1 No continuity

Portion to be inspected (80V vehicles) Standard

CN104-1 (19) - CN136-6 (19) Continuity
CN104-1 (19) - N1 No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-54 1 ELECTRICAL TROUBLESHOOTING

1.4.15 A9-2
Failure mode: F7 fuse / solenoid power line open abnormality

CAUTION
• If CB-1, CB-3 and CB-5 is occurring, give a higher priority to troubleshooting CB-1, CB-3 and CB-5.

Probable cause
▪ Connector connection defect
▪ F7 fuse installation defect
▪ F7 fuse defect
▪ F7 fuse box defect
▪ Harness defect
▪ Main controller defect

Related part
48V

MB F7
P3 CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)
CN102-4 (19, VBMBSL)
Main
F6
Battery CN140-2 CN140-1 (44) CN104-2 (44, VBMB) controller

N1

80V

MB F7
P3 CN136-6 (19) CN102-3 (19, VBMB)
CN102-4 (19, VBMB)
Main
controller
Battery CN104-2 (19, VBMB)

N1

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN104, CN140 (48V vehicles), CN136 (80V
vehicles) connector and visually inspect whether there is no
problem with the inside of the connector and the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN104, CN140 (48V vehicles), CN136 (80V
vehicles) connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.
1 ELECTRICAL TROUBLESHOOTING 1-55

Judgment
1
Result Procedure
No error at A9-2 Connector connection defect
Go to Step 2 (48V vehicles)
Error at A9-2
Go to Step 3 (80V vehicles)

[Link] Step 2
VBMB voltage value inspection
1. Connect the battery plug and turn the key switch ON.
[ANL] I/O TEMP/VOLT 4/5
VBMB

Judgment
Result Procedure
Less than 25V Perform CB-1 troubleshooting
25V or more Go to Step 3

[Link] Step 3
Fuse installation condition inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with F7 fuse in-
stallation.
3. Connect the battery plug and turn the key switch ON.

Judgment
Result Procedure
No error at A9-2 F7 fuse installation defect
Go to Step 5 (48V vehicles)
Error at A9-2
Go to Step 4 (80V vehicles)

[Link] Step 4
VDMD, VPMD voltage inspection
1. Connect the battery plug and turn the key switch ON.
[ANL] I/O TEMP/VOLT 5/5
VDMD
VPMD

Judgment
Result Procedure
Less than 25V (for both) Perform CB-1 troubleshooting
25V or more (either one) Go to Step 5

[Link] Step 5
F7 fuse inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the F7 fuse and measure the resistance at both
ends of the F7 fuse.
1-56 1 ELECTRICAL TROUBLESHOOTING

Judgment
Result Procedure
F7 fuse defect
∞Ω
Replace the F7 fuse and Go to Step 7.
Go to Step 6 (48V vehicles)
0Ω
Go to Step 7 (80V vehicles)

[Link] Step 6
F7 fuse box inspection
1. Install the F7 fuse and disconnect the connector of the F7
fuse box.
2. Measure the resistance at both ends on the connector side
of the F7 fuse box.

Judgment
Result Procedure
∞Ω F7 fuse box defect
0Ω Go to Step 7

[Link] Step 7
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. If the connector of the F7 fuse box was disconnected in the
previous step, connect the connector.
3. Disconnect the CN104, CN140 (48V vehicle) and CN136
(80V vehicle) connectors.
4. Inspect for continuity and short circuiting of the harness.
CN140 Notes:
CN102 1 2 Turn the key switch off, disconnect the battery plug, dis-
3 4 connect the CN104, CN140 (48V vehicles), and CN136 (80V
(48V) vehicles) connectors, visually inspect whether there is no
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19
CN136
problem with the inside of the connector and the wire
20 21 22 23 24 25 26 27 caulking, and then inspect the harness.
28 29 30 31 32 33 34 35
1 2 3 Refer to "BEFORE TROUBLESHOOTING."
4 5 6
(80V) Portion to be inspected (48V and 80V
Standard
vehicles)
CN102-3 (19) - CN140-3 (19) Continuity
CN102-4 (19) - CN140-3 (19) Continuity
CN140-4 - P3 Continuity
CN140-3 (19) - N1 No continuity
CN140-4 - N1 No continuity

Portion to be inspected (80V vehicles) Standard

CN104-2 (19) - CN136-6 Continuity
CN104-2 (19) - N1 No continuity

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-57

1.4.16 AA-1 1
Failure mode: Main controller board temperature sensor open/VCC short circuit
abnormality

CAUTION
• If AA-1 is displayed, it indicates main controller defect. Replace it.

Probable cause
▪ Main controller defect

Related part

Main controller

Temperature sensor
1-58 1 ELECTRICAL TROUBLESHOOTING

1.4.17 AA-2
Failure mode: Drive motor driver board temperature sensor open/VCC short circuit
abnormality

CAUTION
• If AA-2 is displayed, it indicates drive motor driver defect. Replace it.

Probable cause
▪ Drive motor driver defect

Related part

Drive motor driver

Temperature sensor
1 ELECTRICAL TROUBLESHOOTING 1-59

1.4.18 AA-4 1
Failure mode: Pump motor driver board temperature sensor open/VCC short circuit
abnormality

CAUTION
• If AA-4 is displayed, it indicates pump motor driver abnormality. Replace it.

Probable cause
▪ Pump motor driver defect

Related part

Pump motor driver

Temperature sensor
1-60 1 ELECTRICAL TROUBLESHOOTING

1.4.19 AB-1
Failure mode: Cooling fan overcurrent

CAUTION
• When checking for AB-1 errors on 48V vehicles, turn the FAN ON by “ACTIVE TEST” and wait for
100 seconds
(Since it takes 100 seconds to confirm an AB-1 error)

Probable cause
▪ Connector connection defect
▪ Motor driver cooling fan 1 defect
▪ Motor driver cooling fan 2 defect
▪ Harness defect
▪ Main controller defect
▪ Fan power defect
1 ELECTRICAL TROUBLESHOOTING 1-61

Related part
1
48 V
CN102-1 (98, FANDC1) CN112-2
Cooling fan 1
CN104-3 (1, CBAT+) CN112-1
Main
controller
CN104-1 (41, B48V)
CN113-2
Cooling fan 2
CN113-1

80 V
CN104-8 (98, FANDC) CN142-2 CN142-9

CN142-4
CN104-3 (1, CBAT+) CN142-3 Cooling fan
power supply CN142-10
CN101-18 (99, VFAN) CN142-8 CN142-5

Main
controller

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

CN103-5 (N2, N2)

CN112-2
Cooling fan 1
CN112-1

CN113-2
Cooling fan 2
CN113-1
1-62 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn ON the cooling fan
by “ACTIVE TEST” and check for errors.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
No error at AB-1 Connector connection failure
Error at AB-1 Go to Step 2

[Link] Step 2
Cooling fan circuit inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. After disconnecting the CN112 and CN113 connectors, con-
nect the battery plug and turn the key switch ON, forcibly
turn ON the cooling fan by “ACTIVE TEST” and check for
errors.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
No error at AB-1 Go to Step 3
Go to Step 6 (48 V vehicles)
Error at AB-1
Go to Step 5 (80 V vehicles)

[Link] Step 3
Motor driver cooling fan 1 inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN112 connector, disconnecting the CN113
connector, connect the battery plug and turn the key switch
ON, forcibly turn ON the cooling fan by “ACTIVE TEST” and
check for errors.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
No error at AB-1 Go to Step 4
Error at AB-1 Motor driver cooling fan 1 failure
1 ELECTRICAL TROUBLESHOOTING 1-63

[Link] Step 4
1
Motor driver cooling fan 2 inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN113 connector, disconnecting the CN112
connector, connect the battery plug and turn the key switch
ON, forcibly turn ON the cooling fan by “ACTIVE TEST” and
check for errors.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
No error at AB-1 Motor driver cooling fan 1 and 2 failure
Error at AB-1 Motor driver cooling fan 2 failure

[Link] Step 5
Fan power supply inspection (80 V vehicles only)
1. Turn the key switch OFF and disconnect the battery plug.
2. After disconnecting the CN142 connector, connect the bat-
tery plug and turn the key switch ON, forcibly turn ON the
cooling fan by “ACTIVE TEST” and check for errors.
[ANL] ACTIVE TEST 2/3
FAN: OFF → ON

Judgment
Result Procedure
No error at AB-1 Fan power failure
Error at AB-1 Go to Step 6

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN102, CN104, CN112 and CN113 con-
nectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN102 (48 V
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
vehicles), CN104, CN112, CN113, CN101 (80 V vehicles) and
28 29 30 31 32 33 34 35 CN142 (80 V vehicles) connectors, visually inspect whether
there is no problem with the inside of the connector and
CN104 the wire caulking, and then inspect the harness.
Refer to "BEFORE TROUBLESHOOTING."
1 2 3 4 5 6 7
Portion to be inspected (48 V vehicles) Standard
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 CN104-3 - CN102-1 No continuity
26 27 28 29 30 31
CN104-1 - CN102-1 No continuity
1-64 1 ELECTRICAL TROUBLESHOOTING

CN101
Portion to be inspected (80 V vehicles) Standard
1 2 3 4 5 6 7 CN112
8 9 10 11 12 13 14 15 16 17
CN101-18 - CN104-3 No continuity
18 19 20 21 22 23 24 25 26 27 1 2 CN101-18 - CN104-8 No continuity
28 29 30 31 32 33 34
CN104-3 - CN104-8 No continuity
CN104 CN104-1 - CN104-8 No continuity
CN113
CN112-1 - CN112-2 No continuity
1 2 3 4 5 6 7
1 2 CN113-1 - CN113-2 No continuity
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
26 27 28 29 30 31

Judgment
Result Procedure
NG Harness defect
OK Main controller failure
1 ELECTRICAL TROUBLESHOOTING 1-65

1.4.20 AB-2 1
Failure mode: Cooling fan open/short circuit abnormality (80 V vehicle)

Probable cause
▪ Connector connection failure
▪ Fan power failure
▪ Harness defect
▪ Main controller defect

Related part
80 V
CN104-8 (98, FANDC) CN142-2 CN142-9

CN142-4
CN104-3 (1, CBAT+) CN142-3 Cooling fan
power supply CN142-10
CN101-18 (99, VFAN) CN142-8 CN142-5

Main
controller

CN104-4 (N2, N2)

CN104-5 (N2, N2)

CN104-6 (N2, N2)

CN103-5 (N2, N2)

CN112-2

CN112-1 Cooling fan 1

CN113-2
CN113-1 Cooling fan 2
1-66 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN112 and CN113 connector, and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. After connecting the connector, connect the battery plug
and turn the key switch ON, forcibly turn OFF the cooling
fan by “ACTIVE TEST” and check for errors.
[ANL] ACTIVE TEST 2/3
FAN: ON → OFF

Judgment
Result Procedure
No error at AB-2 Connector connection defect
Error at AB-2 Go to Step 2

[Link] Step 2
Fan power supply inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN142 connector and measure the fan
power source resistance.
Portion to be inspected Standard
CN142-2 - CN142-3 Approx. 4.7 kΩ
CN142
CN142-3 - CN142-8 Approx. 4.7 kΩ
5 4 3 2 1
12 11 10 9 8 7 6

Judgment
Result Procedure
NG Fan power defect
OK Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-67

[Link] Step 3
1
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN104, CN112, CN113 and CN142
connectors.
3. Inspect for continuity and short circuiting of the harness.
CN101
Notes:
1 2 3 4 5 6 7 Disconnect the battery plug, disconnect the CN101, CN104,
8 9 10 11 12 13 14 15 16 17 CN112, CN113 and CN142 connectors, visually inspect
18 19 20 21 22 23 24 25 26 27 CN142 whether there is no problem with the inside of the con-
28 29 30 31 32 33 34
5 4 3 2 1 nector and the wire caulking, and then inspect the harness.
CN104
12 11 10 9 8 7 6
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 CN101-18 - CN142-8 Continuity

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-3 - CN142-3 Continuity
CN104-8 - CN142-2 Continuity
CN101-18 - CN104-4 No continuity
CN142-2 - CN104-4 No continuity
CN142-10 - CN104-4 No continuity
CN142-9 - CN104-4 No continuity
CN142-8 - CN104-4 No continuity
CN142-3 - CN104-4 No continuity
CN142-4 - CN104-4 No continuity
CN142-5 - CN104-4 No continuity

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-68 1 ELECTRICAL TROUBLESHOOTING

1.4.21 AC-1
Failure mode: Motor driver power supply abnormality

Probable cause
▪ Harness defect
▪ Drive motor driver defect
▪ Pump motor driver defect
▪ Main controller defect

Related part

MB F1
P2 P4 +
CN110-8 (42) Drive motor driver

N1 +
CN111-8 (42) Pump motor driver

CN103-4 (42, KYSAT)

F5 Main
CN104-1 (41, B48V) controller
CN101-4 (41, VBBT)

[Link] Step 1
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN103, CN104, CN110 and CN111
connectors.
3. Inspect for continuity and short circuiting of the harness.
CN103
Notes:
1 2 3 4 5 6
Turn the key switch off, disconnect the battery plug, dis-
7 8 9 10 11 12 13 14 15 16
connect the CN101, CN103, CN104, CN110, and CN111 con-
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
nectors, visually inspect whether there is no problem with
the inside of the connector and the wire caulking, and then
inspect continuity of the CN103 - CN110 and CN111.
CN110 CN111 Also, inspect for continuity between the harness and N1
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Refer to "BEFORE TROUBLESHOOTING."
9 10 11 12 13 14 15 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 23 Portion to be inspected Standard
CN103-4 (42) - N1 No continuity
CN103-4 (42) - CN110-8 (42) Continuity
CN103-4 (42) - CN111-8 (42) Continuity

Judgment
Result Procedure
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-69

Result Procedure
OK Go to Step 2
1

[Link] Step 2
Main controller inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110 and CN111 connectors and connect
the CN101, CN103 and CN104 connectors.
3. Connect the battery plug and turn the key switch ON to
check for errors.

Judgment
Result Procedure
Error at AC-1 Main controller defect
No error at AC-1 Go to Step 3

[Link] Step 3
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110 and CN111 connectors and connect
the CN101, CN103 and CN104 connectors.
3. Connect the battery plug and turn the key switch ON to
check for errors.

Judgment
Result Procedure
Error/no error at AC-1 Go to Step 4

[Link] Step 4
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110 connector and connect the CN101,
CN103, CN104 and CN111 connectors.
3. Connect the battery plug and turn the key switch ON to
check for errors.

Judgment
Result Procedure
Error at AC-1 in Step 3 Drive motor driver defect
Error at AC-1 in Step 4 Pump motor driver defect
1-70 1 ELECTRICAL TROUBLESHOOTING

1.4.22 AD-1
Failure mode: Drive motor driver to main controller communication abnormality

CAUTION
• If AC-1 is displayed at the same time, give a higher priority to troubleshooting AC-1.
• If AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.

Probable cause
▪ Connector connection defect

Related part

CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H) Drive motor driver
CN103-12 (146, CAN1L) CN110-16 (146, CAN1L)

Main
controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
visually inspect the inside of the CN103 and CN110 con-
nectors and the wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.

Judgment
Result Procedure
Error at AD-1 or AD-2 Perform AD-2 troubleshooting.
No error at AD-1 or AD-2 Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-71

1.4.23 AD-2 1
Failure mode: Drive motor driver to main controller communication abnormality

CAUTION
• If AC-1 is displayed at the same time, give a higher priority to troubleshooting AC-1.

Probable cause
▪ Motor driver of different class
▪ Connector connection defect
▪ Harness defect
▪ Drive motor driver defect
▪ Main controller defect
▪ Pump motor driver defect

Related part

CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

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

CN111-8 (42, KYSAT)

CN70-16 (145, CAN1H) CN111-17 (145, CAN1H)
Display CN70-15 (146, CAN1L) CN111-16 (146, CAN1L)
CN111-6 (152, SETP2) Pump motor driver

NC CN111-7
CN111-23 (152, SETP-)

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
check that the part number of the motor driver is correct.
Especially if you have replaced the motor driver, check that
another model of the motor driver is not installed.

Judgment
Result Procedure
Wrong part No. Motor driver of different class
Correct part No. Go to Step 2
1-72 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Turn the key switch OFF, disconnect the battery plug and
visually inspect the inside of the CN103, CN104, CN110,
CN111 and CN70 connectors and the wire caulking for er-
rors. (Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.
Especially if you replaced the motor driver immediately be-
fore connecting the connector, check that the connector is
properly corrected.

Judgment
Result Procedure
1. No errors starting from AD Connector connection defect
2. All of the below hold true
▪ Error at AD-1 or AD-2 Go to Step 7
▪ Error at AD-5 or AD-6
In cases except for 1. and 2. Go to Step 3

[Link] Step 3
Display error recheck
1. Recheck the errors at Step 2.

Judgment
Result Procedure
Go to Step 4
Error at AD-2
Record the displayed error that starts with AD.
No error at AD-2 Troubleshoot the displayed errors.

[Link] Step 4
Drive motor driver identification check
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN111 connector
3. Connect the battery plug and turn the key switch ON. Re-
cord the displayed errors.
Harness check
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN111 connector and disconnect the CN103
and CN110 connectors.
3. Check the harness according to the error recorded at Step
4.
1 ELECTRICAL TROUBLESHOOTING 1-73

4. Inspect for continuity and short circuiting of the harness.

Notes:
1
CN103 ▪ Disconnect the pump motor driver to check that the
drive motor driver is not operating as a pump motor
1 2 3 4 5 6
CN110 driver.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
▪ Turn the key switch off, disconnect the battery plug,
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 disconnect the CN103 and CN110 connectors, visually
inspect whether there is no problem with the inside of
the connector and the wire caulking, and then inspect
the harness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN110-6 - CN110-23 No continuity
CN110-6 - N2 No continuity
CN103-4 - CN110-8 Continuity
CN103-11 - CN110-17 Continuity
CN103-12 - CN110-16 Continuity

Judgment
Result Procedure
Go to Step 5
NG
Harness defect
Go to Step 5
OK
Drive motor driver defect

[Link] Step 5
1. Check the error recorded at Step 3.

Judgment
Result Procedure
AD-2 error only Replace the defect portion of Step 4.
Error at AD-2 and AD-6 Go to Step 6

[Link] Step 6
Pump motor driver identification check
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110 connector
3. Connect the battery plug and turn the key switch ON. Re-
cord the displayed errors.
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector and disconnect CN103 and
CN111 connectors.
3. Check the harness according to the error recorded at Step
6.
1-74 1 ELECTRICAL TROUBLESHOOTING

4. Inspect for continuity and short circuiting of the harness.

Notes:
CN103 ▪ Disconnect the drive motor driver to check that the
pump motor driver is not operating as a drive motor
1 2 3 4 5 6
CN111 driver.
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
▪ Turn the key switch off, disconnect the battery plug,
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
16 17 18 19 20 21 22 23 disconnect the CN103 and CN111 connectors, visually
inspect whether there is no problem with the inside of
the connector and the wire caulking, and then inspect
the harness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN111-6 - CN111-23 Continuity
CN103-4 - CN111-8 Continuity
CN103-11 - CN111-17 Continuity
CN103-12 - CN111-16 Continuity

Judgment
Result Procedure
Harness defect
NG In addition to the harness, replace the defect portion of Step
4
Pump motor driver defect
OK In addition to the pump motor driver, replace the defect por-
tion of Step 4

[Link] Step 7
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN103, CN104, CN110, CN111 and CN70
connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
CN110 Turn the key switch off, disconnect the battery plug, dis-
CN103
1 2 3 4 5 6 7 8 connect the CN103, CN104, CN110, CN111 and CN70 con-
9 10 11 12 13 14 15
1 2 3 4 5 6 16 17 18 19 20 21 22 23 nectors, visually inspect whether there is no problem with
7 8 9 10 11 12 13 14 15 16 the inside of the connector and the wire caulking, and then
CN111
17 18 19 20 21 22 23 24 25 26 27 inspect the harness.
28 29 30 31 32 33 34 35 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
Refer to "BEFORE TROUBLESHOOTING."
16 17 18 19 20 21 22 23
Portion to be inspected Standard
CN103-4 - CN110-8 Continuity
CN103-11 - CN110-17 Continuity
CN103-12 - CN110-16 Continuity
CN103-4 - CN111-8 Continuity
CN103-11 - CN111-17 Continuity
CN103-12 - CN111-16 Continuity
CN103-4 - CN103-5 No continuity

Judgment
Result Procedure
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-75

Result Procedure
OK Go to Step 8
1

[Link] Step 8
Main control supply voltage check
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN103, CN104 and CN70 connectors and dis-
connect CN110 and CN111 connectors.
3. Connect the battery plug and turn the key switch ON.
4. Inspect the motor driver supply voltage.
Voltage measurement between CN110-8 and N2

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

Judgment
Result Procedure
Less than 15 V Main controller defect
15 V or more Go to Step 9

[Link] Step 9
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN103, CN104 and CN110 connectors and
disconnect the CN111 connector.
3. Connect the battery plug and turn the key switch ON. In-
spect the motor driver supply voltage and errors.
4. Inspect the motor driver supply voltage.
Voltage measurement between CN111-8 and N2
5. Check for errors.
CN111 Notes:
1 2 3 4 5 6 7 8 ▪ Disconnect the pump motor driver and connect the
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 main controller and drive motor driver to perform in-
spection.
▪ Measure the voltage on the disconnected pump motor
driver harness.

Judgment
Result Procedure
Go to Step 10
Voltage: less than 15 V
Record the results.
Voltage: 15 V or more Go to Step 10
Error at AD-2 Record the results.
1-76 1 ELECTRICAL TROUBLESHOOTING

Result Procedure
Voltage: 15 V or more Go to Step 10
No error at AD-2 Record the results.

[Link] Step 10
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN103, CN104 and CN111 connectors and
disconnect the CN110 connector.
3. Connect the battery plug and turn the key switch ON.
4. Inspect the motor driver supply voltage.
Voltage measurement between CN110-8 and N2
5. Check for errors.
CN110 Notes:
1 2 3 4 5 6 7 8 ▪ Disconnect the drive motor driver and connect the main
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 controller and pump motor driver to perform inspec-
tion.
▪ Measure the voltage on the disconnected drive motor
driver harness.

Judgment
Result Procedure
Go to Step 11
Voltage: less than 15 V
Record the results.
Voltage: 15 V or more Go to Step 11
Error at AD-6 Record the results.
Voltage: 15 V or more Go to Step 11
No error at AD-6 Record the results.

[Link] Step 11
1. Check the results of Steps 9 and 10.

Judgment
Result Procedure
Failure of inspection targets of less than 15 V (drive motor
Voltage of one of them: less than 15 V
driver or pump motor driver)
Main controller defect
Voltage of all: 15 V or more If the problem persists after the main controller is replaced,
Error at all connections replace the drive motor driver and pump motor driver, be-
cause there may be other defects.
Voltage of all: 15 V or more Failure of inspection targets with error display (drive motor
No error for any one of them driver or pump motor driver)
1 ELECTRICAL TROUBLESHOOTING 1-77

1.4.24 AD-5 1
Failure mode: Pump motor driver to main controller communication abnormality

CAUTION
• If AC-1 is displayed at the same time, give a higher priority to troubleshooting AC-1.
• If AD-1 or AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.
• If AD-6 is displayed at the same time, give a higher priority to troubleshooting AD-6.

Probable cause
▪ Connector connection defect

Related part

CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H)
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L)
Pump motor driver
Main
controller CN111-6 (152, SETP2)
CN103-5 (N2, N2) CN111-23 (152, SETP-)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
visually inspect the inside of the CN103 and CN111 con-
nectors and the wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.

Judgment
Result Procedure
Error at AD-5 or AD-6 Perform AD-6 troubleshooting
No error at AD-5 and AD-6 Connector connection defect
1-78 1 ELECTRICAL TROUBLESHOOTING

1.4.25 AD-6
Failure mode: Pump motor driver to main controller communication abnormality

CAUTION
• If AC-1 is displayed at the same time, give a higher priority to troubleshooting AC-1.
• If AD-1 or AD-2 is displayed at the same time, give a higher priority to troubleshooting AD-2.

Probable cause
▪ Motor driver of different class
▪ Connector connection defect
▪ Harness defect
▪ Pump motor driver defect

Related part

CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

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

CN111-8 (42, KYSAT)

CN70-16 (145, CAN1H) CN111-17 (145, CAN1H)
Display CN70-15 (146, CAN1L) CN111-16 (146, CAN1L)
CN111-6 (152, SETP2) Pump motor driver

NC CN111-7
CN111-23 (152, SETP-)

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug and
check that the part number of the motor driver is correct.
Especially if you have replaced the motor driver, check that
another model of the motor driver is not installed.

Judgment
Result Procedure
Wrong part No. Motor driver of different class
Correct part No. Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-79

[Link] Step 2
1
1. Turn the key switch OFF, disconnect the battery plug and
visually inspect the inside of the CN111 connector and the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.
Especially if you replaced the motor driver immediately be-
fore connecting the connector, check that the connector is
properly corrected.

Judgment
Result Procedure
No error at AD-5 and AD-6 Connector connection failure
Error at AD-5 or AD-6 Go to Step 3

[Link] Step 3
Pump motor driver identification check
1. Turn the key switch OFF and disconnect the battery plug.
Disconnect the CN110 connector
2. Connect the battery plug and turn the key switch ON. Check
the displayed errors.
Notes:
Disconnect the drive motor driver to check that the pump
motor driver is not operating as a drive motor driver.

Judgment
Result Procedure
No error at AD-2 Go to Step 4
Error at AD-2 Go to Step 5
1-80 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN111 connector and inspect the harness.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn the key switch off, disconnect the battery plug, dis-
CN111
connect the CN111 connector, visually inspect whether
there is no problem with the inside of the connector and
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 the wire caulking, and then inspect the harness.
16 17 18 19 20 21 22 23 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN111-6 (152) - CN111-23 Continuity
CN111-7 - CN111-23 No continuity
CN111-7 - N2 (N2) No continuity

Judgment
Result Procedure
NG Harness defect
OK Pump motor driver defect

[Link] Step 5
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN103 and CN111 connectors and inspect
the harness.
3. Inspect for continuity and short circuiting of the harness.
Notes:
CN103 Turn the key switch off, disconnect the battery plug, dis-
connect the CN103 and CN111 connectors, visually inspect
1 2 3 4 5 6
CN111 whether there is no problem with the inside of the con-
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 nector and the wire caulking, and then inspect the harness.
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
Refer to "BEFORE TROUBLESHOOTING."
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN103-4 (42) - CN111-8 Continuity
CN103-11 (145) - CN111-17 Continuity
CN103-12 (146) - CN111-16 Continuity

Judgment
Result Procedure
NG Harness defect
OK Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-81

1.4.26 AF-1, AF-2, AF-3, AF-4, AF-5, AF-6, AF-7, AF-8 1

Failure mode: Main controller CPU abnormality

CAUTION
• If any of AF-1, AF-2, AF-3, AF-4, AF-5, AF-6, AF-7 or AF-8 are displayed, it indicates main controller
defect. Replace it.

Probable cause
▪ Main controller defect

Related part

Main controller
1-82 1 ELECTRICAL TROUBLESHOOTING

1.4.27 C0-2
Failure mode: Drive motor driver main circuit abnormality

CAUTION
• If CB-3 is displayed at the same time, give a higher priority to troubleshooting CB-3.
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before performing troubleshooting.

Probable cause
▪ Drive motor cable connection defect
▪ Drive motor defect
▪ Drive motor cable defect
▪ Drive motor driver defect
▪ Magnet switch defect
▪ Control panel defect
▪ Harness defect
▪ Display defect
▪ Transformer ASSY defect

Related part
1 - 2 ton vehicles with the on-truck charger

P7
U
Drive motor driver
P8
V Drive motor

P9
W

Transformer
CN70-4 (14, DGND)
CN61

CN70-3 (169, TGND)

CN66-4 CN70-36 (N1, N1)

Power AC plug Magnet Display
switch
CN66-3
CN70-33 (132, CHGMS)
Charging CN69-1
cable CN64-1 (95, MSCH) Control
panel CN70-2 (130, CHGGND)
CN69-3
CN64-3 (136, CHGACS)
1 ELECTRICAL TROUBLESHOOTING 1-83

3 ton vehicles, 1 - 2 ton vehicles without the on-truck charger

1
U P7

Pump motor driver

V P8
Pump motor

W P9

[Link] Step 1
Check for errors
1. Disconnect the battery plug and visually inspect whether
there is no problem with the transformer cable (1 - 2 ton
vehicles with the on-vehicle charger only) or the drive motor
cable tightening and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the transformer cable and the drive motor
cable, connect the battery plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display by stepping on the
accelerator pedal.

Judgment
Result Procedure
Go to Step 9
Error at C0-2
Record the displayed error codes.
No error at C0-2
(1 - 2 ton vehicles with the on-vehicle char- Go to Step 2
ger)
No error at C0-2
(3 ton vehicles and 1 - 2 ton vehicles Drive motor cable connection defect
without the on-vehicle charger)

[Link] Step 2
Check for errors
1. Turn the key switch OFF and connect the battery plug and
the charging plug.
2. Perform a timer test, and check for C0-2 error.

Judgment
Result Procedure
Error at C0-2 Go to Step 3
No error at C0-2 Drive motor cable connection defect
1-84 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Magnet switch check
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN61 connector

Input side
3. Inspect the magnet switch.
Input side Input side
main terminal main terminal
main terminal (S)
Input side
(S) Input side (R) Input side 4. Disconnect the CN61 connector and check that the magnet
main terminal main terminal main terminal
(R) (T) (T) switch is OFF.
Portion to be inspected Standard
Input side main terminal (R) - output side
No continuity
main terminal (R)
Input side main terminal (S) - output side
No continuity
main terminal (S)
Input side main terminal (T) - output side
No continuity
main terminal (T)
Output side Output side Output side Output side Output side Output side
main terminal main terminal main terminal main terminal main terminal main terminal
(R) (S) (T) (R) (S) (T)

CLK-20JT FW-1S
(Abbreviation: M1) (Abbreviation: M2)

Input side Input side Input side

main main main
terminal (R) terminal (S) terminal (T)

CLK-35JT
(Abbreviation: M3)
CLK-50JT
(Abbreviation: M4)

Output side Output side Output side

main main main
terminal (R) terminal (S) terminal (T)

Judgment
Result Procedure
OK (No continuity) Go to Step 4
NG (Continuity) Magnet switch defect
1 ELECTRICAL TROUBLESHOOTING 1-85

[Link] Step 4
1
Control Panel Inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Connect the CN61 connector and disconnect the CN69 con-
nector.
3. Inspect the control panel.
Notes:
Disconnect the CN69 connector, visually inspect whether
there is no problem with the inside of the connector and
CN69 the wire caulking, and then inspect the CN69 connector on
the control panel side.
6 5 4 3 2 1
Refer to "BEFORE TROUBLESHOOTING."
12 11 10 9 8 7
Portion to be inspected Standard
CN69-1 - CN69-3 No continuity

Judgment
Result Procedure
OK Go to Step 5
NG Control panel defect

[Link] Step 5
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
Notes:
Disconnect the CN69 and CN70 connectors, visually in-
spect whether there is no problem with the inside of the
CN70 connector and the wire caulking, and then inspect the con-
nector on the harness side.
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN70-33 - CN70-2 No continuity

Judgment
Result Procedure
OK Go to Step 6
NG Harness defect
1-86 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN64 connector
3. Inspect the harness.
Notes:
Disconnect the CN64 connector, visually inspect whether
there is no problem with the inside of the connector and
CN64
the wire caulking, and then inspect the connector on the
1 magnet switch side.
3 2
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN64-1 - CN64-3 No continuity

Judgment
Result Procedure
OK (No continuity) Go to Step 8
NG (Continuity) Go to Step 7

[Link] Step 7
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN66 connector
3. Inspect the harness.
Notes:
Disconnect the CN66 connector, visually inspect whether
there is no problem with the inside of the connector and
CN66
the wire caulking, and then inspect the connector on the
1 2 magnet switch side.
3 4 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN66-3 - CN66-4 No continuity

Judgment
Result Procedure
Harness defect
OK (No continuity)
Replace the harness between CN64 - CN66
Harness defect
NG (Continuity)
Replace the harness between CN66 - magnet switch
1 ELECTRICAL TROUBLESHOOTING 1-87

[Link] Step 8
1
magnet switch signal inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Connect the CN69 connector and disconnect the CN70 con-
nector.
3. Inspect the CN70 connector on the display side.
4. Inspect the magnet switch signal.
Portion to be inspected Standard
CN70-33 - CN70-2 No continuity
CN70-33 - CN70-3 No continuity
CN70
CN70-33 - CN70-4 No continuity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN70-33 - CN70-36 No continuity

Judgment
Result Procedure
OK (No continuity) Control panel defect
NG (Continuity) Display defect

[Link] Step 9
Drive motor driver inspection
1. Return the direction lever to to the neutral position, turn the
key switch OFF and disconnect the battery plug.
2. Disconnect three drive motor cables on the drive motor
driver side and insulate the terminal of the disconnected
cables.
3. For 1 - 2 ton vehicles with an on-vehicle charger, disconnect
the one transformer cable as well, and insulate the terminal
of the disconnected cable.
4. Connect the battery plug and turn the key switch ON to
check whether C0-2 occurs.

Judgment
Result Procedure
Error at C0-2 Drive motor driver defect
No error at C0-2
(1 - 2 ton vehicles with the on-vehicle char- Go to Step 10
ger)
No error at C0-2
(3 ton vehicle and 1 - 2 ton vehicles without Go to Step 11
the on-vehicle charger)
1-88 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 10
Transformer ASSY inspection
(Refer to “Charger section” in the Transformer ASSY Part.)

Judgment
Result Procedure
OK Go to Step 11
NG Transformer ASSY defect

[Link] Step 11
Drive motor cable inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Individually disconnect the motor driver side and motor side
of the drive motor cable.
3. Inspect continuity and short circuit of the drive motor cable.
Notes:
Disconnect the battery plug, disconnect the drive motor
cable, visually inspect whether there is no problem with the
terminal, cable caulking, and coating, and then inspect the
P7, P8, and P9 cables.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
Both end of P7 cable Continuity
Both end of P8 cable Continuity
Both end of P9 cable Continuity
P7 cable - P8 cable No continuity
P8 cable - P9 cable No continuity
P9 cable - P7 cable No continuity

Judgment
Result Procedure
OK (no E0-2 display at the same time at
Go to Step 12
Step 1)
OK (E0-2 display at the same time at Step
Go to Step 13
1)
NG Drive motor cable defect
1 ELECTRICAL TROUBLESHOOTING 1-89

[Link] Step 12
1
Drive motor driver inspection
1. Exchange the drive motor driver and the pump motor driver.
2. Connect the battery plug and turn the key switch ON.
3. Operate the direction lever forward or backward, and check
the error display.
(Ignore 32-1 and 32-3 errors).

Judgment
Result Procedure
Error at C0-2 Drive motor defect
Drive motor driver defect
Error at E0-2 The motor driver that the drive motor driver was replaced
with is faulty.

[Link] Step 13
Drive motor inspection
1. Return the direction lever to to the neutral position, turn the
key switch OFF and disconnect the battery plug.
2. Inspect the drive motor.

Judgment
Result Procedure
NG Drive motor defect
OK Drive motor driver defect
1-90 1 ELECTRICAL TROUBLESHOOTING

1.4.28 C1-1
Failure mode: Drive motor driver current sensor neutral abnormality

CAUTION
• If F7-6 is displayed at the same time, give a higher priority to troubleshooting F7-6.

Probable cause
▪ Drive motor driver defect

Related part

Drive motor driver

Current main circuit temperature

1 ELECTRICAL TROUBLESHOOTING 1-91

1.4.29 C1-2 1
Failure mode: Drive motor driver current sensor overcurrent abnormality

CAUTION
• C8-1 or C8-2 is displayed with C1-2 at the same time, give a higher priority to troubleshooting C8-1
or C8-2.
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before performing troubleshooting.

Probable cause
▪ Drive motor cable connection defect
▪ Drive motor defect
▪ Drive motor cable defect
▪ Drive motor driver defect
▪ Drive motor rpm sensor defect
▪ Transformer ASSY defect

Related part
1 - 2 ton vehicles with the on-truck charger

U P7

Pump motor driver

V P8
Pump motor

W P9

Transformer

3 ton vehicles, 1 - 2 ton vehicles without the on-truck charger

U P7

Pump motor driver

V P8
Pump motor

W P9
1-92 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Check for errors
1. Turn the key switch OFF/ON to check that C0-2 error is dis-
played.

Judgment
Result Procedure
No error at C0-2 Go to Step 2
Error at C0-2 Perform C0-2 troubleshooting.

[Link] Step 2
Check for errors
1. Disconnect the battery plug and visually inspect whether
there is no problem with the transformer cable (1 - 2 ton
vehicles with the on-vehicle charger only) or the drive motor
cable tightening and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the transformer cable and the drive motor
cable, connect the battery plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display by stepping on the
accelerator pedal.

Judgment
Result Procedure
Go to Step 3
Error at C1-2
Record the displayed error codes.
No error at C1-2
Go to Step 6
(1 - 2 ton vehicles with the on-vehicle char-
Record the displayed error codes.
ger)
No error at C1-2
(3 ton vehicles and 1 - 2 ton vehicles Drive motor cable connection defect
without the on-vehicle charger)

[Link] Step 3
Drive motor cable inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the driver side and the motor side of the drive
motor cable.
3. Inspect continuity and short circuit of the drive motor cable.
Notes:
Disconnect the battery plug, disconnect the drive motor
cable, visually inspect whether there is no problem with the
terminal, cable caulking, and coating, and then inspect the
P7, P8, and P9 cables.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
Both end of P7 cable Continuity
Both end of P8 cable Continuity
Both end of P9 cable Continuity
1 ELECTRICAL TROUBLESHOOTING 1-93

Portion to be inspected Standard

P7 cable - P8 cable No continuity
1
P8 cable - P9 cable No continuity
P9 cable - P7 cable No continuity

Judgment
Result Procedure
OK (no E1-2 display at the same time at
Go to Step 4
Step 2)
OK (E1-2 display at the same time at Step
Go to Step 5
2)
NG Drive motor cable defect

[Link] Step 4
Drive motor driver inspection
1. Exchange the drive motor driver and the pump motor driver.
2. Connect the battery plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display by stepping on the
accelerator pedal. (Ignore 32-1 and 32-3 errors).

Judgment
Result Procedure
Error at C1-2 Drive motor defect
Drive motor driver defect
Error at E1-2 The motor driver that the drive motor driver was replaced
with is faulty.

[Link] Step 5
Drive motor inspection
1. Turn the key switch OFF, disconnect the battery plug, and
inspect the drive motor.

Judgment
Result Procedure
NG Drive motor defect
OK Drive motor driver defect

[Link] Step 6
Transformer ASSY inspection
(Refer to “Charger section” in the Transformer ASSY Part.)

Judgment
Result Procedure
OK Go to Step 3
NG Transformer ASSY defect
1-94 1 ELECTRICAL TROUBLESHOOTING

1.4.30 C2-1
Failure mode: Drive motor temperature abnormal rise

CAUTION
• Do not leave the vehicle in places where it gets hot.

Probable cause
▪ Overheating (overload continuous use)

Related part

CN110-9 (86, STDML+) CN121-2

Drive motor driver Temperature sensor
(drive motor)
CN110-10 (87, STDML) CN121-1

[Link] Step 1
Error display recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"DM" display Go to Step 2
Overheating (overload continuous use)
If the temperature of the drive motor falls, the "DM" display
"DM" not display disappears, and you can use the vehicle as usual. Because
an error occurred due to a continuous use in an overloaded
condition, check the vehicle usage and avoid an overloaded
continuous use.
1 ELECTRICAL TROUBLESHOOTING 1-95

[Link] Step 2
1
Drive motor temperature check and error recheck
1. Record the drive motor temperature values.
[ANL] I/O TEMP/VOLT 1/5
TDM
2. Turn the key switch OFF, leave the vehicle for a while (ap-
proximately 30 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"DM" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the drive motor falls, the "DM" display
"DM" not display disappears, and you can use the vehicle as usual. Because
an error occurred due to a continuous use in an overloaded
condition, check the vehicle usage and avoid an overloaded
continuous use.

[Link] Step 3
Drive motor temperature recheck
1. Check the drive motor temperature value and compare it
with the recorded value.
[ANL] I/O TEMP/VOLT 1/5
TDM

Judgment
Result Procedure
All of the temperatures rose by 5℃ or more. Go to Step 2
Drive motor temperature did not rise by 5℃
Perform troubleshooting from C2-2 Step 2.
or more.
1-96 1 ELECTRICAL TROUBLESHOOTING

1.4.31 C2-2
Failure mode: Drive motor temperature sensor open/short circuit abnormality

Probable cause
▪ Connector connection defect
▪ Drive motor temperature sensor defect
▪ Drive motor temperature sensor harness defect
▪ Drive motor driver defect

Related part

CN110-9 (86, STDML+) CN121-2

Drive motor driver Temperature sensor
(drive motor)
CN110-10 (87, STDML) CN121-1

[Link] Step 1
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN121 connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
Error at C2-2 Go to Step 2
No error at C2-2 Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-97

[Link] Step 2
1
Temperature sensor individual inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN121 connector
3. Carry out a temperature sensor individual inspection.
Measure the resistance of the temperature sensor between
CN121-2 and CN121-1 on the sensor side of the CN121
connector.
CN121
Standard: Approx. 245 Ω - 600 kΩ
2 1
Notes:
Resistance values vary at a low or high temperature. Use
the values in the following table as a guideline.
Temperature sensor resist-
Temperature ance value (between
CN121-2 - CN121-1)
20℃ Approx. 13 kΩ
80℃ Approx. 1.75 kΩ
100℃ Approx. 1 kΩ

Judgment
Result Procedure
OK Go to Step 3
NG Drive motor temperature sensor defect

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110 and CN121 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Disconnect the battery plug, disconnect the CN110 and
CN110 CN121 CN121 connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 caulking with SST disconnected, and then inspect the har-
16 17 18 19 20 21 22 23
ness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN110-9 - CN121-2 Continuity *1
CN110-10 - CN121-1 Continuity *1
CN121-1 - CN121-2 No continuity
*1: Use SST2 to connect CN121-1 and CN121-2 on the har-
ness side. You can check for continuity between CN110-9 -
CN110-10.

Judgment
Result Procedure
OK Drive motor driver defect
NG Drive motor temperature sensor harness defect
1-98 1 ELECTRICAL TROUBLESHOOTING

1.4.32 C3-1
Failure mode: Drive motor driver main circuit temperature sensor open/short circuit
abnormality

CAUTION
• If C3-1 is displayed, it indicates drive motor driver defect. Replace it.

Probable cause
▪ Drive motor driver defect

Related part

Drive motor driver

Current main circuit temperature

1 ELECTRICAL TROUBLESHOOTING 1-99

1.4.33 C4-1 1
Failure mode: accelerator potentiometer POT1 open abnormality

CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Accelerator sensor defect
▪ Main controller defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN26 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C4-1 Connector connection defect
Error at C4-1 Go to Step 2
1-100 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Accelerator sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector
3. Measure the resistance value of the accelerator sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-4 (52) - CN26-6 (50)

Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3

[Link] Step 3
Inspect for continuity of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN26 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102 and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN26 connectors, visually inspect whether there is no problem
28 29 30 31 32 33 34 with the inside of the connector and the wire caulking, and then
CN26
inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-27 (53) - CN26-5 Continuity *1

20 21 22 23 24 25 26 27
CN102-30 (52) - CN26-4 Continuity *1
28 29 30 31 32 33 34 35
CN26-5 (53) - CN26-6 (50) No continuity
CN26-5 (53) - CN26-2 (51) No continuity
CN26-4 (52) - CN26-6 (50) No continuity
CN26-4 (52) - CN26-2 (51) No continuity
*1: Use SST2 (09232-13130-71) to connect CN26-5 and
CN26-4 on the harness side. You can check for continuity
between CN101-27 - CN102-30.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-101

1.4.34 C4-2 1
Failure mode: Accelerator potentiometer POT2 open abnormality

CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Accelerator sensor defect
▪ Main controller defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN26 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C4-2 Connector connection defect
Error at C4-2 Go to Step 2
1-102 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Accelerator sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector
3. Measure the resistance value of the accelerator sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN26-1 (55) - CN26-2 (50) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-3 (54) - CN26-2 (51)

Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN26 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN26 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN26
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-26 (55) - CN26-1 Continuity *1

20 21 22 23 24 25 26 27
CN102-32 (54) - CN26-3 Continuity *1
28 29 30 31 32 33 34 35
CN26-1 (55) - CN26-6 (50) No continuity
CN26-1 (55) - CN26-2 (51) No continuity
CN26-3 (54) - CN26-6 (50) No continuity
CN26-3 (54) - CN26-2 (51) No continuity
*1: Use SST2 (09232-13130-71) to connect CN26-1 and
CN26-3 on the harness side. You can check for continuity
between CN101-26 - CN102-32.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-103

1.4.35 C4-3 1
Failure mode: accelerator potentiometer POT1 VCC short circuit abnormality

CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Accelerator sensor defect
▪ Main controller defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN26 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C4-3 Connector connection defect
Error at C4-3 Go to Step 2
1-104 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Accelerator sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector
3. Measure the resistance value of the accelerator sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-4 (52) - CN26-6 (50)
CN26-3 (54) - CN26-2 (51)

Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN26 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN26 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN26
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-22 (50) - CN26-6 Continuity *1

20 21 22 23 24 25 26 27
CN26-4 (52) - CN26-5 (53) No continuity
28 29 30 31 32 33 34 35
CN26-4 (52) - CN26-1 (55) No continuity
*1: Use SST2 (09232-13130-71) to connect CN26-6 and
CN26-4 on the harness side. You can check for continuity
between CN101-22 - CN102-30.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-105

1.4.36 C4-4 1
Failure mode: Accelerator potentiometer POT2 VCC short circuit abnormality

CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Accelerator sensor defect
▪ Main controller defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN26 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C4-4 Connector connection defect
Error at C4-4 Go to Step 2
1-106 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Accelerator sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector
3. Measure the resistance value of the accelerator sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-3 (54) - CN26-2 (51)

Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN26 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN26 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN26
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-32 (51) - CN26-2 Continuity *1

20 21 22 23 24 25 26 27
CN26-3 (54) - CN26-5 (53) No continuity
28 29 30 31 32 33 34 35
CN26-3 (54) - CN26-1 (55) No continuity
*1: Use SST2 (09232-13130-71) to connect CN26-2 and
CN26-3 on the harness side. You can check for continuity
between CN101-32 - CN102-32.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-107

1.4.37 C4-5 1
Failure mode: Accelerator potentiometer offset abnormality

CAUTION
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Accelerator sensor defect
▪ Main controller defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN26 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C4-5 Connector connection defect
Error at C4-5 Go to Step 2
1-108 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Accelerator sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN26 connector
3. Measure the resistance value of the accelerator sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN26 connector
CN26
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN26-5 (53) - CN26-6 (50) 1.8 - 3.5 kΩ
CN26-1 (55) - CN26-2 (51) 1.8 - 3.5 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN26-4 (52) - CN26-6 (50)
CN26-3 (54) - CN26-2 (51)

Judgment
Result Procedure
NG Accelerator sensor defect
OK Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-109

[Link] Step 3
1
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN26 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN26 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN26
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-27 (53) - CN26-5 Continuity *1

20 21 22 23 24 25 26 27
CN101-22 (50) - CN26-6 Continuity *2
28 29 30 31 32 33 34 35
CN101-26 (55) - CN26-1 Continuity *3
CN101-32 (51) - CN26-2 Continuity *4
CN26-4 (52) - CN26-6 (50) No continuity
CN26-4 (52) - CN26-2 (51) No continuity
CN26-4 (52) - CN26-5 (53) No continuity
CN26-4 (52) - CN26-1 (55) No continuity
CN26-3 (54) - CN26-6 (50) No continuity
CN26-3 (54) - CN26-2 (51) No continuity
CN26-3 (54) - CN26-5 (53) No continuity
CN26-3 (54) - CN26-1 (55) No continuity
CN102-30 (52) - CN102-32 (54) No continuity
*1: You can use SST2 (09232-13130-71) to connect the follow-
ing points and check for continuity between CN101 - CN102.
SST2 connection points / continuity check points
*1: CN26-5 - CN26-4 / CN101-27 - CN102-30
*2: CN26-6 - CN26-3 / CN101-22 - CN102-30
*3: CN26-1 - CN26-3 / CN101-26 - CN102-32
*4: CN26-2 - CN26-3 / CN101-32 - CN102-32

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-110 1 ELECTRICAL TROUBLESHOOTING

1.4.38 C4-6
Failure mode: Accelerator potentiometer matching value abnormality

CAUTION
• If C4-1, 2, 3, 4 and 5 have occurred, perform troubleshooting for C4-1, 2, 3, 4 and 5 first.
• If you carry out inspection after removing the accelerator potentiometer, be sure to perform match-
ing after reassembly.

Probable cause
▪ Main controller defect
▪ Accelerator potentiometer matching defect
▪ Accelerator potentiometer assembly defect

Related part

CN101-27 (53, VRA1+) CN26-5

CN102-30 (52, VRA1) CN26-4
Main controller CN101-22 (50, VRA-) CN26-6
Accelerator sensor
CN101-26 (55, VRA2+) CN26-1
CN102-32 (54, VRA2) CN26-3
CN101-32 (51, POT-) CN26-2

[Link] Step 1
1. Perform accelerator potentiometer matching
(Refer to “Display section” in the Matching Part)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-111

[Link] Step 2
1
Accelerator potentiometer supply voltage check
1. Accelerator sensor 1/2 voltage
[ANL] I/O TRAVELING 1/6
VRA
Notes:
When the accelerator is not operated, check that the
voltage with the accelerator fully depressed is within the
range shown in the below table.
Accelerator pedal position Sensor 1 Sensor 2
When the accelerator is not
0.40 - 1.24 V 0.65 - 2.31 V
operated
When the accelerator is fully
2.00 - 4.79 V 2.42 - 4.79 V
depressed

Judgment
Result Procedure
Within the standard range Main controller defect
Go to Step 3
Outside the standard range Accelerator potentiometer assembly defect
After reassembling it, perform matching

[Link] Step 3
1. After turning the key switch OFF, disconnect the battery
plug. After 30 seconds, connect it again and turn the key
switch ON.

Judgment
Result Procedure
Error at C4-6 Main controller defect
Accelerator potentiometer matching defect
No error at C4-6
The vehicle can be used as is.
1-112 1 ELECTRICAL TROUBLESHOOTING

1.4.39 C5-1
Failure mode: Brake potentiometer POT1 open abnormality

CAUTION
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Brake sensor defect
▪ Main controller defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN6 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C5-1 Connector connection defect
Error at C5-1 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-113

[Link] Step 2
1
Brake sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector
3. Measure the resistance value of the brake sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN6 connector
CN6
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN6-5 (72) - CN6-6 (50) 0.9 - 2.2 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN6-4 (71) - CN6-6 (50)

Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3

[Link] Step 3
Inspect for continuity of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN6 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102 and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN6 connectors, visually inspect whether there is no problem
28 29 30 31 32 33 34 with the inside of the connector and the wire caulking, and then
CN6
inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-34 (72) - CN6-5 Continuity *1

20 21 22 23 24 25 26 27
CN102-33 (71) - CN6-4 Continuity *1
28 29 30 31 32 33 34 35
CN6-5 (72) - CN6-6 (50) No continuity
CN6-5 (72) - CN6-2 (51) No continuity
CN6-4 (71) - CN6-6 (50) No continuity
CN6-4 (71) - CN6-2 (51) No continuity
*1: Use SST2 (09232-13130-71) to connect CN6-5 and CN6-4
on the harness side. You can check for continuity between
CN101-27 - CN102-30.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-114 1 ELECTRICAL TROUBLESHOOTING

1.4.40 C5-2
Failure mode: Brake potentiometer POT2 open abnormality

CAUTION
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Brake sensor defect
▪ Main controller defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN6 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C5-2 Connector connection defect
Error at C5-2 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-115

[Link] Step 2
1
Brake sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector
3. Measure the resistance value of the brake sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN6 connector
CN6
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN6-1 (74) - CN6-2 (51) 0.9 - 2.2 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN6-3 (74) - CN6-2 (51)

Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3

[Link] Step 3
Inspect for continuity of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN6 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102 and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN6 connectors, visually inspect whether there is no problem
28 29 30 31 32 33 34 with the inside of the connector and the wire caulking, and then
CN6
inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-33 (74) - CN6-1 Continuity *1

20 21 22 23 24 25 26 27
CN102-25 (73) - CN6-3 Continuity *1
28 29 30 31 32 33 34 35
CN6-1 (74) - CN6-6 (50) No continuity
CN6-1 (74) - CN6-2 (51) No continuity
CN6-3 (73) - CN6-6 (50) No continuity
CN6-3 (73) - CN6-2 (51) No continuity
*1: Use SST2 (09232-13130-71) to connect CN6-1 and CN6-3
on the harness side. You can check for continuity between
CN101-33 - CN102-25.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-116 1 ELECTRICAL TROUBLESHOOTING

1.4.41 C5-3
Failure mode: Brake potentiometer POT1 VCC short circuit abnormality

CAUTION
• If C5-5 has occurred, perform troubleshooting for C5-5 first.
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Brake sensor defect
▪ Main controller defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN6 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C5-3 Connector connection defect
Error at C5-3 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-117

[Link] Step 2
1
Brake sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector
3. Measure the resistance value of the brake sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN6 connector
CN6
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN6-5 (72) - CN6-6 (50) 0.9 - 2.2 kΩ
CN6-1 (74) - CN6-2 (51) 0.9 - 2.2 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN6-4 (71) - CN6-6 (50)
CN6-3 (73) - CN6-2 (51)

Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN6 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN6 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN6
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-22 (50) - CN6-6 Continuity *1

20 21 22 23 24 25 26 27
CN6-4 (71) - CN6-5 (72) No continuity
28 29 30 31 32 33 34 35
CN6-4 (71) - CN6-1 (74) No continuity
*1: Use SST2 (09232-13130-71) to connect CN6-6 and CN6-4
on the harness side. You can check for continuity between
CN101-22 - CN102-33.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-118 1 ELECTRICAL TROUBLESHOOTING

1.4.42 C5-4
Failure mode: Brake potentiometer POT2 VCC short circuit abnormality

CAUTION
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Brake sensor defect
▪ Main controller defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN6 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C5-4 Connector connection defect
Error at C5-4 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-119

[Link] Step 2
1
Brake sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector
3. Measure the resistance value of the brake sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN6 connector
CN6
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN6-1 (74) - CN6-2 (51) 0.9 - 2.2 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN6-3 (73) - CN6-2 (51)

Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN6 connectors.

CN101
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN6 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN6
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-32 (51) - CN6-2 Continuity *1

20 21 22 23 24 25 26 27
CN6-3 (73) - CN6-5 (72) No continuity
28 29 30 31 32 33 34 35
CN6-3 (73) - CN6-1 (74) No continuity
*1: Use SST2 (09232-13130-71) to connect CN6-2 and CN6-3
on the harness side. You can check for continuity between
CN101-32 - CN102-25.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-120 1 ELECTRICAL TROUBLESHOOTING

1.4.43 C5-5
Failure mode: Brake potentiometer offset abnormality

CAUTION
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Brake sensor defect
▪ Main controller defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector and visually inspect whether
there is no problem with the inside of the connector and the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN6 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at C5-5 Connector connection defect
Error at C5-5 Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-121

[Link] Step 2
1
Brake sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN6 connector
3. Measure the resistance value of the brake sensor.
Notes:
Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN6 connector
CN6
and the wire caulking.
6 5 4 3 2 1 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN6-5 (72) - CN6-6 (50) 0.9 - 2.2 kΩ
CN6-1 (74) - CN6-2 (51) 0.9 - 2.2 kΩ
Also, measure the resistance of both ends the connectors on
the sensor side and check whether the values change when the
sensor section is moved.
CN6-4 (71) - CN6-6 (50)
CN6-3 (73) - CN6-2 (51)

Judgment
Result Procedure
NG Brake sensor defect
OK Go to Step 3
1-122 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN6 connectors.

CN101
3. Inspect for continuity of the harness.
[Inspection Procedure and Standard]
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN6 connectors, visually inspect whether there is no
28 29 30 31 32 33 34 problem with the inside of the connector and the wire
CN6
caulking, and then inspect the harness.
CN102 1 2 3 4 5 6 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-34 (72) - CN6-5 Continuity *1

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-22 (50) - CN6-6 Continuity *2
CN101-33 (74) - CN6-1 Continuity *3
CN101-32 (51) - CN6-2 Continuity *4
CN6-4 (71) - CN6-6 (50) No continuity
CN6-4 (71) - CN6-2 (51) No continuity
CN6-4 (71) - CN6-5 (73) No continuity
CN6-4 (71) - CN6-1 (74) No continuity
CN6-3 (73) - CN6-6 (50) No continuity
CN6-3 (73) - CN6-2 (51) No continuity
CN6-3 (73) - CN6-5 (72) No continuity
CN6-3 (73) - CN6-1 (74) No continuity
CN102-33 (71) - CN102-25 (73) No continuity
*1: You can use SST2 (09232-13130-71) to connect the follow-
ing points and check for continuity between CN101 - CN102.
SST2 connection points / continuity check points
*1: CN6-5 - CN6-4 / CN101-34 - CN102-33
*2: CN6-6 - CN6-4 / CN101-22 - CN102-33
*3: CN6-1 - CN6-3 / CN101-33 - CN102-25
*4: CN6-2 - CN6-3 / CN101-32 - CN102-25

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-123

1.4.44 C5-6 1
Failure mode: Brake potentiometer matching value abnormality

CAUTION
• If C5-1, 2, 3, 4 and 5 have occurred, perform troubleshooting for C5-1, 2, 3, 4 and 5 first.
• If you carry out inspection after removing the brake potentiometer, be sure to perform matching
after reassembly.

Probable cause
▪ Main controller defect
▪ Brake potentiometer matching defect
▪ Brake potentiometer assembly defect

Related part

CN101-34 (72, VRB1+) CN6-5

CN102-33 (71, VRB1) CN6-4
Main controller CN101-22 (50, VRA-) CN6-6
Brake sensor
CN101-33 (74, VRB2+) CN6-1
CN102-25 (73, VRB2) CN6-3
CN101-32 (51, POT-) CN6-2

[Link] Step 1
1. Perform brake potentiometer matching
(Refer to “Display section” in the Matching Part)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3
1-124 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Brake potentiometer voltage check
1. Brake sensor 1/2 voltage
[ANL] I/O TRAVELING 1/6
VRB
Notes:
At the brake operating point, the difference should be
within the range shown in the following table, and 0.40 V or
more from the matching voltage of the brake when not in
operation.
Brake pedal position Sensor 1 Sensor 2
When the brake is not oper-
0.50 - 1.60 V 0.82 - 2.56 V
ated
At the brake operating point 1.00 - 2.94 V 1.42 - 3.66 V

Judgment
Result Procedure
Within the standard range Main controller defect
Go to Step 3
Outside the standard range Accelerator potentiometer assembly defect
After reassembling it, perform matching

[Link] Step 3
1. After turning the key switch OFF, disconnect the battery
plug. After 30 seconds, connect it again and turn the key
switch ON.

Judgment
Result Procedure
Error at C5-6 Main controller defect
Brake potentiometer matching defect
No error at C5-6
The vehicle can be used as is.
1 ELECTRICAL TROUBLESHOOTING 1-125

1.4.45 C8-1 1
Failure mode: Drive motor rpm sensor open abnormality

CAUTION
• Jack up until drive wheels leave the ground and support the vehicle with wooden blocks before per-
forming troubleshooting.

Probable cause
▪ Connector connection defect
▪ Drive motor rpm sensor 1/2 harness defect
▪ Drive motor rpm sensor 1 defect
▪ Drive motor rpm sensor 2 defect
▪ Drive motor rpm sensor 1/2 defect
▪ Drive motor driver defect

Related part

CN110-15 (78, SSDL+) CN202-1 CN122-2

CN203-5
P4 CN202-2
Drive motor
rpm sensor 1
CN110-14 (79, SSDL1) CN122-1
Drive motor
driver CN123-2 CN53-2
N1 Drive motor
rpm sensor 2
CN110-13 (80, SSDL2) CN123-1 CN53-1

[Link] Step 1
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN110, CN122,
CN123, and CN202 connectors and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
No error at C8-1 Connector connection defect
Error at C8-1 Go to Step 2

[Link] Step 2
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110, CN122, CN112 and CN123 con-
nectors.
1-126 1 ELECTRICAL TROUBLESHOOTING

3. Inspect for continuity and short circuiting of the harness.

Notes:
Disconnect the battery plug, disconnect the CN110, CN122
CN110 CN122 CN123 and CN123 connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2 caulking, and then inspect the harness.
16 17 18 19 20 21 22 23
Refer to "BEFORE TROUBLESHOOTING."
Measurement terminals Standard
CN110-15 - CN122-2 Continuity *1
CN110-15 - CN123-2 Continuity *2
CN110-14 - CN122-1 Continuity *1
CN110-13 - CN123-1 Continuity *2
CN110-15 - CN110-13 No continuity
CN110-15 - CN110-14 No continuity
CN110-13 - CN110-14 No continuity
*1: Use SST2 to connect CN122-1 and CN122-2 on the CN110
side. You can check for continuity between CN110-15 -
CN110-14.
*2: Use SST2 to connect CN123-1 and CN123-2 on the CN110
side. You can check for continuity between CN110-15 -
CN110-13.

Judgment
Result Procedure
OK Go to Step 3
Drive motor rpm sensor 1/2 harness defect
NG Harness defect between CN110 and CN122, and between
CN110 and CN123

[Link] Step 3
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector, connect the battery plug
with the CN122 and CN123 connectors disconnected, and
turn the key switch ON.
3. Measure the voltage between CN122-2 and N1 and
between CN123-2 and N1.

CN122 CN123

1 2 1 2

Judgment
Result Procedure
12 - 16 V Go to Step 4
Except 12 - 16 V Drive motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-127

[Link] Step 4
1
Error code check
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector, and use SST2 to connect
between CN122-1 and CN122-2 and between CN123-1 and
CN123-2 with the CN122 and CN123 connectors discon-
nected.
3. Connect the battery plug and turn the key switch ON to
check the error display

CN122 CN123

1 2 1 2

Judgment
Result Procedure
Displays C8-2 error Go to Step 5
Displays C8-1 error or no error Drive motor driver defect

[Link] Step 5
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the SST2, connect the CN110 connector, and
measure the resistance between CN122-1 (CN110 side)
and N1 and between CN123-1 (CN110 side) and N1, with
the CN122 and CN123 connectors disconnected.
CN122 CN123

1 2 1 2

Judgment
Result Procedure
Both are approximately 100 Ω. Go to Step 6
Either is except approximately 100 Ω. Drive motor driver defect
1-128 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 6
Drive motor rpm sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN122 and CN123 connectors.
3. Connect the battery plug and turn the key switch ON to dis-
play C8-1 error.
Drive motor rpm sensor Sensor 1 / Sensor 2
[ANL] I/O TRAVELING 6/6
SSD

Judgment
Result Procedure
Drive motor rpm sensor 1 voltage:
0.3 or less
Drive motor rpm sensor 1 defect
Drive motor rpm sensor 2 voltage:
0.4 - 1.9
Drive motor rpm sensor 1 voltage:
0.4 - 1.9
Drive motor rpm sensor 2 defect
Drive motor rpm sensor 2 voltage:
0.3 or less
Drive motor rpm sensor 1 voltage:
0.3 or less
Drive motor rpm sensor 1/2 defect
Drive motor rpm sensor 2 voltage:
less than 0.3
1 ELECTRICAL TROUBLESHOOTING 1-129

1.4.46 C8-2 1
Failure mode: Drive motor rpm sensor short circuit abnormality

CAUTION
• Jack up until drive wheels leave the ground and support the vehicle with wooden blocks before per-
forming troubleshooting.

Probable cause
▪ Connector connection defect
▪ Drive motor rpm sensor 1/2 harness defect
▪ Drive motor rpm sensor 1 defect
▪ Drive motor rpm sensor 2 defect
▪ Drive motor rpm sensor 1/2 defect
▪ Drive motor driver defect

Related part

CN110-15 (78, SSDL+) CN202-1 CN122-2

CN203-5
P4 CN202-2
Drive motor
rpm sensor 1
CN110-14 (79, SSDL1) CN122-1
Drive motor
driver CN123-2 CN53-2
N1 Drive motor
rpm sensor 2
CN110-13 (80, SSDL2) CN123-1 CN53-1

[Link] Step 1
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN110, CN122,
CN123, and CN202 connectors and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
No error at C8-2 Connector connection defect
Error at C8-2 Go to Step 2

[Link] Step 2
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN110, CN122 and CN123 connectors and
inspect the harness.
1-130 1 ELECTRICAL TROUBLESHOOTING

3. Inspect for continuity and short circuiting of the harness.

Notes:
Disconnect the battery plug, disconnect the CN110, CN122
CN110 CN122 CN123 and CN123 connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2 caulking, and then inspect the harness.
16 17 18 19 20 21 22 23
Refer to "BEFORE TROUBLESHOOTING."
Measurement terminals Standard
CN110-15 - CN122-2 Continuity *1
CN110-15 - CN123-2 Continuity *2
CN110-14 - CN122-1 Continuity *1
CN110-13 - CN123-1 Continuity *2
CN110-15 - CN110-13 No continuity
CN110-15 - CN110-14 No continuity
CN110-13 - CN110-14 No continuity
*1: Use SST2 to connect CN122-1 and CN122-2 on the CN110
side. You can check for continuity between CN110-15 -
CN110-14.
*2: Use SST2 to connect CN123-1 and CN123-2 on the CN110
side. You can check for continuity between CN110-15 -
CN110-13.

Judgment
Result Procedure
OK Go to Step 3
Drive motor rpm sensor 1 and 2 harness defect
NG Harness defect between CN110 and CN122, and between
CN110 and CN123

[Link] Step 3
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector, connect the battery plug
with the CN122 and CN123 connectors disconnected, and
turn the key switch ON.
3. Measure the voltage between CN122-2 and N1 and
between CN123-2 and N1.

CN122 CN123

1 2 1 2

Judgment
Result Procedure
12 - 16 V Go to Step 4
Except 12 - 16 V Drive motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-131

[Link] Step 4
1
Error code check
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector, connect the battery plug
with the CN122 and CN123 connectors disconnected, and
turn the key switch ON to check the error display.

Judgment
Result Procedure
Displays C8-1 error Go to Step 5
Displays C8-2 error or no error Drive motor driver defect

[Link] Step 5
Drive motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN110 connector, measure the resistance
between CN122-1 (CN110 side) and N1 and between
CN123-1 (CN110 side) and N1, with the CN122 and CN123
connectors disconnected.
CN122 CN123

1 2 1 2

Judgment
Result Procedure
Both are approximately 100 Ω. Go to Step 6
Either is except approximately 100 Ω. Drive motor driver defect
1-132 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 6
Drive motor rpm sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN122 and CN123 connectors.
3. Connect the battery plug and turn the key switch ON to dis-
play C8-1 error.
Drive motor rpm sensor Sensor 1 / Sensor 2
[ANL] I/O TRAVELING 6/6
SSD

Judgment
Result Procedure
Drive motor rpm sensor 1 voltage:
2.0 or less
Drive motor rpm sensor 1 defect
Drive motor rpm sensor 2 voltage:
0.4 - 1.9
Drive motor rpm sensor 1 voltage:
0.4 - 1.9
Drive motor rpm sensor 2 defect
Drive motor rpm sensor 2 voltage:
2.0 V or more
Drive motor rpm sensor 1 voltage:
2.0 or more
Drive motor rpm sensor 1/2 defect
Drive motor rpm sensor 2 voltage:
2.0 V or more
1 ELECTRICAL TROUBLESHOOTING 1-133

1.4.47 C9-1 1
Failure mode: Tilt angle sensor open abnormality

Probable cause
▪ Connector contact defect
▪ Tilt angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN132-1

CN103-28 (310, SSLP) CN132-2 Tilt angle

Main controller
sensor
CN101-32 (51, POT-) CN132-3

[Link] Step 1
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN132 connector and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.")
3. After connecting the CN132 connector, connect the battery
plug and turn the key switch ON to check for errors.

Judgment
Result Procedure
Error at C9-1 Go to Step 2
No error at C9-1 Connector contact defect
1-134 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Tilt angle sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN132 connector and connect CN132-1 and
CN132-2 on the harness side with SST2.
3. Connect the battery plug, turn the key switch ON, and check
for error codes.
CN132

1 2 3

Judgment
Result Procedure
Error at C9-1 Go to Step 3
Error at C9-2 Tilt angle sensor defect

[Link] Step 3
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN103 and CN132 connectors and
inspect the harness with SST2 disconnected.
3. Inspect for continuity and short circuiting of the harness.
Notes:
CN103 Disconnect the battery plug, disconnect the CN101, CN103
CN132 and CN132 connectors, visually inspect the inside of the
1 2 3 4 5 6
connectors and the wire caulking for any error without con-
1 2 3
7 8 9 10 11 12 13 14 15 16
necting SST2, and perform inspection.
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
Refer to "BEFORE TROUBLESHOOTING."

Portion to be inspected Standard

CN103-8 (300) - CN132-1 (300) Continuity
CN103-28 (310) - CN132-2 (310) Continuity
CN132-3 (51) - CN132-1 (300) No continuity
CN132-3 (51) - CN132-2 (310) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-135

1.4.48 C9-2 1
Failure mode: Tilt angle sensor short abnormality

Probable cause
▪ Connector contact defect
▪ Tilt angle sensor sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN132-1

CN103-28 (310, SSLP) CN132-2 Tilt angle

Main controller
sensor
CN101-32 (51, POT-) CN132-3

[Link] Step 1
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN132 connector and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.")
3. After connecting the CN132 connector, connect the battery
plug and turn the key switch ON to check for errors.

Judgment
Result Procedure
Error at C9-2 Go to Step 2
No error at C9-2 Connector contact defect
1-136 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN101, CN103, CN112 and CN132 con-
nectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:

CN101
Disconnect the battery plug, disconnect the CN101, CN103,
and CN132 connectors, visually inspect the inside of the
1 2 3 4 5 6 7
connectors and the wire caulking for any error, and per-
CN132
8 9 10 11 12 13 14 15 16 17
form inspection.
18 19 20 21 22 23 24 25 26 27 1 2 3 Refer to "BEFORE TROUBLESHOOTING."
28 29 30 31 32 33 34
Portion to be inspected Standard
CN132-2 (310) - CN132-1 (300) No continuity
CN101-32 (51) - CN132-3 (51) Continuity

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Tilt angle sensor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN132 connector and connect the CN101
and CN103 connectors.
3. Connect the battery plug, turn the key switch ON, and check
error codes.

Judgment
Result Procedure
Error at C9-2 Main controller defect
Error at C9-1 Tilt angle sensor sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-137

1.4.49 C9-3 1
Failure mode: Tilt angle sensor matching value abnormality

CAUTION
• When C9-1 and C9-2 errors are occurring, perform the following only after the troubleshooting has
been completed.

Probable cause
▪ Main controller defect
▪ Tilt angle sensor horizontal matching defect

Main controller

[Link] Step 1
1. Perform tilt angle sensor matching.
(Refer to “Display section” in the Matching Part)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3

[Link] Step 2
Tilt angle sensor voltage inspection
1. Check the voltage of the tilt angle sensor.
[ANL] I/O TRAVELING 3/6
SSLP
Incline of road surface Voltage
Flat ground 2.25 - 2.75 V

Judgment
Result Procedure
Go to Step 3
Out of the limits of the standard values Tilt angle sensor assembly failure. After reassembling it, per-
form matching and then perform Step 3.
Within the limits of the standard values Main controller defect
1-138 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Check error
1. Turn the key switch OFF and disconnect the battery plug.
2. After 30 seconds, connect the battery plug again and turn
the key switch ON.

Judgment
Result Procedure
Error at C9-3 Main controller defect
No error at C9-3 Tilt angle sensor horizontal matching defect
1 ELECTRICAL TROUBLESHOOTING 1-139

1.4.50 CB-1 1
Failure mode: MB contactor open abnormality

CAUTION
• If CB-3 or CB-5 is occurring at the same time, give a higher priority to troubleshooting them.

Probable cause
▪ Connector connection defect
▪ MB contactor defect
▪ Harness defect
▪ F6/F7 fuse defect
▪ F6/F7 fuse box defect
▪ Main controller defect
1-140 1 ELECTRICAL TROUBLESHOOTING

Related part
48 V
MB F1
P2 P3 P4

F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

N1 F6
CN140-2 CN140-1 (44) CN104-2 (44, VBMB) Main
controller
F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

80 V
MB F1
P0 P2 P3 P4

F7
CN136-6 (19) CN102-3 (19, VBMB)

CN102-4 (19, VBMB)

CN104-2 (19, VBMB) Main

controller
F6
CN136-1 (18) CN104-1 (18, B80V)

F5
CN141-2 CN139-3 (41) CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

N1 MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN140 (48 V vehicles), CN136 (80 V
vehicles) connector and visually inspect whether there is no
problem with the inside of the connector and the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN140 (48 V vehicles), CN136 (80 V vehicles)
connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
No error at CB-1 Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-141

Result Procedure
Error at CB-1 Go to Step 2
1

[Link] Step 2
Check the operation of the MB contactor
1. Check whether the MB contactor will operate when the key
switch is turned ON.

Judgment
Result Procedure
Operates Go to Step 4
Does not operate Go to Step 3

[Link] Step 3
Check the connection of the MB contactor
1. Turn the key switch OFF, disconnect the battery plug, and
visually check the MB contactor contact (foreign matter or
freezing).

Judgment
Result Procedure
MB contactor defect
NG
Take measures on the incorrect items, Use the vehicle as is.
OK Perform CB-3 troubleshooting

[Link] Step 4
Fuse inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the F6 (48 V vehicles) / F7 (48 V, 80 V vehicles)
fuses and measure the resistance at both ends of the F6
(48 V vehicles) / F7 (48 V, 80 V vehicles) fuses.

Judgment
Result Procedure
F6/F7 fuse defect
∞Ω
Replace the defective fuse and Go to Step 6.
0Ω Go to Step 5
1-142 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
Fuse box inspection
1. Install the F6 (48 V vehicles) / F7 (48 V, 80 V vehicles)
fuses and disconnect the connector of the fuse box.
2. Measure the resistance at both ends of the F6 (48 V
vehicles) / F7 (48 V, 80 V vehicles) fuse box.

Judgment
Result Procedure
∞Ω F6/F7 fuse box defect
0Ω Go to Step 6

[Link] Step 6
Inspect for continuity and short circuiting of the harness
1. Disconnect the CN102, CN104, CN140 (48 V vehicle) and
CN136 (80 V vehicle) connectors.

CN102
2. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7 CN140
Turn the key switch off, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
1 2 connect the CN102, CN104, CN140 (48 V vehicles), and
3 4
28 29 30 31 32 33 34 35 (48V)
CN136 (80 V vehicles) connectors, visually inspect whether
there is no problem with the inside of the connector and
CN104 the wire caulking, and then inspect the harness.
CN136 Refer to "BEFORE TROUBLESHOOTING."
1 2 3 4 5 6 7
1 2 3 Portion to be inspected (48 V vehicles) Standard
8 9 10 11 12 13 14 15 16 17
4 5 6
18 19 20 21 22 23 24 25 CN140-4 - P3 Continuity
26 27 28 29 30 31 (80V)
CN140-2 - P3 Continuity
CN140-3 (19) - CN102-3 (19) Continuity
CN140-3 (19) - CN102-4 (19) Continuity
CN140-1 (44) - CN104-2 (44) Continuity
CN140-3 (19) - N1 No continuity
CN140-1 (44) - N1 No continuity
CN140-4 - N1 No continuity
CN140-2 - N1 No continuity

Portion to be inspected (80 V vehicles) Standard

CN136-6 - P3 Continuity
CN136-6 (19) - CN102-3 (19) Continuity
CN136-6 (19) - CN102-4 (19) Continuity
CN136-6 (19) - CN104-2 (19) Continuity
CN136-6 (19) - N1 No continuity

Judgment
Result Procedure
NG Harness defect
OK Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-143

[Link] Step 7
1
Voltage inspection
1. After connecting the connector, connect the battery plug
and turn the key switch ON.
2. Measure the voltage at both ends on the contactor contact
1, 2 ton models (48 V) side
P1 P2 F4 F6

P3 F7

F5
F1 P4

3 ton models (80 V)

P1 F4
P2 F6

P3
F7
P4 F5

F1

Judgment
Result Procedure
30 V or more MB contactor defect
Less than 30 V Main controller defect
1-144 1 ELECTRICAL TROUBLESHOOTING

1.4.51 CB-2
Failure mode: MB contactor short circuit abnormality

CAUTION
• AD-5, AD-6, 33-3, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1, EC-2, or EC-3 is displayed with CB-2 at the same
time, give a higher priority to troubleshooting AD-5, AD-6, 33-3, E1-1, E1-2, E0-2, E8-1, E8-2, EC-1,
EC-2, or EC-3.
• If CB-2 error occurs, electric charge remains in the drive motor driver/pump motor driver after dis-
connecting the battery plug. Measure the voltage between P4 and N1 and conduct work when the
voltage becomes 3 V or less.

Probable cause
▪ MB contactor defect
▪ Main controller defect
▪ Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-145

Related part
1
48 V
MB F1
P2 P3 P4

F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

N1 F6
CN140-2 CN140-1 (44) CN104-2 (44, VBMB) Main
controller
F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

80 V
MB F1
P0 P2 P3 P4

F7
CN136-6 (19) CN102-3 (19, VBMB)

CN102-4 (19, VBMB)

CN104-2 (19, VBMB) Main

controller
F6
CN136-1 (18) CN104-1 (18, B80V)

F5
CN141-2 CN139-3 (41) CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

N1 MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

[Link] Step 1
1. Turn the key switch OFF, disconnect the battery plug, con-
nect it again, turn the key switch ON, and wait for five
seconds.
2. Turn the key switch OFF. After five seconds, turn the key
switch ON and check for errors.

Judgment
Result Procedure
Error at CB-2 Go to Step 2
No error at CB-2 No problem Use the vehicle as is.
1-146 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Check whether the MB contactor is isolated with the key
switch OFF.

Judgment
Result Procedure
Isolation Go to Step 3
No isolation Go to Step 4

[Link] Step 3
Voltage inspection
1. Turning the key switch OFF, disconnect the battery plug,
connect it again and turn the key switch ON.
2. Turn the key switch OFF. After five seconds, measure the
1, 2 ton models (48 V) voltage between P4 and N1.
P1 P2 F4 F6

P3 F7

F5
F1 P4

3 ton models (80 V)

P1 F4
P2 F6

P3
F7
P4 F5

F1

Judgment
Result Procedure
Less than 15 V Main controller defect
15 V or more Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-147

[Link] Step 4
1
MB contactor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Measure the voltage between P4 and N1 to check that it is
3 V or less.
3. Visually check the condition of the MB contactor contact.

Judgment
Result Procedure
Welding MB contactor defect
Isolation Perform troubleshooting for CB-3 error
1-148 1 ELECTRICAL TROUBLESHOOTING

1.4.52 CB-3
Failure mode: MB contactor coil side open abnormality

Probable cause
▪ Connector connection defect
▪ MB contactor defect
▪ Harness defect
▪ Main controller defect

Related part
48 V
MB F1
P2 P3 P4

F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

N1 F6
CN140-2 CN140-1 (44) CN104-2 (44, VBMB) Main
controller
F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

80 V
MB F1
P0 P2 P3 P4

F7
CN136-6 (19) CN102-3 (19, VBMB)

CN102-4 (19, VBMB)

CN104-2 (19, VBMB) Main

controller
F6
CN136-1 (18) CN104-1 (18, B80V)

F5
CN141-2 CN139-3 (41) CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

N1 MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)
1 ELECTRICAL TROUBLESHOOTING 1-149

[Link] Step 1
1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN136 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
Error at CB-3 Go to Step 2
No error at CB-3 Connector connection defect

[Link] Step 2
MB contactor coil inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector
3. Inspect MB contactor coil resistance.
Portion to be inspected Standard
15 - 30 Ω
CN136 CN136-3 - CN136-4 (Approx. 20 Ω :
20ºC)
1 2 3
4 5 6

Judgment
Result Procedure
OK Go to Step 3
NG MB contactor defect
1-150 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN104 and CN136 connector.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn the key switch off, disconnect the battery plug, dis-
connect the CN104 and CN136 connectors, visually inspect
CN104
whether there is no problem with the inside of the con-
CN136 nector and the wire caulking, and then inspect the harness.
1 2 3 4 5 6 7
Refer to "BEFORE TROUBLESHOOTING."
8 9 10 11 12 13 14 15 16 17 3 2 1
18 19 20 21 22 23 24 25
26 27 28 29 30 31
6 5 4 Portion to be inspected Standard
CN136-3 (2) - CN104-9 (2) Continuity
CN136-4 (1) - CN104-3 (1) Continuity
CN136-3 (2) - N1 No continuity
CN136-4 (1) - N1 No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-151

1.4.53 CB-4 1
Failure mode: MB contactor drive circuit abnormality

Probable cause
▪ Connector connection defect
▪ MB contactor defect
▪ Harness defect
▪ Main controller defect

Related part
48 V
MB F1
P2 P3 P4

F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

N1 F6
CN140-2 CN140-1 (44) CN104-2 (44, VBMB) Main
controller
F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

80 V
MB F1
P0 P2 P3 P4

F7
CN136-6 (19) CN102-3 (19, VBMB)

CN102-4 (19, VBMB)

CN104-2 (19, VBMB) Main

controller
F6
CN136-1 (18) CN104-1 (18, B80V)

F5
CN141-2 CN139-3 (41) CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

N1 MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)
1-152 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN136 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
Error at CB-4 Go to Step 2
No error at CB-4 Connector connection defect

[Link] Step 2
MB contactor coil inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector
3. Inspect MB contactor coil resistance.
Portion to be inspected Standard
15 - 30 Ω
CN136 CN136-3 - CN136-4 (Approx. 20 Ω :
20ºC)
1 2 3
4 5 6

Judgment
Result Procedure
OK Go to Step 3
NG MB contactor defect
1 ELECTRICAL TROUBLESHOOTING 1-153

[Link] Step 3
1
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN104 and CN136 connector.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn the key switch off, disconnect the battery plug, dis-
CN136 connect the CN104 and CN136 connectors, visually inspect
whether there is no problem with the inside of the con-
3 2 1 nector and the wire caulking, and then inspect the harness.
6 5 4 Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN136-3 (2) - CN136-4 (1) No continuity
CN136-3 (2) - P1 No continuity
CN136-3 (2) - P4 No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-154 1 ELECTRICAL TROUBLESHOOTING

1.4.54 CB-5
Failure mode: MB contactor coil side short circuit abnormality

Probable cause
▪ Connector connection defect
▪ MB contactor defect
▪ Harness defect
▪ Main controller defect

Related part
48 V
MB F1
P2 P3 P4

F7
CN140-4 CN140-3 (19) CN102-3 (19, VBMBSL)

CN102-4 (19, VBMBSL)

N1 F6
CN140-2 CN140-1 (44) CN104-2 (44, VBMB) Main
controller
F5
CN139-4 CN139-3 (41) CN104-1 (41, B48V)

CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)

80 V
MB F1
P0 P2 P3 P4

F7
CN136-6 (19) CN102-3 (19, VBMB)

CN102-4 (19, VBMB)

CN104-2 (19, VBMB) Main

controller
F6
CN136-1 (18) CN104-1 (18, B80V)

F5
CN141-2 CN139-3 (41) CN101-4 (41, VBBT)

CN136-3 (2, CBAT-) CN104-9 (2, CBAT-)

N1 MB
Contactor CN136-4 (1, CBAT+) CN104-3 (1, CBAT+)
1 ELECTRICAL TROUBLESHOOTING 1-155

[Link] Step 1
1
Connector connection inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector and visually inspect
whether there is no problem with the inside of the connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN136 connector and connect the battery plug.
4. Turn the key switch ON and check for any errors.

Judgment
Result Procedure
Error at CB-5 Go to Step 2
No error at CB-5 Connector connection defect

[Link] Step 2
MB contactor coil inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN136 connector
3. Inspect MB contactor coil resistance.
Portion to be inspected Standard
15 - 30 Ω
CN136 CN136-3 - CN136-4 (Approx. 20 Ω :
20ºC)
1 2 3
4 5 6

Judgment
Result Procedure
OK Go to Step 3
NG MB contactor defect
1-156 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect for continuity and short circuiting of the harness
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN104 and CN136 connector.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn the key switch off, disconnect the battery plug, dis-
connect the CN104 and CN136 connectors, visually inspect
whether there is no problem with the inside of the con-
CN136
nector and the wire caulking, and then inspect the harness.
3 2 1
Refer to "BEFORE TROUBLESHOOTING."
6 5 4

Portion to be inspected Standard

CN136-3 (2) - CN136-4 (1) No continuity
CN136-3 (2) - P1 No continuity
CN136-3 (2) - P4 No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-157

1.4.55 CC-1, CC-2, CC-3, CC-4, CC-6 1

Failure mode: Drive motor driver CPU abnormality

CAUTION
• If CC-1, CC-2, CC-3, CC-4 or CC-6 is displayed, it indicates drive motor driver defect. Replace it.

Probable cause
▪ Drive motor driver defect

Related part

Drive motor driver

1-158 1 ELECTRICAL TROUBLESHOOTING

1.4.56 E0-2
Failure mode: Pump motor driver main circuit abnormality

CAUTION
• If CB-3 is displayed at the same time, give a higher priority to troubleshooting CB-3.
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before performing troubleshooting.
• If E0-2 error occurs, electric charge remains in the pump motor/drive motor driver after disconnect-
ing the battery plug. Measure the voltage between P4 and N1 and conduct work when the voltage be-
comes 3 V or less.

Probable cause
▪ Pump motor cable connection defect
▪ Pump motor defect
▪ Pump motor driver defect
▪ Magnetic switch defect
▪ Control panel defect
▪ Harness defect
▪ Display defect
▪ Transformer ASSY defect

Related part
1 - 2 ton vehicles with the on-truck charger

P7
U
Drive motor driver
P8
V Drive motor

P9
W

Transformer
CN70-4 (14, DGND)
CN61

CN70-3 (169, TGND)

CN66-4 CN70-36 (N1, N1)

Power AC plug Magnet Display
switch
CN66-3
CN70-33 (132, CHGMS)
Charging CN69-1
cable CN64-1 (95, MSCH) Control
panel CN70-2 (130, CHGGND)
CN69-3
CN64-3 (136, CHGACS)
1 ELECTRICAL TROUBLESHOOTING 1-159

3 ton vehicles, 1 - 2 ton vehicles without the on-truck charger

1
U P7

Pump motor driver

V P8
Pump motor

W P9

[Link] Step 1
Check for errors
1. Disconnect the battery plug and visually inspect whether
there is no problem with the transformer cable (1 - 2 ton
vehicles with the on-vehicle charger only) or the pump mo-
tor cable tightening and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the transformer cable and the pump motor
cable, connect the battery plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display.

Judgment
Result Action
Go to Step 9
Error at E0-2
Record the displayed error codes.
No error at E0-2
(1 - 2 ton vehicles with the on-vehicle char- Go to Step 2
ger)
No error at E0-2
(3 ton vehicles, 1 - 2 ton vehicles without Pump motor cable connection defect
the on-vehicle charger)

[Link] Step 2
Check for errors
1. Turn the key switch OFF and connect the battery plug and
the charging plug.
2. Perform the timer test, and check for E0-2 errors.

Judgment
Result Action
Error at E0-2 Go to Step 3
No error at E0-2 Pump motor cable connection defect
1-160 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Magnetic switch check
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN61 connector
3. Magnetic switch check
Notes:
Disconnect the CN61 connector and check that the magnet
switch is OFF.
Portion to be inspected Standard
Input side main terminal (R) - output side
No continuity
main terminal (R)
Input side main terminal (S) - output side
No continuity
main terminal (S)
Input side main terminal (T) - output side
No continuity
main terminal (T)

Judgment
Result Action
OK (No continuity) Go to Step 4
NG (Continuity) Magnetic switch defect

[Link] Step 4
Control Panel Inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Connect the CN61 connector and disconnect the CN69 con-
nector.
3. Inspect the control panel.
Notes:
Disconnect the CN69 connector, visually inspect whether
there is no problem with the inside of the connector and
the wire caulking, and then inspect the CN69 connector on
the control panel side.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN69-1 - CN69-3 No continuity

Judgment
Result Action
OK Go to Step 5
NG Control panel defect
1 ELECTRICAL TROUBLESHOOTING 1-161

[Link] Step 5
1
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
Notes:
Disconnect the CN69 and CN70 connectors, visually in-
spect whether there is no problem with the inside of the
connector and the wire caulking, and then inspect the con-
nector on the harness side.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN70-33 - CN70-2 No continuity

Judgment
Result Action
OK Go to Step 6
NG Harness defect

[Link] Step 6
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN64 connector
3. Inspect the harness.
Notes:
Disconnect the CN64 connector, visually inspect whether
there is no problem with the inside of the connector and
the wire caulking, and then inspect the connector on the
magnet switch side.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN64-1 - CN64-3 No continuity

Judgment
Result Action
OK (No continuity) Go to Step 8
NG (Continuity) Go to Step 7
1-162 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 7
Harness inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Disconnect the CN66 connector
3. Inspect the harness.
Notes:
Disconnect the CN66 connector, visually inspect whether
there is no problem with the inside of the connector and
the wire caulking, and then inspect the connector on the
magnet switch side.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN66-3 - CN66-4 No continuity

Judgment
Result Action
Harness defect
OK (No continuity)
Replace the harness between CN64 - CN66
Harness defect
NG (Continuity)
Replace the harness between CN66 - magnet switch

[Link] Step 8
Magnetic switch signal inspection
1. Turn the key switch OFF and disconnect the charging plug
and the battery plug.
2. Connect the CN69 connector and disconnect the CN70 con-
nector.
3. Inspect the magnetic switch signal.
Notes:
Disconnect the CN70 connector, inspect the CN70 con-
nector on the display side.
Portion to be inspected Standard
CN70-33 - CN70-2 No continuity
CN70-33 - CN70-3 No continuity
CN70-33 - CN70-4 No continuity
CN70-33 - CN70-36 No continuity

Judgment
Result Action
OK (No continuity) Control panel defect
NG (Continuity) Display defect
1 ELECTRICAL TROUBLESHOOTING 1-163

[Link] Step 9
1
Pump motor driver inspection
1. Return the direction lever to to the neutral position, turn the
key switch OFF and disconnect the battery plug.
2. Disconnect three pump motor cables on the pump motor
driver side and insulate the terminal of the disconnected
cables.
(For 1 - 2 ton vehicles with an on-vehicle charger, discon-
nect the transformer cable also and insulate the terminal of
the disconnected cables.)
3. Connect the battery plug and turn the key switch ON.
4. Operate the direction lever forward or backward, and check
whether E0-2 will occur.

Judgment
Result Action
Error at E0-2 Pump motor driver defect
No error at E0-2
(1 - 2 ton vehicles with the on-vehicle char- Go to Step 10
ger)
No error at E0-2
(3 ton vehicles and 1 - 2 ton vehicles Go to Step 11
without the on-vehicle charger)

[Link] Step 10
Transformer ASSY inspection
1. Refer to “Charger section” in the Transformer ASSY Part.

Judgment
Result Action
OK (no E0-2 display at the same time at
Go to Step 11
Step 1)
OK (E0-2 display at the same time at Step
Go to Step 12
1)
NG Transformer ASSY defect

[Link] Step 11
Pump motor driver inspection
1. Exchange the pump motor driver and the drive motor driver.
2. Connect the battery plug and turn the key switch ON.
3. Operate the direction lever forward or backward, and check
the error display.
(Ignore 32-1 and 32-3 errors).

Judgment
Result Action
Error at C0-2 Pump motor driver defect
Error at E0-2 Pump motor defect
NG Transformer ASSY defect
1-164 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 12
Pump motor inspection
1. Return the direction lever to to the neutral position, turn the
key switch OFF and disconnect the battery plug.
2. Inspect the pump motor.

Judgment
Result Action
NG Pump motor defect
OK Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-165

1.4.57 E1-1 1
Failure mode: Pump motor driver current sensor neutral abnormality

CAUTION
• If F7-6 is displayed at the same time, give a higher priority to troubleshooting F7-6.

Probable cause
▪ Pump motor driver defect

Related part

Pump motor driver

Current sensor
1-166 1 ELECTRICAL TROUBLESHOOTING

1.4.58 E1-2
Failure mode: Pump motor driver current sensor overcurrent abnormality

CAUTION
• E8-1 or E8-2 is displayed with E1-2 at the same time, give a higher priority to troubleshooting E8-1 or
E8-2.
• Jack up the vehicle until drive wheels leave the ground and support the frame with wooden blocks
before performing troubleshooting.
• If E1-2 error occurs, electric charge remains in the pump motor/drive motor driver after disconnect-
ing the battery plug. Measure the voltage between P4 and N1 and conduct work when the voltage be-
comes 3 V or less.

Probable cause
▪ Pump motor cable connection defect
▪ Pump motor defect
▪ Pump motor driver defect
▪ Pump motor rpm sensor defect
▪ Transformer ASSY defect

Related part
1 - 2 ton vehicles with the on-truck charger

U P7

Pump motor driver

V P8
Pump motor

W P9

Transformer

3 ton vehicles, 1 - 2 ton vehicles without the on-truck charger

U P7

Pump motor driver

V P8
Pump motor

W P9
1 ELECTRICAL TROUBLESHOOTING 1-167

[Link] Step 1
1
Check for errors
1. Turn the key switch OFF/ON to check that E0-2 error is dis-
played.

Judgment
Result Procedure
No error at E0-2 Go to Step 2
Error at E0-2 Perform E0-2 troubleshooting.

[Link] Step 2
Check for errors
1. Disconnect the battery plug and visually inspect whether
there is no problem with the transformer cable (1 - 2 ton
vehicles with the on-vehicle charger only) or the pump mo-
tor cable tightening and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the transformer cable and the pump motor
cable, connect the battery plug and turn the key switch ON.
3. After sitting on the seat, operate the direction lever forward
or backward, and check the error display.

Judgment
Result Action
Go to Step 3
Error at E1-2
Record the displayed error codes.
No error at E1-2
Go to Step 6
(1 - 2 ton vehicles with the on-vehicle char-
Record the displayed error codes.
ger)
No error at E1-2
(3 ton vehicles, 1 - 2 ton vehicles without Pump motor cable connection defect
the on-vehicle charger)

[Link] Step 3
1. Check the error code displayed at Step 2

Judgment
Result Action
No C1-2 display at the same time at Step 2 Go to Step 4
C1-2 display at the same time at Step 2 Go to Step 5
1-168 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Pump motor driver inspection
1. Exchange the pump motor driver and the drive motor driver.
2. Connect the battery plug and turn the key switch ON.
3. Operate the direction lever forward or backward, and check
the error display.
(Ignore 32-1 and 32-3 errors).

Judgment
Result Procedure
Error at C1-2 Pump motor driver defect
Error at E1-2 Pump motor defect

[Link] Step 5
Pump motor inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Inspect the pump motor.

Judgment
Result Action
OK Pump motor driver defect
NG Pump motor defect

[Link] Step 6
Transformer ASSY inspection
1. Refer to “Charger section” in the Transformer ASSY Part.

Judgment
Result Action
OK Go to Step 3
NG Transformer ASSY defect
1 ELECTRICAL TROUBLESHOOTING 1-169

1.4.59 E2-1 1
Failure mode: Pump motor temperature abnormal rise

CAUTION
• Do not leave the vehicle in places where it gets hot.

Probable cause
▪ Overheating (overload continuous use)

Related part

CN111-9 (88, STPM+) CN55-2

Temperature sensor
Pump motor driver (pump motor)
CN111-10 (89, STPM) CN55-1

[Link] Step 1
Error display recheck
1. Turn the key switch ON and check the error display on the
display.

Judgment
Result Procedure
"PM" display Go to Step 2
Overheating (overload continuous use)
If the temperature of the pump motor falls, the "PM" display
"PM" not display disappears, and you can use the truck as usual. Because an
error occurred due to a continuous use in an overloaded con-
dition, check the truck usage and avoid an overloaded con-
tinuous use.
1-170 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Pump motor temperature check and error recheck
1. [ANL] I/O TEMP/VOLT 2/5
TPM
2. Record the pump motor temperature values.
3. Turn the key switch OFF, leave the truck for a while (ap-
proximately 30 minutes), and then turn the key switch ON to
check the error display on the display.

Judgment
Result Procedure
"PM" display Go to Step 3
Overheating (overload continuous use)
If the temperature of the pump motor falls, the "PM" display
"PM" not display disappears, and you can use the truck as usual. Because an
error occurred due to a continuous use in an overloaded con-
dition, check the truck usage and avoid an overloaded con-
tinuous use.

[Link] Step 3
Pump motor temperature recheck
1. [ANL] I/O TEMP/VOLT 2/5
TPM
2. Check the pump motor temperature value and compare it
with the recorded value.

Judgment
Result Procedure
It rose by 5℃ or more. Go to Step 2
It did not rise by 5℃ or more. Perform troubleshooting from E2-2 Step 2.
1 ELECTRICAL TROUBLESHOOTING 1-171

1.4.60 E2-2 1
Failure mode: pump motor temperature sensor open/short circuit abnormality

Probable cause
▪ Connector connection defect
▪ Pump motor temperature sensor defect
▪ Pump motor temperature sensor harness defect
▪ Pump motor driver defect

Related part

CN111-9 (88, STPM+) CN55-2

Temperature sensor
Pump motor driver (pump motor)
CN111-10 (89, STPM) CN55-1

[Link] Step 1
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN55 connector
and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
Error at E2-2 Go to Step 2
No error at E2-2 Connector connection defect
1-172 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Pump motor temperature sensor individual inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN55 connector
3. Carry out a temperature sensor individual inspection.
4. Measure the resistance of the temperature sensor between
CN55-2 and CN55-1 on the sensor side of the CN55 con-
nector.
Standard: Approx. 245 Ω - 600 kΩ
CN55
Notes:
2 1
Resistance values vary at a low or high temperature. Use
the values in the following table as a guideline.
Temperature sensor resist-
Temperature ance value
(between CN55-2 - CN55-1)
20℃ Approx. 13 kΩ
80℃ Approx. 1.75 kΩ
100℃ Approx. 1 kΩ

Judgment
Result Procedure
OK Go to Step 3
NG Pump motor temperature sensor defect

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN111 and CN55 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Disconnect the battery plug, disconnect the CN111 and
CN111 CN55 CN55 connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 caulking with SST disconnected, and then inspect the har-
16 17 18 19 20 21 22 23
ness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN111-9 - CN55-2 Continuity *1
CN111-10 - CN55-1 Continuity *1
CN55-1 - CN55-2 No continuity
*1: Use SST2 to connect CN55-1 and CN55-2 on the harness
side. You can check for continuity between CN111-9 -
CN111-10.

Judgment
Result Procedure
OK Pump motor driver defect
NG Pump motor temperature sensor harness defect
1 ELECTRICAL TROUBLESHOOTING 1-173

1.4.61 E3-1 1
Failure mode: pump motor driver main circuit temperature sensor open/short circuit
abnormality

CAUTION
• If E3-1 is displayed, it indicates pump motor driver abnormality. Replace it.

Probable cause
▪ Pump motor driver defect

Related part

Pump motor driver

Temperature sensor
1-174 1 ELECTRICAL TROUBLESHOOTING

1.4.62 E8-1
Failure mode: Pump motor rpm sensor open abnormality

CAUTION
• If E8-1 error occurs, electric charge remains in the pump motor/drive motor driver after disconnect-
ing the battery plug. Measure the voltage between P4 and N1 and conduct work when the voltage be-
comes 3 V or less.

Probable cause
▪ Connector connection defect
▪ Pump motor rpm sensor harness defect
▪ Pump motor rpm sensor defect
▪ Pump motor driver defect

Related part

P4
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor
driver rpm sensor
CN111-14 (82, SSP1) CN56-1
N1

[Link] Step 1
1. Disconnect the battery plug and visually inspect the inside
of the CN56 and CN111 connectors and the wire caulking
for any error.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
Error at E8-1 Go to Step 2
No error at E8-1 Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-175

[Link] Step 2
1
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN111 and CN56 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Disconnect the battery plug, disconnect the CN111 and
CN111 CN56 CN56 connectors, visually inspect whether there is no
problem with the inside of the connector and the wire
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 caulking with SST disconnected, and then inspect the har-
16 17 18 19 20 21 22 23
ness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN111-15 - CN56-2 Continuity *1
CN111-14 - CN56-1 Continuity *1
CN111-15 - CN111-14 No continuity
*1: Use SST2 to connect CN56-1 and CN56-2 on the harness
side. You can check for continuity between CN111-15 -
CN111-14.

Judgment
Result Procedure
OK Go to Step 3
NG Pump motor rpm sensor harness defect

[Link] Step 3
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN111 connector, connect the battery plug
with the CN56 connector disconnected, and turn the key
switch ON.
3. Measure the voltage between CN56-2 (CN111 side) and
N2.

CN56

1 2

Judgment
Result Procedure
12 - 16 V Go to Step 4
Except 12 - 16 V Pump motor driver defect
1-176 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Error code check
1. Turn the key switch OFF and disconnect the battery plug.
2. Use SST2 to connect between CN56-1 and CN56-2 at the
CN111 side, with the CN56 connector disconnected.
3. Connect the battery plug and turn the key switch ON to
check the error display
CN56

1 2

Judgment
Result Procedure
Displays E8-2 error Go to Step 5
Displays E8-1 error or no error Pump motor driver defect

[Link] Step 5
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Remove the SST2, measure the resistance between
CN56-1 (CN111 side) and N2, with the CN56 connector dis-
connected.

CN56

1 2

Judgment
Result Procedure
Approx. 100 Ω Pump motor rpm sensor defect
Approx. other than 100 Ω Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-177

1.4.63 E8-2 1
Failure mode: Pump motor rpm sensor short circuit abnormality

CAUTION
• If E8-2 error occurs, electric charge remains in the pump motor/drive motor driver after disconnect-
ing the battery plug. Measure the voltage between P4 and N1 and conduct work when the voltage be-
comes 3 V or less.

Probable cause
▪ Connector connection defect
▪ Pump motor rpm sensor harness defect
▪ Pump motor rpm sensor defect
▪ Pump motor driver defect

Related part

P4
CN111-15 (81, SSP+) CN56-2
Pump motor Pump motor
driver rpm sensor
CN111-14 (82, SSP1) CN56-1
N1

[Link] Step 1
1. Disconnect the battery plug and visually inspect the inside
of the CN56 and CN111 connectors and the wire caulking
for any error.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
Error at E8-2 Go to Step 2
No error at E8-2 Connector connection defect
1-178 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN111 and CN56 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
CN111 CN56 Disconnect the battery plug, disconnect the CN111 and
1 2 3 4 5 6 7 8 CN56 connectors, visually inspect whether there is no
1 2
9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
problem with the inside of the connector and the wire
caulking with SST disconnected, and then inspect the har-
ness.
Refer to "BEFORE TROUBLESHOOTING."
Portion to be inspected Standard
CN111-15 - CN56-2 Continuity *1
CN111-14 - CN56-1 Continuity *1
CN111-15 - CN111-14 No continuity
*1: Use SST2 to connect CN56-1 and CN56-2 on the harness
side. You can check for continuity between CN111-15 -
CN111-14.

Judgment
Result Procedure
OK Go to Step 3
NG Pump motor rpm sensor harness defect

[Link] Step 3
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the CN111 connector, connect the battery plug
with the CN56 connector disconnected, and turn the key
switch ON.
3. Measure the voltage between CN56-2 (CN111 side) and
N2.

CN56

1 2

Judgment
Result Procedure
12 - 16 V Go to Step 4
Except 12 - 16 V Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-179

[Link] Step 4
1
Error code check
1. Turn the key switch OFF and disconnect the battery plug.
2. Connect the battery plug with the CN56 connector discon-
nected, and turn the key switch ON to check the error dis-
play.

Judgment
Result Procedure
Displays E8-1 error Go to Step 5
Displays E8-2 error or no error Pump motor driver defect

[Link] Step 5
Pump motor driver inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Measure the resistance between CN56-1 (CN111 side) and
N2, with the CN56 connector disconnected.

CN56

1 2

Judgment
Result Procedure
Approx. 100 Ω Pump motor rpm sensor defect
Approx. other than 100 Ω Pump motor driver defect
1-180 1 ELECTRICAL TROUBLESHOOTING

1.4.64 EC-1, EC-2, EC-3, EC-4, EC-6

Failure mode: Pump motor driver CPU abnormality

CAUTION
• If EC-1, EC-2, EC-3, EC-4 or EC-6 is displayed, it indicates pump motor driver defect. Replace it.

Probable cause
▪ Pump motor driver defect

Related part

Pump motor driver

1 ELECTRICAL TROUBLESHOOTING 1-181

1.4.65 ED-1 1
Failure mode: CAN bridge communication disruption

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Telematics power source semiconductor relay defect
▪ Main controller defect
▪ CAN bridge controller defect

Related part

48 V MB
P2 P3

F5 CN209-6 (41, B48V)

CN103-11 (145, CAN1H)
CN209-1 (334, PSACC+) CN104-14
Telematics power Main CN103-12 (146, CAN1L)
source CN209-2 (333, OACC3) CN102-8
controller
semiconductor
relay SSR3 CN104-5 (N2, N2)

CN100-5 Numeric
CN209-4 (440, VBRY) CN100-14 (IG) keypad
CN100-9
CAN bridge
CN100-13 (N2, E1) controller
N1
CN100-4 (N2, E1)

80V MB
P2 P3
P0
F5 CN209-6 (41, B48V)
CN136-2 CN103-11 (145, CAN1H)
CN209-1 (334, PSACC+) CN104-14
Telematics power CN102-8 Main CN103-12 (146, CAN1L)
CN209-2 (333, OACC3)
source controller
semiconductor
relay SSR3 CN104-5 (N2, N2)

CN100-5 Numeric
CN209-4 (440, VBRY) CN100-14 (IG) keypad
CAN bridge CN100-9
controller
CN100-13 (N2, E1)
N1
CN100-4 (N2, E1)
1-182 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Telematics power source check
1. With the the battery plug connected, sit on the seat and turn
the key switch ON.
2. Press the logoff button (red [○] button) on the numeric
keypad, and check whether the red lamp on the numeric
keypad will turn on every time you press it.

Judgment
Result Procedure
Not lit Go to Step 2
Lit Go to Step 6

[Link] Step 2
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN100, CN102, CN104 and CN209 connectors and
the wire caulking.
3. After connecting the CN100, CN102, CN104 and CN209
connectors, connect the battery plug and turn the key switch
ON. Wait for 10 seconds or more and then check for errors.

Judgment
Result Procedure
No ED-1 Connector connection defect
ED-1 exists Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN100, CN102, CN104, CN209 and CN136
(80V vehicles) connectors.

CN102
3. Inspect for continuity and short circuiting of the harness.
CN100 Notes:
1 2 3 4 5 6 7
1 2 3 4 5 Disconnect the battery plug, disconnect the CN100, CN102,
8 9 10 11 12 13 14 15 16 17 18 19 6 7 8 9
20 21 22 23 24 25 26 27
10 11 12 13 14 CN104, CN209, and CN136 (80V vehicles) connectors, visu-
28 29 30 31 32 33 34 35 ally inspect whether there is no problem with the inside of
the connector and the wire caulking, and then inspect the
CN104 CN209 harness.
Portion to be inspected Standard
1 2 3 4 5 6 7 1 2 3
8 9 10 11 12 13 14 15 16 17
4 5 6
CN209-1 (334) - CN104-14 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN209-2 (333) - CN102-8 Continuity
CN209-4 (440) - CN100-14 Continuity
CN209-6 (41) - P2 Continuity
CN104-5 (N2) - CN100-13 Continuity
CN104-14 (334) - CN102-8 (333) No continuity
CN104-14 (334) - N1 (N1) No continuity
1 ELECTRICAL TROUBLESHOOTING 1-183

1
Portion to be inspected (80V vehicles) Standard
CN136
CN209-6 (41) - CN136-2 Continuity
3 2 1
6 5 4

Judgment
Result Procedure
NG Harness defect
OK Go to Step 4

[Link] Step 4
Semiconductor relay inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN209 connector, and check the resistance
at the relay side.
Notes:
CN209 The following CN209(333)(+) - CN209-1(334)(+) are the
measurement methods of an analog tester
3 2 1
▪ Since diodes are connected inside the relay, the meas-
6 5 4
urement method could differ depending on the tester
used.
(For details, refer to INSPECTION OF ELECTRIC
PARTS)
Portion to be inspected Standard
CN209-2 (333) - CN209-1 (334) Approx. 750 Ω
(Tester range: Ω x 10)

Judgment
Result Procedure
NG Telematics power source semiconductor relay defect
OK Go to Step 5
1-184 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
Main controller inspection
1. Turn the key switch ON, and turn the seat switch ON.
2. Measure the voltage at both ends of the relay
Portion to be inspected Standard
CN209-1 (334) - CN209-2 (333) Approx. 15 V

CN209

3 2 1

6 5 4

Judgment
Result Procedure
NG Telematics power source semiconductor relay defect
OK Main controller defect

[Link] Step 6
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN100, CN103 and CN104 connectors and the wire
caulking.
3. After connecting the CN100, CN103 and CN104 connect-
ors, connect the battery plug and turn the key switch ON.
Wait for 10 seconds or more and then check for errors.

Judgment
Result Procedure
No ED-1 Connector connection defect
ED-1 exists Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-185

[Link] Step 7
1
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN100, CN103 and CN104 connectors.

CN103
3. Inspect for continuity and short circuiting of the harness.
CN100 Notes:
1 2 3 4 5 6
1 2 3 4 5 Disconnect the battery plug, disconnect the CN100, CN103,
7 8 9 10 11 12 13 14 15 16 6 7 8 9
17 18 19 20 21 22 23 24 25 26 27
10 11 12 13 14 and CN104 connectors, visually inspect the inside of the
28 29 30 31 32 33 34 35 connectors and the wire caulking for any error, and per-
form inspection.
CN104 CN209
Portion to be inspected Standard
1 2 3 4 5 6 7 1 2 3 CN103-11 (145) - CN100-9 Continuity
8 9 10 11 12 13 14 15 16 17
4 5 6 CN103-12 (146) - CN100-5 Continuity
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN104-5 (N2) - CN100-13 Continuity
CN209-4 (440) - CN100-14 Continuity

Judgment
Result Procedure
NG Harness defect
OK CAN bridge controller defect
1-186 1 ELECTRICAL TROUBLESHOOTING

1.4.66 ED-4
Failure mode: CAN bridge controller / operation management system communication
disruption

CAUTION
• If ED-1 is occurring, give a higher priority to troubleshooting ED-1.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Operation management system defect

Related part

48V MB
P2 P3

F5 CN209-6 (41, B48V)

CN103-11
CN209-1 (334, PSACC+) CN104-14 (145, CAN1H)
Semiconductor
relay for CN103-12
telematics CN209-2 (333, OACC3) CN102-8 Main (146, CAN1L)
power controller
supply CN104-5 (N2, N2)
SSR3
CN284-1
CN100-5 Data
CN209-4 (440, VBRY) CN100-14 (IG) Handling
CAN CN100-9 Unit
bridge (DHU2)
CN100-13 (N2, E1) controller CN100-2 (443, CAN3L)
N1 CN284-3
CN100-4 (N2, E1) CN100-3 (442, CAN3H)
CN284-2

CN284-8
(N2, E1)

80V MB
P2 P3
P0
F5
CN136-2 CN209-6 (41, B48V)
CN103-11
CN209-1 (334, PSACC+) CN104-14 (145, CAN1H)
Semiconductor
relay for CN103-12
telematics
CN209-2 (333, OACC3) CN102-8 Main (146, CAN1L)
controller
power
supply CN104-5 (N2, N2)
SSR3
CN284-1
CN100-5 Data
CN209-4 (440, VBRY) CN100-14 (IG) Handling
CN100-9 Unit
CAN (DHU2)
bridge
CN100-13 (N2, E1) controller CN100-2 (443, CAN3L) CN284-3
N1
CN100-4 (N2, E1) CN100-3 (442, CAN3H) CN284-2

CN284-8
(N2, E1)
1 ELECTRICAL TROUBLESHOOTING 1-187

[Link] Step 1
1
Telematics power source check
1. With the the battery plug connected, sit on the seat and turn
the key switch ON.
2. Check the lighting of green LED on the operation manage-
ment system.

Judgment
Result Procedure
Not lit Go to Step 2
Lit Go to Step 4

[Link] Step 2
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN100 and CN209 connectors and the wire caulking.
3. After connecting the CN100 and CN209 connectors, con-
nect the battery plug and turn the key switch ON. Wait for
10 seconds or more and then check for errors.

Judgment
Result Procedure
No ED-4 Connector connection defect
ED-4 exists Go to Step 3

[Link] Step 3
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN100 and CN209 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Disconnect the battery plug, disconnect the CN100 and
CN209 CN209 connectors, visually inspect the inside of the con-
nectors and the wire caulking for any error, and perform in-
3 2 1
spection.
6 5 4
Portion to be inspected Standard
CN209-4 (440) - CN284-1 Continuity
CN284-8 - N1 (N1) Continuity

Judgment
Result Procedure
NG Harness defect
OK Operation management system defect
1-188 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Connector inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Visually inspect whether there is no problem with the inside
of the CN100 and CN284 connectors and the wire caulking.
3. After connecting the CN100 and CN284 connectors, con-
nect the battery plug and turn the key switch ON. Wait for
10 seconds or more and then check for errors.

Judgment
Result Procedure
No ED-4 Connector connection defect
ED-4 exists Go to Step 5

[Link] Step 5
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN100 and CN284 connectors.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Disconnect the battery plug, disconnect the CN110 and
CN209 CN284 connectors, visually inspect whether there is no
CN100 problem with the inside of the connector and the wire
1 2 3 4 5 1 2 3 caulking, and then inspect the harness.
6 7 8 9
10 11 12 13 14 4 5 6
Portion to be inspected Standard
CN100-2 (443) - CN284-3 Continuity
CN100-3 (442) - CN284-2 Continuity
CN100-13 - N1 (N1) Continuity
CN100-2 (443) - CN100-13 (N1) No continuity
CN100-3 (442) - CN100-13 (N1) No continuity
CN209-4 (440) - CN284-1 Continuity

Judgment
Result Procedure
NG Harness defect
OK Operation management system defect
1 ELECTRICAL TROUBLESHOOTING 1-189

1.4.67 EE-1, EE-2 1

Failure mode: Display to main controller communication abnormality

CAUTION
• If the EE-1 or EE-2 memories were confirmed on the display, the communication with the display has
already recovered. Use the vehicle as is.

Probable cause
▪ Display defect
▪ Main controller defect

Related part

CN103-11 (145, CAN1H) CN70-16

Main controller Display
CN103-12 (146, CAN1L) CN70-15

[Link] Step 1
Check for errors
1. Check whether F1-1 or F1-2 error is occurring on the dis-
play screen.

Judgment
Result Procedure
Occurring Go to F1-1 or F1-2 troubleshooting
Not occurring Display defect, or main controller defect
1-190 1 ELECTRICAL TROUBLESHOOTING

1.4.68 F1-1
Failure mode: Main controller to display communication abnormality

Probable cause
▪ Connector connection defect

Related part

CN103-3 (14, DGND) CN70-4

CN103-14 (16, D7V) CN70-5
Main controller Display
CN103-11 (145, CAN1H) CN70-16
CN103-12 (146, CAN1L) CN70-15

[Link] Step 1
Error recheck
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN103 and CN70
connectors and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.

Judgment
Result Procedure
Displays F1-1 or F1-2 Perform F1-2 troubleshooting
Connector connection defect
Does not display F1-1 or F1-2
Use the vehicle as is
1 ELECTRICAL TROUBLESHOOTING 1-191

1.4.69 F1-2 1
Failure mode: Main controller to display communication abnormality

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Display defect
▪ Main controller defect

Related part

CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H)
Main CN103-12 (146, CAN1L) CN110-16 (146, CAN1L)
controller CN103-3 (14, DGND) CN110-6 Drive motor driver
NC
CN103-14 (16, D7V) NC CN110-7
CN103-5 (N2, N2) NC CN110-23

CN70-5 (16, D7V)

CN70-4 (14, DGND) CN111-8 (42, KYSAT)
Display CN70-16 (145, CAN1H) CN111-17 (145, CAN1H)
CN70-15 (146, CAN1L) CN111-16 (146, CAN1L)
CN111-6 (152, SETP2) Pump motor driver

NC CN111-7
CN111-23 (152, SETP-)

[Link] Step 1
1. Disconnect the battery plug and visually inspect whether
there is no problem with the inside of the CN103 and CN70
connectors and the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
2. After connecting the connector, connect the battery plug
and turn the key switch ON to check for errors.

Judgment
Result Procedure
Error at F1-2 Go to Step 2
No error at F1-2 Connector connection defect
1-192 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Harness inspection
1. Turn the key switch OFF and disconnect the battery plug.
2. Disconnect the CN70 and CN103 connectors.
3. Inspect for continuity and short circuiting of the harness.
CN70
Portion to be inspected Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN103-11 - CN70-16 Continuity (Approx. 0 Ω)
CN103-12 - CN70-15 Continuity (Approx. 0 Ω)
CN103
No continuity (other than
CN70-15 - CN70-16
1 2 3 4 5 6
0 Ω)
7 8 9 10 11 12 13 14 15 16 No continuity (other than
CN70-15 - CN70-4
17 18 19 20 21 22 23 24 25 26 27 0 Ω)
28 29 30 31 32 33 34 35
No continuity (other than
CN70-15 - CN70-5
0 Ω)
No continuity (other than
CN70-16 - CN70-4
0 Ω)
No continuity (other than
CN70-16 - CN70-5
0 Ω)
No continuity (other than
CN103-11 - CN103-4
0 Ω)
No continuity (other than
CN103-12 - CN103-5
0 Ω)
No continuity (other than
CN103-11 - CN103-5
0 Ω)
No continuity (other than
CN103-12 - CN103-4
0 Ω)

Judgment
Result Procedure
NG Harness defect
OK Go to Step 3

[Link] Step 3
1. Turn the key switch OFF and disconnect the battery plug.
2. After connecting the CN70 and CN103 connectors, connect
the battery plug and turn the key switch ON to check the op-
eration of traveling and load handling.

Judgment
Result Procedure
Display defect
Traveling and load handling can operate If the problem persists after the display is replaced, replace
the main controller, because there may be other failures.
Main controller defect
Traveling and load handling cannot operate If the problem persists after the main controller is replaced,
replace the display, because there may be other failures.
1 ELECTRICAL TROUBLESHOOTING 1-193

1.4.70 F4-1, F4-2, F4-3, F4-4, F4-5, F4-6, F4-7, F4-8 1

Failure mode: Display CPU abnormality

CAUTION
• If any of F4-1, F4-2, F4-3, F4-4, F4-5, F4-6, F4-7 or F4-8 are displayed, it indicates display defect. Re-
place it.

Probable cause
▪ Display defect

Related part

Display
1-194 1 ELECTRICAL TROUBLESHOOTING

1.4.71 F5-1
Failure mode: Sensor for battery fluid temperature vehicle connection harness open
abnormality

CAUTION
• Connect the battery plug after connecting the CN35 connector, because connecting the battery plug
before connecting the CN35 connector may cause an error.
If an error is caused by connecting the battery plug before connecting the CN35 connector, a normal
error disappears after about one minute.

Probable cause
▪ Connector connection defect
▪ Sensor for battery fluid level and temperature improper connection
▪ Truck connection harness defect
▪ Sensor for battery fluid level and temperature defect
▪ Display defect
▪ Sensor for battery fluid temperature defect

Related part

P1
Battery fluid level connector
Sensor
Battery fluid level detection G output signal CN70-26
Y (140, SLLT)
Sensor power supply R Display
CN35
Sensor for
battery fluid
level and
Battery fluid temperature B temperature
Sensor for
battery fluid
Battery fluid temperature W
temperature

Battery fluid temperature connector

N1

Battery

[Link] Step 1
1. Check that the sensor installed on the battery is the battery
fluid level sensor and fluid temperature sensor.

Judgment
Result Procedure
OK Go to Step 2
With the display service function, change the battery unit set-
NG
tings (Option set → Multifunction display DX : B UNIT).
1 ELECTRICAL TROUBLESHOOTING 1-195

[Link] Step 2
1
1. Disconnect the battery plug, and visually inspect the CN35
connector on the truck side is connected to the battery fluid
level sensor and fluid temperature sensor.
2. After connecting the connector, connect the battery plug,
and turn the key switch ON to check for errors.

Judgment
Result Procedure
F5-1 displayed Go to Step 3
F5-1 not displayed Connector connection defect

[Link] Step 3
Harness inspection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN35 and CN70 connectors.
3. Inspect conduction, and short circuit of the harness.
CN35 Notes:
Disconnect the battery plug, disconnect the CN35 and
1
CN70 connectors, and conduct after visually inspecting
there are no problems inside the connector, and on the
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
CN70 Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN35 connector to CN70-26 Conduction
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Judgment
Result Procedure
OK Go to Step 4
NG Truck connection harness defect
1-196 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the sensor for battery fluid level sensor and fluid tem-
perature output current
1. Disconnect the CN35 connector.
2. Connect the battery plug, and while the key switch is OFF,
check the output current of the battery fluid level sensor and
fluid temperature sensor.
Notes:
CN35 Disconnect the CN35 connector, and connect the battery
plug, and while the key switch is OFF, check the output
1
current on the battery fluid level between CN35 connector
and N1 terminal on the sensor side, and the fluid temperat-
ure sensor.
For an analog type tester, use the red tester probe for the
CN35 connector, and the black tester probe for the N1 ter-
minal.
Inspected point Standard
H current, L current:
CN35 connector to N1 terminal
Approx. 2 mA to 15 mA

Judgment
Result Procedure
OK Go to Step 5
NG Battery fluid level sensor and fluid temperature sensor defect

[Link] Step 5
Single unit inspect the battery fluid temperature sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the battery fluid temperature sensor connector.
3. Individually inspect the sensor for battery fluid temperature.
4. Measure the resistance of the sensor for battery fluid tem-
perature between the fluid temperature B terminal and the
fluid temperature W terminal on the battery fluid temperat-
ure sensor side.
Standard value: Approx. 330 kΩ to Approx. 35 kΩ
(Battery fluid temperature 0 to 50 ℃)
Notes:
Resistance values vary at a low or high temperature; there-
fore, use the values in the following table as guideline.
Resistance of
Battery fluid temperature battery fluid tem-
perature sensor
0℃ Approx. 330 kΩ
20 ℃ Approx. 124 kΩ
50 ℃ Approx. 35 kΩ

Judgment
Result Procedure
OK Display defect
NG Battery fluid temperature sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-197

1.4.72 F5-2 1
Failure mode: Battery fluid temperature sensor truck connection harness short circuit
abnormality

Probable cause
▪ Connector connection defect
▪ Truck connection harness defect
▪ Battery fluid level and fluid temperature sensors defect
▪ Display defect
▪ Battery fluid temperature sensor defect

Related part

P1
Battery fluid level connector

Battery fluid level detection G Sensor CN70-26

output Y CN35 (140, SLLT)
Sensor power supply R Display
Battery fluid CN70-1 (128, CHG7V)
level sensor CN70-5 (16, D7V)
and fluid CN70-6 (162, ITKY3)
temperature CN70-8 (160, ITKY1)
Battery fluid temperature B
sensors CN70-15 (146, CAN1L)
Battery fluid CN70-16 (145, CAN1H)
temperature CN70-18 (43, VBKY)
Battery fluid temperature W
sensor CN70-20 (161, ITKY2)
CN70-21 (163, IPSTKY1)
CN70-22 (123, SW1)
Battery fluid temperature connector CN70-23 (122, SW2)
CN70-24 (121, SW3)
N1 CN70-25 (129, CHGAC)
CN70-28 (139, SWTT)
Battery CN70-33 (132, CHGMS)

[Link] Step 1
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN35 and CN70 connectors, and on
the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
and turn the key switch ON to check for errors.

Judgment
Result Procedure
F5-2 displayed Go to Step 2
F5-2 not displayed Connector connection defect
1-198 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the display voltage
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN35 connector.
3. Connect the battery plug, and inspect the display voltage
with the key switch ON.
Notes:
Disconnect the CN35 connector, and connect the battery
CN35 plug, and while the key switch is ON, check the voltage
between the CN35 connector to N1 terminal.
1
Inspected point Standard
CN35 connector (Main harness side) to N1
0V
terminal

Judgment
Result Procedure
NG (except 0 V) Go to Step 3
OK (0 V) Go to Step 5

[Link] Step 3
Inspect the harness voltage
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN35 and CN70 connectors.
3. Connect the battery plug, and inspect the harness voltage
with the key switch ON.
Notes:
Disconnect the CN35 and CN70 connectors, and connect
CN35 the battery plug, and while the key switch ON, inspect the
voltage between the CN35 connector and N1 terminal.
1
Inspected point Standard
CN35 connector (Main harness side) to N1
0V
terminal

Judgment
Result Procedure
OK (0 V) Go to Step 4
NG (except 0 V) Truck connection harness defect
1 ELECTRICAL TROUBLESHOOTING 1-199

[Link] Step 4
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN35 and CN70 connectors.
3. Inspect conduction, and short circuit of the harness.
Notes:
Disconnect the battery plug, disconnect the CN35 and
CN70 connectors, and conduct after visually inspecting
CN70 there are no problems inside the connector, and on the
wire caulking.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 (Refer to "BEFORE TROUBLESHOOTING").
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Inspected point Standard

CN70-26 to CN70-1 No conduction
CN70-26 to CN70-5 No conduction
CN70-26 to CN70-6 No conduction
CN70-26 to CN70-8 No conduction
CN70-26 to CN70-15 No conduction
CN70-26 to CN70-16 No conduction
CN70-26 to CN70-18 No conduction
CN70-26 to CN70-20 No conduction
CN70-26 to CN70-21 No conduction
CN70-26 to CN70-22 No conduction
CN70-26 to CN70-23 No conduction
CN70-26 to CN70-24 No conduction
CN70-26 to CN70-25 No conduction
CN70-26 to CN70-28 No conduction
CN70-26 to CN70-33 No conduction

Judgment
Result Procedure
OK Display defect
NG Truck connection harness defect
1-200 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
Single unit inspect the battery fluid temperature sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the battery fluid temperature sensor connector.
3. Inspect the battery fluid temperature sensor as a single unit.
Measure the resistance of the battery fluid temperature
sensor between the fluid temperature B terminal and the
fluid temperature W terminal on the battery fluid sensor
side.
Standard value: Approx. 330 kΩ to Approx. 35 kΩ
(Battery fluid temperature 0 to 50 ℃)
Notes:
Resistance values vary at a low or high temperature; there-
fore, use the values in the following table as guideline.
Resistance value
of battery fluid
Battery fluid temperature
temperature
sensor
0℃ Approx. 330 kΩ
20 ℃ Approx. 124 kΩ
50 ℃ Approx. 35 kΩ

Judgment
Result Procedure
OK Battery fluid level sensor and fluid temperature sensor defect
NG Battery fluid temperature sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-201

1.4.73 F5-3 1
Failure mode: Battery fluid temperature open abnormality

CAUTION
• Park the truck in room temperature, because leaving it in a low-temperature environment (-20 ℃ or
less) may cause an error.
If an error is displayed by leaving the truck in a low-temperature environment for a long time, there
is no problem using it with the error displayed.
If the sensor is normal, the error disappears if the battery fluid temperature becomes higher than -20
℃.
(The battery temperature can be checked in the multifunction display DX: [ANL] I/O TEMP/VOLT 3/5
TSLLT; however, it is displayed as -20 ℃ for the temperature -20 ℃ or less)
If the user's work environment is always at a low temperature, and the error often occurs, set the op-
tion set “B UNIT” to “A” to prevent the error from displayed; however, the battery fluid level and
fluid temperature detection functions are also disabled.

Probable cause
▪ Connector connection defect
▪ Usage at low battery fluid temperature (-20 ℃ or less)
▪ Sensor for Battery Fluid Temperature defect
▪ Sensor for Battery Fluid Level and Temperature defect

Related part

P1
Battery fluid level connector
Sensor
Battery fluid level detection G output signal CN70-26
Y (140, SLLT)
Sensor power supply R Display
CN35
Sensor for
battery fluid
level and
Battery fluid temperature B temperature
Sensor for
battery fluid
Battery fluid temperature W
temperature

Battery fluid temperature connector

N1

Battery
1-202 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
1. Disconnect the battery plug, and visually inspect there are
no problems inside the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
and turn the key switch ON to check for errors.

Judgment
Result Procedure
F5-3 displayed Go to Step 2
F5-3 not displayed Connector connection defect

[Link] Step 2
Single unit inspect of the battery fluid temperature sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the battery fluid temperature sensor connector.
3. Single unit inspect the battery fluid temperature sensor.
Measure the resistance of the battery fluid temperature
sensor between the fluid temperature B terminal to the fluid
temperature W terminal on the battery fluid temperature
sensor side.
Standard value: Approx. 330 kΩ to Approx. 35 kΩ
(Battery fluid temperature 0 to 50 ℃)
Notes:
Resistance values vary at a low or high temperature; there-
fore, use the values in the following table as guideline.
Resistance value
of battery fluid
Battery fluid temperature
temperature
sensor
0℃ Approx. 330 kΩ
20℃ Approx. 124 kΩ
50℃ Approx. 35 kΩ

Judgment
Result Procedure
OK Battery fluid level sensor and fluid temperature sensor defect
NG Battery fluid temperature sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-203

1.4.74 F5-4 1
Failure mode: Battery fluid temperature sensor temperature abnormality

CAUTION
• If F5-1 is displayed at the same time, give a higher priority to troubleshooting of F5-1.
When the battery plug is connected before connecting the CN35 connector, it may cause error;
therefore, connect the battery plug after connecting the CN35 connector.
If an error occurs by connecting the battery plug before connecting the CN35 connector, the error
disappears after about one minute if everything is normal.

Probable cause
▪ Connector connection defect
▪ Battery fluid level sensor and fluid temperature sensor improper connection
▪ Battery fluid temperature sensor defect
▪ Battery fluid level sensor and fluid temperature sensor defect

Related part

P1
Battery fluid level connector
Sensor
Battery fluid level detection G output signal CN70-26
Y (140, SLLT)
Sensor power supply R Display
CN35
Sensor for
battery fluid
level and
Battery fluid temperature B temperature
Sensor for
battery fluid
Battery fluid temperature W
temperature

Battery fluid temperature connector

N1

Battery

[Link] Step 1
1. Check that the sensor installed on the battery is the battery
fluid level sensor and fluid temperature sensor.

Judgment
Result Procedure
OK Go to Step 2
With the display service function, change the battery unit set-
NG
tings (Option set “B UNIT”).
1-204 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Disconnect the battery plug, and visually inspect there are
no problems inside the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
and turn the key switch ON to check for errors.

Judgment
Result Procedure
F5-4 displayed Go to Step 3
F5-4 not displayed Connector connection failure

[Link] Step 3
Single unit inspect the battery fluid temperature sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the battery fluid temperature sensor connector.
3. Single unit inspect the battery fluid temperature sensor.
Measure the resistance of the battery fluid temperature
sensor failure between the fluid temperature B terminal to
the fluid temperature W terminal on the battery fluid temper-
ature sensor side.
Standard: Abnormal with approximately 6 kΩ or less

Judgment
Result Procedure
OK Battery fluid level sensor and fluid temperature sensor failure
NG Battery fluid temperature sensor failure
1 ELECTRICAL TROUBLESHOOTING 1-205

1.4.75 F6-1 (1-2 ton model) 1

Failure mode: On-truck charger charging failure (total timer activation) (1-2 ton model)

CAUTION
• Check Option set > CHARGER TYPE is A. If CHARGER TYPE is B, change to A.
• If FB-1 or FB-2 is recorded in the dialog, perform troubleshooting for FB-1 or FB-2 first.
• Check if the battery capacity setting in the display matches the equipped battery’s capacity.
• Check the equipped battery is within the transformer conformity. (Refer to APPLICABLE CHARGER
LIST (FOR TRUCK) in CHARGER CHAPTER of this machinery)

Probable cause
▪ Overheating (Continuous operation and high temperature environment)
▪ Battery fluid temperature low temperature
▪ Battery over-discharging
▪ Connection defect
▪ Charging cable defect
▪ Power supply voltage defect
▪ Battery defect
▪ Harness defect
▪ Cleaning fan defect
▪ Connector connection defect
▪ Battery current sensor defect
▪ Main controller defect
▪ Drive motor driver defect
▪ Pump motor driver defect
1-206 1 ELECTRICAL TROUBLESHOOTING

Related part
Contactor panel
Battery current
sensor P4
P1
+
CN137-2 CN135-2
CN137-3 CN135-3
CN137-1 CN135-1 Drive
motor
driver
-
+ -
Battery

CN104-10 CN102-1 (98, FNDC1)

(303, CSBAT+) Main CN104-3 (1, CBAT+)
Transformer +
CN102-24 (304, CSBAT) controller
CN102-35 (305, CSBAT-)
Pump

CN61-1
CN61-2
CN61-4
CN112-1 motor
Cleaning CN112-2 driver
fan 1 -
N1
CN113-1
Cleaning
fan 2 CN113-2

2,U
Power AC Magnet 4,V
plug switch 6,W

CN62-1
CN62-2
Charging
cable N2
Cleaning
fan 3

[Link] Step 1
Checking the operating environment
1. Check continuous operation and operation in high temperat-
ure environment in a short duration are not conducted.

Judgment
Result Action
OK Go to Step 2
Overheating (Continuous operation and high temperature en-
vironment)
Continuous operation and operation in high Leave the truck for a while (approx. 30 minutes), and if the
temperature environment problem is not solved after recharging in the normal temper-
ature environment, other causes may be possible; therefore,
go to Step 2 and after
1 ELECTRICAL TROUBLESHOOTING 1-207

[Link] Step 2
1
Check the battery condition
1. Check battery fluid low temperature and battery over char-
ging are not observed.

Judgment
Result Action
OK Go to Step 3
Battery fluid temperature low temperature
Wait until the battery fluid is in normal temperature, and if the
Battery fluid temperature low temperature problem is not solved after recharging in the normal temper-
ature environment, other causes may be possible; therefore,
go to Step 3 and after
Battery over-discharging
Battery over-discharging Charge in the early stage. If the problem is not solved after
recharging in the no over-charging condition, other causes
may be possible; therefore, go to Step 3 and after

[Link] Step 3
Connection inspection
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Inspect connection.
Notes:
Check AC plug for contact defect. (Check roughness of the
terminal and heating during power conduction are not ob-
served).
Check that the charging cable is not damaged.

Judgment
Result Action
OK Go to Step 4
NG Connection defect
1-208 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each terminal of AC plug.

Judgment
Result Action
OK (Approx. 190 V or more) Go to Step 6
NG (Approx. less than 190 V) Go to Step 5

[Link] Step 5
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each power supply terminal.

Judgment
Result Action
OK (Approx. 190 V or more) Charging cable defect
Power supply voltage defect
NG (Approx. less than 190 V) Charge with 191 V or more. If the problem is not solved after
recharging with 191 V or more, other causes may be pos-
sible; therefore, go to Step 6 and after
1 ELECTRICAL TROUBLESHOOTING 1-209

[Link] Step 6
1
Inspect the battery
1. (Refer to BATTERY CHAPTER)
When no error is found in inspection, conduct charging
again.

Judgment
Result Action
OK (After recharging, no F6-1 error) No problem Use it as is.
OK (After recharging, F6-1 error occurs) Go to Step 7
NG Battery defect

[Link] Step 7
Inspect the fan operation
Cleaning fan 1 and 2
1. Disconnect the AC plug, and turn the key switch ON.
2. Turn the cooling fan output ON forcibly with “ACTIVE
TEST”, and check the rotation condition of the cooling fan.
(Check both cleaning fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
Cleaning fan 3
1. Turn the key switch OFF, and connect the AC plug.
2. Start charging by pushing the charge button, and check the
rotation condition of the cooling fan.

Judgment
Result Action
OK (Cooling fan is rotating) Go to Step 12
OK (Cooling fan 1 or 2 is not rotating) Go to Step 8
NG (Cooling fan 3 is not rotating) Go to Step 10

[Link] Step 8
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Disconnect the CN102, CN104, CN112, and CN113 con-
nectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the CN102, CN104, CN112, and CN113 connect-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
ors, and conduct with the connector on the harness side
28 29 30 31 32 33 34 35 after visually inspecting there are no problems inside the
connector, and on the wire caulking.
CN104 (Refer to "BEFORE TROUBLESHOOTING").
CN113 Inspected point Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN104-3 to CN112-1 Conduction
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-3 to CN113-1 Conduction
CN102-1 to CN112-2 Conduction
1-210 1 ELECTRICAL TROUBLESHOOTING

Inspected point Standard

CN102-1 to CN113-2 Conduction
CN104-3 to CN102-1 No conduction

Judgment
Result Action
OK Go to Step 9
NG Harness defect

[Link] Step 9
Inspect the fan operation
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Connect the CN102, CN104, CN112, and CN113 connect-
ors.
3. Connect the battery plug, and turn the key switch ON.
4. Turn the cooling fan output ON forcibly with “ACTIVE
TEST”, and check the rotation condition of the cooling fan.
(Check both cleaning fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON

Judgment
Result Action
OK (Cooling fan is rotating) Connector connection defect
Cleaning fan defect
NG (Cooling fan is not rotating) Even after replacing the cooling fan, when the cooling fan
does not rotate with “ACTIVE TEST”, other problems may be
considered; therefore, replace the main controller

[Link] Step 10
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Disconnect the CN62 connector.
3. Inspect the harness
Inspected point Standard
CN62-1 to Magnet switch terminal 2 Conduction
CN62 CN62-2 to Magnet switch terminal 4 Conduction

1 2
1 ELECTRICAL TROUBLESHOOTING 1-211

CLK-20JT FW-1S CLK-35JT, 50JT 1

(No: M1) (No: M2) (No: M3, M4)

2 4 2 4 2 4

Judgment
Result Action
OK Go to Step 11
NG Harness defect

[Link] Step 11
Inspect the fan operation
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Connect the CN62 connector.
3. Connect the battery plug, and the AC plug.
4. Start charging by pushing the charge button, and check the
rotation condition of the cooling fan 3.

Judgment
Result Action
OK (Cooling fan is rotating) Connector connection defect
NG (Cooling fan is not rotating) Cleaning fan defect

[Link] Step 12
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Inspect the connector connection
Notes:
Disconnect the CN135 and CN137 connectors, and conduct
after visually inspecting there are no problems inside the
connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 13
NG Connector connection defect
1-212 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 13
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104, and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the CN102, CN104 and CN137 connectors, and
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
conduct after visually inspecting there are no problems in-
28 29 30 31 32 33 34 35 side the connector, and on the wire caulking.
CN137
(Refer to "BEFORE TROUBLESHOOTING").
CN104 1 2
3 Inspected point Standard
1 2 3 4 5 6 7 CN104-10 to CN137-1 Conduction⁽¹⁾
8 9 10 11 12 13 14 15 16 17 CN102-24 to CN137-3 Conduction⁽¹⁾
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-35 to CN137-2 Conduction⁽²⁾
CN137-1 to CN137-2 No conduction
CN137-3 to CN137-1 No conduction
CN137-3 to CN137-2 No conduction
⁽¹⁾: Using SST2, connect CN137-1 and CN137-3 on the har-
ness side, and check conduction between CN104-10 and
CN102-24.
⁽²⁾: Using SST2, connect CN137-2 and CN137-3 on the har-
ness side, and check conduction between CN102-24 and
CN102-35.

Judgment
Result Action
OK Go to Step 14
NG Harness defect

[Link] Step 14
Inspect battery current sensor
1. Connect the CN102, CN104, CN135, and CN137 connect-
ors, and the battery plug, and turn the key switch ON.
2. Check the value of the battery current sensor on the ana-
lyzer screen.
[ANL] I/O OTHERS 1/1 CSBAT
(Refer to "ANALYZER IN/OUT MONITOR (I/O OTHERS)” in
MULTIFUNCTION DISPLAY CHAPTER)

Judgment
Result Action
Main controller defect
OK When the problem is not solved after the main controller is
replaced, replace the motor driver because motor driver de-
fect may be considered
Battery current sensor defect
NG When the problem is not solved after the battery current
sensor is replaced, replace the main controller because the
problem may be caused by a main controller defect.
1 ELECTRICAL TROUBLESHOOTING 1-213

1.4.76 F6-1 (3 ton model) 1

Failure mode: On-truck charger charging failure (Safety timer operating) (3 ton model)

CAUTION
• Before troubleshooting, turn the key switch ON, and check that other error codes are not detected. If
an error code is detected, give a higher priority to troubleshooting of the applicable error code.
• Before conducting troubleshooting, inspect the magnet switch, and check the thermal relay is not
operating. When it is operating, check the charger component parts (magnet switch and transformer
ASSY) first.
• Except for probable causes, when no error code is displayed, refer to “Charging completes normally
but insufficient charging” or “Charging cannot be started by pushing the Charge button (The char-
ging screen is shown on the display).”

Probable cause
▪ Power supply voltage defect
▪ Charging cable defect
▪ Display defect
1-214 1 ELECTRICAL TROUBLESHOOTING

Related part

F5 fuse
CN104-1 (18, B80V)
Main
CN112-1 CN104-3 (1, CBAT+) controller
Cleaning
fan 1 CN112-2 CN102-1 (98, FNDC1)

CN113-1
Cleaning
fan 2 CN113-2

Transformer thermo
FCH switch
fuse
CN68-1 CN70-28 (139, SWTT)
P2 CN68-2 CN70-4 (14, DGND)
CN70-3 (169, TGND)
Transformer CN70-5 (16, D7V)
Transformer CN70-15 (146, CAN1L)
CN61-1
CN61-2
CN61-4

ASSY CN70-16 (145, CAN1H)

CN70-18 (43, VBKY)
Battery

CN70-36 (N2, N1)

CN69-1 CN70-33 (132, CHGMS)
CN62-2 Display
Cleaning CN69-2 CN70-25 (129, CHGAC)
fan 3 CN62-1
CN69-3 CN70-2 (130, CHGGND)
N1 CN69-4 CN70-1 (128, CHG7V)
Control CN69-5 CN70-24 (121, SW3)
panel
6,W
2,U
4,V

CN69-6 CN70-23 (122, SW2)

CN66-2 CN69-7 CN70-22 (123, SW1)
AC CN66-4 Magnet CN69-8 CN70-32 (124, LED4)
Power
plug CN66-1 switch CN69-9 CN70-29 (125, LED3)
CN66-3 CN69-10 CN70-30 (126, LED2)
CN69-11 CN70-31 (127, LED1)
Charging CN64-1 (95, MSCH)
cable CN64-2 (135, CHGACR)
CN64-3 (136, CHGACS)

[Link] Step 1
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each power supply terminal.
Inspected place Standard
Each power supply terminal AC191 to 220 V
1 ELECTRICAL TROUBLESHOOTING 1-215

Judgment
1
Result Action
OK (AC191 - 220 V) Go to Step 2
NG (0 V, or abnormal voltage drop and
Power supply voltage defect
open phase)

[Link] Step 2
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each terminal of AC plug.
Inspected place Standard
AC plug each terminal AC191 to 220 V

Judgment
Result Action
OK (AC191 - 220 V) Go to Step 3
NG (0 V, or abnormal voltage drop and
Charging cable defect
open phase)

[Link] Step 3
Inspect the charger timer test
1. Refer to “TIMER TEST” in CHARGER CHAPTER.
Notes:
When a timer test cannot be started, conduct the
troubleshooting for “The magnet switch does not apply
when the CHARGE button is pushed” when the error code
is not displayed or “Charging does not stop when the
STOP button is pushed during charging.”

Judgment
Result Action
Conduct the troubleshooting “The charging completes nor-
OK (Normal completion) mally, but insufficient charging” when the error code is not
displayed
Display an error code Perform troubleshooting of the applicable error code
After a test is started, it takes 10 seconds or
less (or more) until the capacity meter be- Display defect
comes 10
1-216 1 ELECTRICAL TROUBLESHOOTING

1.4.77 F6-2 (1-2 ton)

Failure mode: On-truck charger transformer overheat

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting of AB-1.
• Check the battery capacity setting on the display matches the equipped battery capacity.
• Check the equipped battery is within the range of the transformer compatibility. (Refer to “APPLIC-
ABLE CHARGER LIST (FOR VEHICLES)” in CHARGER CHAPTER)

Probable cause
▪ Harness defect
▪ Connector contact defect
▪ Cooling fan defect
▪ Transformer thermo switch defect
▪ Transformer ASSY defect
▪ Display defect
▪ Main controller not required

Related part

CN112-1 CN104-3 (1, CBAT+)

Cooling
fan 1 CN112-2 CN102-1 (98, FNDC1)
Main
controller
CN113-1
Cooling
fan 2 CN113-2

Transformer thermo switch

CN68-1 CN70-28 (139, SWTT)
CN68-2 CN70-4 (14, DGND)
Transformer Display
CN61-1
CN61-2
CN61-3

CN62-1
Cooling
CN62-2 fan 3
6, W
2, U
4, V

Magnet
switch
1 ELECTRICAL TROUBLESHOOTING 1-217

[Link] Step 1
1
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug. Conduct a timer test, and check if F6-2 error is
generated.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
No F6-2 error not generated Go to Step 2
F6-2 error generated Go to Step 8

[Link] Step 2
Check the fan operation
Cooling fan 1 and 2
1. Disconnect the AC plug, and turn the key switch ON.
2. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
Cooling fan 3
1. Turn the key switch OFF, and connect the AC plug.
2. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan.

Judgment
Result Action
OK (Cooling fan is rotating) Go to Step 7
NG (Cooling fan 1 or 2 is not rotating) Go to Step 3
NG (Cooling fan 3 is not rotating) Go to Step 5
1-218 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN102, CN104, CN112, and CN113 con-
nectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the CN102, CN104, CN112, and CN113 connect-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
ors, and after visually inspecting there are no problems in-
28 29 30 31 32 33 34 35 side the connector, and on the wire caulking, conduct with
the connector on the main harness side.
CN104 (Refer to "BEFORE TROUBLESHOOTING").
CN113 Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN104-3 to CN112-1 Conduction
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-3 to CN113-1 Conduction
CN102-1 to CN112-2 Conduction
CN102-1 to CN113-2 Conduction
CN104-3 to CN102-1 No conduction

Judgment
Result Action
OK Go to Step 4
NG Harness defect

[Link] Step 4
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN102, CN104, CN112, and
CN113 connectors.
2. Connect the battery plug, and turn the key switch ON.
3. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON

Judgment
Result Action
OK (Cooling fan is rotating) Connector contact defect
Cooling fan defect
NG (Cooling fan is not rotating) After replacing the cooling fan, when the cooling fan does not
rotate with “ACTIVE TEST”, other problems can be con-
sidered; therefore, replace the main controller.
1 ELECTRICAL TROUBLESHOOTING 1-219

[Link] Step 5
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN62 connector.
3. Inspect the harness.
Inspected place Standard
CN62-1 to Magnet switch terminal 2 Conduction
CN62 CN62-2 to Magnet switch terminal 4 Conduction

1 2

CLK-20JT FW-1S CLK-35JT, 50JT

(No: M1) (No: M2) (No: M3, M4)

2 4 2 4 2 4

Judgment
Result Action
OK Go to Step 6
NG Harness defect

[Link] Step 6
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN62 connector.
2. Connect the battery plug, and the AC plug.
3. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan 3.

Judgment
Result Action
OK (Cooling fan is rotating) Connector contact defect
NG (Cooling fan is not rotating) Cooling fan defect
1-220 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 7
Inspect the transformer ASSY
1. (Refer to “TRANSFORMER ASSY” in CHARGER
CHAPTER)

Judgment
Result Action
OK No error
NG Transformer ASSY defect

[Link] Step 8
Inspect the overheat detection function
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN68 connector, and connect between
CN68-1 and CN68-2 on the main harness side with SST2.
Connect the battery plug, and the AC plug, and conduct a
timer test.
3. Check F6-2 is generated.
CN68
(Refer to “TIMER TEST” in CHARGER CHAPTER)
1 2

Judgment
Result Action
No F6-2 error not generated Transformer thermo switch defect
F6-2 error generated Go to Step 9
1 ELECTRICAL TROUBLESHOOTING 1-221

[Link] Step 9
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the Cn68 and CN70 connectors, and conduct an
inspection.
3. Inspect the harness.
CN68 Notes:
1 2
Disconnect the CN68 and CN70 connectors, and after visu-
ally inspecting there are no problems inside the connector,
and on the wire caulking, conduct with the connector on
the main harness side.
(Refer to "BEFORE TROUBLESHOOTING").
CN70 Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Between CN68-1 and CN70-28 (Main harness
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Conduction⁽¹⁾
side)
Between CN68-2 and CN70-4 (Main harness
Conduction⁽¹⁾
side)
Between CN68-1 and CN68-2 (Main harness
No conduction
side)
⁽¹⁾: Connect between CN68-1 and CN68-2 on the harness side
with SST2, and check conduction between CN70-28 and
CN70-4.

Judgment
Result Action
OK Display defect
NG Harness defect
1-222 1 ELECTRICAL TROUBLESHOOTING

1.4.78 F6-2 (3ton)

Failure mode: On-truck charger transformer overheat (3 ton models)

CAUTION
• If AB-1 is displayed at the same time, give a higher priority to troubleshooting of AB-1.

Probable cause
▪ Transformer ASSY defect
▪ Tap adjustment defect
▪ Transformer thermo switch defect
▪ Harness defect
▪ Connector contact defect
▪ Cooling fan defect
▪ Display defect
1 ELECTRICAL TROUBLESHOOTING 1-223

Related part
1
F5 fuse
CN104-1 (18, B80V)
Main
CN112-1 CN104-3 (1, CBAT+) controller
Cleaning
fan 1 CN112-2 CN102-1 (98, FNDC1)

CN113-1
Cleaning
fan 2 CN113-2

Transformer thermo
FCH switch
fuse
CN68-1 CN70-28 (139, SWTT)
P2 CN68-2 CN70-4 (14, DGND)
CN70-3 (169, TGND)
Transformer CN70-5 (16, D7V)
Transformer CN70-15 (146, CAN1L)
CN61-1
CN61-2
CN61-4

ASSY CN70-16 (145, CAN1H)

CN70-18 (43, VBKY)
Battery

CN70-36 (N2, N1)

CN69-1 CN70-33 (132, CHGMS)
CN62-2 Display
Cleaning CN69-2 CN70-25 (129, CHGAC)
fan 3 CN62-1
CN69-3 CN70-2 (130, CHGGND)
N1 CN69-4 CN70-1 (128, CHG7V)
Control CN69-5 CN70-24 (121, SW3)
panel
6,W
2,U
4,V

CN69-6 CN70-23 (122, SW2)

CN66-2 CN69-7 CN70-22 (123, SW1)
AC CN66-4 Magnet CN69-8 CN70-32 (124, LED4)
Power
plug CN66-1 switch CN69-9 CN70-29 (125, LED3)
CN66-3 CN69-10 CN70-30 (126, LED2)
CN69-11 CN70-31 (127, LED1)
Charging CN64-1 (95, MSCH)
cable CN64-2 (135, CHGACR)
CN64-3 (136, CHGACS)

[Link] Step 1
Inspect the transformer ASSY
1. (Refer to “TRANSFORMER ASSY” in CHARGER
CHAPTER)

Judgment
Result Action
OK Go to Step 2
Transformer ASSY defect
NG In case of a transformer ASSY defect, the causes can be in
others; therefore, after replacing the transformer ASSY, con-
duct checks on Step 2 and later.
1-224 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the tap changer
1. Refer to “BEFORE CHARGING” in CHARGER CHAPTER.

Judgment
Result Action
OK Go to Step 3
NG Tap adjustment defect

[Link] Step 3
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug.
2. Check if F6-2 error is generated when the AC plug is con-
nected.

Judgment
Result Action
OK (F6-2 error not generated) Go to Step 6
NG (F6-2 error generated immediately after
Go to Step 4
connecting the AC plug)

[Link] Step 4
Inspect the overheat detection function
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN68 connector, and connect between
CN68-1 and CN68-2 on the main harness side with SST2.
3. Connect the battery plug, and the AC plug, and check if
F6-2 error occurs.
CN68 4. Inspect the thermo switch operation

1 2

Judgment
Result Action
OK (F6-2 error not generated) Transformer thermo switch defect
NG (F6-2 error generated) Go to Step 5
1 ELECTRICAL TROUBLESHOOTING 1-225

[Link] Step 5
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN68 and CN70 connectors.
3. Inspect the harness.
CN68 Notes:
1 2
Disconnect the CN68 and CN70 connectors, and after visu-
ally inspecting there are no problems inside the connector,
and on the wire caulking, conduct with the connector on
the main harness side.
(Refer to "BEFORE TROUBLESHOOTING").
CN70 Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Between CN68-1 and CN70-28 (Main har-
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Conduction⁽¹⁾
ness side)
Between CN68-2 and CN70-4 (Main harness
Conduction⁽¹⁾
side)
Between CN68-1 and CN68-2 (Main harness
No conduction
side)
⁽¹⁾: Connect between CN68-1 and CN68-2 on the harness side
with SST2, and check conduction between CN70-28 and
CN70-4.

Judgment
Result Action
OK Display defect
NG Harness defect

[Link] Step 6
Check the fan operation
Cooling fan 1 and 2
1. Disconnect the AC plug, and turn the key switch ON.
2. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
Cooling fan 3
1. Turn the key switch OFF, and connect the AC plug.
2. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan.

Judgment
Result Action
OK (Cooling fan is rotating) No error
NG (Cooling fan 1 or 2 is not rotating) Go to Step 7
NG (Cooling fan 3 is not rotating) Go to Step 9
1-226 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 7
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN102, CN104, CN112, and CN113 con-
nectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the CN102, CN104, CN112, and CN113 connect-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
ors, and after visually inspecting there are no problems in-
28 29 30 31 32 33 34 35 side the connector, and on the wire caulking, conduct with
the connector on the main harness side.
CN104 (Refer to "BEFORE TROUBLESHOOTING").
CN113 Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN104-3 to CN112-1 Conduction
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-3 to CN113-1 Conduction
CN102-1 to CN112-2 Conduction
CN102-1 to CN113-2 Conduction
CN104-3 to CN102-1 No conduction

Judgment
Result Action
OK Go to Step 8
NG Harness defect

[Link] Step 8
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN102, CN104, CN112, and
CN113 connectors.
2. Connect the battery plug, and turn the key switch ON.
3. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON

Judgment
Result Action
OK (Cooling fan is rotating) Connector contact defect
Cooling fan defect
NG (Cooling fan is not rotating) After replacing the cooling fan, when the cooling fan does not
rotate with “ACTIVE TEST”, other problems can be con-
sidered; therefore, replace the main controller.
1 ELECTRICAL TROUBLESHOOTING 1-227

[Link] Step 9
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN62 connector.
3. Inspect the harness.
Notes:
Disconnect the CN62 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN62 wire caulking, conduct with the connector on the magnet
1 2
switch side.
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN62-1 to Magnet switch terminal 2 Conduction
CN62-2 to Magnet switch terminal 4 Conduction

CLK-35JT, 50JT
(No. M3, M4)

2 4

Judgment
Result Action
OK Go to Step 10
NG Harness defect

[Link] Step 10
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN62 connector.
2. Connect the battery plug, and the AC plug.
3. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan 3.

Judgment
Result Action
OK (Cooling fan is rotating) Connector contact defect
NG (Cooling fan is not rotating) Cooling fan defect
1-228 1 ELECTRICAL TROUBLESHOOTING

1.4.79 F6-3
Failure mode: On-truck charger charging failure (safety timer activation)

CAUTION
• When FB-1 or FB-2 is recorded in the dialog, give a higher priority to troubleshooting of FB-1 or
FB-2.
• Check the battery capacity setting on the display matches the equipped battery capacity.
• Check the equipped battery is within the range of the transformer compatibility. (Refer to “APPLIC-
ABLE CHARGER LIST” in CHARGER CHAPTER)

Probable cause
▪ Overheating (Continuous operation and high temperature environment)
▪ Battery fluid temperature low
▪ Battery over-discharge
▪ Connection defect
▪ Charging cable defect
▪ Power supply voltage defect
▪ Battery defect
▪ Harness defect
▪ Cooling fan defect
▪ Connector connection defect
▪ Battery current sensor defect
▪ Main controller defect
▪ Drive motor driver defect
▪ Pump motor driver defect
1 ELECTRICAL TROUBLESHOOTING 1-229

Related part
1
Contactor panel
Battery current
sensor P4
P1
+
CN137-2 CN135-2
CN137-3 CN135-3
CN137-1 CN135-1 Drive
motor
driver
-
+ -
Battery

CN104-10 CN102-1 (98, FNDC1)

(303, CSBAT+) Main CN104-3 (1, CBAT+)
Transformer +
CN102-24 (304, CSBAT) controller
CN102-35 (305, CSBAT-)
Pump

CN61-1
CN61-2
CN61-4
CN112-1 motor
Cleaning CN112-2 driver
fan 1 -
N1
CN113-1
Cleaning
fan 2 CN113-2

2,U
Power AC Magnet 4,V
plug switch 6,W

CN62-1
CN62-2
Charging
cable N2
Cleaning
fan 3

[Link] Step 1
Check the operating environment
1. Check continuous operation in a short duration, and opera-
tion under high temperature are not conducted.

Judgment
Result Action
OK Go to Step 2
Overheating (Continuous operation and high temperature en-
vironment)
Continuous operation in a short duration,
and operation under high temperature are After leaving the truck for a while (approx. 30 minutes), and
conducted charging under the normal temperature environment does
not improve the symptom, other causes can be considered;
therefore, conduct Step 2 and later

[Link] Step 2
Check the battery condition
1. Check the battery fluid temperature is not low, and battery
over-discharging is not happening.

Judgment
Result Action
OK Go to Step 3
1-230 1 ELECTRICAL TROUBLESHOOTING

Result Action
Battery fluid temperature low
After setting the battery fluid temperature in normal temperat-
Battery fluid temperature is low ure, and charging is conducted again, if the symptom does
not improve, other causes can be considered; therefore, con-
duct Step 3 and later
Battery over-discharge
Charge in the earlier timing. After charging is conducted
Battery is over-discharging again in no over-discharging state, if the symptom does not
improve, other causes can be considered; therefore, conduct
Step 3 and later

[Link] Step 3
Inspect the connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connection.
Notes:
Check that there is no contact defect in the AC plug.
(Check there is no roughness of the terminal or heating
during power conduction).
Check that the charging cable is not damaged.

Judgment
Result Action
OK Go to Step 4
NG Connection defect

[Link] Step 4
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each terminal of charging plug.

Judgment
Result Action
OK (Approx. 190 V or more) Go to Step 6
NG (Approx. less than 190 V) Go to Step 5
1 ELECTRICAL TROUBLESHOOTING 1-231

[Link] Step 5
1
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each power supply terminal.

Judgment
Result Action
OK (Approx. 190 V or more) Charging cable defect
Power supply voltage shortage
Charge with 191 V or more. After charging with 191 V or more
NG (Approx. less than 190 V) is conducted again, if the symptom does not improve, other
causes can be considered; therefore, conduct Step 6 and
later

[Link] Step 6
Inspect the battery
1. Refer to “BATTERY CHAPTER”.
When no errors are found in inspection, conduct charging
again.

Judgment
Result Action
OK (F6-3 error not generated after rechar-
No error. It can be used as it is.
ging)
OK (F6-3 error generated after recharging) Go to Step 7
NG Battery defect

[Link] Step 7
Check the fan operation
Cooling fan 1 and 2
1. Disconnect the AC plug, and turn the key switch ON.
2. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON
Cooling fan 3
1. Turn the key switch OFF, and connect the AC plug.
2. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan.
1-232 1 ELECTRICAL TROUBLESHOOTING

Judgment
Result Action
OK (Cooling fan is rotating) Go to Step 12
NG (Cooling fan 1 or 2 is not rotating) Go to Step 8
NG (Cooling fan 3 is not rotating) Go to Step 10

[Link] Step 8
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN102, CN104, CN112, and CN113 con-
nectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7 CN112 Disconnect the CN102, CN104, CN112, and CN113 connect-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 1 2
ors, and after visually inspecting there are no problems in-
28 29 30 31 32 33 34 35 side the connector, and on the wire caulking, conduct with
the connector on the main harness side.
CN104 (Refer to "BEFORE TROUBLESHOOTING").
CN113 Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 1 2
CN104-3 to CN112-1 Conduction
18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-3 to CN113-1 Conduction
CN102-1 to CN112-2 Conduction
CN102-1 to CN113-2 Conduction
CN104-3 to CN102-1 No conduction

Judgment
Result Action
OK Go to Step 9
NG Harness defect

[Link] Step 9
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN102, CN104, CN112, and
CN113 connectors.
2. Connect the battery plug, and turn the key switch ON.
3. Turn the output of the cooling fan ON forcibly by “ACTIVE
TEST”, and check the rotation state of the cooling fan.
(Check both cooling fan 1 and 2)
[ANL] ACTIVE TEST 2/3
FAN OFF → ON

Judgment
Result Action
OK (Cooling fan is rotating) Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-233

Result Action
Cooling fan defect
1
NG (Cooling fan is not rotating) After replacing the cooling fan, if the cooling fan does not ro-
tate with “ACTIVE TEST”, other problems can be considered;
therefore, replace the main controller.

[Link] Step 10
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN62 connector.
3. Inspect the harness.
Inspected place Standard
CN62-1 to Magnet switch terminal 2 Conduction
CN62 CN62-2 to Magnet switch terminal 4 Conduction

1 2

CLK-20JT FW-1S CLK-35JT, 50JT

(No: M1) (No: M2) (No: M3, M4)

2 4 2 4 2 4

Judgment
Result Action
OK Go to Step 11
NG Harness defect
1-234 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 11
Check the fan operation
1. Turn the key switch OFF, disconnect the AC plug and the
battery plug, and connect the CN62 connector.
2. Connect the battery plug, and the AC plug.
3. Start charging by pressing the CHARGE button, and check
the rotation state of the cooling fan 3.

Judgment
Result Action
OK (Cooling fan is rotating) Connector connection defect
NG (Cooling fan is not rotating) Cooling fan defect

[Link] Step 12
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connector connection
Notes:
Disconnect the CN135 and CN137 connectors, and visually
inspect there are no problems inside the connector, and on
the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 13
NG Connector connection defect

[Link] Step 13
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the CN102, CN104, and CN137 connectors, con-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
duct after visually inspecting there are no problems inside
28 29 30 31 32 33 34 35 the connector, and on the wire caulking.
CN137
(Refer to "BEFORE TROUBLESHOOTING").
CN104 1 2
3 Inspected place Standard
1 2 3 4 5 6 7 CN104-10 to CN137-1 Conduction⁽¹⁾
8 9 10 11 12 13 14 15 16 17 CN102-24 to CN137-3 Conduction⁽¹⁾
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-35 to CN137-2 Conduction⁽²⁾
CN137-1 to CN137-2 No conduction
CN137-3 to CN137-1 No conduction
CN137-3 to CN137-2 No conduction
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
1 ELECTRICAL TROUBLESHOOTING 1-235

⁽²⁾: Connect CN137-2 and CN137-3 on the harness side by us-

ing SST2, and inspect conduction between CN102-24 and 1
CN102-35.

Judgment
Result Action
OK Go to Step 14
NG Harness defect

[Link] Step 14
Inspect the battery current sensor
1. After disconnecting the CN102, CN104, CN135, and CN137
connectors, connect the battery plug, and turn the key
switch ON.
2. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O OTHERS)" in MULTIFUNCTION DISPLAY CHAPTER)
Notes:
After checking the value when the truck is stopped, con-
duct load handling operation (relief), and check the battery
current sensor value fluctuates on the analyzer screen.

Judgment
Result Action
Main controller defect
OK When the symptom does not improve after replacing the main
controller, the motor driver defect can be considered; there-
fore, replace the motor driver
Battery current sensor defect
NG If the symptom does not improve after replacing the battery
current sensor, the main controller defect can be considered;
therefore, replace the main controller.
1-236 1 ELECTRICAL TROUBLESHOOTING

1.4.80 F6-4
Failure mode: On-truck charger charging disabled

Probable cause
▪ Connection defect
▪ Cable defect
▪ Battery current sensor defect
▪ Display defect
▪ Main controller defect
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part
Contactor panel
Battery current
sensor
P1
FCH
CN137-2 CN135-2
CN137-3 CN135-3
CN137-1 CN135-1

fuse P4
+
N1 Drive
-
Transformer P8 motor
M driver
T
Battery

CN104-10
(303, CSBAT+) Main
CN102-24 (304, CSBAT) controller
Pump
CN102-35 (305, CSBAT-) motor
P15 driver
N1

CN66-2
Power AC CN66-4 Magnet
supply plug CN66-1 switch
CN66-3

Charging CN64-1 (95, MSCH) CN69-1 CN70-33 (132, CHGMS)

cable CN64-2 (135, CHGACR) Control Display
panel CN69-3 CN70-2 (130, CHGGND)
CN64-3 (136, CHGACS)
1 ELECTRICAL TROUBLESHOOTING 1-237

[Link] Step 1
1
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug.
2. Conduct a timer test, and check if F7-1 error is generated.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
No F7-1 error not generated Go to Step 2
F7-1 error generated Perform troubleshooting of F7-1

[Link] Step 2
Inspect the connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connection.
• Inspect the transformer cable (+, -)
Check that the transformer cable (P4) and the trans-
former cable (N2) are correctly connected, and there is
no looseness.
• Inspect the transformer cable (M, T)
Check that the transformer cable (M) and the trans-
former cable (T) are correctly connected, and there is
no looseness.
Notes:
Check that there is no contact defect in the AC plug.
(Check there is no roughness of the terminal or heating
during power conduction)
Check that the charging cable is not damaged.

Judgment
Result Action
OK Go to Step 3
NG Connection defect
1-238 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect the transformer cable (+)
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the transformer side (+) of the transformer
cable, and the contactor (P4) side.
3. Inspect conduction of the transformer cable.
Notes:
Inspect by disconnecting the transformer cable. (Refer to
"BEFORE TROUBLESHOOTING").
Inspected place Standard
Transformer cable both ends (+) Conduction

Judgment
Result Action
OK (Conduction) Go to Step 4
NG (No conduction) Cable defect

[Link] Step 4
Inspect the battery current sensor
1. Connect the battery plug, and turn the key switch ON.
2. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O OTHERS)" in MULTIFUNCTION DISPLAY CHAPTER)
Notes:
After checking the value when the truck is stopped, con-
duct load handling operation (relief), and check the battery
current sensor value fluctuates on the analyzer screen.

Judgment
Result Action
Display defect
If the symptom does not improve after replacing the display,
OK the main controller defect or the motor driver defect can be
considered; therefore, replace the main controller or the mo-
tor driver.
Battery current sensor defect
NG If the symptom does not improve after replacing the battery
current sensor, the main controller defect can be considered;
therefore, replace the main controller.
1 ELECTRICAL TROUBLESHOOTING 1-239

1.4.81 F6-5 1
Failure mode: On-truck charger charging current abnormality

CAUTION
• When C8-1, C8-2, E8-1, E8-2 or FB-1 is recorded in the dialog, give a higher priority to troubleshoot-
ing of C8-1, C8-2, E8-1, E8-2 or FB-1

Probable cause
▪ Operation during charging
▪ Battery current sensor defect
▪ Connector connection defect
▪ Harness defect
▪ Main controller defect
▪ Motor rotation sensor defect
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part
Contactor panel
Battery current
sensor
P1
CN137-2 CN135-2
CN137-3 CN135-3
CN137-1 CN135-1
Battery

CN104-10
(303, CSBAT+) Main
CN102-24 (304, CSBAT) controller
CN102-35 (305, CSBAT-)
N1
+ CN109-15 (78, SSDL+) CN202-1 CN122-2
P4 CN203-5 CN202-2 Drive motor
Drive CN109-14 (79, SSDL1) CN122-1 rotation sensor 1
motor
driver CN123-2 CN53-2
Drive motor
- rotation sensor 2
CN109-13 (80, SSDL2) CN123-1 CN53-1

CN111-15 (81, SSP+) CN56-2

Pump Pump motor
motor rotation sensor
driver CN111-14 (82, SSP1) CN56-1

-
N1
1-240 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug.
2. Conduct a timer test, and check if F6-5 error is generated.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
F6-5 error generated Go to Step 2
Operation during charging
An error may be detected if auxiliary equipment and the key
No error are turned ON during charging, and if the machine moves. Do
not operate auxiliary equipment and turn the key ON during
charging, and charge in a stable location.

[Link] Step 2
Inspect for errors
1. Disconnect the AC plug.
2. Turn the key ON, and check for errors.

Judgment
Result Action
C8-1, C8-2, E8-1, E8-2 or FB-1 error gener-
Perform troubleshooting of the applicable error
ated
No error Go to Step 3

[Link] Step 3
Inspect the battery current sensor
1. Turn the key switch to ON.
2. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O OTHERS)" in MULTIFUNCTION DISPLAY CHAPTER)
Notes:
After checking the value when the truck is stopped, con-
duct load handling operation (relief), and check the battery
current sensor value fluctuates on the analyzer screen.

Judgment
Result Action
OK Go to Step 4
NG Go to Step 5
1 ELECTRICAL TROUBLESHOOTING 1-241

[Link] Step 4
1
Inspect the motor rotation sensor
1. Without traveling and load handling operation, check the
motor rotation value on the analyzer screen.
Drive motor driver
[ANL] I/O TRAVELING 5/6
SPDDM
Pump motor driver
[ANL] I/O [Link] 3/8
SPDPM

Judgment
Result Action
Drive motor driver is other than 0 Go to Step 5
Pump motor driver is other than 0 Go to Step 10
Both the drive motor driver and the pump
Conduct Step 5, 7, 10 and later respectively
motor driver are approx. 0

[Link] Step 5
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN135 and CN137 connectors.
3. Inspect the connector connection
Notes:
Disconnect the CN135 and CN137 connectors, and visually
inspect there are no problems inside the connector, and on
the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 6
NG Connector connection defect

[Link] Step 6
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.
1-242 1 ELECTRICAL TROUBLESHOOTING

CN102
3. Inspect the harness.
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19
CN104-10 to CN137-1 Conduction⁽¹⁾
20 21 22 23 24 25 26 27 CN102-24 to CN137-3 Conduction⁽¹⁾
28 29 30 31 32 33 34 35
CN137 CN102-35 to CN137-2 Conduction⁽²⁾
CN104 1 2 CN137-1 to CN137-2 No conduction
3
CN137-3 to CN137-1 No conduction
1 2 3 4 5 6 7
CN137-3 to CN137-2 No conduction
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
26 27 28 29 30 31
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
⁽²⁾: Connect CN137-2 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN102-24 and
CN102-35.

Judgment
Result Action
OK Battery current sensor defect
NG Harness defect

[Link] Step 7
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN109, CN122, CN123 and CN202 con-
nectors.
3. Inspect the connector connection
Notes:
Disconnect the battery plug, and visually inspect there are
no problems inside the CN109, CN122, CN123, and CN202
connectors. and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 8
NG Go to Step 3

[Link] Step 8
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN109, CN122 and CN123 connectors.
1 ELECTRICAL TROUBLESHOOTING 1-243

3. Inspect conduction and short circuiting of the harness.

1
Inspected place Standard
CN109-15 to CN122-2 Conduction⁽¹⁾
CN109 CN122 CN123 CN109-15 to CN123-2 Conduction⁽²⁾
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 1 2
CN109-14 to CN122-1 Conduction⁽¹⁾
16 17 18 19 20 21 22 23
CN109-13 to CN123-1 Conduction⁽²⁾
CN109-15 to CN109-13 No conduction
CN109-15 to CN109-14 No conduction
CN109-13 to CN109-14 No conduction
⁽¹⁾: Connect between CN122-1 and CN122-2 on the CN109
side with SST2, and check conduction between CN109-15 and
CN109-14.
⁽¹⁾: Connect between CN123-1 and CN123-2 on the CN109
side with SST2, and check conduction between CN109-15 and
CN109-13.
Notes:
Disconnect the CN109, CN122, and CN123 connectors, and
conduct after visually inspecting there are no problems in-
side the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 9
NG Harness defect

[Link] Step 9
Inspect the drive motor driver
1. Turn the key switch OFF, and disconnect the battery plug.
2. Connect the CN109 connector, connect the battery plug
while the CN122 and CN123 connectors are disconnected,
and turn the key switch ON.
3. Measure the voltage between CN122-2 and N1, and
between CN123-2 and N1.

CN122 CN123

1 2 1 2

Judgment
Result Action
12 to 16 V Motor rotation sensor defect
Other than 12 to 16 V Pump motor driver defect
1-244 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 10
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN56 and CN111.
3. Inspect the connector connection
Notes:
Visually inspect there are no problems inside the CN56 and
CN111 connectors, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 11
NG Connector connection defect

[Link] Step 11
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN111 and CN56.
3. Inspect conduction and short circuiting of the harness.
Notes:
Conduct after visually inspecting there are no problems in-
CN111 CN56 side the CN111 and CN56 connectors, and on the wire
caulking.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 1 2 (Refer to "BEFORE TROUBLESHOOTING").
16 17 18 19 20 21 22 23
Inspected place Standard
CN111-15 to CN56-2 Conduction⁽¹⁾
CN111-14 to CN56-1 Conduction⁽¹⁾
CN111-15 to CN111-14 No conduction
⁽¹⁾: Connect between CN56-1 and CN56-2 on the harness side
with SST2, and check conduction between CN111-15 and
CN111-14.

Judgment
Result Action
OK Go to Step 12
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-245

[Link] Step 12
1
Inspect the pump motor driver
1. Turn the key switch OFF, and disconnect the battery plug.
2. Connect the CN111 connector, connect the battery plug
while the CN56 connector is disconnected, and turn the key
switch ON.
3. Measure the voltage between CN56-2 (CN111 side) and
N2.

CN56

1 2

Judgment
Result Action
12 to 16 V Motor rotation sensor defect
Other than 12 to 16 V Pump motor driver defect
1-246 1 ELECTRICAL TROUBLESHOOTING

1.4.82 F6-6
Failure mode: On-truck charger charging voltage abnormality

CAUTION
• Operation check after repairs is conducted by a timer test.

Probable cause
▪ Main controller defect
▪ Harness defect
▪ Drive motor driver defect
▪ Pump motor driver defect
▪ Cable defect
▪ MB contactor defect
▪ Copper bar defect

Related part

MB
F1 fuse P4
P2 +
Drive
motor
- driver

+
Battery

Pump
motor
driver
-
N2

N1 CN104-1 (41, B48V)

Main
CN103-5 (N2, N2)
CN104-4 (N2, N2) controller
CN104-5 (N2, N2)
CN104-6 (N2, N2)
1 ELECTRICAL TROUBLESHOOTING 1-247

[Link] Step 1
1
Check the voltage
1. Inspect the battery voltage, drive motor driver voltage, and
pump motor driver voltage that three voltages are equival-
ent.
• Inspect the battery voltage
[ANL] I/O TEMP/VOLT 4/5
B48/80V
• Inspect the drive motor driver voltage
[ANL] I/O TEMP/VOLT 5/5
VDMD
• Inspect the pump motor driver voltage
[ANL] I/O TEMP/VOLT 5/5
VPMD
2. When three voltages are equivalent, conduct Step 6.

Judgment
Result Action
Go to Step 2
Battery voltage (B48/80 V) is NG
Record the battery voltage (B48/80 V)
Go to Step 7
Drive motor driver voltage is NG
Record the drive motor driver voltage (VDMD)
Go to Step 8
Pump motor driver voltage is NG
Record the pump motor driver voltage (VPMD)

[Link] Step 2
Inspect VBMB
1. Turn the key ON, and check the battery voltage and the
voltage value after MB contactor are equivalent.
• Inspect the battery voltage
[ANL] I/O TEMP/VOLT 4/5
B48/80V
• Inspect the voltage after MB contactor
[ANL] I/O TEMP/VOLT 4/5
VBMB

Judgment
Result Action
OK Go to Step 3
NG Go to Step 5
1-248 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect the battery voltage
1. Compare between the displayed value and actual value
(between P2 and N1).
[ANL] I/O TEMP/VOLT 4/5
B48/80 V

Judgment
Result Action
OK (B48/80 V is within the actual value ± Cable defect
approx.10 %) Replace the cable between P4 and the motor driver
NG (B48/80 V is out of the range of actual
Go to Step 4
value ± approx.10 %)

[Link] Step 4
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN103 and CN104 connectors.
3. Inspect conduction and short circuit of the harness.
Notes:
Disconnect the CN103 and CN104 connectors, and after
CN103 CN104 visually inspecting there are no problems inside the con-
nector, and on the wire caulking, inspect conduction of
1 2 3 4 5 6 1 2 3 4 5 6 7 CN103 and CN104.
7 8 9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 (Refer to "BEFORE TROUBLESHOOTING").
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 27 28 29 30 31 Inspected place Standard
CN103-5 to N1 Conduction
CN104-4 to N1 Conduction
CN104-5 to N1 Conduction
CN104-6 to N1 Conduction

Judgment
Result Action
OK Main controller defect
NG Harness defect

[Link] Step 5
Inspect the voltage
1. Turn the key ON, and check the voltage between P2 and
N1 and the voltage between P4 and N1 are almost the
same (± approx. 10 % or less).

Judgment
Result Action
OK Go to Step 6
NG MB contactor defect
1 ELECTRICAL TROUBLESHOOTING 1-249

[Link] Step 6
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN104 connector.
3. Inspect conduction and short circuit of the harness.
Notes:
Disconnect the CN104 connector, and after visually in-
CN104 specting there are no problems inside the connector, and
on the wire caulking, inspect conduction of CN104.
1 2 3 4 5 6 7 (Refer to "BEFORE TROUBLESHOOTING").
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 Inspected place Standard
26 27 28 29 30 31
CN104-1 to P2 Conduction

Judgment
Result Action
OK Main controller defect
NG Harness defect

[Link] Step 7
Check the drive motor driver voltage
1. Compare between the displayed value and actual value
(P4: Between drive motor driver + terminal and N1).
Inspect the drive motor driver voltage
[ANL] I/O TEMP/VOLT 5/5
VDMD

Judgment
Result Action
OK (VDMD is within the actual value ± ap- Cable defect
prox. 10 %) Replace the cable on the control panel P4 to the motor driver.
NG (VDMD is out of the range of actual
Drive motor driver defect
value ± approx. 10 %)
1-250 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 8
Check the voltage
1. Compare between the displayed value and actual value
(P4: Between pump motor driver + terminal and N1).
Inspect the pump motor driver voltage
[ANL] I/O TEMP/VOLT 5/5
VPMD

Judgment
Result Action
Copper bar defect
OK (VPMD is within the actual value ± ap-
prox. 10 %) Replace the copper bar of P4 between the drive motor driver
and the pump motor driver.
NG (VPMD is out of the range of actual
Pump motor driver defect
value ± approx. 10 %)
1 ELECTRICAL TROUBLESHOOTING 1-251

1.4.83 F7-1 (1-2 ton) 1

Failure mode: On-truck charger charging start failure (1-2 ton models)

CAUTION
• Check Option Set > CHARGER TYPE is A. When CHARGER TYPE is B, change to A.
• Inspect the magnet switch, and verify the thermal relay is not operating. When it is operating, con-
duct the inspection on the charger structure parts. “Magnetic switch and Transformer ASSY”, first.
• Disconnect the AC plug, turn the key ON, conduct traveling and load handling operation, and when
there are errors in the behavior, give a higher priority to troubleshooting of the applicable symptom
of a displayed error code or non-displayed error code.

Probable cause
▪ Power supply voltage defect
▪ Charging cable defect
▪ Connection defect
▪ Magnetic switch defect
▪ Harness defect
▪ Control panel defect
▪ FCH fuse defect
▪ Cable defect
▪ Transformer ASSY defect
▪ Display defect
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part

P2 P4

+
FCH Drive
fuse P7 motor
Drive P8 driver
- +
motor -
P9
M
Transformer
T
+
CN61

Pump
P14 motor
Pump P15 driver
CN66-2 -
motor P16
Power AC CN66-4 Magnet
supply plug CN66-1 switch
CN66-3

Charging CN64-1 (95, MSCH) CN69-1 CN70-33 (132, CHGMS)

cable CN64-2 (135, CHGACR) Control
Display
CN64-3 (136, CHGACS) panel CN69-3 CN70-2 (130, CHGGND)

N2
1-252 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect and record the voltage of each power supply ter-
minal.

Judgment
Result Action
Go to Step 2
No open phase
Record the voltage value of each power supply terminal.
Open phase Power supply voltage defect
1 ELECTRICAL TROUBLESHOOTING 1-253

[Link] Step 2
1
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage of each terminal of AC plug, and com-
pare with the voltage value recorded in Step 1.

Judgment
Result Action
The voltage value difference is approx. 1 V
Go to Step 3
or less.
The voltage value difference is approx. 1 V
Charging cable defect
or more.

[Link] Step 3
Inspect the connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect connection.
• Inspect the transformer cable (+, -)
Check that the transformer cable (P4) and the trans-
former cable (N2) are correctly connected, and there is
no looseness.
• Inspect the transformer cable (M, T)
Check that the transformer cable (M) and the trans-
former cable (T) are correctly connected, and there is
no looseness.
Notes:
Check that there is no contact defect in the AC plug.
(Check there is no roughness of the terminal and heating
during power conduction) Check that the charging cable is
not damaged.

Judgment
Result Action
OK Go to Step 4
NG Connection defect
1-254 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the magnetic switch signal
1. Connect the battery plug, and the AC plug.
2. Press the CHARGE button, and check if the magnetic
switch operates.
Inspect in approx. 2 seconds until F7-1 detection

Judgment
Result Action
Apply Go to Step 9
Not apply Go to Step 5

[Link] Step 5
Inspect the magnetic switch
1. Refer to “MAGNETIC SWITCH ASSY” in CHARGER
CHAPTER.
In addition to the inspection described in “MAGNET
SWITCH ASSY”, inspect conduction on the output side of
CN61 the magnet switch.
1 2 Notes:
3 4 Inspect what is described in “MAGNET SWITCH ASSY”,
and conduction on the output side of the magnet switch.
Inspected place
CN61-1(U) to Magnet switch terminal 2 Conduction
CN61-2(V) to Magnet switch terminal 4 Conduction
CN61-4(W) to Magnet switch terminal 6 Conduction
CLK-20JT FW-1S CLK-35JT, 50JT
(No. M1) (No. M2) (No. M3, M4)

2 4 6 2 4 6 2 4 6

Judgment
Result Action
OK Go to Step 6
NG Magnetic switch defect
1 ELECTRICAL TROUBLESHOOTING 1-255

[Link] Step 6
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN64 connector.
3. Inspect the harness.
Notes:
Disconnect the CN64 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN64
wire caulking, conduct with the connector on the magnet
1 switch side.
2 3 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN64-1 to Magnet switch terminal 95 Conduction

CLK-20JT FW-1S CLK-35JT, 50JT

(No. M1) (No. M2) (No. M3, M4)

95

Judgment
Result Action
OK Go to Step 7
NG Harness defect
1-256 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 7
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN66 connector.
3. Inspect the harness.
Notes:
Disconnect the CN66 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN66
wire caulking, conduct with the connector on the magnet
2 1 switch side.
4 3
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN66-3 to Magnet switch terminal 95 Conduction

CLK-20JT FW-1S CLK-35JT, 50JT

(No. M1) (No. M2) (No. M3, M4)

95

Judgment
Result Action
OK Go to Step 8
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-257

[Link] Step 8
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
CN69 Notes:
Disconnect the CN69 and CN70 connectors, and after visu-
1 2 3 4 5 6
ally inspecting there are no problems inside the connector,
7 8 9 10 11 12
and on the wire caulking, conduct with the connector on
the main harness side.
(Refer to "BEFORE TROUBLESHOOTING").
CN70 Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN69-1 to CN70-33 Conduction
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN69-3 to CN70-2 Conduction

Judgment
Result Action
Control panel defect
OK If the problem persists after the control panel is replaced, re-
place the display because display defects can be considered.
NG Harness defect

[Link] Step 9
Inspect the FCH fuse
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect conduction of both ends of the FCH fuse.

Judgment
Result Action
OK (Conduction) Go to Step 10
NG (No conduction) FCH fuse defect
1-258 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 10
Inspect the transformer ASSY
1. Inspect the insulation resistance, and no-load secondary
voltage in the machine mounting state.
(For the measurement location, refer to “TRANSFORMER
ASSY” in CHARGER CHAPTER)
2. Inspect conduction of the transformer primary side.
The transformer cable is not necessary to disconnect.

CN61 Inspected place Standard

1 2
CN61-1(U) to Transformer U terminal Conduction
3 4 CN61-2(V) to Transformer V terminal Conduction
CN61-4(W) to Transformer W terminal Conduction

CN61

U terminal W terminal V terminal

Judgment
Result Action
When the voltage value recorded in Step 1 is 190 V or less, it is
considered that F7-1 error is generated because of low voltage
value; therefore, charge with 191 V or more. When the symptom
OK
does not improve after charging with 191 V, display or motor
driver defect can be considered; therefore, replace the display or
the motor driver.
NG Go to Step 11
1 ELECTRICAL TROUBLESHOOTING 1-259

[Link] Step 11
1
Inspect the transformer cable
1. Turn the key switch OFF, and disconnect the battery plug,
and the AC plug.
2. Disconnect the transformer cable (+, -) on the transformer
side, the P4 terminal side, the N2 terminal side, and the
transformer cable (M, T) on the transformer side and the
motor driver side respectively.
3. Visually inspect there are no problems on the tightening part
of the transformer cable, and on the caulking part.
4. Inspect conduction of the transformer cable.
Inspected place Standard
Transformer cable (+) both ends Conduction
Transformer cable (-) both ends Conduction
Transformer cable (M) both ends Conduction
Transformer cable (T) both ends Conduction

Judgment
Result Action
Transformer ASSY defect
OK For the malfunction location inside the transformer, conduct
inspection described in “TRANSFORMER ASSY” in CHAR-
GER CHAPTER).
NG Cable defect
1-260 1 ELECTRICAL TROUBLESHOOTING

1.4.84 F7-1 (3 ton)

Failure mode: On-truck charger charging start failure (Charging start disabled) (3 ton
models)

CAUTION
• Check Option Set > CHARGER TYPE is B. When CHARGER TYPE is A, change to B.
• If F6-1 is displayed at the same time, give a higher priority to troubleshooting of F6-1.
• Before conducting troubleshooting, inspect the magnet switch, and check the thermal relay is not
operating. When it is operating, conduct the inspection on the charger structure parts. “Magnetic
switch and Transformer ASSY”, first.

Probable cause
▪ Main controller defect
▪ Connection defect
▪ Capacity not compatible
▪ Tap adjustment defect
▪ FCH fuse defect
▪ Transformer ASSY defect
▪ Magnetic switch defect
▪ Harness defect
▪ Control panel defect
▪ Display defect
1 ELECTRICAL TROUBLESHOOTING 1-261

Related part
1
F5 fuse
CN104-1 (18, B80V)
Main
CN112-1 CN104-3 (1, CBAT+) controller
Cleaning
fan 1 CN112-2 CN102-1 (98, FNDC1)

CN113-1
Cleaning
fan 2 CN113-2

Transformer thermo
FCH switch
fuse
CN68-1 CN70-28 (139, SWTT)
P2 CN68-2 CN70-4 (14, DGND)
CN70-3 (169, TGND)
Transformer CN70-5 (16, D7V)
Transformer CN70-15 (146, CAN1L)
CN61-1
CN61-2
CN61-4

ASSY CN70-16 (145, CAN1H)

CN70-18 (43, VBKY)
Battery

CN70-36 (N2, N1)

CN69-1 CN70-33 (132, CHGMS)
CN62-2 Display
Cleaning CN69-2 CN70-25 (129, CHGAC)
fan 3 CN62-1
CN69-3 CN70-2 (130, CHGGND)
N1 CN69-4 CN70-1 (128, CHG7V)
Control CN69-5 CN70-24 (121, SW3)
panel
6,W
2,U
4,V

CN69-6 CN70-23 (122, SW2)

CN66-2 CN69-7 CN70-22 (123, SW1)
AC CN66-4 Magnet CN69-8 CN70-32 (124, LED4)
Power
plug CN66-1 switch CN69-9 CN70-29 (125, LED3)
CN66-3 CN69-10 CN70-30 (126, LED2)
CN69-11 CN70-31 (127, LED1)
Charging CN64-1 (95, MSCH)
cable CN64-2 (135, CHGACR)
CN64-3 (136, CHGACS)

[Link] Step 1
Inspect the battery voltage
1. [ANL] I/O TEMP/VOLT 4/5
B48/80 V
Compare between the displayed value and the actual value
(between P2 and N1).

Judgment
Result Action
OK (B48/80 V is within the actual value ±10
Go to Step 2
%)
NG (B48/80 V is out of the range of actual
Main controller defect
value ±10 %)
1-262 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connection.
• Check that the charger cable (P2) and the charger cable
(N2) are correctly connected, and there is no looseness.
• Check that the CN69, CN70, CN61, CN64, and CN66
connectors are correctly connected.
Notes:
Check that the battery plug and AC plug are free from con-
tact defect. (There is no roughness of the terminal or heat-
ing during power conduction) Check that the charging
cable is not damaged.

Judgment
Result Action
OK Go to Step 3
NG Connection defect

[Link] Step 3
Inspect the transformer ASSY conduction
1. While the key switch is OFF, connect the battery plug and
AC plug.
2. Press the CHARGE button to check the conduction sound
of the transformer ASSY.
3. * After checking, press the STOP button to stop charging.

Judgment
Result Action
OK (Conduction sound can be heard) Go to Step 4
NG (Conduction sound cannot be heard)) Go to Step 6

[Link] Step 4
Check compatibility between the battery capacity and the trans-
former capacity.
1. Refer to “APPLICABLE CHARGER LIST” in CHARGER
CHAPTER.

Judgment
Result Action
OK Go to Step 5
NG Capacity not compatible
1 ELECTRICAL TROUBLESHOOTING 1-263

[Link] Step 5
1
Inspect the tap changer
1. Refer to “BEFORE CHARGING” in CHARGER CHAPTER.

Judgment
Result Action
OK Transformer ASSY defect
NG Tap adjustment defect

[Link] Step 6
Inspect the FCH fuse
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the FCH fuse, and inspect both ends.

Judgment
Result Action
OK (Conduction) Go to Step 7
NG (No conduction) FCH fuse defect

[Link] Step 7
Inspect the transformer ASSY primary side voltage
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Install the FCH fuse, and disconnect the CN61 connector.
3. Connect the battery plug, and the AC plug, and press the
CHARGE button to conduct an inspection.
4. Inspect the transformer ASSY primary side voltage with the
connector on the charger panel side.
Inspected place Standard
CN61
CN61-1(U) to CN61-2(V) AC191 to 220 V
CN61-2(V) to CN61-4(W) AC191 to 220 V
1 2
CN61-4(W) to CN61-1(U) AC191 to 220 V
3 4

Judgment
Result Action
OK Transformer ASSY defect
NG Go to Step 8
1-264 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 8
Inspect the magnetic switch voltage
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN61 connector.
3. Connect the battery plug, and the AC plug, and press the
CHARGE button to conduct an inspection.
4. Inspect the magnetic switch voltage.
CLK-35JT, 50JT
(No. M3, M4) A1 Inspected place Operation Standard
A1 terminal to 96 ter- Press the CHARGE
AC191 to 220 V
minal button
A1 terminal to 96 ter- Press the STOP but-
AC0 V
minal ton

96

Judgment
Result Action
NG Go to Step 9
OK Magnetic switch defect
1 ELECTRICAL TROUBLESHOOTING 1-265

[Link] Step 9
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN64 connector.
3. Inspect the harness.
Notes:
Disconnect the CN64 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN64
wire caulking, conduct with the connector on the magnet
1 switch side.
2 3 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN64-1 to Magnet switch terminal 95 Conduction

CLK-35JT, 50JT
(No. M3, M4)

95

Judgment
Result Action
OK Go to Step 10
NG Harness defect
1-266 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 10
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN66 connector.
3. Inspect the harness.
Notes:
Disconnect the CN66 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN66
wire caulking, conduct with the connector on the magnet
2 1 switch side.
4 3
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN66-3 to Magnet switch terminal 95 Conduction

CLK-35JT, 50JT
(No. M3, M4)

95

Judgment
Result Action
OK Go to Step 11
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-267

[Link] Step 11
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
CN69 Notes:
Disconnect the CN69 and CN70 connectors, and after visu-
1 2 3 4 5 6
ally inspecting there are no problems inside the connector,
7 8 9 10 11 12
and on the wire caulking, conduct with the connector on
the main harness side.
(Refer to "BEFORE TROUBLESHOOTING").
CN70 Inspected place Standard
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN69-1 to CN70-33 Conduction
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
CN69-3 to CN70-2 Conduction

Judgment
Result Action
Control panel defect
OK If the problem persists after the control panel is replaced, re-
place the display because display defects can be considered.
NG Harness defect
1-268 1 ELECTRICAL TROUBLESHOOTING

1.4.85 F7-2
Failure mode: On-truck charger charging over-voltage

CAUTION
• When the battery plug is removed during charging, F7-2 occurs. (It does not happen when the
EMERGENCY STOP switch is pushed)
• Disconnect the AC plug, turn the key ON, conduct traveling and load handling operation (relief), and
when there are errors in the behavior, give a higher priority to troubleshooting of the applicable
symptoms of a displayed error code or non-displayed error code.

Probable cause
▪ Battery fluid temperature low
▪ Connection defect
▪ Connector connection defect
▪ Harness defect
▪ Battery current sensor defect
▪ Battery defect
▪ Main controller defect
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part

Contactor panel
MB
Battery current sensor F1 fuse P4
P1 P2 P3 +
Drive
CN135-2
CN135-3
CN135-1

motor
- driver
CN137-2
CN137-3
CN137-1

+
Pump
motor
driver
-
N2

CN104-10 (303, CSBAT+)

N1 CN102-24 (304, CSBAT)
CN102-35 (305, CSBAT-)
Main
controller
CN136-3 CN104-9 (2, CBAT-)
MB
contactor CN136-4 CN104-3 (1, CBAT+)
1 ELECTRICAL TROUBLESHOOTING 1-269

[Link] Step 1
1
Check the battery condition
1. Check the battery fluid temperature is not low.
Fluid temperature can be checked by actual measurement
or on the analyzer screen.
[ANL] I/O TEMP/VOLT 3/5
TSLLT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O TEMP/VOLT)" in MULTIFUNCTION DISPLAY
CHAPTER)

Judgment
Result Action
OK Go to Step 2
Battery fluid temperature low
Set the battery fluid temperature in normal temperature, and
NG (Battery fluid temperature low) after charging is conducted again, when the symptom does
not improve, other causes can be considered; therefore, con-
duct Step 2 and later

[Link] Step 2
Inspect the connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connection, and check the contact resistance is
not increased.
• Inspect the contactor panel terminal
Check that the P1, P2, P3, and P4 terminals of the con-
tactor panel are correctly connected, and there is no
looseness.
• Inspect the contactor panel contact point
Check there is no roughness and damage in the con-
tactor panel contact point.
• Inspect the motor driver terminal
Each of the (+, -) terminals of the drive motor driver and
the pump motor driver are correctly connected, and
there is no looseness.
Notes:
Check that the battery plug is free from contact defect.
(Check there is no roughness of the terminal, damage, or
heating during power conduction)

Judgment
Result Action
OK Go to Step 3
NG Connection defect
1-270 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Inspect the connector connection
Notes:
Disconnect the CN135 and CN137 connectors, and visually
inspect there are no problems inside the connector, and on
the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 4
NG Connector connection defect

[Link] Step 4
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the CN102, CN104, and CN137 connectors, and
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
visually inspect there are no problems inside the con-
28 29 30 31 32 33 34 35 nector, and on the wire caulking.
CN137
(Refer to "BEFORE TROUBLESHOOTING").
CN104 1 2
3 Inspected place Standard
1 2 3 4 5 6 7 CN104-10 to CN137-1 Conduction⁽¹⁾
8 9 10 11 12 13 14 15 16 17 CN102-24 to CN137-3 Conduction⁽¹⁾
18 19 20 21 22 23 24 25
26 27 28 29 30 31 CN102-35 to CN137-2 Conduction⁽²⁾
CN137-1 to CN137-2 No conduction
CN137-3 to CN137-1 No conduction
CN137-3 to CN137-2 No conduction
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
⁽²⁾: Connect CN137-2 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN102-24 and
CN102-35.

Judgment
Result Action
OK Go to Step 5
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-271

[Link] Step 5
1
Inspect the battery current sensor
1. After disconnecting the CN102, CN104, CN135, CN136,
and CN137 connectors, connect the battery plug, and turn
the key switch ON.
2. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O OTHERS)" in MULTIFUNCTION DISPLAY CHAPTER)

Judgment
Result Action
OK Go to Step 6
Battery current sensor defect
NG If the error is still displayed after replacing the battery current
sensor, replace the main control because the main controller
defect can be considered

[Link] Step 6
Inspect the battery
1. Refer to “BATTERY CHAPTER”.

Judgment
Result Action
Main controller defect
OK When the symptom does not improve after replacing the main
controller, the motor driver defect can be considered; there-
fore, replace the motor driver
NG Battery defect
1-272 1 ELECTRICAL TROUBLESHOOTING

1.4.86 F7-3
Failure mode: On-truck charger overcurrent abnormality

CAUTION
• Check the battery capacity setting on the display matches the equipped battery capacity.

Probable cause
▪ Battery current sensor defect
▪ Harness defect
▪ Main controller defect
▪ Battery over-discharge
▪ Battery high temperature
▪ Battery defect
▪ Transformer ASSY defect

Related part

Contactor panel
Battery current
sensor P4
P1
+
CN137-2 CN135-2
CN137-3 CN135-3
CN137-1 CN135-1

Drive
motor
driver
-
Battery

CN104-10
(303, CSBAT+) M
Main +
CN102-24 (304, CSBAT) controller Transformer
CN102-35 (305, CSBAT-) T
Pump
motor
driver
N2 -
N1

[Link] Step 1
1. Turn the key switch OFF/ON, and check that FB-1 or FB-2
error is displayed.

Judgment
Result Action
Applicable error Conduct troubleshooting of the displayed error
No applicable error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-273

[Link] Step 2
1
Inspect the battery current sensor
1. After disconnecting the CN102, CN104, and CN137 con-
nectors, connect the battery plug, and turn the key switch
ON.
2. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
(For details, refer to the "ANALYZER IN/OUT MONITOR (I/
O OTHERS)" in MULTIFUNCTION DISPLAY CHAPTER)

Judgment
Result Action
OK Go to Step 6
NG Go to Step 3

[Link] Step 3
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. After disconnecting the CN137 connector, connect the bat-
tery plug, and turn the key switch ON.
3. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT

Judgment
Result Action
Approx. 0.00 Battery current sensor defect
Other than 0.00 Go to Step 5
1-274 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN137 connector, and connect between
CN137-1 and CN137-3 with SST2.
3. Connect the battery plug, and turn the key switch ON.
4. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT
Notes:
After checking the value when the truck is stopped, con-
duct load handling operation (relief), and check the battery
current sensor value fluctuates on the analyzer screen.

Judgment
Result Action
Approx. 5.00 Battery current sensor defect
Other than 5.00 Go to Step 5

[Link] Step 5
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the CN102, CN104, and CN137 connectors, and
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
visually inspect there are no problems inside of each con-
28 29 30 31 32 33 34 35 nector, and on the wire caulking
CN137
(Note: Perform inspection in the state that SST is not con-
CN104 1 2 nected)
3
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 CN104-10 to CN137-1 Conduction⁽¹⁾

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-24 to CN137-3 Conduction⁽¹⁾
CN102-35 to CN137-2 Conduction⁽²⁾
CN137-1 to CN137-2 No conduction
CN137-3 to CN137-1 No conduction
CN137-3 to CN137-2 No conduction
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
⁽²⁾: Connect CN137-2 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN102-24 and
CN102-35.

Judgment
Result Action
OK Battery current sensor defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-275

[Link] Step 6
1
Check the operating environment
1. Check the battery is not over-discharging and in high tem-
perature

Judgment
Result Action
OK Go to Step 7
Battery over-discharge
After charging the battery by using other chargers, even if
Battery over-discharge charged again with the charger on the machine, when F7-3 er-
ror is still generated. other causes can be considered; there-
fore, conduct Step 5 and later
Battery high temperature
Set the battery fluid temperature in normal temperature, and
Battery high temperature after charging is conducted again, when F7-3 error is still
generated, other causes can be considered; therefore, con-
duct Step 5 and later

[Link] Step 7
Inspect the battery
1. Refer to “BATTERY CHAPTER”.

Judgment
Result Action
OK Go to Step 8
NG Battery defect

[Link] Step 8
Inspect the transformer ASSY
1. For the measurement location and method, refer to
“TRANSFORMER ASSY” in CHARGER CHAPTER.

Judgment
Result Action
Battery current sensor defect
OK If the error is still displayed after replacing the battery current
sensor, replace the main control because main controller de-
fect can be considered
NG Transformer ASSY defect
1-276 1 ELECTRICAL TROUBLESHOOTING

1.4.87 F7-4
Failure mode: On-truck charger charge current control abnormality

CAUTION
• If F7-8 is recorded in the dialog memory, give a higher priority to troubleshooting of F7-8.
• Disconnect the AC plug, turn the key ON, conduct traveling and load handling operation (relief), and
when there are errors in the behavior, give a higher priority to troubleshooting of the applicable
symptoms of a displayed error code or non-displayed error code.

Probable cause
▪ Connection defect
▪ Cable defect
▪ Transformer ASSY defect
▪ Charging cable defect
▪ Large power voltage difference between phases
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part

P2 P4

+
FCH Drive
fuse P7 motor
Drive P8 driver
- +
motor -
P9
M
Transformer
T
+
CN61

Pump
P14 motor
Pump P15 driver
CN66-2 -
motor P16
Power AC CN66-4 Magnet
supply plug CN66-1 switch
CN66-3

Charging CN64-1 (95, MSCH) CN69-1 CN70-33 (132, CHGMS)

cable CN64-2 (135, CHGACR) Control
Display
CN64-3 (136, CHGACS) panel CN69-3 CN70-2 (130, CHGGND)

N2
1 ELECTRICAL TROUBLESHOOTING 1-277

[Link] Step 1
1
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug.
2. Conduct a timer test, and check if F7-4 error is generated.
Refer to “TIMER TEST” in CHARGER CHAPTER.

Judgment
Result Action
No F7-4 error generated Go to Step 5
F7-4 error generated Go to Step 2
Other errors generated than F7-4 Perform troubleshooting of the applicable error.

[Link] Step 2
1. Disconnect the battery plug, and visually inspect there is no
looseness and abrasion in the bolt tightened part shown be-
low.
• Drive motor driver (＋, U, V, W, －terminal)
• Pump motor driver (＋, U, V, W, －terminal)
• Drive motor (U, V, W terminal）
• Transformer (+, -, M, T terminal)

Judgment
Result Action
OK Go to Step 3
NG Connection defect

[Link] Step 3
Inspect the transformer ASSY
1. Inspect diode conduction, and insulation resistance in the
machine mounting state.
(For the measurement location, refer to “TRANSFORMER
ASSY” in CHARGER CHAPTER.)
2. Inspect conduction on the no-load secondary voltage and
transformer on the primary side.

Judgment
Result Action
OK Go to Step 5
NG Go to Step 4
1-278 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the transformer cable
1. Turn the key switch OFF, and disconnect the battery plug,
and the AC plug.
2. Disconnect the transformer side of the transformer cable (+,
-), and the P4 terminal and the N2 terminal side.
3. Visually inspect there are no problems on the tightening part
of the transformer cable, and on the caulking part.
4. Inspect conduction of the transformer cable.
+ Terminal Inspected place Standard
Transformer cable (+) both ends Conduction
Transformer cable (-) both ends Conduction

- Terminal

Judgment
Result Action
Transformer ASSY defect
OK For the malfunction location inside the transformer, conduct
inspection as described in “TRANSFORMER ASSY” in CHAR-
GER CHAPTER).
NG Cable defect
1 ELECTRICAL TROUBLESHOOTING 1-279

[Link] Step 5
1
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage between phases of each AC plug ter-
minal.

Judgment
Result Action
The error may be generated because of the voltage difference
between phases on power supply during charging, charge
OK (The difference of voltage between
again. When there is no difference in voltage between phases
phases of each terminal is approx. 5 V or
of power supply during charging, and the symptom does not
less)
improve, the motor driver defect can be considered; there-
fore, replace the motor driver
NG (The difference of voltage between
phases of each terminal is approx. 5 V or Go to Step 6
more)

[Link] Step 6
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage between phases of each power supply
terminal.

Judgment
Result Action
OK
(The difference of voltage between phases
Charging cable defect
of each power supply terminal is approx. 5
V or less)
Large voltage difference between phases in power supply
NG The error may be generated because of the voltage difference
(The difference of voltage between phases between phases on each power supply terminal; therefore,
of each power supply terminal is approx. 5 charge in other locations or check the factory power supply.
V or more) When the symptom does not improve, the motor driver defect
can be considered; therefore, replace the motor driver
1-280 1 ELECTRICAL TROUBLESHOOTING

1.4.88 F7-5
Failure mode: On-truck charger magnet abnormality

CAUTION
• Check traveling and load handling operation, and when other errors are displayed or there are errors
in the behavior, give a higher priority to the applicable troubleshooting.

Probable cause
▪ Magnet switch defect
▪ Control panel defect
▪ Display defect
▪ Harness defect
▪ Drive motor driver defect
▪ Pump motor driver defect
▪ Transformer ASSY defect
▪ Cable defect

Related part

P2 P4

+
FCH Drive
fuse P7 motor
Drive P8 driver
- +
motor -
P9
M
Transformer
T
+
CN61

Pump
P14 motor
Pump P15 driver
CN66-2 -
motor P16
Power AC CN66-4 Magnet
supply plug CN66-1 switch
CN66-3

Charging CN64-1 (95, MSCH) CN69-1 CN70-33 (132, CHGMS)

cable CN64-2 (135, CHGACR) Control
Display
CN64-3 (136, CHGACS) panel CN69-3 CN70-2 (130, CHGGND)

N2
1 ELECTRICAL TROUBLESHOOTING 1-281

[Link] Step 1
1
Inspect the magnet switch
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.

Input side
2. Inspect the magnet switch.
Input side Input side
main terminal main terminal
main terminal (S)
Input side
(S) Input side (R) Input side Notes:
main terminal main terminal main terminal
(T) (T)
(R) Check that the magnet switch is OFF.
Inspected place Standard
Input side main terminal (R) to output side
No conduction
main terminal (R)
Input side main terminal (S) to output side
No conduction
main terminal (S)
Input side main terminal (T) to output side
No conduction
main terminal (T)
Output side Output side Output side Output side Output side Output side
main terminal main terminal main terminal main terminal main terminal main terminal
(R) (S) (T) (R) (S) (T)

CLK-20JT FW-1S
(Abbreviation: M1) (Abbreviation: M2)

Input side Input side Input side

main main main
terminal (R) terminal (S) terminal (T)

CLK-35JT
(No. M3)
CLK-50JT
(No. M4)

Output side Output side Output side

main main main
terminal (R) terminal (S) terminal (T)

Judgment
Result Action
OK (No conduction) Go to Step 2
NG (Conduction) Magnet switch defect

[Link] Step 2
Inspect the magnet switch
1. Connect the battery plug.
2. Check the applied sound of the magnet switch cannot be
heard by inserting the AC plug, and the release sound of
the magnet switch cannot be heard by extracting the AC
plug.

Judgment
Result Action
OK Go to Step 8
NG Go to Step 3
1-282 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Inspect the control panel
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Connect the CN61 connector, and disconnect the CN64,
and CN69 connectors.
3. Inspect the control panel.
Notes:
CN69
Disconnect the CN64 and CN69 connector, and after visu-
6 5 4 3 2 1 ally inspecting there are no problems inside the connector,
12 11 10 9 8 7 and on the wire caulking, conduct with the CN64 and CN69
connectors on the control panel side.
(Refer to "BEFORE TROUBLESHOOTING").
CN64

1
Inspected place Standard
3 2 CN69-1 to CN69-3 No conduction
CN64-1 to CN64-3 No conduction

Judgment
Result Action
OK Go to Step 4
NG Control panel defect

[Link] Step 4
Inspect the magnet switch signal
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Connect the CN69 connector, and disconnect the CN70
connector.
3. Inspect the magnet switch signal.
Notes:
Disconnect the CN70 connector, and inspect with the CN70
connector on the display side.
CN70 (Refer to "BEFORE TROUBLESHOOTING").
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Inspected place Standard
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19
CN70-33 to CN70-2 No conduction

Judgment
Result Action
OK Go to Step 5
NG Display defect
1 ELECTRICAL TROUBLESHOOTING 1-283

[Link] Step 5
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN64 connector.
3. Inspect the harness.
Notes:
Disconnect the CN64 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
CN64
wire caulking, conduct with the connector on the magnet
1 switch side.
2 3 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN64-1 to CN64-3 No conduction

Judgment
Result Action
OK (No conduction) Go to Step 7
NG (Conduction) Go to Step 6

[Link] Step 6
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN66 connector.
3. Inspect the harness.
Notes:
Disconnect the CN66 connector, and after visually inspect-
ing there are no problems inside the connector, and on the
wire caulking, conduct with the connector on the magnet
switch side.
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN66-3 to CN66-4 No conduction

Judgment
Result Action
Harness defect
OK (No conduction)
Replace the harness between CN64 and CN66.
Harness defect
NG (Conduction)
Replace the harness between the CN66-magnet switch.
1-284 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 7
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
Notes:
Disconnect the CN69 and CN70 connectors, and after visu-
ally inspecting there are no problems inside the connector,
CN70 and on the wire caulking, conduct with the connector on
the harness side.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 (Refer to "BEFORE TROUBLESHOOTING").
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Inspected place Standard

CN70-33 to CN70-2 No conduction
CN70-33 to CN70-3 No conduction
CN70-33 to CN70-4 No conduction
CN70-33 to CN70-36 No conduction

Judgment
Result Action
OK (No conduction) Display defect
NG (Conduction) Harness defect

[Link] Step 8
Inspect the drive motor driver
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Connect the CN64 and CN70 connectors, and disconnect
the transformer cable (M) from the transformer M or from
the drive motor driver V phase.
3. Connect the battery plug, and the AC plug, and conduct a
timer test to check if F7-1 error occurs.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
F7-1 error generated Go to Step 9
No F7-1 error not generated Drive motor driver defect

[Link] Step 9
Inspect the pump motor driver
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Connect the transformer cable (M) to the transformer M or
to the drive motor driver V phase, and disconnect the trans-
former cable (T) from the transformer T or from the pump
motor driver V phase.
3. Connect the battery plug, and the AC plug, and conduct a
timer test to check if F7-1 error occurs.
(Refer to “TIMER TEST” in CHARGER CHAPTER)
1 ELECTRICAL TROUBLESHOOTING 1-285

Judgment
1
Result Action
F7-1 error generated Go to Step 10
No F7-1 error not generated Pump motor driver defect

[Link] Step 10
Inspect the transformer ASSY
1. Inspect the diode.
(For the measurement location and method, refer to
“TRANSFORMER ASSY” in CHARGER CHAPTER)

Judgment
Result Action
OK Go to Step 11
NG Transformer ASSY defect

[Link] Step 11
Inspect the cable
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the terminal of each cable, and check the cable
conduction.
3. Inspect conduction of the cable.
Notes:
After visually inspecting there are no problems on the ter-
minal, cable caulking, and coating, inspect each cable.
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
Transformer cable (M) terminal to P4 terminal No conduction
Transformer cable (T) terminal to P4 terminal No conduction
Drive motor cable (V phase) to P4 terminal No conduction
Drive motor cable (U phase) to P4 terminal No conduction
Pump motor cable (V phase) to P4 terminal No conduction
Pump motor cable (U phase) to P4 terminal No conduction

Judgment
Result Action
OK Display defect
NG Cable defect
1-286 1 ELECTRICAL TROUBLESHOOTING

1.4.89 F7-6
Failure mode: On-truck charger driver overcurrent

Probable cause
▪ Power supply voltage defect
▪ Transformer ASSY defect
▪ Battery over-discharge
▪ Battery fluid temperature high
▪ Battery defect
▪ Cable connection defect
▪ Cable defect
▪ Drive motor driver defect
▪ Pump motor driver defect
▪ Drive motor defect
▪ Pump motor defect

Related part

P2 P4

+
FCH Drive
fuse P7 motor
Drive P8 driver
- +
-
Battery

motor P9
M
Transformer
T
+

Pump
P14 motor
N1 Pump P15 driver
motor -
P16

N2

[Link] Step 1
1. Turn the key switch OFF/ON to check that C0-2, E0-2,
C1-2, or E1-2 error is displayed.

Judgment
Result Action
Applicable error Troubleshoot the displayed error
No applicable error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-287

[Link] Step 2
1
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage between terminals of each power sup-
ply.

Judgment
Result Action
OK (Approx. 220 V or less) Go to Step 3
NG (Approx. 220 V or more) Power supply voltage defect

[Link] Step 3
Inspect the transformer
1. Inspect diode in the machine mounting state.
2. Inspect no-load secondary voltage in the machine mounting
state.
(Refer to “TRANSFORMER ASSY” in CHARGER
CHAPTER)

Judgment
Result Action
OK Go to Step 4
NG Transformer ASSY defect
1-288 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Check the operating environment
1. Check the battery is not over-discharging and in high tem-
perature

Judgment
Result Action
OK Go to Step 5
Battery over-discharge
After charging the battery by using other chargers, when F7-6
Battery over-discharge error is still generated even after charged on the machine,
other causes can be considered; therefore, conduct Step 5
and later
Battery fluid temperature high
Set the battery fluid temperature in normal temperature, and
Battery high temperature after charging is conducted again, when F7-6 error is still
generated, other causes can be considered; therefore, con-
duct Step 5 and later

[Link] Step 5
Inspect the battery
1. Refer to “BATTERY CHAPTER”.

Judgment
Result Action
OK Go to Step 6
NG Battery defect

[Link] Step 6
1. Conduct a timer test
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
No error, it can be used as it is.
OK F7-6 error may be generated by low voltage on the battery;
therefore, charge in the early stage.
NG Go to Step 7
1 ELECTRICAL TROUBLESHOOTING 1-289

[Link] Step 7
1
Inspect the cable connection
1. Disconnect the battery plug, and visually inspect there is no
looseness and abrasion in the bolt tightening part shown
below.
• Drive motor driver (＋, U, V, W, －terminal)
• Pump motor driver (＋, U, V, W, －terminal)
• Transformer (+, -, M, T terminal)

Judgment
Result Action
OK Go to Step 8
NG Cable connection defect

[Link] Step 8
1. Conduct a timer test, and check LED of the drive motor
driver, and pump motor driver.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
LED of the drive motor driver flashes Go to Step 9
LED of the pump motor driver flashes Go to Step 12
1-290 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 9
Inspect the drive motor cable connection
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the drive motor cable connection.
Notes:
Disconnect the battery plug, and visually inspect there are
no problems on the mounting part of the drive motor cable,
and on the caulking.
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
P7 cable both ends Conduction
P8 cable both ends Conduction
P9 cable both ends Conduction
P7 cable to P8 cable No conduction
P8 cable to P9 cable No conduction
P9 cable to P7 cable No conduction

Judgment
Result Action
OK Go to Step 10
NG Cable connection defect

[Link] Step 10
Inspect the drive motor cable
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect and inspect the driver side and the motor side of
the drive motor cable.
3. Inspect conduction, and short circuit of the drive motor
cable.
Notes:
After visually inspecting there are no problems on the ter-
minal, cable caulking, and coating, inspect the P7, P8, and
P9 cables.
(Refer to "BEFORE TROUBLESHOOTING").

Judgment
Result Action
OK Go to Step 11
NG Cable defect
1 ELECTRICAL TROUBLESHOOTING 1-291

[Link] Step 11
1
Inspect the drive motor driver
1. Exchange the drive motor driver, and the pump motor
driver.
2. Connect the battery plug, and the AC plug, and conduct a
timer test.
(Ignore 32-1 and 32-3 errors).
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
LED of the motor driver connected to the
Drive motor defect
drive motor flashes
Drive motor driver defect
LED of the motor driver connected to the
pump motor flashes The motor driver that was the drive motor driver before ex-
changing is faulty

[Link] Step 12
Inspect the pump motor driver
1. Exchange the drive motor driver and the pump motor driver.
2. Connect the battery plug, and the AC plug, and conduct a
timer test.
(Ignore 32-1 and 32-3 errors).
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
Pump motor driver defect
LED of the motor driver connected to the
drive motor flashes The motor driver that was the pump motor driver before ex-
changing is faulty
LED of the motor driver connected to the
Pump motor defect
pump motor flashes
1-292 1 ELECTRICAL TROUBLESHOOTING

1.4.90 F7-7
Failure mode: Connection error of on-truck charger transformer cable

Probable cause
▪ Error connection of the transformer cable
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part

P4
+
N2 Drive
Transformer
- motor
P8 driver
M
T

Pump
motor
P15 driver

[Link] Step 1
Inspect the connection of the transformer cable
1. The transformer M cable shall be connected to the drive
motor driver V phase
2. The transformer T cable shall be connected to the motor
driver V phase

Judgment
Result Procedure
OK Go to Step 2
NG Error connection of the transformer cable
1 ELECTRICAL TROUBLESHOOTING 1-293

[Link] Step 2
1
1. Conduct charging, and check LED of the drive motor driver,
and pump motor driver.

Judgment
Result Procedure
LED of the drive motor driver flashes Drive motor driver defect
LED of the pump motor driver flashes Pump motor driver defect
1-294 1 ELECTRICAL TROUBLESHOOTING

1.4.91 F7-8
Failure mode: On-truck charger charge current control abnormality

CAUTION
• Disconnect the AC plug, turn the key ON, conduct traveling and load handling operation (relief), and
when there are errors in the behavior, give a higher priority to troubleshooting of the applicable
symptoms of a displayed error code or non-displayed error code.

Probable cause
▪ Connection defect
▪ Cable defect
▪ Transformer ASSY defect
▪ Charging cable defect
▪ Large voltage difference between phases in power supply
▪ Drive motor driver defect
▪ Pump motor driver defect

Related part

P2 P4

+
FCH Drive
fuse P7 motor
Drive P8 driver
- +
motor -
P9
M
Transformer
T
+
CN61

Pump
P14 motor
Pump P15 driver
CN66-2 -
motor P16
Power AC CN66-4 Magnet
supply plug CN66-1 switch
CN66-3

Charging CN64-1 (95, MSCH) CN69-1 CN70-33 (132, CHGMS)

cable CN64-2 (135, CHGACR) Control
Display
CN64-3 (136, CHGACS) panel CN69-3 CN70-2 (130, CHGGND)

N2
1 ELECTRICAL TROUBLESHOOTING 1-295

[Link] Step 1
1
Check for errors
1. Turn the key switch OFF, and connect the battery plug, and
the AC plug.
2. Conduct a timer test, and check if F7-8 or F7-4 error is gen-
erated.
When F7-8 is generated, after completion of the timer test,
push the Enter switch on the display, and check on the
menu screen of the display.
(Refer to “TIMER TEST” in CHARGER CHAPTER)

Judgment
Result Action
No error generated Go to Step 5
F7-8 or F7-4 error generated Go to Step 2
Error generated other than F7-8 and F7-4 Perform troubleshooting of the applicable error

[Link] Step 2
1. Disconnect the battery plug, and visually inspect there is no
looseness and abrasion in the bolt tightening part shown
below.
• Drive motor driver (V terminal)
• Pump motor driver (V terminal)
• Transformer (+, -, M, T terminal)
2. Check above first, and when no errors are found, check the
following also.
• Drive motor driver (＋, U, W, －terminal)
• Pump motor driver (＋, U, W, －terminal)
• Drive motor (U, V, W terminal）

Judgment
Result Action
OK Go to Step 3
NG Connection defect

[Link] Step 3
Inspect the transformer ASSY
1. Inspect diode conduction, and insulation resistance in the
machine mounting state.
(For the measurement location, refer to “TRANSFORMER
ASSY” in CHARGER CHAPTER)
2. Inspect conduction on the no-load secondary voltage and
transformer on the primary side.

Judgment
Result Action
OK Go to Step 5
NG Go to Step 4
1-296 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the transformer cable
1. Turn the key switch OFF, and disconnect the battery plug
and the AC plug.
2. Disconnect the transformer side of the transformer cable (+,
-), the P4 terminal side, and the N2 terminal side.
3. Visually inspect there are no problems on the tightening part
of the transformer cable, and on the caulking part.
4. Inspect conduction of the transformer cable.
+ Terminal Inspected place Standard
Transformer cable (+) both ends Conduction
Transformer cable (-) both ends Conduction

- Terminal

Judgment
Result Action
Transformer ASSY defect
OK For the malfunction location inside the transformer, conduct
inspection described in “TRANSFORMER ASSY” in CHAR-
GER CHAPTER).
NG Cable defect
1 ELECTRICAL TROUBLESHOOTING 1-297

[Link] Step 5
1
Inspect the AC plug terminal voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage between phases of each AC plug ter-
minal.

Judgment
Result Action
The error may be generated because of the voltage difference
between phases on power supply during charging; therefore,
OK (The difference of voltage between
charge again. When there is no difference in voltage between
phases of each terminal is approx. 5 V or
phases of power supply during charging, and the symptom
less)
does not improve, the motor driver defect can be considered;
therefore, replace the motor driver
NG (The difference of voltage between
phases of each terminal is approx. 5 V or Go to Step 6
more)

[Link] Step 6
Inspect the power supply voltage
1. Turn the key switch OFF, and disconnect the AC plug.
2. Inspect the voltage between phases of each power supply
terminal.

Judgment
Result Action
OK (The difference of voltage between
phases of each power supply terminal is Charging cable defect
approx. 5 V or less)
Large voltage difference between phases in power supply
NG (The difference of voltage between The error may be generated because of the voltage difference
phases of each power supply terminal is between phases on each power supply terminal; therefore,
approx. 5 V or more) charge in other locations or check the factory power supply.
When the symptom does not improve, the motor driver defect
can be considered; therefore, replace the motor driver
1-298 1 ELECTRICAL TROUBLESHOOTING

1.4.92 F8-1
Failure mode: On-truck charger charging completion failure (Charging completion
disabled) (3 ton models)

CAUTION
• Turn the switchboard breaker OFF to stop AC200 V supply to the AC plug, and then conduct an in-
spection.
• Before conducting troubleshooting, inspect the magnet switch, and check the thermal relay is not
operating. When it is operating, conduct the inspection on the charger structure parts. “Magnet
switch and Transformer ASSY”, first.

Probable cause
▪ Main controller defect
▪ Magnet switch defect
▪ Control panel defect
▪ Harness defect
▪ Display defect
1 ELECTRICAL TROUBLESHOOTING 1-299

Related part
1
F5 fuse
CN104-1 (18, B80V)
Main
CN112-1 CN104-3 (1, CBAT+) controller
Cleaning
fan 1 CN112-2 CN102-1 (98, FNDC1)

CN113-1
Cleaning
fan 2 CN113-2

Transformer thermo
FCH switch
fuse
CN68-1 CN70-28 (139, SWTT)
P2 CN68-2 CN70-4 (14, DGND)
CN70-3 (169, TGND)
Transformer CN70-5 (16, D7V)
Transformer CN70-15 (146, CAN1L)
CN61-1
CN61-2
CN61-4

ASSY CN70-16 (145, CAN1H)

CN70-18 (43, VBKY)
Battery

CN70-36 (N2, N1)

CN69-1 CN70-33 (132, CHGMS)
CN62-2 Display
Cleaning CN69-2 CN70-25 (129, CHGAC)
fan 3 CN62-1
CN69-3 CN70-2 (130, CHGGND)
N1 CN69-4 CN70-1 (128, CHG7V)
Control CN69-5 CN70-24 (121, SW3)
panel
6,W
2,U
4,V

CN69-6 CN70-23 (122, SW2)

CN66-2 CN69-7 CN70-22 (123, SW1)
AC CN66-4 Magnet CN69-8 CN70-32 (124, LED4)
Power
plug CN66-1 switch CN69-9 CN70-29 (125, LED3)
CN66-3 CN69-10 CN70-30 (126, LED2)
CN69-11 CN70-31 (127, LED1)
Charging CN64-1 (95, MSCH)
cable CN64-2 (135, CHGACR)
CN64-3 (136, CHGACS)

[Link] Step 1
Inspect the battery voltage
1. Inspect the battery voltage.
[ANL] I/O TEMP/VOLT 4/5
B48/80 V
Compare the displayed value on the display and the actual
value (between P2 and N1).

Judgment
Result Action
OK (B48/80 V is within the actual value ±10
Go to Step 2
%)
NG (B48/80 V is out of the range of actual
Main controller defect
value ±10 %)
1-300 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the magnet switch
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN61 connector.
3. Inspect the magnet switch.
Input side Input side Input side
main main main
terminal (R) terminal (S) terminal (T)
NOTICE! :
Disconnect the CN61 connector, and check that the magnet
switch is OFF.
Inspected place Standard
Input side main terminal (R) to output side
No conduction
main terminal (R)
CLK-35JT Input side main terminal (S) to output side
(No. M3) No conduction
main terminal (S)
CLK-50JT
(No. M4) Input side main terminal (T) to output side
No conduction
main terminal (T)
Output side Output side Output side
main main main
terminal (R) terminal (S) terminal (T)

Judgment
Result Action
OK (No conduction) Go to Step 3
NG (Conduction) Magnet switch defect

[Link] Step 3
Inspect the control panel
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Connect the CN61 connector, and disconnect the CN69
connector.
3. Inspect the control panel.
NOTICE! :
Disconnect the CN69 connector, and after visually inspect-
CN69 ing there are no problems inside the connector, and on the
wire caulking, conduct with the CN69 connector on the
6 5 4 3 2 1
control panel side.
12 11 10 9 8 7
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN69-1 to CN69-3 No conduction

Judgment
Result Action
OK Go to Step 4
NG Control panel defect
1 ELECTRICAL TROUBLESHOOTING 1-301

[Link] Step 4
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN69 and CN70 connectors.
3. Inspect the harness.
NOTICE! :
Disconnect the CN69 and CN70 connectors, and after visu-
ally inspecting there are no problems inside the connector,
CN70 and on the wire caulking, conduct with the connector on
the harness side.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN70-33 to CN70-2 No conduction
CN70-33 to CN70-3 No conduction
CN70-33 to CN70-4 No conduction
CN70-33 to CN70-36 No conduction

Judgment
Result Action
OK Go to Step 5
NG Harness defect

[Link] Step 5
Harness inspection
1. Turn the key switch OFF, and disconnect the AC plug and
the battery plug.
2. Disconnect the CN64 connector.
3. Inspect the harness.
NOTICE! :
Disconnect the CN64 connector, and after visually inspect-
CN64
ing there are no problems inside the connector, and on the
wire caulking, conduct with the connector on the magnet
1 switch side.
2 3
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN64-1 to CN64-3 No conduction

Judgment
Result Action
OK (No conduction) Go to Step 7
NG (Conduction) Go to Step 6
1-302 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 6
Inspect the harness
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Disconnect the CN66 connector.
3. Inspect the harness.
NOTICE! :
Disconnect the CN66 connector, and after visually inspect-
CN66 ing there are no problems inside the connector, and on the
wire caulking, conduct with the connector on the magnet
1 2
switch side.
3 4
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN66-3 to CN66-4 No conduction

Judgment
Result Action
Harness defect
OK (No conduction)
Replace the harness between CN64 and CN66.
Harness defect
NG (Conduction)
Replace the harness between the CN66-magnet switch.

[Link] Step 7
Inspect the magnet switch signal
1. Turn the key switch OFF, and disconnect the AC plug, and
the battery plug.
2. Connect the CN69 connector, and disconnect the CN70
connector.
3. Inspect the magnet switch signal.
NOTICE! :
Disconnect the CN70 connector, and inspect with the CN70
connector on the display side.
CN70
Inspected place Standard
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 CN70-33 to CN70-2 No conduction

Judgment
Result Action
OK (No conduction) Control panel defect
NG (Conduction) Display defect
1 ELECTRICAL TROUBLESHOOTING 1-303

1.4.93 F8-2 1
Failure mode: On-truck charger system abnormality

CAUTION
• Disconnect the AC plug, turn the key switch ON, and conduct the troubleshooting on the error code
in the memory.
1-304 1 ELECTRICAL TROUBLESHOOTING

1.4.94 FA-1, FA-2, and FA-3

Failure mode: CAN bridge controller CPU abnormality

CAUTION
• If FA-2, FA-2, and FA-3 are displayed, it indicates the CAN bridge controller defect; therefore, replace
it.

Probable cause
▪ CAN bridge controller defect

Related part

CAN bridge controller

1 ELECTRICAL TROUBLESHOOTING 1-305

1.4.95 FB-1 1
Failure mode: Battery current sensor neutral abnormality

CAUTION
• If the error is still displayed after replacing the battery current sensor, other causes can be con-
sidered; therefore, replace the main controller.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Battery current sensor defect
▪ Main controller defect

Related part

Contactor panel
CN104-10 (303, CSBAT+) CN137-1
Main
controller CN102-24 (304, CSBAT) CN137-3
Battery current sensor
CN102-35 (305, CSBAT-) CN137-2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN137 connector, and visually inspect in-
side the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting the connector, connect the battery plug
and turn the key switch ON to check the error display.

Judgment
Result Procedure
FB-1 error displayed Go to Step 2
FB-1 error not displayed Connector connection defect
1-306 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Turn the key switch OFF, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
connect the CN102, CN104, and CN137 connectors, and
28 29 30 31 32 33 34 35 visually inspect inside each connector, and on the wire
CN137
caulking part. (Note: Perform inspection in the state that
CN104 1 2 SST is not connected)
3
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 CN104-10 (303) to CN137-1 (303) Conduction⁽¹⁾

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-24 (304) to CN137-3 (304) Conduction⁽¹⁾
CN102-35 (305) to CN137-2 (305) Conduction⁽²⁾
CN137-1 (303) to CN137-2 (305) No conduction
CN137-3 (304) to CN137-1 (303) No conduction
CN137-3 (304) to CN137-2 (305) No conduction
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
⁽¹⁾: Connect CN137-2 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN102-24 and
CN102-35.

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. After disconnecting the CN137 connector, connect the bat-
tery plug, and turn the key switch ON.
3. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT

Judgment
Result Procedure
Approx. 0.00 Go to Step 4
Other than 0.00 Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-307

[Link] Step 4
1
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN137 connector, and connect CN137-1
and CN137-3 with SST2.
3. Connect the battery plug, and turn the key switch ON.

CN137
4. Check the battery current sensor value on the analyzer
screen.
1 2
3
[ANL] I/O OTHERS 1/1
CSBAT

Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Other than 5.00 Main controller defect
1-308 1 ELECTRICAL TROUBLESHOOTING

1.4.96 FB-2
Failure mode: Battery current sensor overcurrent

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Battery current sensor defect
▪ Main controller defect

Related part

Contactor panel
CN104-10 (303, CSBAT+) CN137-1
Main
controller CN102-24 (304, CSBAT) CN137-3
Battery current sensor
CN102-35 (305, CSBAT-) CN137-2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN137 connector, and visually inspect in-
side the connector, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting the connector, connect the battery plug,
and turn the key switch ON to check the error display.

Judgment
Result Procedure
FB-2 error display Go to Step 2
FB-2 no error display Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-309

[Link] Step 2
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN104 and CN137 connectors.

CN102
3. Inspect the harness.
Notes:
1 2 3 4 5 6 7
Turn the key switch OFF, disconnect the battery plug, dis-
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
connect the CN102, CN104, and CN137 connectors, and
28 29 30 31 32 33 34 35 visually inspect there are no problems inside each con-
CN137
nector, and on the wire caulking. (Note: Perform inspection
CN104 1 2 in the state that SST is not connected)
3
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 CN104-10 (303) to CN137-1 (303) Conduction⁽¹⁾

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN102-24 (304) to CN137-3 (304) Conduction⁽¹⁾
CN102-35 (305) to CN137-2 (305) Conduction⁽²⁾
CN137-1 (303) to CN137-2 (305) No conduction
CN137-3 (304) to CN137-1 (303) No conduction
CN137-3 (304) to CN137-2 (305) No conduction
⁽¹⁾: Connect CN137-1 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN104-10 and
CN102-24.
⁽¹⁾: Connect CN137-2 and CN137-3 on the harness side by us-
ing SST2, and inspect conduction between CN102-24 and
CN102-35.

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. After disconnecting the CN137 connector, connect the bat-
tery plug, and turn the key switch ON.
3. Check the battery current sensor value on the analyzer
screen.
[ANL] I/O OTHERS 1/1
CSBAT

Judgment
Result Procedure
Approx. 0.00 Go to Step 4
Other than 0.00 Main controller defect
1-310 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the battery current sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN139 connector, and connect CN137-1
and CN137-3 with SST2.
3. Connect the battery plug, and turn the key switch ON.

CN137
4. Check the battery current sensor value on the analyzer
screen.
1 2
3
[ANL] I/O OTHERS 1/1
CSBAT

Judgment
Result Procedure
Approx. 5.00 Battery current sensor defect
Other than 5.00 Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-311

1.4.97 FC-1 1
Failure mode: Battery fluid temperature overheat

CAUTION
• Do not leave the truck in the environment the temperature is high.

Probable cause
▪ The temperature around the battery is high
▪ Overheating (overload continuous use)
▪ Battery fluid level and fluid temperature sensor defect

Related part

CN70-26 (140, SLLT) CN35 Battery fluid level

Display and fluid temperature sensor

[Link] Step 1
Check error
1. Turn the key switch ON, and check the battery overheat in-
dicator on the display.

Judgment
Result Procedure
When the battery fluid temperature drops, the battery over-
heat indicator turns OFF, and the truck can be used; how-
ever, it is considered that continuous operation under over-
Indicator turns OFF
loaded condition caused the error; therefore, check the oper-
ating condition, and do not conduct continuous operation in
overloaded state.
Indicator ON Go to Step 2
1-312 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Check the battery fluid temperature, and recheck the error
1. Check the battery fluid temperature on the analyzer screen,
and record the value.
[ANL] I/O TEMP/VOLT 3/5
TSLLT
2. Turn the key switch OFF, and after leaving the truck for 12
hours or longer, turn the key switch ON, and check the bat-
tery overheat indicator on the display.

Judgment
Result Procedure
When the battery fluid temperature drops, the battery over-
heat indicator turns OFF, and the truck can be used; how-
ever, it is considered that continuous operation under over-
Indicator OFF
loaded condition caused the error; therefore, check the oper-
ating condition, and do not conduct continuous operation in
overloaded state.
Indicator ON Go to Step 3

[Link] Step 3
Recheck the battery fluid temperature
1. Check the battery fluid temperature on the analyzer screen,
and compare it with the value recorded last time.
[ANL] I/O TEMP/VOLT 3/5
TSLLT

Judgment
Result Procedure
It did not decrease for 5 ℃ or more Perform troubleshooting for F5-3 and F5-4 errors
It decreased for 5 ℃ or more Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-313

1.4.98 FF-1 1
Failure mode: Display power supply circuit overcurrent

CAUTION
• FF-1 error during occurrence cannot be checked on the display; therefore, follow the troubleshoot-
ing when the error is not displayed to conduct inspection and repair.

Probable cause
▪ Connector connection defect
▪ Display defect
▪ Harness defect
▪ Main controller defect

Related part

CN103-14 (16, D7V) CN70-5

Main controller Display

CN103-3 (14, DGND) CN70-4

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
Visually inspect there are no problems inside the CN103
and CN70 connectors, and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
turn the key switch ON, and check the screen display.

Judgment
Result Procedure
Displayed and no FF-1 error Connector connection defect
Not displayed Go to Step 2

[Link] Step 2
1. Follow troubleshooting when the error is not displayed to
conduct inspection and repair.
Troubleshooting when no error is displayed:
[Control type] Power supply related [Phenomenon gener-
ated in machine] Display is not displayed (the truck moves)
1-314 1 ELECTRICAL TROUBLESHOOTING

1.4.99 FF-2
Failure mode: Steering sensor power supply circuit overcurrent

Probable cause
▪ Connector connection defect
▪ Steering sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN103-13 (311, SSTR+) CN19-1

Main controller Steering

sensor
CN103-6 (51, LS-) CN19-2

[Link] Step 1
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN19 connector, and on the wire
caulking
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
turn the key switch ON, and check the screen display.

Judgment
Result Procedure
FF-2 error Go to Step 2
No FF-2 error Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-315

[Link] Step 2
1
Inspect the steering sensor power
1. Turn the key switch OFF, and disconnect the battery plug.
2. After disconnecting the CN19 connector, connect the bat-
tery plug, and turn the key switch ON.
3. Measure the voltage between CN19-1 and CN19-2 of the
CN19 connectors on the harness side.
4. Inspect the steering sensor power.
Notes:
CN19
1 2
Disconnect the battery plug, and visually inspect there are
3 4 5 6 no problems inside the CN19 connector, and on the wire
caulking
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN19-1 (311) to CN19-2 (51) Approx. 15 V

Judgment
Result Procedure
NG Go to Step 3
OK Steering sensor defect

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN19 and CN103 connectors.
3. Inspect conduction and short circuit of the harness.
Notes:
CN103 Disconnect the battery plug, disconnect the CN19 and CN103
connectors, and conduct after visually inspecting there are no
CN19
1 2 3 4 5 6 problems inside the connector, and on the wire caulking.
7 8 9 10 11 12 13 14 15 16
1 2 (Refer to "BEFORE TROUBLESHOOTING").
3 4 5 6
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 Inspected place Standard
CN103-13 (311) to CN19-1 (311) Conduction
CN103-6 (51) to CN19-2 (51) Conduction
CN19-1 (311) to CN19-2 (51) No conduction

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-316 1 ELECTRICAL TROUBLESHOOTING

1.4.100 32-1
Failure mode: Drive motor driver :controller ID abnormality

CAUTION
• When a driver as using a pump motor driver is installed as derive motor driver on the vehicle, the
32-1 error always occurs. But it is not abnormality.
• If AD-5, AD-6 occurs, perform troubleshooting for that first.

Probable cause
▪ Connector contact defect
▪ Drive motor driver failure

Related part

CN110-6
NC
Drive motor CN110-7
driver NC
CN110-23
NC

CN111-6 (152, SETP1)

Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN110, CN111 connector, check
the inside of connector and the caulked portion of wire
whether it has defect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN110, CN111 connector, connect the battery
plug.
4. Turn on the key switch to see if an error occurs.

Judgment
Result Procedure
32-1error occurs. Drive motor driver failure
32-1error does not occur. Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-317

1.4.101 32-3 1
Failure mode: Pump motor driver (RH) : controller ID abnormality

CAUTION
• When a new motor driver or a driver as using drive motor driver is installed as pump motor driver on
the vehicle, the 32-3 error always occurs. But it is not abnormality.
• If AD-1 or AD-2 occurs, perform troubleshooting for that first.

Probable cause
▪ Connector contact defect
▪ Pump motor driver failure

Related part

CN110-6
NC
Drive motor CN110-7
driver NC
CN110-23
NC

CN111-6 (152, SETP1)

Pump motor CN111-7

driver NC
CN111-23 (152, SETP-)

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN110, CN111 connector, check
the inside of connector and the caulked portion of wire
whether it has defect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN110, CN111 connector, connect the battery
plug.
4. Turn on the key switch to see if an error occurs.

Judgment
Result Procedure
32-3error occurs. Pump motor driver failure
32-3error does not occur. Connector contact defect
1-318 1 ELECTRICAL TROUBLESHOOTING

1.4.102 33-1
Failure mode: Main controller to Drive motor driver : communication abnormality

CAUTION
• If AD-1 or AD-2 occurs, perform troubleshooting for AD-1 or AD-2 first.

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Drive motor driver defect
▪ Main controller defect

Related part

CN103-4 (42, KYSAT) CN110-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN110-17 (145, CAN1H) Drive motor
CN110-16 (146, CAN1L) driver
CN103-12 (146, CAN1L)

Main
controller
CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN103, CN104 and CN110 con-
nector, check the inside of connector and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN103, CN104 and CN110 connector, connect
the battery plug.
4. Turn on the key switch to see if an error occurs.
Especially if the drive motor driver has just been replaced,
check if the connector is connected correctly.

Judgment
Result Procedure
33-1error occurs. Go to Step 2
33-1error does not occur. Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-319

[Link] Step 2
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN103, CN104 and CN110 connectors.
3. Inspect for continuity of the harness.
Notes:
CN103 Perform this check with the battery plug and the CN103,
CN104, CN110 connectors disconnected, and visually
1 2 3 4 5 6
CN110 check inside the connector and the caulked portion of its
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 wire for defects.
17 18 19 20 21 22 23 24 25 26 27 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
(Refer to "BEFORE TROUBLESHOOTING")
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN103-4(42) - CN110-8(42) Continuity
CN103-11(145) - CN110-17(145) Continuity
CN103-12(146) - CN110-16(146) Continuity
CN110-8(42) - CN110-17(145) No continuity
CN110-8(42) - CN110-16(146) No continuity
CN110-17(145) - CN110-16(146) No continuity
CN103-4(42) - CN103-5(N2) No continuity
CN103-11(145) - CN103-5(N2) No continuity
CN103-12(146) - CN103-5(N2) No continuity

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Motor driver inspection
1. Replace the drive motor driver with the pump motor driver.
2. Connect the battery plug and turn on the key switch to con-
firm the error occurs.
(Ignore the error codes 32-1 and 32-3.)

Judgment
Result Procedure
Drive motor driver defect
33-3error occurs. The motor driver that is drive motor driver before replace-
ment
33-1error occurs. Main controller defect
1-320 1 ELECTRICAL TROUBLESHOOTING

1.4.103 33-3
Failure mode: Main controller to Pump motor driver : communication abnormality

CAUTION
• If AD-5 or AD-6 occurs, perform troubleshooting for AD-5 or AD-6 first.

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Pump motor driver failure
▪ Main controller defect

Related part

CN103-4 (42, KYSAT) CN111-8 (42, KYSAT)

CN103-11 (145, CAN1H) CN111-17 (145, CAN1H)
Pump motor driver
CN103-12 (146, CAN1L) CN111-16 (146, CAN1L)

Main controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN103, CN104, CN111 connector,
whether it has defect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN103, CN104, CN111 connector, connect the
battery plug.
4. Turn on the key switch to see if an error occurs.
Especially if the pump motor driver has just been replaced,
check if the connector is connected correctly.

Judgment
Result Procedure
33-3error occurs. Go to Step 2
33-3error does not occur. Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-321

[Link] Step 2
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN103, CN104 and CN111 connectors
3. Inspect for continuity of the harness.
Notes:
CN103 Perform this check with the battery plug and the CN103,
CN111 CN104, CN111 connectors disconnected, and visually
1 2 3 4 5 6 check inside the connector and the caulked portion of its
1 2 3 4 5 6 7 8
7 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 wire for defects.
16 17 18 19 20 21 22 23
17 18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING")
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN103-4(42) - CN111-8(42) Continuity
CN103-11(145) - CN111-17(145) Continuity
CN103-12(146) - CN111-16(146) Continuity
CN111-8(42) - CN111-17(145) No continuity
CN111-8(42) - CN111-16(146) No continuity
CN111-17(145) - CN111-16(146) No continuity
CN103-4(42) - CN103-5(N2) No continuity
CN103-11(145) - CN103-5(N2) No continuity
CN103-12(146) - CN103-5(N2) No continuity

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Motor driver inspection
1. Replace the drive motor driver with the pump motor driver.
2. Connect the battery plug and turn on the key switch to con-
firm the error occurs.
(Ignore the error codes 32-1 and 32-3.)

Judgment
Result Procedure
Pump motor driver failure
33-1error occurs. The motor driver that is pump motor driver before replace-
ment is defect.
33-3error occurs. Main controller defect
1-322 1 ELECTRICAL TROUBLESHOOTING

1.4.104 52-1
Failure mode: Yaw rate sensor open abnormality

Probable cause
▪ Connector contact defect
▪ Yaw rate sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN104-13 (321, SYR+) CN79-1

CN103-27 (322, SYR) CN79-3 Yaw rate

Main controller sensor

CN104-11 (323, SYR-) CN79-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN79 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
52-1 error Go to Step 2
No 52-1 error Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-323

[Link] Step 2
1
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector, and short between CN79-1
to CN79-3 on the main harness side with SST2
(09232-13130-71).
3. Connect the battery plug, and turn the key switch ON to
CN79 check for errors.
1 2
3

Judgment
Result Procedure
No 52-2 error Go to Step 3
52-2 error Yaw rate sensor defect

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN103 connector, CN104 connector, and
SST.

CN103
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6
Disconnect the battery plug, the CN103 connector, the
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27
CN104 connector, and SST, and conduct after visually in-
28 29 30 31 32 33 34 35 specting there are no problems inside the connector, and
CN79
on the wire caulking.
CN104 1 2 (Refer to "BEFORE TROUBLESHOOTING").
3

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 Inspected place Standard

18 19 20 21 22 23 24 25
26 27 28 29 30 31
CN104-13 (321) to CN79-1⁽¹⁾ Conduction
CN103-27 (322) to CN79-3⁽¹⁾ Conduction
CN79-3 (322) to CN79-2 (323) No conduction
CN79-1 (321) to CN79-2 (323) No conduction
⁽¹⁾: Connect between CN79-1 and CN79-3 with SST2
(09232-13130-71), and conduction can be checked between
CN104-13 and CN103-27.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-324 1 ELECTRICAL TROUBLESHOOTING

1.4.105 52-2
Failure mode: Yaw rate sensor short abnormality

Probable cause
▪ Connector contact defect
▪ Yaw rate sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN104-13 (321, SYR+) CN79-1

CN103-27 (322, SYR) CN79-3 Yaw rate

Main controller sensor

CN104-11 (323, SYR-) CN79-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN79 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
52-2 error Go to Step 2
No 52-2 error Connector contact defect

[Link] Step 2
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector.
3. Connect the battery plug, and turn the key switch ON to
check for errors.

Judgment
Result Procedure
No 52-1 error Go to Step 3
52-1 error Yaw rate sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-325

[Link] Step 3
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79, CN103, and CN104 connectors.
3. Inspect conduction of the harness.
Notes:
Disconnect the battery plug, disconnect the CN79, CN103
CN104 and CN104 connectors, and conduct after visually inspect-
ing there are no problems inside the connector, and on the
CN79
1 2 3 4 5 6 7 wire caulking.
8 9 10 11 12 13 14 15 16 17
1 2 (Refer to "BEFORE TROUBLESHOOTING").
18 19 20 21 22 23 24 25 3
26 27 28 29 30 31
Inspected place Standard
CN104-11 (323) to CN79-2⁽¹⁾ Conduction
CN79-3 (322) to CN79-1 (321) No conduction
⁽¹⁾: Connect between CN79-3 and CN79-2 with SST2
(09232-13130-71), and conduction can be checked between
CN103-27 and CN104-11.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-326 1 ELECTRICAL TROUBLESHOOTING

1.4.106 52-3
Failure mode: Yaw rate sensor neutral voltage abnormality

Probable cause
▪ Connector contact defect
▪ Yaw rate sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN104-13 (321, SYR+) CN79-1

CN103-27 (322, SYR) CN79-3 Yaw rate

Main controller sensor

CN104-11 (323, SYR-) CN79-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN79 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
52-3 error Go to Step 2
No 52-3 error Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-327

[Link] Step 2
1
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79 connector.
3. Connect the battery plug, and turn the key switch ON to
check for errors.

Judgment
Result Procedure
No 52-1 error Go to Step 3
52-1 error Yaw rate sensor defect

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN79, CN103, and CN104 connectors.
3. Inspect conduction of the harness.
Notes:
Disconnect the battery plug, disconnect the CN79, CN103
CN104 and CN104 connectors, and conduct after visually inspect-
ing there are no problems inside the connector, and on the
CN79
1 2 3 4 5 6 7 wire caulking.
8 9 10 11 12 13 14 15 16 17
1 2 (Refer to "BEFORE TROUBLESHOOTING").
18 19 20 21 22 23 24 25 3
26 27 28 29 30 31
Inspected place Standard
CN104-11 (323) to CN79-2⁽¹⁾ Conduction
CN79-3 (322) to CN79-1 (321) No conduction
CN79-3 (322) to CN79-2 (323) No conduction
⁽¹⁾: Connect between CN79-3 and CN79-2 on the harness side
with SST2 (09232-13130-71), and conduction can be checked
between CN103-27 and CN104-11.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-328 1 ELECTRICAL TROUBLESHOOTING

1.4.107 54-1
Failure mode: Swing solenoid open abnormality

CAUTION
• When 54-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 54-3.
• When one of CB-1, CB-3, CB-5, A8-2 (48V truck), and A9-2 (80V truck) is displayed simultaneously,
give a higher priority to troubleshooting of CB-1, CB-3, CB-5, or A8-2 (48V truck) or A9-2 (80V truck).

Probable cause
▪ Connector connection defect
▪ Swing solenoid defect
▪ Harness defect
▪ Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-329

Related part
1
48V
MB F6
P2 P3 CN104-2 (44, VBMB)

CN140-2 CN140-1

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

80V
MB F7
P2 P3 CN104-2 (19, VBMB)
CN136-6

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN95, and make
sure no abnormalities in the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting the connector, connect the battery plug,
turn the key switch ON, set SWING SOL ON with “ACTIVE
TEST”, and check for errors.
[ANL] ACTIVE TEST 1/3
SWING SOL

Judgment
Result Action
54-1 error Go to Step 2
No 54-1 error Connector connection defect
1-330 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the swing solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN95 connector.
3. Measure resistance of the swing solenoid.
Inspected place Standard
CN95-1 to CN95-2 Approx. 5.5 Ω
CN95

2 1

Judgment
Result Action
NG Swing solenoid defect
OK Go to Step 3

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN95 and CN103 connectors.
3. Inspect conduction and short circuit of the harness.
Notes:
CN103 Disconnect the CN95 and CN103 connectors, and conduct
after visually inspecting there are no problems inside the
1 2 3 4 5 6
CN95 connector, and on the wire caulking.
7 8 9 10 11 12 13 14 15 16 (Refer to "BEFORE TROUBLESHOOTING").
17 18 19 20 21 22 23 24 25 26 27 2 1
28 29 30 31 32 33 34 35 Inspected place Standard
CN103-1 to CN95-1 Conduction
CN103-2 to CN95-2 Conduction
CN103-1 to CN103-5 No conduction
CN103-2 to CN103-5 No conduction

Judgment
Result Action
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-331

1.4.108 54-2 1
Failure mode: Swing solenoid short abnormality

CAUTION
• When 54-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 54-3.

Probable cause
▪ Connector connection defect
▪ Swing solenoid defect
▪ Harness defect
▪ Main controller defect

Related part
48V
MB F6
P2 P3 CN104-2 (44, VBMB)

CN140-2 CN140-1

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

80V
MB F7
P2 P3 CN104-2 (19, VBMB)
CN136-6

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
1-332 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN95, and make
sure no abnormalities inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting the connector, connect the battery plug,
turn the key switch ON, set SWING SOL ON with “ACTIVE
TEST”, and check for errors.
[ANL] ACTIVE TEST 1/3
SWING SOL

Judgment
Result Action
54-2 error Go to Step 2
No 54-2 error Connector connection defect

[Link] Step 2
Inspect the swing solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN95 connector.
3. Measure resistance of the swing solenoid.
Inspected place Standard
CN95-1 to CN95-2 Approx. 5.5 Ω
CN95

2 1

Judgment
Result Action
NG Swing solenoid defect
OK Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-333

[Link] Step 3
1
Inspect harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN95 and CN103 connectors.
3. Inspect conduction and short circuit of the harness.
Notes:
CN103 Disconnect the CN95 and CN103 connectors, and conduct
after visually inspecting there are no problems inside the
1 2 3 4 5 6
CN95 connector, and on the wire caulking.
7 8 9 10 11 12 13 14 15 16 (Refer to "BEFORE TROUBLESHOOTING").
17 18 19 20 21 22 23 24 25 26 27 2 1
28 29 30 31 32 33 34 35 Inspected place Standard
CN95-1 to CN95-2 No conduction
CN103-2 to P2 No conduction
CN103-2 to P3 No conduction

Judgment
Result Action
NG Harness defect
OK Main controller defect
1-334 1 ELECTRICAL TROUBLESHOOTING

1.4.109 54-3
Failure mode: Swing solenoid drive circuit abnormality

Probable cause
▪ Swing solenoid defect
▪ Harness defect
▪ Main controller defect

Related part
48V
MB F6
P2 P3 CN104-2 (44, VBMB)

CN140-2 CN140-1

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

80V
MB F7
P2 P3 CN104-2 (19, VBMB)
CN136-6

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2
1 ELECTRICAL TROUBLESHOOTING 1-335

[Link] Step 1
1
Inspect the swing solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN95.
3. Measure resistance of the swing solenoid.
Inspected place Standard
CN95-1 to CN95-2 Approx. 5.5 Ω
CN95

2 1

Judgment
Result Action
Go to Step 2
NG
Swing solenoid defect
OK Go to Step 2

[Link] Step 2
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN95 and CN103.
3. Inspect conduction and short circuit of the harness.
Notes:
CN103 Disconnect the battery plug, and visually inspect there are
no problems inside the CN95 and CN103 connectors, and
1 2 3 4 5 6
CN95 on the wire caulking
7 8 9 10 11 12 13 14 15 16 (Refer to "BEFORE TROUBLESHOOTING").
17 18 19 20 21 22 23 24 25 26 27 2 1
28 29 30 31 32 33 34 35 Inspected place Standard
CN95-1 to CN95-2 No conduction
CN103-2 to P2 No conduction
CN103-2 to P3 No conduction

Judgment
Result Action
Go to Step 2
NG
Main controller defect
OK Main controller defect
1-336 1 ELECTRICAL TROUBLESHOOTING

1.4.110 54-4
Failure mode: Swing solenoid open/short abnormality

CAUTION
• When 54-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 54-3.
• When one of A8-2 (48V truck) and A9-2 (80V truck) is displayed simultaneously, give a higher priority
to troubleshooting of A8-2 (48V truck) and A9-2 (80V truck).

Probable cause
▪ Connector connection defect
▪ F6 (48V truck)/F7 (80V truck) Fuse installation defect
▪ F6 (48V truck)/F7 (80V truck) Fuse defect
▪ F6 (48V truck)/F7 (80V truck) Fuse box defect
▪ Swing solenoid defect
▪ Harness defect
▪ Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-337

Related part
1
48V
MB F6
P2 P3 CN104-2 (44, VBMB)

CN140-2 CN140-1

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

80V
MB F7
P2 P3 CN104-2 (19, VBMB)
CN136-6

CN95-1 (B) CN103-1 (327, SLSW+)

Swing
N1 solenoid
CN95-2 (E) CN103-2 (328, SLSW-) Main
controller

CN103-5 (N2, N2)

CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN95 connector, and on the wire
caulking
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
turn the key switch ON, and check for errors.

Judgment
Result Action
54-4 error Go to Step 2
No 54-4 error Connector connection defect
1-338 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
F6 (48V truck)/F7 (80V truck) Fuse installation state defect
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect there are no problems with fuse installation.
3. After connecting the fuse, connect the battery plug, turn the
key switch ON, and check for errors.

Judgment
Result Action
No 64-4 error F6 (48V truck)/F7 (80V truck) Fuse installation defect
64-4 error Go to Step 3

[Link] Step 3
F6 (48V truck)/F7 (80V truck) Fuse single unit inspection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Remove the F6 (48V truck)/F7 (80V truck) fuse, and meas-
ure the resistance at both ends of the fuse.

Judgment
Result Action
F6 (48V truck)/F7 (80V truck) Fuse defect
∞Ω
After replacing the fuse, go Go to Step 5
0Ω Go to Step 4

[Link] Step 4
Inspect F6 (48V truck)/F7 (80V truck) fuse box
1. Turn the key switch OFF, and disconnect the battery plug.
2. Install the F6(48V truck)/F7 (80V truck) fuse, and discon-
nect the connector of the fuse box.
3. Measure the resistance at both ends of the fuse box.

Judgment
Result Action
∞Ω F6 (48V truck)/F7 (80V truck) Fuse box defect
0Ω Go to Step 5
1 ELECTRICAL TROUBLESHOOTING 1-339

[Link] Step 5
1
Single unit inspection on the swing solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN95, and measure the swing solenoid resist-
ance.
3. Measure the resistance of the swing solenoid.
Notes:
Disconnect the battery plug, and visually inspect there are
no problems inside the CN95 connector, and on the wire
CN95
caulking
1
(Refer to "BEFORE TROUBLESHOOTING").
2

Inspected place Standard

CN95-1 to CN95-2 Approx. 5.5 Ω

Judgment
Result Action
Swing solenoid defect
NG When the fuse is replaced in the previous step, conduct Step
6.
OK Go to Step 6

[Link] Step 6
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN103, CN104, and CN95 connectors.
3. Inspect conduction and short circuit of the harness.
Notes:
CN103 Disconnect the battery plug, disconnect the CN103, CN104,
and CN95 connectors, and conduct after visually inspect-
1 2 3 4 5 6
CN95 ing inside the connector, and on the wire caulking for er-
7 8 9 10 11 12 13 14 15 16 rors.
2 1
17 18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 35

Inspected place Standard

CN103-1 to CN95-1 Conduction⁽¹⁾
CN103-2 to CN95-2 Conduction⁽¹⁾
CN95-1 to CN95-2 No conduction⁽¹⁾
CN103-1 to CN103-5 No conduction
CN103-2 to CN103-5 No conduction
⁽¹⁾: When it is judged there are no solenoid defects in the previ-
ous step, connect CN95, and if the resistance value between
CN103-1 and CN103-2 is approx. 5.5 Ω, it is regarded as OK.

Judgment
Result Action
NG Go to Step 6
OK Go to Step 7
1-340 1 ELECTRICAL TROUBLESHOOTING

1.4.111 61-1
Failure mode: Load sensor open abnormality

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Load sensor defect
▪ Main controller defect

Related part

CN104-12 (58, SPLF+) CN91-1

Main controller CN103-29 (59, SPLF) CN91-2 Load sensor

CN101-32 (51, POT-) CN91-3

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN91 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
61-1 error Go to Step 2
No 61-1 error Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-341

[Link] Step 2
1
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91 connector, and short between CN91-1
and CN91-2 on the main harness side with SST
(09230-13700-71).
CN91 3. Connect the battery plug, and turn the key switch ON to
check for errors.
1

Judgment
Result Procedure
61-2 error Load sensor defect
No 61-2 error Go to Step 3

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91, CN101, CN103, and CN104 connect-
ors, and SST.

CN101 CN103
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6
Disconnect the battery plug, the CN91, CN101, CN103, and
8 9 10 11 12 13 14 15 16 17 7 8 9 10 11 12 13 14 15 16
18 19 20 21 22 23 24 25 26 27 17 18 19 20 21 22 23 24 25 26 27
CN104 connectors, and SST, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting there are no problems inside the connector, and
on the wire caulking.
CN104 CN91 (Refer to "BEFORE TROUBLESHOOTING").

1
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 2
CN104-12 (58) to CN91-1 (58) Conduction
18 19 20 21 22 23 24 25
26 27 28 29 30 31 3
CN103-29 (59) to CN91-2 (59) Conduction
CN101-32 (51) to CN91-3 (51) Conduction
CN91-1 (58) to CN91-2 (59) No conduction
CN91-1 (58) to CN91-3 (51) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-342 1 ELECTRICAL TROUBLESHOOTING

1.4.112 61-2
Failure mode: Load sensor short abnormality

Probable cause
▪ Connector connection failure
▪ Load sensor failure
▪ Harness failure
▪ Main controller failure

Related part

CN104-12 (58, SPLF+) CN91-1

Main controller CN103-29 (59, SPLF) CN91-2 Load sensor

CN101-32 (51, POT-) CN91-3

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN91 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
61-2 error Go to Step 2
No 61-2 error Connector connection defect

[Link] Step 2
Inspect the load sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91 connector.
3. Connect the battery plug, and turn the key switch ON.
4. Check for errors.

Judgment
Result Procedure
61-1 error Load sensor defect
No 61-1 error Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-343

[Link] Step 3
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN91, CN101, CN103, and CN104 connect-
ors.
3. Inspect conduction of the harness.
Notes:
CN101 CN91
Disconnect the battery plug, the CN91, CN101, CN103, and
CN104 connectors, and conduct after visually inspecting
1 2 3 4 5 6 7 1 there are no problems inside the connector, and on the
8 9 10 11 12 13 14 15 16 17
2
wire caulking.
18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 3

Inspected place Standard

CN91-1 (58) to CN91-2 (59) No conduction
CN101-32 (51) to CN91-3 (51) Conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-344 1 ELECTRICAL TROUBLESHOOTING

1.4.113 62-1
Failure mode: Tilt angle sensor open abnormality

Probable cause
▪ Connector contact defect
▪ Tilt angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN101-20 (57, VRTA+) CN86-1

Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor

CN101-32 (51, POT-) CN86-3

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN86 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING.").
3. Connect the CN86 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
62-1 error Go to Step 2
No 62-1 error Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-345

[Link] Step 2
1
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN86 connector, and short between CN86-1
and CN86-2 on the main harness side with SST2
(09232-13130-71).
3. Connect the battery plug, and turn the key switch ON to
CN86 check for errors.
1 2 3

Judgment
Result Procedure
No 62-2 error Go to Step 3
62-2 error Tilt angle sensor defect

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101 connector, CN103 connector, and
SST.

CN101
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, the CN101 connector, the
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN103 connector, and SST, and conduct after visually in-
28 29 30 31 32 33 34
CN86 specting there are no problems inside the connector, and
on the wire caulking.
1 2 3
CN103 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 CN101-20 (57) to CN86-1 (57)⁽¹⁾ Conduction

17 18 19 20 21 22 23 24 25 26 27
CN103-17 (56) to CN86-2 (56)⁽¹⁾ Conduction
28 29 30 31 32 33 34 35
CN86-3 (51) to CN86-2 (56) No conduction
CN86-3 (51) to CN86-1 (57) No conduction
⁽¹⁾: Connect between CN86-1 and CN86-2 with SST2
(09232-13130-71), and conduction can be checked between
CN101-20 and CN103-17.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-346 1 ELECTRICAL TROUBLESHOOTING

1.4.114 62-2
Failure mode: Tilt angle sensor short abnormality

Probable cause
▪ Connector contact defect
▪ Tilt angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN101-20 (57, VRTA+) CN86-1

Main controller CN103-17 (56, VRTA) CN86-2 Tilt angle

sensor

CN101-32 (51, POT-) CN86-3

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN86 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN86 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
62-2 error Go to Step 2
No 62-2 error Connector contact defect

[Link] Step 2
Inspect the sensor
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN86 connector.
3. Connect the battery plug, and turn the key switch ON to
check for errors.

Judgment
Result Procedure
No 62-1 error Go to Step 3
62-1 error Tilt angle sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-347

[Link] Step 3
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN86 and CN101 connectors.
CN101 3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 Disconnect the battery plug, disconnect the CN86 and

18 19 20 21 22 23 24 25 26 27 CN101 connectors, and conduct after visually inspecting
28 29 30 31 32 33 34 there are no problems inside the connector, and on the
CN86
wire caulking.
CN103 1 2 3 (Refer to "BEFORE TROUBLESHOOTING").

1 2 3 4 5 6 Inspected place Standard

7 8 9 10 11 12 13 14 15 16 CN101-32 (51) to CN86-3 (51)⁽¹⁾ Conduction
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 CN86-2 (56) to CN86-1 (57) No conduction
⁽¹⁾: Connect between CN86-2 and CN86-3 with SST2
(09232-13130-71), and conduction can be checked between
CN103-17 and CN101-32.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-348 1 ELECTRICAL TROUBLESHOOTING

1.4.115 63-1
Failure mode: Tilt switch forward/backward tilt simultaneous short circuit abnormality

Probable cause
▪ Tilt lever switch installation defect
▪ Tilt lever switch defect
▪ Harness defect

Related part

Tilt lever switch

CN102-23 (61, SWTF) CN89-1

CN102-22 (62, SWTR) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN89 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN89 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
No A6-3 error Go to Step 2
A6-3 error To A6-3 troubleshooting

[Link] Step 2
Inspect the switch
1. Operate the tilt lever forward and backward to check for er-
rors on 63-1.

Judgment
Result Procedure
In the past, the forward and backward tilt switches were ON
No 63-1 error simultaneously (Installation adjustment inspection of each
switch)
63-1 error Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-349

[Link] Step 3
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN89 and CN102 connectors, and inspect
conduction of the main harness side.
3. Inspect conduction and short circuit of the harness.
Notes:
Disconnect the battery plug, disconnect the CN89 and
CN89 CN102 connectors, and conduct after visually inspecting
there are no problems inside the connector, and on the
1 2 wire caulking.
3 4 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN89-1 (61) to CN89-3 (62) No conduction

Judgment
Result Procedure
Tilt lever switch installation defect
OK
Tilt lever switch defect
NG Harness defect
1-350 1 ELECTRICAL TROUBLESHOOTING

1.4.116 63-2
Failure mode: Tilt switch forward tilt continuous short circuit abnormality

Probable cause
▪ Tilt lever switch installation defect
▪ Tilt lever switch defect

Related part

Tilt lever switch

CN102-23 (61, SWTF) CN89-1

CN102-22 (62, SWTR) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN89 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN89 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
No A6-3 error Go to Step 2
A6-3 error To A6-3 troubleshooting

[Link] Step 2
Inspect the switch
1. After operating the tilt lever between neutral ⇔ forward re-
peatedly, check the switch condition when it is returned to
neutral.
[ANL] I/O [Link] 6/8
SWTF

Judgment
Result Procedure
No matter how many times it is repeated, it Detect by continuing the tilt forwarding for two minutes. Use
shows “0” it as is.
When repeated for several times, it some- Tilt lever switch installation defect
times shows “1” Tilt lever switch defect
1 ELECTRICAL TROUBLESHOOTING 1-351

1.4.117 63-3 1
Failure mode: Continuous tilt switch backward tilting Short abnormality

Probable cause
▪ Tilt lever switch installation defect
▪ Tilt lever switch defect

Related part

Tilt lever switch

CN102-23 (61, SWTF) CN89-1

CN102-22 (62, SWTR) CN89-3
Main
controller CN102-26 (51, POT-) CN89-4
CN89-2

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN89 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN89 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
No A6-3 error Go to Step 2
A6-3 error To A6-3 troubleshooting

[Link] Step 2
Inspect the switch
1. After operating the tilt lever between neutral ⇔ backward
tilting repeatedly, check the switch condition when it is re-
turned to neutral.
[ANL] I/O [Link] 6/8
SWTR

Judgment
Result Procedure
No matter how many times it is repeated, it Detect by continuing the tilt backward for two minutes. Use it
shows “0” as is.
When repeated for several times, it some- Tilt lever switch installation defect
times shows “1” Tilt lever switch defect
1-352 1 ELECTRICAL TROUBLESHOOTING

1.4.118 64-1
Failure mode: Lift lock solenoid open abnormality

CAUTION
• When 64-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 64-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Lift lock solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-2 (3) CN102-16 (4, SLLL-) controller
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN88 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
64-4 error Perform troubleshooting for 64-4
No 64-4 error Go to Step 2

[Link] Step 2
1. Turn the output of lift solenoid ON forcibly with “ACTIVE
TEST”, and check for errors.
1 ELECTRICAL TROUBLESHOOTING 1-353

[ANL] ACTIVE TEST 1/3

LIFT LWR SOL: OFF → ON
1

Judgment
Result Procedure
No 64-1 error Connector connection defect
64-1 error Go to Step 3

[Link] Step 3
Single unit inspect the lift solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the lift lock solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-2 to CN88-6 Approx. 10 Ω

Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to Step 4
1-354 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the harness
1. Disconnect the CN101, CN102, CN103, CN104, and CN88
connectors.

CN101 CN102
2. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, CN104, and CN88 connectors, and conduct after
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 visually inspecting inside the connector, and on the wire
caulking for errors.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 CN101-1 (3) to CN88-2 (3) Conduction⁽¹⁾
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
CN102-16 (4) to CN88-6 Conduction⁽¹⁾
28 29 30 31 32 33 34 35
CN101-1 (3) to CN103-5 (N2) No conduction
CN102-16 (4) to CN103-5 (N2) No conduction
⁽¹⁾: When CN88 is connected, and the resistance value
between CN101-1(3) and CN102-16 (4) is approx. 10 Ω, it is re-
garded as OK.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-355

1.4.119 64-2 1
Failure mode: Lift lock solenoid short abnormality

CAUTION
• When 64-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 64-3.

Probable cause
▪ Connector connection defect
▪ Lift lock solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-2 (3) CN102-16 (4, SLLL-) controller
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for abnormalities.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN88 connector, and connect the battery plug.
4. Turn the key switch ON, and check for errors.

Judgment
Result Procedure
64-4 error Perform troubleshooting for 64-4.
No 64-4 error Go to Step 2
1-356 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Turn the output of lift solenoid ON forcibly with “ACTIVE
TEST”, and check for errors.
[ANL] ACTIVE TEST 1/3
LIFT LWR SOL: OFF → ON

Judgment
Result Procedure
64-2 error Go to Step 3
No 64-2 error Connector connection defect

[Link] Step 3
Single unit inspect the lift solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the lift lock solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-2 (3) to CN88-6 (4) Approx. 10 Ω

Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to Step 4
1 ELECTRICAL TROUBLESHOOTING 1-357

[Link] Step 4
1
Inspect the harness
1. Disconnect the CN101, CN102, and CN88 connectors.
2. Inspect conduction and short circuit of the harness.
Notes:
CN102 Disconnect the battery plug, disconnect the CN101, CN102,
CN88
and CN88 connectors, and conduct after visually inspect-
1 2 3 4 5 6 7 ing inside the connector, and on the wire caulking for er-
8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 rors.
20 21 22 23 24 25 26 27
5 6 7 8 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 35

Inspected place Standard

CN88-2 (3) to CN88-6 (4) No conduction
CN102-16 (4) to P2 No conduction
CN102-16 (4) to P3 No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-358 1 ELECTRICAL TROUBLESHOOTING

1.4.120 64-3
Failure mode: Lift lock solenoid driving circuit abnormality

Probable cause
▪ Lift lock solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-2 (3) CN102-16 (4, SLLL-) controller
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Inspect the lift lock solenoid
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. Turn the key switch OFF, and disconnect the battery plug.
3. Disconnect CN88.
4. Measure the resistance of the lift lock solenoid.
Inspected place Standard
CN88 CN88-2 (3) to CN88-6 (4) Approx. 10 Ω

4 3 2 1

8 7 6 5
1 ELECTRICAL TROUBLESHOOTING 1-359

Judgment
1
Result Procedure
Lift lock solenoid defect
NG
To Step 2
OK To Step 2

[Link] Step 2
Inspect the harness
1. Disconnect the CN101, CN102, and CN88 connectors.
2. Inspect conduction and short circuit of the harness.

CN101
Notes:
Disconnect the battery plug, and visually inspect inside the
1 2 3 4 5 6 7 CN101, CN102 and CN88 connectors, and on the wire
8 9 10 11 12 13 14 15 16 17 caulking for errors.
18 19 20 21 22 23 24 25 26 27 CN88 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34

Inspected place Standard

1 2 3 4
CN102
CN88-2 (3) to CN88-6 (4) No conduction
5 6 7 8
1 2 3 4 5 6 7
CN101-1 (3) to CN102-16 (4) No conduction
8 9 10 11 12 13 14 15 16 17 18 19 CN102-16 (4) to P2 No conduction
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN102-16 (4) to P3 No conduction

Judgment
Result Procedure
Harness defect
NG
Main controller defect
OK Main controller defect
1-360 1 ELECTRICAL TROUBLESHOOTING

1.4.121 64-4
Failure mode: Lift lock solenoid open/short abnormality

CAUTION
• When 64-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 64-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Lift lock solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-2 (3) CN102-16 (4, SLLL-) controller
N1 Lift lock
solenoid CN88-6 (4) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
2. After connecting the connector, connect the battery plug,
turn the key switch ON, and check for errors.

Judgment
Result Procedure
64-4 error Go to Step 2
No 64-4 error Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-361

[Link] Step 2
1
Single unit inspect the lift lock solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the lift lock solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-2 (3) to CN88-6 (4) Approx. 10 Ω

Judgment
Result Procedure
NG Lift lock solenoid defect
OK Go to Step 3

[Link] Step 3
Inspect the harness
1. Disconnect the CN101, CN102, CN103, and CN88 connect-
ors.

CN101 CN102
2. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, and CN88 connectors, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting inside the connector, and on the wire caulking for
errors.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").

1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 Inspected place Standard
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
CN101-1 (3) to CN88-2 (3) Conduction⁽¹⁾
CN102-16 (4) to CN88-6 (4) Conduction⁽¹⁾
CN88-2 (3) to CN88-6 (4) No conduction⁽¹⁾
CN101-1 (3) to CN103-5 (N2) No conduction
CN102-16 (4) to CN103-5 (N2) No conduction
⁽¹⁾: When CN88 is connected, and the resistance value
between CN101-1(3) and CN102-16 (4) is approx. 10 Ω, it is re-
garded as OK.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-362 1 ELECTRICAL TROUBLESHOOTING

1.4.122 65-1
Failure mode: Tilt solenoid open abnormality

CAUTION
• When 65-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 65-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Tilt solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-2 (6, SLTFB+)

Main
CN88-3 (6) CN102-19 (7, SLTFL-) controller
N1 Tilt
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting CN88, connect the battery plug, turn the
key switch ON, and check for errors.

Judgment
Result Procedure
65-4 error Perform troubleshooting for 65-4.
No 65-4 error Go to Step 2

[Link] Step 2
1. Turn the output of tilt solenoid ON forcibly with “ACTIVE
TEST”, and check for errors.
1 ELECTRICAL TROUBLESHOOTING 1-363

[ANL] ACTIVE TEST 1/3

TILT SOL: OFF → ON
1

Judgment
Result Procedure
No 65-1 error Connector connection defect
65-1 error Go to Step 3

[Link] Step 3
Single unit inspect the tilt solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the tilt solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-3 (6) to CN88-7 (7) Approx. 10 Ω

Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to Step 4
1-364 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the harness
1. Disconnect the CN101, CN102, CN103, and CN88 connect-
ors.

CN101 CN102
2. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, and CN88 connectors, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting inside the connector, and on the wire caulking for er-
rors.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").

1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 Inspected place Standard
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
CN101-2 (6) to CN88-3 (6) Conduction⁽¹⁾
CN102-19 (7) to CN88-7 (7) Conduction⁽¹⁾
CN101-2 (6) to CN103-5 (N2) No conduction
CN102-19 (7) to CN103-5 (N2) No conduction
⁽¹⁾: Connect CN88, and it can be checked that the measured
resistance value between CN101-2 and CN102-19 is approx.
10 Ω.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-365

1.4.123 65-2 1
Failure mode: Tilt solenoid short abnormality

CAUTION
• When 65-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 65-3.

Probable cause
▪ Connector connection defect
▪ Tilt solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-2 (6, SLTFB+)

Main
CN88-3 (6) CN102-19 (7, SLTFL-) controller
N1 Tilt
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting CN88, connect the battery plug, turn the
key switch ON, and check for errors.

Judgment
Result Procedure
65-4 error Perform troubleshooting for 65-4.
No 65-4 error Go to Step 2
1-366 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Turn the output of tilt solenoid ON forcibly with “ACTIVE
TEST”, and check for errors.
[ANL] ACTIVE TEST 1/3
TILT SOL: OFF → ON

Judgment
Result Procedure
No 65-2 error Connector connection defect
65-2 error Go to Step 3

[Link] Step 3
Single unit inspect the tilt solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the tilt solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-3 (6) to CN88-7 (7) Approx. 10 Ω

Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to Step 4
1 ELECTRICAL TROUBLESHOOTING 1-367

[Link] Step 4
1
Inspect the harness
1. Disconnect CN102 and CN88.
2. Inspect conduction and short circuit of the harness.
Notes:
CN102 Disconnect the battery plug, disconnect the CN102 and
CN88
CN88 connectors, and conduct after visually inspecting
1 2 3 4 5 6 7 there are no problems inside the connector, and on the
8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 wire caulking.
20 21 22 23 24 25 26 27
5 6 7 8 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 35

Inspected place Standard

CN88-3 (6) to CN88-7 (7) No conduction
CN102-19 (7) to P2 No conduction
CN102-19 (7) to P3 No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-368 1 ELECTRICAL TROUBLESHOOTING

1.4.124 65-3
Failure mode: Tilt solenoid driving circuit abnormality

Probable cause
▪ Tilt solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-2 (6, SLTFB+)

Main
CN88-3 (6) CN102-19 (7, SLTFL-) controller
N1 Tilt
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Inspect the tilt solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the tilt solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-3 (6) to CN88-7 (7) Approx. 10 Ω

Judgment
Result Procedure
Go to Step 2
NG
Tilt solenoid defect
OK Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-369

[Link] Step 2
1
Inspect the harness
1. Disconnect CN101, CN102 and CN88.

CN101
2. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
and CN88 connectors, and conduct after visually inspect-
18 19 20 21 22 23 24 25 26 27 CN88
28 29 30 31 32 33 34 ing there are no problems inside the connector, and on the
wire caulking.
1 2 3 4
CN102 (Refer to "BEFORE TROUBLESHOOTING").
5 6 7 8
Inspected place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN88-3 (6) to CN88-7 (7) No conduction

20 21 22 23 24 25 26 27
CN101-2 (6) to CN102-19 (7) No conduction
28 29 30 31 32 33 34 35
CN102-19 (7) to P2 No conduction
CN102-19 (7) to P3 No conduction

Judgment
Result Procedure
Harness defect
NG
Main controller defect
OK Main controller defect
1-370 1 ELECTRICAL TROUBLESHOOTING

1.4.125 65-4
Failure mode: Tilt solenoid open/short abnormality

CAUTION
• When 65-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for 65-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Tilt solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-2 (6, SLTFB+)

Main
CN88-3 (6) CN102-19 (7, SLTFL-) controller
N1 Tilt
solenoid CN88-7 (7) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. After connecting CN88, connect the battery plug, turn the
key switch ON, and check for errors.

Judgment
Result Procedure
65-4 error Go to Step 2
No 65-4 error Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-371

[Link] Step 2
1
Single unit inspect the tilt solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the tilt solenoid.
Notes:
CN88 Disconnect the battery plug, and visually inspect there are
no problems inside the CN88 connector, and on the wire
4 3 2 1
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Inspected place Standard
CN88-3 (6) to CN88-7 (7) Approx. 10 Ω

Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to Step 3

[Link] Step 3
Inspect the harness
1. Disconnect the CN101, CN102, CN103, and CN88 connect-
ors.

CN101 CN102
2. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, and CN88 connectors, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting inside the connector, and on the wire caulking for
errors.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 CN101-2 (6) to CN88-3 (6) Conduction⁽¹⁾
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
CN102-19 (7) to CN88-7 (7) Conduction⁽¹⁾
28 29 30 31 32 33 34 35
CN88-3 (6) to CN88-7 (7) No conduction⁽¹⁾
CN101-2 (6) to CN103-5 (N2) No conduction
CN102-19 (7) to CN103-5 (N2) No conduction
⁽¹⁾: If no solenoid defect is found in the previous step, connect
CN88, and it can be checked that the measured resistance
value between CN101-2 and CN102-19 is approx. 10 Ω.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-372 1 ELECTRICAL TROUBLESHOOTING

1.4.126 66-1
Failure mode: Tilt matching value out of range abnormality

Probable cause
▪ Main controller defect
▪ Tilt sensor matching defect

Related part

Main controller

[Link] Step 1
1. Conduct a tilt horizontal angle matching and tilt forward tilt
angle matching.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3

[Link] Step 2
Inspect the tilt sensor voltage
1. Check the voltage of the tilt sensor.
[ANL] I/O [Link] 2/8
VRTA
Tilt angle position Voltage
At horizontal condition 0.85 V to 4.51 V

Judgment
Result Procedure
Go to Step 3
Standard value out of the range Tilt sensor assembly defect. After reassembling, perform
matching, and conduct Step 3.
Within in the standard value range Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-373

[Link] Step 3
1
Check error
1. Turn the key switch OFF, and disconnect the battery plug.
2. Reconnect the battery plug after 30 seconds, and turn the
key switch ON.

Judgment
Result Procedure
66-1 error displayed Main controller defect
Tilt sensor matching defect
66-1 error not displayed
Use it as is.
1-374 1 ELECTRICAL TROUBLESHOOTING

1.4.127 67-1
Failure mode: Lifting height switch open / short abnormality

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Lifting height switch defect
▪ Main controller defect

Related part
Related part (1)
CN103-6 (51, LS-)
CN104-22 (90, SH1)
Main
Controller CN103-24 (91, SH2-1) N.C.
CN103-31 (92, SH2-2) N.C.

Related part (2)

CN103-6 (51, LS-) CN92-1
Main CN104-22 (90, SH1) CN92-2 Low lifting
Controller CN103-24 (91, SH2-1) CN92-3 height switch
CN103-31 (92, SH2-2)

Related part (3)

CN103-6 (51, LS-) CN92-1
CN104-22 (90, SH1) CN92-2 Low lifting
CN92-3 height switch
Main
Controler
CN93-1
CN103-24 (91, SH2-1) CN93-2 High lifting
CN103-31 (92, SH2-2) CN93-3 height switch

Related part (4)

CN103-6 (51, LS-) CN92-1
CN104-22 (90, SH1) CN92-2 Low lifting
CN92-3 height switch
Main
Controller
CN103-24 (91, SH2-1)
CN103-31 (92, SH2-2) CN99-5
CN103-13 (311, SSTR+) CN99-4
CN99-3 Ultrasonic sensor
CN99-2
CN99-1
1 ELECTRICAL TROUBLESHOOTING 1-375

[Link] Step 1
1
1. Disconnect the battery negative terminal.
2. After inspecting and correcting disconnection and water
entry of CN103、CN104、CN92 and CN93(CN99), recon-
nect all connectors and the battery negative terminal.
3. Turn the key switch ON and check whether or not there is
an error.
Raise the lift lever from the fully lowered position until an er-
ror is detected.

Judgment
Result Procedure
Error Go to Step 2
No error Connector contact defect

[Link] Step 2
Inspection of lifting height switch input value
ANL.: I/O [Link] 2/8
1. Maintain the error status and check the display.
2. Check the condition of the lifting height switch (I/O monitor:
SH).
SH: 000 (first 3 digit) displayed → Check the mast
height at the time of error detection
SH: Except 000 (first 3 digit) → Go to Step 3

Judgment
Result Procedure
SH: Except 000 (first 3 digit) Go to Step 3
SH: 000 displayed (first 3 digit) Go to Step 5

[Link] Step 3
Inspection for harness continuity and short circuit
ANL.: I/O [Link] 2/8
1. Put the lift in fully lowered state.
2. Turn the ignition key switch OFF and disconnect CN92 and
CN93 (CN99).
3. Turn the key switch ON and check the display.
SH: 000 (first 3 digit) displayed → Lifting height switch
defect
SH: Except 000 (first 3 digit) →Go to Step 4

Judgment
Result Procedure
SH: Except 000 (first 3 digit) Go to Step 4
SH: 000 displayed (first 3 digit) Lifting height switch defect
1-376 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspection for harness continuity and short circuit
1. Put the lift in fully lowered state.

CN103
2. Turn the key switch OFF and disconnect CN103, CN104,
CN92 and CN93 (CN99).
1 2 3 4 5 6
Portion to be inspected Standard
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 CN103-6 - CN104-22 No continuity
28 29 30 31 32 33 34 35
CN103-6 - CN103-24 No continuity
CN104
CN103-6 - CN103-31 No continuity
CN104-22 - CN103-24 No continuity
1 2 3 4 5 6 7 CN103-24 - CN103-31 No continuity
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 CN103-31 - CN104-22 No continuity
26 27 28 29 30 31
CN104-22 - Frame No continuity
CN103-24 - Frame No continuity
CN103-31 - Frame No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect

[Link] Step 5
nspection of mast height
1. Check the mast height at the time of error detection.

Judgment
Result Procedure
Mast height less than 2500mm Go to Step 6
H2500 - H4500 Go to Step 7
Mast height more than 4500mm Go to Step 8

[Link] Step 6
Individual inspection of lifting height switch
1. Maintain the error status
2. Turn the key switch OFF and disconnect CN92(93)
Portion to be inspected (Switch side) Standard
CN92-1 - CN92-2 Continuity
CN92-1 - CN92-3 No continuity
CN92

1 2 3
1 ELECTRICAL TROUBLESHOOTING 1-377

Judgment
1
Result Procedure
OK Go to Step 8
NG Lift height switch defect

[Link] Step 7
Individual inspection of lifting height switch
1. Maintain the error status.
2. Turn the key switch OFF and disconnect CN92, CN93
(CN99).
Portion to be inspected (Switch side) Standard
CN92-1 - CN92-2 No continuity
CN92 CN92-1 - CN92-3 Continuity
1 2 3

Judgment
Result Procedure
OK Go to Step 8
NG Lifting height switch defect

[Link] Step 8
Inspection for harness continuity and short circuit
1. Put the lift in fully lowered state.
2. Turn the key switch OFF and disconnect CN103, CN104,
CN92 and CN93(CN99).
3. Use SST 09236-13900-71 to short circuit the terminals.
CN103 CN104
Portion to be Short circuit ter- Tar-
Standard
1 2 3 4 5 6 1 2 3 4 5 6 7 checked minals get
8 9 10 11 12 13 14 15 16 17
7 8 9 10 11 12 13 14 15 16
CN103-6 - CN104-22 CN92-1 - CN92-2 Continuity -
17 18 19 20 21 22 23 24 25 26 27 18 19 20 21 22 23 24 25
28 29 30 31 32 33 34 35 26 27 28 29 30 31 CN103-6 - CN104-24 CN92-1 - CN92-3 Continuity *1
CN92 CN93 CN103-24 - CN103-31 CN93-2 - CN93-3 Continuity *2
CN103-24 - CN103-31 CN99-2 - CN99-3 Continuity *3
1 2 3 1 2 3
CN92-1 - CN93-1 - Continuity *2
CN99
CN103-6 - CN103-13 CN92-1 - CN99-1 Continuity *3
1 2 3 4 5
CN92-1 - CN99-5 - Continuity *3
CN92-3 - CN99-4 - Continuity *3
*1：except *2,*3
*2：Related part (3)
*3：Related part (4)

Judgment
Result Procedure
OK Go to Step 9
1-378 1 ELECTRICAL TROUBLESHOOTING

Result Procedure
NG Harness defect

[Link] Step 9
Inspection for harness continuity and short circuit
ANL.: I/O [Link] 2/8
1. Put the lift in fully lowered state.
2. Turn the key switch OFF and disconnect CN92 and CN93
(CN99).
3. Use SST 09236-13900-71 to short circuit the terminals.
4. Turn the key switch ON and check the display(I/O monitor
：SH)
CN92 CN93

1 2 3 1 2 3
Standard
Short circuit terminals Target
(first 3 digit)
CN99 CN92-1 - CN93-2 SH：010 *2
1 2 3 4 5 CN92-1 - CN93-3 SH：001 *2
CN92-1 - CN99-2 SH：010 *3
CN92-1 - CN99-3 SH：001 *3
*2：Related part (3)
*3：Related part (4)

Judgment
Result Procedure
OK Lifting height switch defect
NG Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-379

1.4.128 67-5 1
Failure mode: Lift height 800 mm switch short abnormality

CAUTION
• Lift from the lift lowest state to the highest state slowly, and if 67-1 occurs in any lift height, take a
higher priority on troubleshooting of 67-1.

Probable cause
▪ Connector contact defect
▪ Lift height 800 mm switch defect
▪ Harness defect
▪ Main controller defect

Related part

CN90 Lift height

CN103-6 (51, LS-) 4 4 CN92-1 switch

CN104-22 (90, SH1) 3 3 CN92-2

CN103-24 (91, SH2-1) 5 5 CN92-3

Main controller

CN261 CN260
CN103-34 (420, SWH08) 2 2 2 2 2 2
Lift height
800 mm
1 1 1 1 1 switch

[Link] Step 1
Inspect the connector connection
1. Turn the key switch OFF in the lift at the lowest state, and
disconnect the battery plug.
2. Visually inspect inside the connector of CN90, CN260, and
CN261, and on the wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. After disconnecting the CN90, CN260, and CN261 connect-
ors, connect the battery plug, and turn the key switch ON.
4. Lift until both the lift height 800 mm switch lever and the lift
height switch lever are released, and check for errors.
Notes:
Be cautious that the standard of inspection contents differs
depending on the condition of the lift height 800 mm switch
lever and the lift height switch lever.

Judgment
Result Procedure
No 67-5 error Connector contact defect
1-380 1 ELECTRICAL TROUBLESHOOTING

Result Procedure
67-5 error Go to Step 2

[Link] Step 2
Inspect the lift height 800 mm switch
1. Turn the key switch OFF in the lift at the lowest state, and
disconnect the battery plug.
2. After disconnecting the CN260 connector, connect the bat-
tery plug, and turn the key switch ON.
3. Lift until both the lift height 800 mm switch lever and the lift
height switch lever are released, and check for errors.
Notes:
Be cautious that the standard of inspection contents differs
depending on the condition of the lift height 800 mm switch
lever and the lift height switch lever.

Judgment
Result Procedure
No 67-5 error Lift height 800 mm switch defect
67-5 error Go to Step 3

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF in the lift at the lowest state, and
disconnect the battery plug.
2. Disconnect the CN103 and CN260 connectors.
3. Inspect conduction of the harness.
Notes:
CN103 Disconnect the battery plug, disconnect the CN103 and
CN260 connectors, and conduct after visually inspecting
CN260
1 2 3 4 5 6 there are no problems inside the connector, and on the
7 8 9 10 11 12 13 14 15 16 1 2 3 wire caulking for errors.
17 18 19 20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 35

Inspected place Standard

CN103-34 (420) to CN260-2 (420) Conduction⁽¹⁾
CN103-6 (51) to CN260-1 (51) Conduction⁽¹⁾
CN260-1 (51) to CN260-2 (420) No conduction
⁽¹⁾: Connect between CN260-1 and CN260-2 with SST2
(09232-13130-71), and conduction can be checked between
CN103-6 and CN103-34.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-381

1.4.129 71-1 1
Failure mode: Tire angle sensor open abnormality

Probable cause
▪ Connector contact defect
▪ Tire angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN101-23 (316, VRTRA+) CN97-3

CN102-31 (317, VRTRA) CN97-2 Tire angle

Main controller
sensor

CN102-26 (51, POT-) CN97-1

[Link] Step 1
Connector inspection
1. Turn off the key switch and disconnect the battery plug.
2. Visually check inside the connector of CN97, and the
caulked portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
3. Visually check inside the connector of After connecting the
CN97 connector, connect the battery plug and turn key
switch ON to confirm error.

Judgment
Result Procedure
71-1error occurs. Go to Step 2
71-1error does not occur. Connector contact defect
1-382 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Tire angle sensor isnpection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN97 connector, and connect between
CN97-3 and CN97-2 with SST2.
3. Reconnect the battery plug and turn on the key switch, and
check the error code.

CN97

1 2 3

Judgment
Result Procedure
71-1error occurs. Go to Step 3
71-2error occurs. Tire angle sensor defect

[Link] Step 3
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102, and CN97 connector, and
inspect harness with SST disconnected.

CN101
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
the CN101, CN102 and CN97 connectors and with SST dis-
28 29 30 31 32 33 34 CN97 connected visually check inside each connector and the
caulked portion of each wire for defects.
CN102
1 2 3 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-23(316) - CN97-3(316) Continuity

20 21 22 23 24 25 26 27
CN102-31(317) - CN97-2(317) Continuity
28 29 30 31 32 33 34 35
CN97-1(51) - CN97-3(316) No continuity
CN97-1(51) - CN97-2(317) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-383

1.4.130 71-2 1
Failure mode: Tire angle sensor short abnormality

Probable cause
▪ Connector contact defect
▪ Tire angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN101-23 (316, VRTRA+) CN97-3

CN102-31 (317, VRTRA) CN97-2 Tire angle

Main controller
sensor

CN102-26 (51, POT-) CN97-1

[Link] Step 1
Connector inspection
1. Turn off the key switch and disconnect the battery plug.
2. Visually check inside the connector of CN97, and the
caulked portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
3. Visually check inside the connector of After connecting the
CN97 connector, connect the battery plug and turn key
switch ON to confirm error.

Judgment
Result Procedure
71-2error occurs. Go to Step 2
71-2error does not occur. Connector contact defect
1-384 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN97 connectors and
check the harnesses.

CN101
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
the CN101, CN102 and CN97 connectors and visually check
28 29 30 31 32 33 34 CN97 inside each connector and the caulked portion of each wire
for defects.
CN102
1 2 3 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN97-2(317) - CN97-3(316) No continuity

20 21 22 23 24 25 26 27
CN102-26(51) - CN97-1(51) Continuity
28 29 30 31 32 33 34 35
CN101-23(316) - CN102-31(317) No continuity

Judgment
Result Procedure
OK Go to Step 3
NG Harness defect

[Link] Step 3
Tire angle sensor isnpection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN97 connector, then connect the CN101
and CN102 connectors.
3. バReconnect the battery plug and turn on the key switch
ON, and check the error code.

Judgment
Result Procedure
71-2error occurs. Main controller defect
71-1error occurs. Tire angle sensor defect
1 ELECTRICAL TROUBLESHOOTING 1-385

1.4.131 71-3 1
Failure mode: Tire angle sensor anchoring abnormality

Probable cause
▪ Connector contact defect
▪ Tire angle sensor defect
▪ Harness defect
▪ Main controller defect

Related part

CN101-23 (316, VRTRA+) CN97-3

CN102-31 (317, VRTRA) CN97-2 Tire angle

Main controller
sensor

CN102-26 (51, POT-) CN97-1

[Link] Step 1
Connector inspection
1. Turn off the key switch and disconnect the battery plug.
2. Visually check inside the connector of CN97, and the
caulked portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting the CN97 connector, connect the battery
plug and turn on the key switch to confirm error with turning
steering wheel.

Judgment
Result Procedure
71-3error occurs. Go to Step 2
71-3error does not occur. Connector contact defect

[Link] Step 2
Tire angle sensor isnpection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN97 connector, then connect the CN101
and CN102 connectors.
3. バReconnect the battery plug and turn on the key switch
ON, and check the error code.

Judgment
Result Procedure
71-1error occurs. Go to Step 3
71-1error does not occur. Go to Step 4
1-386 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Tire angle sensor isnpection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN97 connector, then connect the CN101
and CN102 connectors. Connect between CN97-3 and CN
97-2 for harness side with SST2 connected.
3. Reconnect the battery plug and turn on the key switch, and
CN97 check the error code.
1 2 3

Judgment
Result Procedure
71-2error occurs. Tire angle sensor defect
71-2error does not occur. Go to Step 4

[Link] Step 4
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN101, CN102 and CN97 connectors and
check the harnesses.

CN101
3. Inspect for continuity and short circuiting of the harness.
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
the CN101, CN102 and CN97 connectors and visually check
28 29 30 31 32 33 34 CN97 inside each connector and the caulked portion of each wire
for defects.
CN102
1 2 3 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-23(316) - CN97-3(316) Continuity

20 21 22 23 24 25 26 27
CN102-31(317) - CN97-2(317) Continuity
28 29 30 31 32 33 34 35
CN102-26(51) - CN97-1(51) Continuity
CN97-1(51) - CN97-3(316) No continuity
CN97-1(51) - CN97-2(317) No continuity
CN97-2(317) - CN97-3(316) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-387

1.4.132 72-1 1
Failure mode: Steering-wheel angle sensor SS1 open abnormality

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Steering angle sensor defect
▪ Main controller defect

Related part

CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Main controller CN104-31 (313, SSTR2) CN19-4 Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN103-6 (51, LS-) CN19-2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN19 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.(Refer to BEFORER
TOUBLESHOOTING)
3. Connect the CN19 connector, connect the battery plug.
4. Turn on the key switch, and check if error occurs with turn-
ing steering wheel.

Judgment
Result Procedure
72-1error occurs. Go to Step 2
72-1error does not occur. Connector contact defect

[Link] Step 2
Sensor inspection
1. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 3
1** (* represents either 0 or 1.) Go to Step 5
1-388 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector and connect CN19-2 to
CN19-3 on the harness side through SST2
(09232-13130-71).
3. Reconnect the battery plug and turn on the key switch.
CN19
4. Check the condition of the sensor with operating steering
1 2
3 4 5 6 [ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 4
1** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 4
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103, CN104 connectors and SST.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN19,
CN103, CN104 connectors disconnected, and visually
CN19
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its
1 2
8 9 10 11 12 13 14 15 16 17 wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-30(312) - CN19-3(312) Continuity
CN19-1(311) - CN19-3(312) No continuity
CN19-2(51) - CN19-3(312) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-389

[Link] Step 5
1
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector.
3. Reconnect the battery plug and turn on the key switch.
4. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
1** (* represents either 0 or 1.) Go to Step 6
0** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 6
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103 and CN104 connectors.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN19,
CN103 and CN104 connectors disconnected, and visually
CN19
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its
1 2
8 9 10 11 12 13 14 15 16 17 wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-30(312) - CN19-3(312) Continuity
CN19-1(311) - CN19-3(312) No continuity
CN19-2(51) - CN19-3(312) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-390 1 ELECTRICAL TROUBLESHOOTING

1.4.133 72-2
Failure mode: Steering-wheel angle sensor SS2 open abnormality

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Steering angle sensor defect
▪ Main controller defect

Related part

CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Main controller CN104-31 (313, SSTR2) CN19-4 Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN103-6 (51, LS-) CN19-2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN19 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN19 connector, connect the battery plug.
4. Turn on the key switch, and check if error occurs with turn-
ing steering wheel.

Judgment
Result Procedure
72-2error occurs. Go to Step 2
72-2error does not occur. Connector contact defect

[Link] Step 2
Sensor inspection
1. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 3
1** (* represents either 0 or 1.) Go to Step 5
1 ELECTRICAL TROUBLESHOOTING 1-391

[Link] Step 3
1
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector and connect CN19-2 to
CN19-4 on the harness side through SST2
(09232-13130-71).
3. Reconnect the battery plug and turn on the key switch.
CN19
4. Check the condition of the sensor with operating steering
1 2
3 4 5 6 [ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 4
1** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 4
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103, CN104 connectors and SST.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN19,
CN103, CN104 connectors disconnected, and visually
CN19
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its
1 2
8 9 10 11 12 13 14 15 16 17 wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-31(313) - CN19-4(313) Continuity
CN19-1(311) - CN19-4(313) No continuity
CN19-2(51) - CN19-4(313) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-392 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 5
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector.
3. Reconnect the battery plug and turn on the key switch.
4. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
1** (* represents either 0 or 1.) Go to Step 6
0** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 6
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103 and CN104 connectors.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN19,
CN103 and CN104 connectors disconnected, and visually
CN19
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its
1 2
8 9 10 11 12 13 14 15 16 17 wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-31(313) - CN19-4(313) Continuity
CN19-1(311) - CN19-4(313) No continuity
CN19-2(51) - CN19-4(313) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-393

1.4.134 72-3 1
Failure mode: Steering-wheel angle sensor SSC open abnormality

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Steering angle sensor defect
▪ Main controller defect

Related part

CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Main controller CN104-31 (313, SSTR2) CN19-4 Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN103-6 (51, LS-) CN19-2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN19 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN19 connector, connect the battery plug.
4. Turn on the key switch, and check if error occurs with turn-
ing steering wheel (over one revolution).

Judgment
Result Procedure
72-2error occurs. Go to Step 2
72-2error does not occur. Connector contact defect

[Link] Step 2
Sensor inspection
1. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 3
1** (* represents either 0 or 1.) Go to Step 5
1-394 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector and connect CN19-2 to
CN19-5 on the harness side through SST2
(09232-13130-71).
3. Reconnect the battery plug and turn on the key switch.
4. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
0** (* represents either 0 or 1.) Go to Step 4
1** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 4
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103, CN104 connectors and SST.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN19,
CN103, CN104 connectors disconnected, and visually
CN19
1 2 3 4 5 6 7 check inside the connector and the caulked portion of its
1 2
8 9 10 11 12 13 14 15 16 17 wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-24(314) - CN19-5(314) Continuity
CN19-1(311) - CN19-5(314) No continuity
CN19-2(51) - CN19-5(314) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-395

[Link] Step 5
1
Sensor inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector.
3. Reconnect the battery plug and turn on the key switch.
4. Check the condition of the sensor with operating steering
[ANL] I/O STEERING 1/1
SSTR

Judgment
Result Procedure
1** (* represents either 0 or 1.) Go to Step 6
0** (* represents either 0 or 1.) Steering angle sensor defect

[Link] Step 6
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. CN104、Disconnect the CN19 connector.
3. Inspect for continuity of the harness.
Notes:
CN104 Perform this check with the battery plug and the CN101,
CN103, CN104 and CN19 connectors disconnected, and
CN19
1 2 3 4 5 6 7 visually check inside the connector and the caulked por-
1 2
8 9 10 11 12 13 14 15 16 17 tion of its wire for defects.
3 4 5 6
18 19 20 21 22 23 24 25 (Refer to "BEFORE TROUBLESHOOTING")
26 27 28 29 30 31

Portion to be inspected Standard

CN104-24(314) - CN19-5(314) Continuity
CN19-1(311) - CN19-5(314) No continuity
CN19-2(51) - CN19-5(314) No continuity
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-396 1 ELECTRICAL TROUBLESHOOTING

1.4.135 72-4
Failure mode: Steering-wheel angle sensor : sensor power source open abnormality

CAUTION
• Turning the steering angle sensor without turning the steering wheel may cause error code 72-4 to
be set.

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Steering angle sensor defect
▪ Main controller defect

Related part

CN103-13 (311, SSTR+) CN19-1

CN104-30 (312, SSTR1) CN19-3
Main controller CN104-31 (313, SSTR2) CN19-4 Steering angle
sensor
CN104-24 (314, SSTRC) CN19-5
CN103-6 (51, LS-) CN19-2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN19 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN19 connector, connect the battery plug.
4. Turn on the key switch, and turn the steering wheel to see if
an error occurs. (If the steering wheel cannot be turned eas-
ily, perform this check with the direction switch in the For-
ward or Reverse position.)

Judgment
Result Procedure
72-4error occurs. Go to Step 2
72-4error does not occur. Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-397

[Link] Step 2
1
Check of sensor supply voltage
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19 connector.
3. Reconnect the battery plug and turn on the key switch.
4. Check the supply voltage to the sensor.
CN19-1 to CN19-2

Judgment
Result Procedure
approx.0V Go to Step 3
approx.15V Go to Step 4

[Link] Step 3
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN19, CN103 and CN104 connectors.

CN102
3. Inspect for continuity of the harness.
Notes:
1 2 3 4 5 6 7
Perform this check with the battery plug and the CN19,
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27
CN103 and CN104 connectors disconnected, and visually
28 29 30 31 32 33 34 35
CN19 check inside the connector and the caulked portion of its
1 2 wire for defects.
CN103 3 4 5 6 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 CN103-13(311) - CN19-1(311) Continuity

17 18 19 20 21 22 23 24 25 26 27
CN103-6(51) - CN19-2(51) Continuity
28 29 30 31 32 33 34 35
CN19-1(311) - CN19-2(51) No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect

[Link] Step 4
1. Turn off the key switch and disconnect the battery plug.
2. Connect the CN19 connector.
3. Connect the battery plug and turn on the key switch.
Perform troubleshooting for 72-1 (SSTR1).
Perform troubleshooting for 72-2 (SSTR2).
1-398 1 ELECTRICAL TROUBLESHOOTING

1.4.136 73-1
Failure mode: Steering knob position synchronizer solenoid open abnormality

CAUTION
• If 73-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 73-3.
• If A9-2 occurs at same time, perform troubleshooting for A9-2 first.

Probable cause
▪ Connector contact defect
▪ Steering knob position synchronizer solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19,VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19,VBMBSL)

CN102-7 (329,SLS+)
Main controller
CN98-2 (329) CN102-14 (330,SLS-)
Steering knob
N1 position
syncohonizer CN98-1 (330)
solenoid CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN98 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN98 connector, connect the battery plug.
4. Turn on the key switch to see if an error occurs.

Judgment
Result Procedure
73-4error occurs. Perform troubleshooting for 73-4.
73-4error does not occur. Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-399

[Link] Step 2
1
Connector contact inspection
1. Using [ACTIVE TEST], forcibly turn on the output of the
steering knob position synchronizer solenoid to see if an er-
ror occurs.
[ANL] ACTIVE TEST 1/3
STEERING SOL : OFF → ON

Judgment
Result Procedure
73-1error does not occur. Connector contact defect
73-1error occurs. Go to Step 3

[Link] Step 3
Steering knob position synchronizer solenoid inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98 connector.
3. Inspect the solenoid resistance.
Notes:
Perform this check with the battery plug and the CN98 con-
nector disconnected, and visually check inside the con-
CN98 nector and the caulked portion of its wire for defects.
2 1 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
7 - 17Ω
CN98-2(485) - CN98-1(330) (approx.10Ω :
20°C)

Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to Step 4
1-400 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98, CN101, CN102, CN103 and CN104
connectors and check the harnesses for their continuities.
3. Inspect for continuity of the harness.
Notes:
CN102 Perform this check with the battery plug and the CN98,
CN101, CN102, CN103 and CN104 connectors disconnec-
CN98
1 2 3 4 5 6 7 ted, and visually check inside the connector and the
8 9 10 11 12 13 14 15 16 17 18 19
1 2 caulked portion of its wire for defects.
20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING")
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN102-7(329) - CN98-2(329) Continuity *1
CN102-14(330) - CN98-1(330) Continuity *1
CN98-2(329) - N2 No continuity
CN98-1(330) - N2 No continuity
*1 : In case of the OK in the steering knob position synchronizer
solenoid, connect the CN98 connector and measure the resist-
ance between CN102-7 and CN102-14. And it is OK if this res-
istance is between 7 and 17 Ω (approx. 10 Ω at 20°C).

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-401

1.4.137 73-2 1
Failure mode: Steering knob position synchronizer solenoid short abnormality

CAUTION
• If 73-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 73-3.

Probable cause
▪ Connector contact defect
▪ Harness defect
▪ Steering knob position synchronizer solenoid defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19,VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19,VBMBSL)

CN102-7 (329,SLS+)
Main controller
CN98-2 (329) CN102-14 (330,SLS-)
Steering knob
N1 position
syncohonizer CN98-1 (330)
solenoid CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN98 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN98 connector, connect the battery plug.
4. Turn on the key switch to see if an error occurs.

Judgment
Result Procedure
73-4error occurs. Perform troubleshooting for 73-4.
73-4error does not occur. Go to Step 2
1-402 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Connector contact inspection
1. Using [ACTIVE TEST], forcibly turn on the output of the
steering knob position synchronizer solenoid to see if an er-
ror occurs.
[ANL] ACTIVE TEST 1/3
STEERING SOL : OFF → ON

Judgment
Result Procedure
73-2error does not occur. Connector contact defect
73-2error occurs. Go to Step 3

[Link] Step 3
Steering knob position synchronizer solenoid inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98 connector.
3. Check the resistance of steering knob position synchronizer
solenoid.
Notes:
Perform this check with the battery plug and the CN98 con-
CN98 nector disconnected, and visually check inside the con-
2 1 nector and the caulked portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
7 - 17Ω
CN98-2(329) - CN98-1(330) (approx.10Ω :
20°C)

Judgment
Result Procedure
NG Steering knob position synchronizer solenoid defect
OK Go to Step 4
1 ELECTRICAL TROUBLESHOOTING 1-403

[Link] Step 4
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98, CN101, CN103 and CN104 connect-
ors.
3. Inspect for continuity of the harness.
Notes:
Perform this check with the battery plug and the CN98,
CN101, CN103 and CN104 connectors disconnected, and
CN98 visually check inside the connector and the caulked por-
1 2 tion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
CN98-2(329) - CN98-1(330) No continuity
CN98-1(330) - P2 No continuity
CN98-1(330) - P3 No continuity

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-404 1 ELECTRICAL TROUBLESHOOTING

1.4.138 73-3
Failure mode: Steering knob position synchronizer solenoid power-circuit abnormality

Probable cause
▪ Harness defect
▪ Steering knob position synchronizer solenoid defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19,VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19,VBMBSL)

CN102-7 (329,SLS+)
Main controller
CN98-2 (329) CN102-14 (330,SLS-)
Steering knob
N1 position
syncohonizer CN98-1 (330)
solenoid CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Steering knob position synchronizer solenoid inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98 connector.
3. Inspect the solenoid resistance.

Notes:
CN98
Perform this check with the battery plug and the CN98 con-
nector disconnected, and visually check inside the con-
2 1
nector and the caulked portion of its wire for defects.
(Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
7 - 17Ω
CN98-2(329) - CN98-1(330) (approx.10Ω :
20°C)

Judgment
Result Procedure
Go to Step 2
NG
Steering knob position synchronizer solenoid defect
OK Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-405

[Link] Step 2
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98, CN101, CN102, CN103 and CN104
connectors and check the harnesses for their continuities.
3. Inspect for continuity of the harness.
Notes:
CN102 Perform this check with the battery plug and the CN98,
CN101, CN102, CN103 and CN104 connectors disconnec-
CN98
1 2 3 4 5 6 7 ted, and visually check inside the connector and the
8 9 10 11 12 13 14 15 16 17 18 19
1 2 caulked portion of its wire for defects.
20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING")
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN98-2(329) - CN98-1(330) No continuity
CN102-7(329) - CN102-14(330) No continuity
CN98-1(330) - P2 No continuity
CN98-1(330) - P3 No continuity

Judgment
Result Procedure
NG Harness defect、Main controller defect
OK Main controller defect
1-406 1 ELECTRICAL TROUBLESHOOTING

1.4.139 73-4
Failure mode: Steering knob position synchronizer solenoid (open / short) abnormality

CAUTION
• If 73-3 also occurs, disconnect the battery plug at once, perform troubleshooting with priority given
to 73-3.
• If A9-2 occurs at same time, perform troubleshooting for A9-2 first.

Probable cause
▪ Connector contact defect
▪ Tilt solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19,VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19,VBMBSL)

CN102-7 (329,SLS+)
Main controller
CN98-2 (329) CN102-14 (330,SLS-)
Steering knob
N1 position
syncohonizer CN98-1 (330)
solenoid CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Connector contact inspection
1. Turn off the key switch and disconnect the battery plug.
2. After disconnection the CN98 connector, check the inside of
connector and the caulked portion of wire whether it has de-
fect or not by visual confirm.
(Refer to BEFORER TOUBLESHOOTING)
3. Connect the CN98 connector, connect the battery plug.
4. Turn on the key switch to see if an error occurs.

Judgment
Result Procedure
73-4error occurs. Go to Step 2
73-4error does not occur. Connector contact defect
1 ELECTRICAL TROUBLESHOOTING 1-407

[Link] Step 2
1
Steering knob position synchronizer solenoid inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98 connector.
3. Inspect the solenoid resistance.
Notes:
Perform this check with the battery plug and the CN98 con-
nector disconnected, and visually check inside the con-
CN98 nector and the caulked portion of its wire for defects.
2 1 (Refer to "BEFORE TROUBLESHOOTING")
Portion to be inspected Standard
7 - 17Ω
CN98-2(329) - CN98-1(330) (approx.10Ω :
20°C)

Judgment
Result Procedure
NG Tilt solenoid defect
OK Go to Step 3

[Link] Step 3
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN98, CN101, CN102, CN103 and CN104
connectors and check the harnesses for their continuities.
3. Inspect for continuity of the harness.
Notes:
CN102 Perform this check with the battery plug and the CN98, CN101,
CN102, CN103 and CN104 connectors disconnected, and visu-
CN98
1 2 3 4 5 6 7 ally check inside the connector and the caulked portion of its
8 9 10 11 12 13 14 15 16 17 18 19
1 2 wire for defects.
20 21 22 23 24 25 26 27 (Refer to "BEFORE TROUBLESHOOTING")
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN102-7(329) - CN98-2(329) Continuity *1
CN102-14(330) - CN98-1(330) Continuity *1
CN102-7(329) - CN102-14(330) No continuity *1
CN98-2(329) - N2 No continuity
CN98-1(330) - N2 No continuity
*1 : Connect the CN98 connector and measure the resistance
between CN102-7 and CN102-14. And it is OK if this resistance
is between 7 and 17 Ω (approx.10Ω : 20°C).

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-408 1 ELECTRICAL TROUBLESHOOTING

1.4.140 74-1
Failure mode: Tire angle matching: matching value abnormality

CAUTION
• If 71-1,71-2,71-3 occurs, give priority to troubleshooting for 71-1,71-2,71-3. After that, perform the fol-
lowing.

Probable cause
▪ Main controller defect
▪ Tire angle matching defect

Related part

Main controller

[Link] Step 1
1. Perform tire angle matching.
(Refer to page "MATCHING" of Display section)

Judgment
Result Procedure
NG matching Go to Step 2
OK matching Go to Step 3

[Link] Step 2
Tire angle sensor voltage inspection
1. Check the tire angle sensor voltage.
[ANL] I/O STEERING 1/1
VRTRA
Tire angle position Voltage
When straight running condition 1.83V - 2.51V

Judgment
Result Procedure
Go to Step 3
Outside standard value Tire angle sensor assembly defect. After reassemble, perform
matching and Step 3.
Within standard value Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-409

[Link] Step 3
1
Check the error
1. Turn off the key switch and disconnect the battery plug.
2. After 30 seconds, reconnect the battery plug and turn on the
After 30 seconds, reconnect the battery plug and turn on the
key switch.

Judgment
Result Procedure
74-1error occurs. Main controller defect
74-1error does not occur. Tire angle matching defect
1-410 1 ELECTRICAL TROUBLESHOOTING

1.4.141 G5-1
Failure mode: Shock sensor 1 open abnormality

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error.

Judgment
Result Procedure
G5-1error does not occur. Connector contact defect
G5-1error occurs. Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-411

[Link] Step 2
1
Shock sensor1 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129 connector and connect the CN129-3
to CN129-2 on the harness side through SST2
(09232-13130-71).
CN129 3. Reconnect the battery plug and turn on the key switch, and
check the error code.
1 2

3 4

Judgment
Result Procedure
G5-1error occurs. Go to Step 3
G5-2error occurs. Shock sensor defect

[Link] Step 3
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn off the key switch and disconnect the battery plug,
CN103
CN129 disconnect CN129, CN101 and CN103, and perform the
check without connecting SST2 (09232-13130-71).
1 2 3 4 5 6
1 2
(Refer to "BEFORE TROUBLESHOOTING")
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 3 4 Portions to be checked Standard
28 29 30 31 32 33 34 35
CN103-8(300) - CN129-1(300) Continuity *1
CN103-30(301) - CN129-3(301) Continuity *1
CN129-2(301) - CN129-4(51) No continuity
CN129-3(300) - CN129-4(51) No continuity
*1 : It is OK to connect CN129-2 to CN129-3 through SST2
(09232-13130-71) and check if there is continuity between
CN103-30 and CN103-8.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-412 1 ELECTRICAL TROUBLESHOOTING

1.4.142 G5-2
Failure mode: Shock sensor 1 short abnormally

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error.

Judgment
Result Procedure
G5-2error does not occur. Connector contact defect
G5-2error occurs. Go to Step 2

[Link] Step 2
Shock sensor1 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN129.
3. Reconnect the battery plug and turn on the key switch, and
check the error code.

Judgment
Result Procedure
G5-1error occurs. Shock sensor defect
G5-2error occurs. Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-413

[Link] Step 3
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
CN101
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug,
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
disconnect CN129, CN101 and CN103, and perform the
28 29 30 31 32 33 34 CN129 check.
(Refer to "BEFORE TROUBLESHOOTING")
1 2
CN103
3 4 Portions to be checked Standard
1 2 3 4 5 6
CN101-32(51) - CN129-4(51) Continuity *1
7 8 9 10 11 12 13 14 15 16 CN129-1(300) - CN129-3(301) No continuity
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1 : It is OK to connect CN129-1 to CN129-2 through SST2
(09232-13130-71) and check if there is continuity between
CN101-32 and CN103-30.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-414 1 ELECTRICAL TROUBLESHOOTING

1.4.143 G5-3
Failure mode: Shock sensor 1 : neutral voltage abnormality

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error (one minute later).

Judgment
Result Procedure
G5-3error does not occur. Connector contact defect
G5-3error occurs. Go to Step 2

[Link] Step 2
Shock sensor1 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN129.
3. Reconnect the battery plug and turn on the key switch, and
check the error code.

Judgment
Result Procedure
G5-1error occurs. Shock sensor defect
G5-1error does not occur. Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-415

[Link] Step 3
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
CN101
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug,
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
disconnect CN129, CN101 and CN103, and perform the
28 29 30 31 32 33 34 CN129 check.
(Refer to "BEFORE TROUBLESHOOTING")
1 2
CN103
3 4 Portions to be checked Standard
1 2 3 4 5 6
CN101-32(51) - CN129-4(51) Continuity *1
7 8 9 10 11 12 13 14 15 16 CN129-1(300) - CN129-3(301) No continuity
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1 : It is OK to connect CN129-1 to CN129-2 through SST2
(09232-13130-71) and check if there is continuity between
CN101-32 and CN103-30.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-416 1 ELECTRICAL TROUBLESHOOTING

1.4.144 G5-4
Failure mode: Shock sensor 2 open abnormality

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error.

Judgment
Result Procedure
G5-4error does not occur. Connector contact defect
G5-4error occurs. Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-417

[Link] Step 2
1
Shock sensor2 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129 connector and connect the CN129-1
to CN129-2 on the harness side through SST2
(09232-13130-71).
CN129 3. Reconnect the battery plug and turn on the key switch, and
check the error code.
1 2

3 4

Judgment
Result Procedure
G5-4error occurs. Go to Step 3
G5-5error occurs. Shock sensor defect

[Link] Step 3
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
Notes:
Turn off the key switch and disconnect the battery plug,
CN103
CN129 disconnect CN129, CN101 and CN103, and perform the
check without connecting SST2 (09232-13130-71).
1 2 3 4 5 6
1 2
(Refer to "BEFORE TROUBLESHOOTING")
7 8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 25 26 27 3 4 Portions to be checked Standard
28 29 30 31 32 33 34 35
CN103-8(300) - CN129-1(300) Continuity *1
CN103-19(302) - CN129-2(302) Continuity *1
CN129-2(302) - CN129-4(51) No continuity
CN129-1(300) - CN129-4(51) No continuity
*1 : It is OK to connect CN129-1 to CN129-2 through SST2
(09232-13130-71) and check if there is continuity between
CN103-19 and CN103-8.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-418 1 ELECTRICAL TROUBLESHOOTING

1.4.145 G5-5
Failure mode: Shock sensor 2 short abnormally

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error.

Judgment
Result Procedure
G5-5error does not occur. Connector contact defect
G5-5error occurs. Go to Step 2

[Link] Step 2
Shock sensor2 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN129.
3. Reconnect the battery plug and turn on the key switch, and
check the error code.

Judgment
Result Procedure
G5-4error occurs. Shock sensor defect
G5-5error occurs. Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-419

[Link] Step 3
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
CN101
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug,
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
disconnect CN129, CN101 and CN103, and perform the
28 29 30 31 32 33 34 CN129 check.
(Refer to "BEFORE TROUBLESHOOTING")
1 2
CN103
3 4 Portions to be checked Standard
1 2 3 4 5 6
CN101-32(51) - CN129-4(51) Continuity *1
7 8 9 10 11 12 13 14 15 16 CN129-1(300) - CN129-2(302) No continuity
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1 : It is OK to connect CN129-2 to CN129-4 through SST2
(09232-13130-71) and check if there is continuity between
CN101-32 and CN103-19.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-420 1 ELECTRICAL TROUBLESHOOTING

1.4.146 G5-6
Failure mode: Shock sensor 2 : neutral voltage error

Probable cause
▪ Connector contact defect
▪ Shock sensor defect
▪ Shock sensor harness defect
▪ Main controller defect

Related part

CN103-8 (300, IPL+) CN129-1 (300)

CN103-19 (302, IPL2) CN129-2 (302)
Shock sensor
Main controller CN103-30 (301, IPL1) CN129-3 (301) 1, 2
CN101-32 (51, POT-) CN129-4 (51)

[Link] Step 1
1. Turn off the key switch and disconnect the battery plug.
2. Check the inside of connector CN129 and the caulked por-
tion of wire whether it has defect or not by visual confirm.
(Refer to "BEFORE TROUBLESHOOTING")
3. After connecting CN129, connect the battery plug and turn
on the key switch to confirm error (one minute later).

Judgment
Result Procedure
G5-6error does not occur. Connector contact defect
G5-6error occurs. Go to Step 2

[Link] Step 2
Shock sensor2 inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect CN129.
3. Reconnect the battery plug and turn on the key switch, and
check the error code.

Judgment
Result Procedure
G5-4error occurs. Shock sensor defect
G5-4error does not occur. Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-421

[Link] Step 3
1
Harness inspection
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the CN129, CN101 and CN103 connector, then
check the harness.
3. Inspect for continuity and short circuiting of the harness.
CN101
Notes:
1 2 3 4 5 6 7
Turn off the key switch and disconnect the battery plug,
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
disconnect CN129, CN101 and CN103, and perform the
28 29 30 31 32 33 34 CN129 check.
(Refer to "BEFORE TROUBLESHOOTING")
1 2
CN103
3 4 Portions to be checked Standard
1 2 3 4 5 6
CN101-32(51) - CN129-4(51) Continuity *1
7 8 9 10 11 12 13 14 15 16 CN129-1(300) - CN129-2(302) No continuity
17 18 19 20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35 *1 : It is OK to connect CN129-2 to CN129-4 through SST2
(09232-13130-71) and check if there is continuity between
CN101-32 and CN103-19.

Judgment
Result Procedure
NG Shock sensor harness defect
OK Main controller defect
1-422 1 ELECTRICAL TROUBLESHOOTING

1.4.147 H1-1
Failure mode: Lift lever potentiometer open abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.
• In case of the simple automatic lift height stop, replace CN115 with CN162.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Lift lever potentiometer error
▪ Main controller defect

Related part

CN101-25 (28, VRL+) CN115-4

Main CN103-26 (20, VRL1) CN115-3

Lift lever
controller potentiometer
CN103-18 (21, VRL2) CN115-2
CN102-26 (51, POT-) CN115-1

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN115 connector first, and then connect the
battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H1-1 error Connector connection defect
H1-1 error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-423

[Link] Step 2
1
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect CN115-3 on the harness side and CN115-4 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN115

1 2 3 4

Judgment
Result Procedure
H1-2 error Go to Step 3
No H1-2 error Go to Step 4

[Link] Step 3
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect CN115-2 on the harness side, and CN115-4 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN115

1 2 3 4

Judgment
Result Procedure
H1-2 error Lift lever potentiometer open error
No H1-2 error Go to Step 4
1-424 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN103, and CN115 connectors.

CN101
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN103
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN115 connectors, and conduct after visually inspect-
28 29 30 31 32 33 34
CN115 ing there are no problems inside the connector, and on the
1 2 3 4
wire caulking.
CN103 (Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 CN101-25 (28) to CN115-4 Conduction

17 18 19 20 21 22 23 24 25 26 27
CN103-26 (20) to CN115-3 Conduction
28 29 30 31 32 33 34 35
CN103-18 (21) to CN115-2 Conduction
CN115-3 (20) to CN115-1 (51) No conduction
CN115-2 (21) to CN115-1 (51) No conduction
CN115-4 (28) to CN115-1 (51) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-425

1.4.148 H1-2 1
Failure mode: Lift lever potentiometer Short abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Lift lever potentiometer error
▪ Main controller defect

Related part

CN101-25 (28, VRL+) CN115-4

Main CN103-26 (20, VRL1) CN115-3

Lift lever
controller potentiometer
CN103-18 (21, VRL2) CN115-2
CN102-26 (51, POT-) CN115-1

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN115 connector first, and then connect the
battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H1-2 error Connector connection defect
H1-2 error Go to Step 2
1-426 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect the battery plug, and turn the key switch ON to
check the error display

Judgment
Result Procedure
H1-1 error Lift lever potentiometer error
No H1-1 error Go to Step 3

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN102, CN103, and CN115 connectors.
3. Inspect conduction of the harness.
Notes:
CN102
CN115 Disconnect the battery plug, disconnect the CN102, CN103
1 2 3 4 5 6 7 and CN115 connectors, and conduct after visually inspect-
8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 ing there are no problems inside the connector, and on the
20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
Inspected place Standard
CN102-26 (51) to CN115-1 Conduction
CN115-3 (20) to CN115-4 (28) No conduction
CN115-2 (21) to CN115-4 (28) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-427

1.4.149 H1-3 1
Failure mode: Lift lever potentiometer sensor output deviation abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Lift lever potentiometer error
▪ Main controller defect

Related part

CN101-25 (28, VRL+) CN115-4

Main CN103-26 (20, VRL1) CN115-3

Lift lever
controller potentiometer
CN103-18 (21, VRL2) CN115-2
CN102-26 (51, POT-) CN115-1

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN115 connector first, and then connect the
battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H1-3 error Connector connection defect
H1-3 error Go to Step 2
1-428 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect the battery plug, and turn the key switch ON to
check the error display

Judgment
Result Procedure
No H1-1 error Go to Step 3
H1-1 error Go to Step 4

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103, and CN115 con-
nectors.

CN101 CN102
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103 and CN115 connectors, and conduct after visually
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 inspecting there are no problems inside the connector, and
on the wire caulking.
CN103 (Refer to "BEFORE TROUBLESHOOTING").
CN115
Inspected place Standard
1 2 3 4 5 6

7 8 9 10 11 12 13 14 15 16
1 2 3 4 CN101-25 (28) to CN115-4 Conduction
17 18 19 20 21 22 23 24 25 26 27
CN103-26 (20) to CN115-3 Conduction
28 29 30 31 32 33 34 35
CN103-18 (21) to CN115-2 Conduction
CN102-26 (51) to CN115-1 Conduction
CN115-3 (20) to CN115-4 (28) No conduction
CN115-2 (21) to CN115-4 (28) No conduction
CN115-3 (20) to CN115-1 (51) No conduction
CN115-2 (21) to CN115-1 (51) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-429

[Link] Step 4
1
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect CN115-4 on the harness side and CN115-3 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN115

1 2 3 4

Judgment
Result Procedure
H1-2 error display Go to Step 5
H1-2 no error display Go to Step 3

[Link] Step 5
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector.
3. Connect CN115-4 on the harness side and CN115-2 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN115

1 2 3 4

Judgment
Result Procedure
H1-2 error display Lift lever potentiometer error
H1-2 no error display Go to Step 3
1-430 1 ELECTRICAL TROUBLESHOOTING

1.4.150 H1-4
Failure mode: Lift lever potentiometer neutral abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.
• When the key switch is ON or the emergency SW is restored while operating the lift lever, H1-4 error
is displayed.

Probable cause
▪ Connector connection defect
▪ Lift lever potentiometer error
▪ Lift lever potentiometer assembly error

Related part

CN101-25 (28, VRL+) CN115-4

Main CN103-26 (20, VRL1) CN115-3

Lift lever
controller potentiometer
CN103-18 (21, VRL2) CN115-2
CN102-26 (51, POT-) CN115-1

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN115 connector, and visually inspect there
are no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN115 connector first, and then connect the
battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H1-4 error Connector connection defect
H1-4 error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-431

[Link] Step 2
1
Inspect the lift lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Make sure that the lift lever potentiometer is installed cor-
rectly.
3. Connect the battery plug, and turn the key switch ON to
check the error display
4. Conduct matching of the lift lever potentiometer.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Lift lever potentiometer error
Matching OK Lift lever potentiometer assembly error
1-432 1 ELECTRICAL TROUBLESHOOTING

1.4.151 H1-5
Failure mode: Lift lever potentiometer matching value abnormality

CAUTION
• When H1-1, 2, 3, and 4 are generated, perform troubleshooting of H1-1, 2, 3, and 4 first.
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Main controller defect
▪ Lift lever potentiometer matching error
▪ Lift lever potentiometer assembly error

Related part

CN101-25 (28, VRL+) CN115-4

Main CN103-26 (20, VRL1) CN115-3

Lift lever
controller potentiometer
CN103-18 (21, VRL2) CN115-2
CN102-26 (51, POT-) CN115-1

[Link] Step 1
1. Conduct matching of the lift lever potentiometer.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-433

[Link] Step 2
1
Inspect voltage of the lift lever potentiometer
1. Lift lever angle sensor 1/2 sensor voltage (V)
[ANL] I/O M. HANDLING 5/8
VRL
Notes:
For the most upward lifting/the most downward lowering,
the difference should be within the range shown in the fol-
lowing table, and 0.79 V or more with the sensor neutral
matching voltage.
Models with standard lever
Lift lever position
Sensor 1 Sensor 2
Neutral position 1.65 to 2.87 V 1.52 to 3.01 V
At the most upward lift-
0.30 to 2.87 V 1.52 to 4.50 V
ing
At the lowest lowering 1.65 to 4.50 V 0.30 to 3.01 V

Judgment
Result Procedure
Within the limits of the standard values Main controller defect
Go to Step 3
Out of the limits of the standard values Lift lever potentiometer assembly error
After reassembling, perform matching.

[Link] Step 3
1. After turning the key switch OFF, disconnect the battery
plug. After 30 seconds, connect the battery plug again, and
turn the key switch ON.

Judgment
Result Procedure
Lift lever potentiometer matching error
H1-5 no error display
Use it as is.
H1-5 error display Main controller defect
1-434 1 ELECTRICAL TROUBLESHOOTING

1.4.152 H3-1
Failure mode: Attachment 1 lever potentiometer open abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 1 lever potentiometer error
▪ Main controller defect

Related part

CN101-29 (30, VRAT1+) CN119-4 (30)

Main CN102-21 (24, VRA11) CN119-3 (24)

Attachment 1 lever
controller
CN102-20 (25, VRA12) CN119-2 (25) potentiometer error
CN102-26 (51, POT-) CN119-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN119, and make
sure no problems inside the connector and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN119 connector, and then connect the bat-
tery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H3-1 no error display Connector connection defect
H3-1 error display Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-435

[Link] Step 2
1
Inspect the attachment 1 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Switch the connector of attachment 1 lever potentiometer
and the connector of lift lever potentiometer (CN119 and
CN115).
3. Connect the battery plug, turn the key switch ON, and check
error codes.
H1-3, H1-4, H3-3, and H3-4 can be ignored.

Judgment
Result Procedure
H3-1 error display Go to Step 3
H1-1 error display Attachment 1 lever potentiometer error

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN101, CN102 and CN119.

CN101
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN119 connectors, and conduct after visually inspect-
28 29 30 31 32 33 34 CN119 ing there are no problems inside the connector, and on the
wire caulking.
CN102 1 2 3 4 (Refer to "BEFORE TROUBLESHOOTING").

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 Checked place Standard

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-29 (30) to CN119-4 (30) Conduction⁽¹⁾
CN102-21 (24) to CN119-3 (24) Conduction⁽¹⁾
CN102-20 (25) to CN119-2 (25) Conduction⁽¹⁾
CN119-2 (25) to CN119-1 (51) No conduction
CN119-3 (24) to CN119-1 (51) No conduction
CN119-4 (30) to CN119-1 (51) No conduction
⁽¹⁾: “Connect between CN119-3 and CN119-4 on the harness
side with SST2, and conduction can be checked between
CN101-29 and CN102-21” and “Connect between CN119-2 and
CN119-4 on the harness side with SST2 (09232-13130-71),
and conduction can be checked between CN101-29 to
CN102-20” can be performed.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-436 1 ELECTRICAL TROUBLESHOOTING

1.4.153 H3-2
Failure mode: Attachment 1 lever potentiometer short abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 1 lever potentiometer error
▪ Main controller defect

Related part

CN101-29 (30, VRAT1+) CN119-4 (30)

Main CN102-21 (24, VRA11) CN119-3 (24)

Attachment 1 lever
controller
CN102-20 (25, VRA12) CN119-2 (25) potentiometer error
CN102-26 (51, POT-) CN119-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN119, and make
sure no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN119 connector, and then connect the bat-
tery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H3-2 no error display Connector connection defect
H3-2 error display Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-437

[Link] Step 2
1
Inspect the attachment 1 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Switch the connector of attachment 1 lever potentiometer
and the connector of lift lever potentiometer (CN119 and
CN115).
3. Connect the battery plug, turn the key switch ON, and check
the error codes.
H1-3, H1-4, H3-3, and H3-4 can be ignored.

Judgment
Result Procedure
H3-2 error display Go to Step 3
H1-2 error display Attachment 1 lever potentiometer error

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN102 and CN119.

CN101
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN102 and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN119 connectors, and conduct after visually inspecting
28 29 30 31 32 33 34 CN119 there are no problems inside the connector, and on the
wire caulking.
CN102 1 2 3 4 (Refer to "BEFORE TROUBLESHOOTING").
Checked place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN102-26 (51) to CN119-1 (51) Conduction⁽¹⁾

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN119-2 (25) to CN119-4 (30) No conduction
CN119-3 (24) to CN119-4 (30) No conduction
⁽¹⁾: Connect between CN119-1 and CN119-4 with SST2
(09232-13130-71), and conduction can be checked between
CN102-26 and CN101-29.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1-438 1 ELECTRICAL TROUBLESHOOTING

1.4.154 H3-3
Failure mode: Attachment 1 lever potentiometer sensor output deviation abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 1 lever potentiometer error
▪ Main controller defect

Related part

CN101-29 (30, VRAT1+) CN119-4 (30)

Main CN102-21 (24, VRA11) CN119-3 (24)

Attachment 1 lever
controller
CN102-20 (25, VRA12) CN119-2 (25) potentiometer error
CN102-26 (51, POT-) CN119-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN119, and make
sure no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN119 connector, and then connect the bat-
tery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H3-3 no error display Connector connection defect
H3-3 error display Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-439

[Link] Step 2
1
Inspect the attachment 1 potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN119 connector.
3. Connect the battery plug, turn the key switch ON, and check
the error codes.

Judgment
Result Procedure
H3-1 no error display Go to Step 3
H3-1 error display Go to Step 4

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN102, and CN119 connectors.

CN101
3. Inspect conduction of the harness.

1 2 3 4 5 6 7
Notes:
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 Disconnect the battery plug, disconnect the CN101, CN102
28 29 30 31 32 33 34 CN119 and CN119 connectors, and conduct after visually inspect-
ing there are no problems inside the connector, and on the
CN102 1 2 3 4
wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 Checked place Standard

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN101-29 (30) to CN119-4 (30) Conduction
CN102-21 (24) to CN119-3 (24) Conduction
CN102-20 (25) to CN119-2 (25) Conduction
CN102-26 (51) to CN119-1 (51) Conduction
CN119-3 (24) to CN119-4 (30) No conduction
CN119-2 (25) to CN119-4 (30) No conduction
CN119-3 (24) to CN119-1 (51) No conduction
CN119-2 (25) to CN119-1 (51) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-440 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the attachment 1 potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN119 connector.
3. Connect CN119-4 on the harness side and CN119-3 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN119

1 2 3 4

Judgment
Result Procedure
H3-2 error display Go to Step 5
H3-2 no error display Go to Step 3

[Link] Step 5
Inspect the attachment 1 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN119 connector.
3. Connect CN119-4 on the harness side and CN119-2 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN119

1 2 3 4

Judgment
Result Procedure
H3-2 error display Attachment 1 lever potentiometer error
H3-2 no error display Go to Step 3
1 ELECTRICAL TROUBLESHOOTING 1-441

1.4.155 H3-4 1
Failure mode: Attachment 1 lever potentiometer neutral abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.
• When the key switch is ON or the emergency SW is restored while operating the attachment 1 lever,
H3-4 error is displayed.

Probable cause
▪ Connector connection defect
▪ Attachment 1 lever potentiometer error
▪ Attachment 1 lever potentiometer assembly error

Related part

CN101-29 (30, VRAT1+) CN119-4 (30)

Main CN102-21 (24, VRA11) CN119-3 (24)

Attachment 1 lever
controller
CN102-20 (25, VRA12) CN119-2 (25) potentiometer error
CN102-26 (51, POT-) CN119-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN119, and make
sure no problems inside the connector, and on the wire
caulking.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect the CN119 connector, and then connect the bat-
tery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H3-4 error Connector connection defect
H3-4 error Go to Step 2
1-442 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the attachment 1 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Make sure that the attachment 1 lever potentiometer is in-
stalled correctly.
3. Connect the battery plug, and turn the key switch ON.
4. Conduct matching of the lift lever potentiometer.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Attachment 1 lever potentiometer error
Matching OK Attachment 1 lever potentiometer assembly error
1 ELECTRICAL TROUBLESHOOTING 1-443

1.4.156 H3-5 1
Failure mode: Attachment 1 lever potentiometer matching value abnormality

Probable cause
▪ Main controller defect
▪ Attachment 1 lever potentiometer matching error

Related part

Main controller

[Link] Step 1
1. Conduct matching of the attachment 1 lever.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3

[Link] Step 2
Inspect the attachment 1 lever potentiometer voltage
1. Check the voltage of attachment 1 lever.
Voltage of attachment 1 lever potentiometer
[ANL] I/O [Link] 7/8
VRA1
Attachment 1 lever position Sensor 1 Sensor 2
1.65 V to 2.87
Neutral (For standard lever) 1.52V to 3.01V
V

Judgment
Result Procedure
Go to Step 3
Out of the limits of the standard values Attachment 1 lever assembly error After reassembling, per-
form matching, and conduct Step 3.
Within the standard value range Main controller defect
1-444 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 3
Check error
1. Turn the key switch OFF, and disconnect the battery plug.
2. Reconnect the battery plug after 30 seconds, and turn the
key switch ON.

Judgment
Result Procedure
H3-5 error display Main controller defect
Attachment 1 lever potentiometer matching error
H3-5 no error display
Use it as is.
1 ELECTRICAL TROUBLESHOOTING 1-445

1.4.157 H4-1 1
Failure mode: Attachment 2 lever potentiometer open abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 2 lever potentiometer error
▪ Main controller defect

Related part

CN101-30 (31, VRAT2+) CN120-4 (31)

Main CN102-29 (26, VRA21) CN120-3 (26)

Attachment 2 lever
controller
CN102-28 (27, VRA22) CN120-2 (27) potentiometer error
CN102-26 (51, POT-) CN120-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN120, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN120 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H4-1 no error display Connector connection defect
H4-1 error display Go to Step 2
1-446 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Switch the connector of attachment 2 lever potentiometer
and the connector of lift lever potentiometer (CN120 and
CN115).
3. Connect the battery plug, turn the key switch ON, and check
error codes.
H1-3, H1-4, H4-3, and H4-4 can be ignored.

Judgment
Result Procedure
H4-1 error display Go to Step 3
H1-1 error display Attachment 2 lever potentiometer error

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN101, CN102, and CN120.

CN101
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN120 connectors, and conduct after visually inspect-
28 29 30 31 32 33 34 CN120 ing there are no problems inside the connector, and on the
wire caulking.
CN102 1 2 3 4 (Refer to "BEFORE TROUBLESHOOTING").
Checked place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-30 (31) to CN120-4 (31) Conduction⁽¹⁾

20 21 22 23 24 25 26 27
CN102-29 (26) to CN120-3 (26) Conduction⁽¹⁾
28 29 30 31 32 33 34 35
CN102-28 (27) to CN120-2 (27) Conduction⁽¹⁾
CN120-2 (27) to CN120-1 (51) No conduction
CN120-3 (26) to CN120-1 (51) No conduction
CN120-4 (31) to CN120-1 (51) No conduction
⁽¹⁾: “Connect between CN120-3 and CN120-4 on the harness
side with SST2, and conduction can be checked between
CN101-30 and CN102-29” and “Connect between CN120-2 and
CN120-4 on the harness side with SST2 (09232-13130-71),
and conduction can be checked between CN101-30 and
CN102-28” can be performed.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-447

1.4.158 H4-2 1
Failure mode: Attachment 2 lever potentiometer short abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 2 lever potentiometer error
▪ Main controller defect

Related part

CN101-30 (31, VRAT2+) CN120-4 (31)

Main CN102-29 (26, VRA21) CN120-3 (26)

Attachment 2 lever
controller
CN102-28 (27, VRA22) CN120-2 (27) potentiometer error
CN102-26 (51, POT-) CN120-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN120, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN120 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H4-2 no error display Connector connection defect
H4-2 error display Go to Step 2
1-448 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Switch the connector of attachment 2 lever potentiometer
and the connector of lift lever potentiometer (CN120 and
CN115).
3. Connect the battery plug, turn the key switch ON, and check
error codes.
H1-3, H1-4, H4-3, and H4-4 can be ignored.

Judgment
Result Procedure
H4-2 error display Go to Step 3
H1-2 error display Attachment 2 lever potentiometer error

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN102 and CN120.

CN101
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN102 and
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
CN120 connectors, and conduct after visually inspecting
28 29 30 31 32 33 34 CN120 there are no problems inside the connector, and on the
wire caulking.
CN102 1 2 3 4 (Refer to "BEFORE TROUBLESHOOTING").
Checked place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN102-26 (51) to CN120-1 (51) Conduction⁽¹⁾

20 21 22 23 24 25 26 27
28 29 30 31 32 33 34 35
CN120-2 (27) to CN120-4 (31) No conduction
CN120-3 (26) to CN120-4 (31) No conduction
⁽¹⁾: Connect between CN120-1 and CN120-4 with SST2
(09232-13130-71) on the harness side, and conduction can be
checked between CN102-26 and CN101-30.

Judgment
Result Procedure
OK Main controller defect
NG Harness defect
1 ELECTRICAL TROUBLESHOOTING 1-449

1.4.159 H4-3 1
Failure mode: Attachment 2 lever potentiometer sensor output deviation abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.

Probable cause
▪ Connector connection defect
▪ Harness defect
▪ Attachment 2 lever potentiometer error
▪ Main controller defect

Related part

CN101-30 (31, VRAT2+) CN120-4 (31)

Main CN102-29 (26, VRA21) CN120-3 (26)

Attachment 2 lever
controller
CN102-28 (27, VRA22) CN120-2 (27) potentiometer error
CN102-26 (51, POT-) CN120-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN120, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN120 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
H4-3 no error display Connector connection defect
H4-3 error display Go to Step 2
1-450 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN120 connector.
3. Connect the battery plug, turn the key switch ON, and check
the error codes.

Judgment
Result Procedure
H4-1 error display Go to Step 3
H4-1 no error display Go to Step 4

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN102, and CN120 connectors.

CN101
3. Inspect conduction of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27
and CN120 connectors, and conduct after visually inspect-
28 29 30 31 32 33 34 CN120 ing there are no problems inside the connector, and on the
wire caulking.
CN102 1 2 3 4 (Refer to "BEFORE TROUBLESHOOTING").
Checked place Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN101-30 (31) to CN120-4 (31) Conduction

20 21 22 23 24 25 26 27
CN102-29 (26) to CN120-3 (26) Conduction
28 29 30 31 32 33 34 35
CN102-28 (27) to CN120-2 (27) Conduction
CN102-26 (51) to CN120-1 (51) Conduction
CN120-3 (26) to CN120-4 (31) No conduction
CN120-2 (27) to CN120-4 (31) No conduction
CN120-3 (26) to CN120-1 (51) No conduction
CN120-2 (27) to CN120-1 (51) No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-451

[Link] Step 4
1
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN120 connector.
3. Connect CN120-4 on the harness side and CN120-3 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN120

1 2 3 4

Judgment
Result Procedure
H4-2 error display Go to Step 5
H4-2 no error display Go to Step 3

[Link] Step 5
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN120 connector.
3. Connect CN120-4 on the harness side and CN120-2 with
SST2.
4. Connect the battery plug, and turn the key switch ON to
check the error display
CN120

1 2 3 4

Judgment
Result Procedure
H4-2 error display Attachment 2 lever potentiometer error
H4-2 no error display Go to Step 3
1-452 1 ELECTRICAL TROUBLESHOOTING

1.4.160 H4-4
Failure mode: Attachment 2 lever potentiometer neutral abnormality

CAUTION
• If inspection is performed with the lever removed, be sure to perform matching after the lever is re-
assembled.
• When the key switch is ON or the emergency SW is restored while operating the attachment 2 lever,
H4-4 error is displayed.

Probable cause
▪ Connector connection defect
▪ Attachment 2 lever potentiometer error
▪ Attachment 2 lever potentiometer assembly error

Related part

CN101-30 (31, VRAT2+) CN120-4 (31)

Main CN102-29 (26, VRA21) CN120-3 (26)

Attachment 2 lever
controller
CN102-28 (27, VRA22) CN120-2 (27) potentiometer error
CN102-26 (51, POT-) CN120-1 (51)

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN120, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN120 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
No H4-4 error Connector connection defect
H4-4 error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-453

[Link] Step 2
1
Inspect the attachment 2 lever potentiometer
1. Turn the key switch OFF, and disconnect the battery plug.
2. Make sure that the attachment 2 lever potentiometer is in-
stalled correctly.
3. Connect the battery plug, and turn the key switch ON.
4. Conduct matching of the lift lever potentiometer.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Attachment 2 lever potentiometer error
Matching OK Attachment 2 lever potentiometer assembly error
1-454 1 ELECTRICAL TROUBLESHOOTING

1.4.161 H4-5
Failure mode: Attachment 2 lever potentiometer matching value abnormality

Probable cause
▪ Main controller defect
▪ Attachment 2 lever potentiometer matching error

Related part

Main controller

[Link] Step 1
1. Conduct matching of the attachment 2 lever.
(Refer to “MATCHING” in DISPLAY CHAPTER)

Judgment
Result Procedure
Matching NG Go to Step 2
Matching OK Go to Step 3

[Link] Step 2
Inspect the attachment 2 lever potentiometer voltage
1. Check the voltage of attachment 2 lever.
Voltage of attachment 2 lever potentiometer
[ANL] I/O [Link] 8/8
VRA2
Attachment 2 lever position Sensor 1 Sensor 2
1.65 V to 2.87
Neutral (For standard lever) 1.52V to 3.01V
V

Judgment
Result Procedure
Go to Step 3
Standard value out of the range Attachment 2 lever assembly error After reassembling, per-
form matching, and conduct Step 3.
Within the standard value range Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-455

[Link] Step 3
1
Check error
1. Turn the key switch OFF, and disconnect the battery plug.
2. Reconnect the battery plug after 30 seconds, and turn the
key switch ON.

Judgment
Result Procedure
H4-5 error display Main controller defect
Attachment 2 lever potentiometer matching error
H4-5 no error display
Use it as is.
1-456 1 ELECTRICAL TROUBLESHOOTING

1.4.162 HC-1
Failure mode: Unload solenoid Open abnormality

CAUTION
• When HC-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for HC-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Unload solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-1 (3) CN102-17 (5, SLUL-) controller
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN88 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
HC-4 error Perform HC-4 troubleshooting.
No HC-4 error Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-457

[Link] Step 2
1
1. Turn the output of unload solenoid ON forcibly with “ACT-
IVE TEST”, and check for error.
[ANL] ACTIVE TEST 2/3
UNLOAD SOL: OFF → ON

Judgment
Result Procedure
No HC-1 error Connector connection defect
HC-1 error Go to Step 3

[Link] Step 3
Single unit inspect the unload solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the unload solenoid.
Notes:
CN88 Disconnect the battery plug, and conduct after visually in-
specting there are no problems inside the CN88 connector,
4 3 2 1
and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Portion to be inspected Standard
CN88-1 (3) to CN88-5 (5) Approx. 10 Ω

Judgment
Result Procedure
NG Unload solenoid defect
OK Go to Step 4
1-458 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 4
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103, and CN88 connect-
ors.

CN101 CN102
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, and CN88 connectors, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting inside the connector, and on the wire caulking for
error.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").
Portion to be inspected Standard
1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 CN101-1 (3) to CN88-1 (3) Conduction⁽¹⁾
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
CN102-17 (5) to CN88-5 (5) Conduction⁽¹⁾
28 29 30 31 32 33 34 35
CN101-1 (3) to CN103-5 (N2) No conduction
CN102-17 (5) to CN103-5 (N2) No conduction
⁽¹⁾: Connect CN88, and it can be checked that the measured
resistance value between CN101-1 and CN102-17 is approx.
10 Ω.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1 ELECTRICAL TROUBLESHOOTING 1-459

1.4.163 HC-2 1
Failure mode: Unload solenoid short abnormality

CAUTION
• When HC-3 is generated, promptly disconnect the battery plug, and perform troubleshooting for
HC-3.

Probable cause
▪ Connector connection defect
▪ Unload solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-1 (3) CN102-17 (5, SLUL-) controller
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN88 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
HC-4 error Perform HC-4 troubleshooting
No HC-4 error Go to Step 2
1-460 1 ELECTRICAL TROUBLESHOOTING

[Link] Step 2
1. Turn the output of unload solenoid ON forcibly with “ACT-
IVE TEST”, and check for errors.
[ANL] ACTIVE TEST 2/3
UNLOAD SOL: OFF → ON

Judgment
Result Procedure
No HC-2 error Connector connection defect
HC-2 error Go to Step 3

[Link] Step 3
Single unit inspect the unload solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the unload solenoid.
Notes:
CN88 Disconnect the battery plug, and conduct after visually inspect-
ing there are no problems inside the CN88 connector, and on
4 3 2 1
the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Portion to be inspected Standard
CN88-1 (3) to CN88-5 (5) Approx. 10 Ω

Judgment
Result Procedure
NG Unload solenoid defect
OK Go to Step 4
1 ELECTRICAL TROUBLESHOOTING 1-461

[Link] Step 4
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN102 and CN88.
3. Inspect conduction and short circuit of the harness.
Notes:
CN102 Disconnect the battery plug, disconnect the CN102 and
CN88 CN88 connectors, and conduct after visually inspecting
1 2 3 4 5 6 7 there are no problems inside the connector, and on the
8 9 10 11 12 13 14 15 16 17 18 19
1 2 3 4 wire caulking.
20 21 22 23 24 25 26 27
5 6 7 8
(Refer to "BEFORE TROUBLESHOOTING").
28 29 30 31 32 33 34 35

Portion to be inspected Standard

CN88-1 (3) to CN88-5 (5) No conduction
CN102-17 (5) to P2 No conduction
CN102-17 (5) to P3 No conduction

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-462 1 ELECTRICAL TROUBLESHOOTING

1.4.164 HC-3
Failure mode: Unload solenoid driving circuit abnormality

Probable cause
▪ Unload solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-1 (3) CN102-17 (5, SLUL-) controller
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
Inspect the unload solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the unload solenoid.
Notes:
CN88 Disconnect the battery plug, and conduct after visually in-
specting there are no problems inside the CN88 connector,
4 3 2 1
and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Portion to be inspected Standard
CN88-1 (3) to CN88-5 (5) Approx. 10 Ω

Judgment
Result Procedure
Go to Step 2
NG
Unload solenoid defect
OK Go to Step 2
1 ELECTRICAL TROUBLESHOOTING 1-463

[Link] Step 2
1
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN101, CN102 and CN88.

CN101
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102
8 9 10 11 12 13 14 15 16 17
and CN88 connectors, and conduct after visually inspect-
18 19 20 21 22 23 24 25 26 27 CN88
28 29 30 31 32 33 34 ing there are no problems inside the connector, and on the
wire caulking.
1 2 3 4
CN102 (Refer to "BEFORE TROUBLESHOOTING").
5 6 7 8
Portion to be inspected Standard
1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 CN88-1 (3) to CN88-5 (5) No conduction

20 21 22 23 24 25 26 27
CN101-1 (3) to CN102-17 (5) No conduction
28 29 30 31 32 33 34 35
CN102-17 (5) to P2 No conduction
CN102-17 (5) to P3 No conduction

Judgment
Result Procedure
Harness defect
NG Main controller defect Replace along with the failed part in
Step 1
Main controller defect Replace along with the failed part in
OK
Step 1
1-464 1 ELECTRICAL TROUBLESHOOTING

1.4.165 HC-4
Failure mode: Unload solenoid open/short abnormality

CAUTION
• When HC-3 occurs, promptly disconnect the battery plug, and perform troubleshooting for HC-3.
• If A9-2 is displayed at the same time, give a higher priority to troubleshooting of A9-2.

Probable cause
▪ Connector connection defect
▪ Unload solenoid defect
▪ Harness defect
▪ Main controller defect

Related part

MB
P2 P3 CN102-3 (19, VBMBSL)

CN136-6 (19) F7
CN140-4 CN140-3 (19) CN102-4 (19, VBMBSL)

CN101-1 (3, SOLLU+)

Main
CN88-1 (3) CN102-17 (5, SLUL-) controller
N1 Unload
solenoid CN88-5 (5) CN103-5 (N2, N2)
CN104-4 (N2, N2)
CN104-5 (N2, N2)
CN104-6 (N2, N2)
N2

[Link] Step 1
1. Turn the key switch OFF, and disconnect the battery plug.
2. Visually inspect inside the connector of CN88, and on the
wire caulking for errors.
(Refer to "BEFORE TROUBLESHOOTING").
3. Connect CN88 first, and then connect the battery plug.
4. Turn the key switch ON, and check the error display.

Judgment
Result Procedure
HC-4 error Go to Step 2
No HC-4 error Connector connection defect
1 ELECTRICAL TROUBLESHOOTING 1-465

[Link] Step 2
1
Single unit inspect the unload solenoid
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect CN88.
3. Measure the resistance of the unload solenoid.
Notes:
CN88 Disconnect the battery plug, and conduct after visually in-
specting there are no problems inside the CN88 connector,
4 3 2 1
and on the wire caulking.
(Refer to "BEFORE TROUBLESHOOTING").
8 7 6 5
Portion to be inspected Standard
CN88-1 (3) to CN88-5 (5) Approx. 10 Ω

Judgment
Result Procedure
NG Unload solenoid defect
OK Go to Step 3

[Link] Step 3
Inspect the harness
1. Turn the key switch OFF, and disconnect the battery plug.
2. Disconnect the CN101, CN102, CN103, and CN88 connect-
ors.

CN101 CN102
3. Inspect conduction and short circuit of the harness.
Notes:
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Disconnect the battery plug, disconnect the CN101, CN102,
8 9 10 11 12 13 14 15 16 17 8 9 10 11 12 13 14 15 16 17 18 19
18 19 20 21 22 23 24 25 26 27 20 21 22 23 24 25 26 27
CN103, and CN88 connectors, and conduct after visually in-
28 29 30 31 32 33 34 28 29 30 31 32 33 34 35 specting inside the connector, and on the wire caulking for
errors.
CN103 CN88
(Refer to "BEFORE TROUBLESHOOTING").

1 2 3 4 5 6
1 2 3 4
7 8 9 10 11 12 13 14 15 16 Portion to be inspected Standard
17 18 19 20 21 22 23 24 25 26 27 5 6 7 8
28 29 30 31 32 33 34 35
CN101-1 (3) to CN88-1 (3) Conduction⁽¹⁾
CN102-17 (5) to CN88-5 (5) Conduction⁽¹⁾
CN88-1 (3) to CN88-5 (5) No conduction⁽¹⁾
CN101-1 (3) to CN103-5 (N2) No conduction
CN102-17 (5) to CN103-5 (N2) No conduction
⁽¹⁾: Connect CN88, and it can be checked that the measured
resistance value between CN101-1 and CN102-17 is approx.
10 Ω.

Judgment
Result Procedure
NG Harness defect
OK Main controller defect
1-466 1 ELECTRICAL TROUBLESHOOTING

1.4.166 COLD DCR (Safety motor)

Failure mode: Drive motor driver temperature low
1. If the warning indicator is ON, leave the truck for 20 to 30
minutes at normal temperature (0 to 40℃) with the key
switch ON.

1.4.167 COLD PCR (Safety motor)

Failure mode: Pump motor driver temperature low
1. If the warning indicator is ON, leave the truck for 20 to 30
minutes at normal temperature (0 to 40℃) with the key
switch ON.
1 ELECTRICAL TROUBLESHOOTING 1-467

1.5 NO ERROR CODE IS DISPLAYED 1

When an error is displayed or the wrench mark is ON, always give a priority to the
error or the mark.

1.5.1 Power related

1-468 1 ELECTRICAL TROUBLESHOOTING

Control category/Power related

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Emergency power shut-down
button body (With the emer- ▪ Release the emer-
gency power shutdown button - gency power shut-
attached) down button
: Pushed state of the switch
Inspect the battery
voltage
Battery
: Check the battery plug ▪ Battery charge
: Low voltage
OFF state
and battery voltage
Key switch body
: Open failure
Emergency power shut-down ▪ Inspect and replace
button body (With the emer- the switch
gency power shutdown button
▪ Harness check, repair,
attached)
- and replace
: Open failure
▪ Replace F5 fuse
Key switch harness
▪ Replace F6 fuse (80V
: Disconnection, short circuit, truck)
and leakage problem (Harness,
battery plug, connector, F5
fuse, and F6 fuse (80V truck))
The power cannot Numerical key harness (Oper-
be applied when the ator authentication device at- ▪ Harness check, repair,
key switch and/or tached) -
and replace
the numeric key is
operated : Open failure
(The multifunction Check operation of each
display is not dis- switch
played and the truck : Check a specific switch
does not move) does not respond (LED,
and buzzer sound)
In the combination of
Numerical key body (Operator (1,2,3), the combination of
authentication device attached) (4,5,6), the combination of ▪ Replace the numeric
key body
: Failure of each switch (7,8,9), and the combina-
tion of (OFF, 0, ON).
When there are switches
that respond and do not
respond in each combina-
tion, it is certainly a switch
failure.
Multifunction display (Operator
authentication device attached) Check if PIN is registered ▪ Register PIN in the
in the Administrator menu Administrator menu
: PIN not registered
Numeric keypad harness
(Telematics equipped type) ▪ Harness check, repair,
-
and replace
: Open failure
Check operation of each
Numeric keypad body switch
(Telematics equipped type) ▪ Replace the numeric
: Check all or only a spe-
: Internal failure cific switch do not re- key body
: Failure of each switch spond (Green LED or
RED LED ON)
1 ELECTRICAL TROUBLESHOOTING 1-469

Control category/Power related

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
▪ Using TruckCom,
switch the operator
Numeric key body (Telematics authentication function
equipped truck) of the numeric key
-
body to server man-
: Not server management agement (Refer to re-
placing the numeric
key)
Operation management system
(Telematics equipped truck) Check PIN code is re- ▪ Register PIN code in
gistered in the Web site the Web site
: PIN code not registered
▪ From the Truck Man-
agement screen in the
Operation management system Web site, start com-
(Telematics equipped truck) munication (Permis-
- sion to manage the
: PIN code cannot be down- truck is required) or
loaded start communication
The power cannot forcibly using Truck-
be applied when the Com
key switch and/or Display power and grand har-
the numeric key is ness (Operator authentication
operated device attached or Telematics
(The multifunction equipped truck)
display is not dis- : Disconnection, short circuit,
played and the truck and leakage problem (Harness ▪ Harness check, repair,
does not move) and connector) and replace
Multifunction display (Operator - ▪ Replace the display
authentication device attached ▪ Replace the main con-
or Telematics equipped truck) troller
: Internal failure
Main controller
: Internal failure (D7V and
DGND)
CAN bridge controller power
and grand harness (Telematics
equipped truck)
▪ Harness check, repair,
: Disconnection, short circuit,
and replace
and leakage problem (Harness -
and connector) ▪ Replace the CAN
bridge controller
CAN bridge controller
: Internal failure (Operation
management system attached)
Display power and grand har-
ness
: Disconnection, short circuit, ▪ Harness check, repair,
and leakage problem (Harness and replace
Multifunction display
and connector)
is not displayed (The - ▪ Replace the display.
truck moves) Multifunction display
▪ Replace the main con-
: Internal failure troller
Main controller
: Internal failure
1-470 1 ELECTRICAL TROUBLESHOOTING

1.5.2 Traveling
Control category/Traveling
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Check the warning display *Not an error
and warning sound on the
display The warm-up function
may be activated for a few
*Depending on how a seconds after the key
customer uses (for ex- switch is turned ON to
Warm-up function at low tem- ample, leaving a truck in protect the controller.
perature protection activated low temperature for a long
duration), when the warn- Note that traveling and
ing-up function is activ- load handling operations
ated, the warning is dis- are unavailable during
played and the warning warming-up. Perform this
sound notifies the cus- operations after the warn-
tomer. ing sound stops.
After the key is turned
ON, set acceleration-off
and direction neutral
After the key is turned ON, it is once, and then conduct
not set to acceleration-off and - traveling operation.
direction neutral Until acceleration-off and
direction neutral are de-
tected, traveling cannot
be conducted.
Unable to travel (the Inspect the direction
travel motor does switch by using an ana-
not rotate) or cannot lyzer
climb a slope sud- Direction switch body
: Accelerator full-closed ▪ Inspect and replace
denly : Open failure state the switch
Direction switch harness Operate the direction
▪ Harness check, repair,
: Disconnection, and short cir- switch to check ON/OFF
and replace
cuit (Harness and connector) (When forward and re-
verse are ON at the same
time, traveling cannot be
conducted)
Accelerator sensor body
: Internal failure Inspect the accelerator
Accelerator sensor installed sensor by using an ana-
part lyzer ▪ Inspect and replace
: Link, installed part damage, : Direction neutral state the sensor
and damage Perform accelerator full- ▪ Harness check, repair,
Accelerator sensor harness closed to full-open, and and replace
check the input signal
: Disconnection, short circuit, change
and leakage problem (Harness
and connector)
Accelerator sensor Full-open,
full-close matching value Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
1 ELECTRICAL TROUBLESHOOTING 1-471

Control category/Traveling
Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Brake sensor body
: Internal failure
Inspect the brake sensor
Brake sensor installed part
by using an analyzer ▪ Inspect and replace
: Link, installed part damage, the sensor
: Direction neutral state
and damage
Perform accelerator full- ▪ Harness check, repair,
Brake sensor harness closed to full-open, and and replace
: Disconnection, short circuit, check the voltage change
and leakage problem (Harness
and connector)
Brake sensor Full-closed, Oper-
ating point matching Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
Seat switch body Inspect the seat switch by
using an analyzer ▪ Inspect and replace
: Open failure
: Direction neutral, accel- the seat
Seat switch harness
erator full-closed state ▪ Harness check, repair,
: Disconnection (Harness and Sit on the seat and leave and replace
connector) the seat to check ON/OFF
Inspect the brake/travel-
ing motor
Brake ▪ Inspect, repair, and
: In the battery plug
Unable to travel (the : Dragging (Internal failure) OFF, the parking brake replace the brake
travel motor does Travel motor released, and front ▪ Inspect, repair, and
not rotate) or cannot
: Traveling motor fixation, and wheels raised state replace the traveling
climb a slope sud- turn the tires with your motor
dragging (Internal failure)
denly hands to check if they ro-
tate
Traveling motor rotation sensor
body Inspect the traveling mo-
: Internal failure tor rotation sensor voltage
by using an analyzer ▪ Inspect, adjust, and
Traveling motor rotation sensor
: In sitting on the seat, dir- replace the traveling
installed part
ection forward, and brake motor rotation sensor
: Gap adjustment failure
released state ▪ Harness check, repair,
Traveling motor harness Operate the accelerator, and replace
: Disconnection, short circuit, and check the rotation
and leakage problem (Harness sensor voltage change
and connector)
Inspect the traveling mo-
Traveling motor driver tor current sensor voltage
by using an analyzer
: Internal failure ▪ Cable check, repair,
: In sitting on the seat, dir- and replace
Motor cable
ection forward, and brake
: Disconnection, short circuit, ▪ Replace the traveling
released state
and leakage problem (Cable motor driver
Operate the accelerator,
and machine stand) and check the current
sensor voltage change
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-472 1 ELECTRICAL TROUBLESHOOTING

Control category/Traveling
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
*Not an error
Traveling control is Check the warning display
Truck performance control is
applied (Telematics and warning sound on the Contact the administrator,
applied due to shock detection and request to release the
equipped truck) display
control.

1.5.3 Traveling control (OPT)

Control category/Traveling control (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Inspect the load sensor
Load sensor body voltage by using an ana-
: Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Harness check, repair,
and leakage problem (Harness lowering to at most up- and replace
and connector) ward lifting (relief), and
check the voltage change
Display settings
Check the tire diameter in
: Does not match the tire dia- ▪ Correct settings
the matching screen
meter data with the truck state
Traveling control influ-
ences attachment, and
own weight of the mast
also influences the truck’s
forward and reverse sta-
bility; therefore, it is
treaded as load weight.
Heavy attachment, and lifted
- Speed control may be ap-
height mast
plied even with no load if
In case of no load,
the own weight of inner
speed control is ap-
and middle mast is heavy
plied in the high lift
for the heavy class attach-
height
ment and high lift height
mast among the FSV
masts.
After the most upward lift-
ing, the relief pressure re-
mains in the lift cylinder
pressure that detects with
the load sensor, and it
cannot be distinguished
with the hauling state of
Detect the lift relief pressure - weight load.
After lift relief, by lowering
a little, the relief pressure
is released; therefore,
when it causes a problem
in operation, use by
lowering a little from the
most upward lifting state.
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-473

Control category/Traveling control (OPT)

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Inspect the load sensor
Load sensor body voltage by using an ana-
: Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Harness check, repair,
and leakage problem (Harness lowering to at most up- and replace
and connector) ward lifting (relief), and
check the voltage change
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the low lift lyzer ▪ Inspect and replace
height : In NL state the switch
Lift switch harness Operate the lift at lowest ▪ Harness check, repair,
Even though load is lowering to at most up- and replace
hauled, speed con- : Disconnection, and short cir- ward lifting, and check
trol is not applied in cuit (Harness and connector) ON/OFF
the high lift height
Display settings
: Disabling the traveling control
settings
Check the setting values
Disabling the load sensing ▪ Change settings
in the Option Set screen
speed control
(Option set ASC W/LOAD,
MODE)
Display settings
Check the tire diameter in
: Does not match the tire dia- ▪ Correct settings
the matching screen
meter data with the truck state
Main controller ▪ Replace the main con-
-
: Internal failure troller
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the high lift lyzer ▪ Inspect and replace
height : In NL state the switch
In low lift height,
speed control is ap- Lift height switch harness Operate the lift at lowest ▪ Harness check, repair,
plied when load is : Disconnection, and short cir- lowering to at most up- and replace
hauled cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
Display settings
: Maximum speed control, and Check setting values ▪ Change settings
low speed setting
Regardless of lift
height and load, the Display settings
Check the tire diameter in
speed control is al- : Does not match the tire dia- ▪ Correct settings
the matching screen
ways applied meter data with the truck state
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-474 1 ELECTRICAL TROUBLESHOOTING

1.5.4 Traveling turning control (OPT)

1 ELECTRICAL TROUBLESHOOTING 1-475

Control category/Traveling turning control (OPT)

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
▪ Inspect and replace
Tire body
tires
: Type, diameter, and air pres- -
▪ Inspect and repair air
sure
pressure
Inspect the load sensor
Load sensor body voltage by using an ana-
: Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Harness check, repair,
and leakage problem (Harness lowering to at most up- and replace
and connector) ward lifting (release), and
check the voltage change
Load sensor no load matching
value Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the low lift lyzer ▪ Inspect and replace
height : In NL state the switch
Lift height switch harness Operate the lift at lowest ▪ Harness check, repair,
: Disconnection, and short cir- lowering to at most up- and replace
cuit (Harness and connector) ward lifting, and check
ON/OFF
Tire angle sensor body
No stability during : Internal failure
traveling Inspect the tire angle
Tire angle sensor installation sensor voltage by using
(Speed control is dif- ▪ Inspect and replace
an analyzer
ficult during turning : Installed part damage, and the sensor
or no control is ap- damage : Direction neutral, accel-
▪ Harness check, repair,
plied) Tire angle sensor harness erator full-closed state
and replace
Steer and check the
: Disconnection, short circuit, voltage change.
and leakage problem (Harness
and connector)
Matching value of the tire angle
sensor at the straight traveling
angle Check the matching value
▪ Re-matching
in the matching screen
: Does not match with the truck
state
Traveling motor rotation sensor
body
: Internal failure ▪ Inspect and replace
Drive motor rotation sensor har- the sensor
ness ▪ Harness check, repair,
-
: Disconnection, short circuit, and replace
and leakage problem (Harness ▪ Replace the traveling
and connector) motor driver
Drive motor driver
: Internal failure
Display settings
Check the tire diameter in
: Does not match the tire dia- ▪ Correct settings
the matching screen
meter data with the truck state
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-476 1 ELECTRICAL TROUBLESHOOTING

1.5.5 Handling & power steering

Control category/Handling & power steering
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Check the warning display *Not an error
and warning sound on the
display The warm-up function
may be activated for a few
*Depending on how a seconds after the key
customer uses (for ex- switch is turned ON to
Warm-up function at low tem- ample, leaving a truck in protect the controller.
perature protection activated low temperature for a long
duration), when the warn- Note that traveling and
ing-up function is activ- load handling operations
ated, the warning is dis- are unavailable during
played and the warning warming-up. Perform this
sound notifies the cus- operations after the warn-
tomer. ing sound stops.
Pump motor rotation sensor
body
: Internal failure Inspect the Pump motor
rotation sensor voltage by ▪ Inspect, adjust, and
Unable to handle, Pump motor rotation sensor in-
using an analyzer replace the Pump mo-
and steering is stalled part
: In sitting on the seat tor rotation sensor
heavy : Gap adjustment failure
Operate the direction, and ▪ Harness check, repair,
(In all load handling, Pump motor harness check the rotation sensor and replace
steering, and direc- voltage change
tion operation, the : Disconnection, short circuit,
handling motor does and leakage problem (Harness
not rotate) and connector)
Inspect the pump motor
Pump motor driver current sensor voltage by
: Internal failure using an analyzer ▪ Motor cable check, re-
Motor cable : In sitting state on the pair, and replace

: Disconnection, short circuit, seat ▪ Replace the pump

and leakage problem (Cable Operate the direction, and motor driver
and machine stand) check the current sensor
voltage change
▪ Inspect, repair, and
Load handling pump replace the load hand-
: Fixed ling pump
-
Pump motor ▪ Inspect, repair, and
: Fixed replace the Pump mo-
tor
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-477

Control category/Handling & power steering

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Load handling lever poten-
tiometer body
Inspect the load handling
: Internal failure lever potentiometer
Load handling lever poten- voltage by using an ana-
tiometer attachment lyzer ▪ Inspect and replace
: Installed part damage, and : In unseated state on the the sensor
damage seat ▪ Harness check, repair,
Load handling lever poten- Operate the load handle and replace
tiometer harness lever forward tilt to rear
tilt, and check the voltage
: Disconnection, short circuit, change.
and leakage problem (Harness
and connector)
Forward tilt/rear tilt switch body
(Standard lever truck)
: Internal failure Inspect the lift forwarding/
Forward tilt/rear tilt attachment rearing switch by using an
(Standard lever truck) analyzer ▪ Inspect and replace
: Installed part damage, and : In unseated state on the the switch
damage seat ▪ Harness check, repair,
Forward tilt/rear tilt switch har- Operate the forward tilt and replace
Load handling only lever to rear tilt, and
is not possible ness (Standard lever truck)
check ON/OFF.
(In steering, and dir- : Disconnection, short circuit,
ection operation, ro- and leakage problem (Harness
tate the pump motor and connector)
with the direction op- Seat switch body Inspect the seat switch by
eration) using an analyzer ▪ Inspect and replace
: Open failure
: Load handling lever the seat
Seat switch harness
neutral state ▪ Harness check, repair,
: Disconnection (Harness and Sit on the seat and leave and replace
connector) the seat to check ON/OFF
Oil control valve (Standard
lever truck) ▪ Replace, repair, and
replace the oil control
: Unload valve fixation, and valve
leakage
- ▪ Inspect and replace
Unload solenoid harness the unload solenoid
: Disconnection, short circuit, ▪ Harness check, repair,
and leakage problem (Harness and replace
and connector)
▪ Inspect, repair, and
Load handling pump replace the load hand-
: Leakage ling pump
-
Priority valve ▪ Inspect, repair, and
: Leakage and fixation replace the priority
valve
Main controller ▪ Replace the main con-
-
: Internal failure troller
Unable to descent Set the descending lock
▪ Inspect, repair, and
(Able to ascend, and Descent lock valve solenoid ON in the active
replace the descent
other load handling : Fixed (Internal damage) test, and conduct des-
lock valve
is possible) cending operation
1-478 1 ELECTRICAL TROUBLESHOOTING

Control category/Handling & power steering

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Unable to forward tilt Set the forward tilt lock
▪ Inspect, repair, and
only (Able to tilt rear, Forward tilt lock valve solenoid ON in the active
replace the forward tilt
and other load hand- : Fixed (Internal damage) test, and conduct forward
lock valve
ling is possible) tilt operation
Unable to tilt rear Set the backward tilt lock
▪ Inspect, repair, and
only (Able to tilt for- Backward tilt lock valve solenoid ON in the active
replace the backward
ward, and other load : Fixed (Internal damage) test, and conduct tilt rear
tilt lock valve
handling is possible) operation
Inspect the direction
Direction switch switch by using an ana-
lyzer ▪ Inspect and replace
: Open failure
: Accelerator full-closed the switch
Direction switch harness
state ▪ Check, repair, and re-
: Disconnection problem (Har- Operate the direction place the harness
ness and connector) switch to check ON/OFF

Steering-wheel angle sensor

body
: Internal damage
Inspect the steering-wheel
Steering-wheel angle sensor at-
angle sensor by using an ▪ Inspect and replace
tachment
analyzer the sensor
Steering is heavy : Cam or steering wheel failure
: Check the input single ▪ Check, repair, and re-
(In load handling op- Steering-wheel angle sensor
by conducting steering place the harness
eration, the pump harness operation
motor rotates)
: Disconnection, short circuit,
and leakage problem (Harness
and connector)
▪ Inspect, repair, and
Load handling pump
replace the load hand-
: Leakage ling pump
Priority valve ▪ Inspect, repair, and
-
: Leakage and fixation replace the priority
valve
PS valve
▪ Inspect, repair, and
: Leakage and fixation
replace the PS valve
Main controller ▪ Replace the main con-
-
: Internal failure troller
When ATT1 (ATT2) Display settings
is operated, it does
not function : The serial number of oil con-
Check the setting values
trol valve does not match the Change settings
(The pump motor in the Option Set screen
machine stand specification
does not also rotate
by ATT operation) (Option set OCV WAY)
1 ELECTRICAL TROUBLESHOOTING 1-479

1.5.6 Tilt control (OPT) 1

Control category/Tilt control (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Tilt angle sensor body
: Internal damage Inspect the tilt angle
sensor voltage by using
Tilt angle sensor installation
an analyzer ▪ Inspect, adjust, and
: Link, installed part damage, replace the sensor
: NL state
and damage
Operate from the front ▪ Check, repair, and re-
Tilt angle sensor harness most tilting to the last tilt- place the harness
: Disconnection, short circuit, ing, and check the voltage
and leakage problem (Harness change.
and connector)
Horizontal matching value of
the tilt angle sensor Check the matching value
▪ Re-matching
: Does not match with the in the matching screen
truck state
Automatic horizontal switch
Forward tilt auto- body
matic leveling stop Inspect the automatic ho-
: Open failure
does not work rizontal switch by using an
Automatic horizontal switch de-
(Forward most tilt in- analyzer ▪ Inspect and replace
tection mechanism part
stead of stopping in : Load handling neutral the switch
the level position) : Gap adjustment failure on the
state ▪ Check, repair, and re-
detection part
Operate the automatic ho- place the harness
Automatic horizontal switch rizontal switch to check
harness ON/OFF
: Disconnection problem (Har-
ness and connector)
Oil control valve Inspect the tilt control ▪ Replace, repair, and
: Tilt control valve fixation, and valve with the active test replace the oil control
leakage valve
: Force OFF the tilt control
Tilt solenoid harness solenoid (forward tilt stop) ▪ Inspect and replace
state the solenoid
: Short circuit and leakage
problem (Harness and con- Conduct forward tilt, and ▪ Check, repair, and re-
nector) check the operation place the harness
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-480 1 ELECTRICAL TROUBLESHOOTING

Control category/Tilt control (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Tire angle sensor body
: Internal damage Inspect the tilt angle
sensor voltage by using
Tilt angle sensor installation
an analyzer ▪ Inspect, adjust, and
: Link, installed part damage, replace the sensor
: NL state
and damage
Operate from the front ▪ Check, repair, and re-
Tilt angle sensor harness most tilting to the last tilt- place the harness
: Disconnection, short circuit, ing, and check the voltage
and leakage problem (Harness change.
and connector)
Horizontal matching value of
Forward tilt auto- the tilt angle sensor Check the matching value
▪ Re-matching
matic leveling stop : Does not match with the truck in the matching screen
does not work state
(Stops in the posi- Inspect the load sensor
Load sensor body voltage by using an ana-
tion shifted from ho-
rizontal position) : Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Check, repair, and re-
and leakage problem (Harness lowering to at most up- place the harness
and connector) ward lifting (release), and
check the voltage change
Load sensor no load matching
value Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-481

Control category/Tilt control (OPT)

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Tire angle sensor body
: Internal damage Inspect the tilt angle
sensor voltage by using
Tilt angle sensor installation
an analyzer ▪ Inspect, adjust, and
: Link, installed part damage, replace the sensor
: NL state
and damage
Operate from the front ▪ Check, repair, and re-
Tilt angle sensor harness most tilting to the last tilt- place the harness
: Disconnection, short circuit, ing, and check the voltage
and leakage problem (Harness change.
and connector)
Horizontal matching value of
the tilt angle sensor Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
Inspect the load sensor
Forward tilt auto- Load sensor body voltage by using an ana-
matic leveling stop : Internal damage lyzer ▪ Inspect and replace
does not work the sensor
Load sensor harness : In NL state
(Stops on the posi- Operate the lift at lowest ▪ Check, repair, and re-
tion that the auto- : Disconnection, short circuit,
matic horizontal and leakage problem (Harness lowering to at most up- place the harness
and connector) ward lifting (release), and
switch is pushed) check the voltage change
Load sensor no load matching
value Check the matching value
▪ Re-matching
: Does not match with the truck in the matching screen
state
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the high lift lyzer ▪ Inspect and replace
height : In NL state the switch
Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
: Disconnection, and short cir- lowering to at most up- place the harness
cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-482 1 ELECTRICAL TROUBLESHOOTING

Control category/Tilt control (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Automatic horizontal switch
body
: Open failure Inspect the automatic ho-
rizontal switch by using an
Automatic horizontal switch de-
analyzer ▪ Inspect and replace
tection mechanism part
: Load handling neutral the switch
: Gap adjustment failure on the
state ▪ Check, repair, and re-
detection part
Operate the automatic ho- place the harness
Automatic horizontal switch rizontal switch to check
harness ON/OFF
The mast forward tilt : Disconnection problem (Har-
control is not con- ness and connector)
trolled
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the low lift lyzer ▪ Inspect and replace
height : In NL state the switch
Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
: Disconnection, and short cir- lowering to at most up- place the harness
cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-483

Control category/Tilt control (OPT)

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Automatic horizontal switch
body
: Short failure Inspect the automatic ho-
rizontal switch by using an
Automatic horizontal switch de-
analyzer ▪ Inspect and replace
tection mechanism part
: Load handling neutral the switch
: Gap adjustment failure on the
state ▪ Check, repair, and re-
detection part
Operate the automatic ho- place the harness
Automatic horizontal switch rizontal switch to check
harness ON/OFF
: Short circuit (Harness and
connector)
Oil control valve Check the forward tilt lock ▪ Replace, repair, and
: Forward tilt lock valve fixation valve with the active test replace the oil control
and leakage valve
: Force OFF the Forward
Forward tilt solenoid harness tilt solenoid (No tilt rear ▪ Inspect and replace
tilting speed limit) state the solenoid
: Short circuit and leakage
The mast rear tilt problem (Harness and con- Conduct tilt rear tilting, ▪ Check, repair, and re-
speed of the mast is nector) and check the operation place the harness
constantly slow Check the backward tilt
Oil control valve ▪ Replace, repair, and
lock valve with the active replace the oil control
: Backward tilt lock valve fixa-
test valve
tion and leakage
: Force ON the backward ▪ Inspect and replace
Backward tilt solenoid harness
tilt solenoid (No tilt rear the solenoid
: Disconnection, short circuit, tilting speed limit) state
and leakage problem (Harness Conduct tilt rear tilting, ▪ Check, repair, and re-
and connector) and check the operation place the harness
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the high lift lyzer ▪ Inspect and replace
height : In NL state the switch
Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
: Disconnection, and short cir- lowering to at most up- place the harness
cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
Display settings
: Forward tilt speed regulated Check the setting values
▪ Change settings
control “NO” (Disabled) settings in the Option Set screen
(Option set T F-SPD LIM)
Inspect the lift height
Lift height switch body switch by using an ana-
The forward tilt
speed of the mast is : Always detect the low lift lyzer ▪ Inspect and replace
not controlled in high height : In NL state the switch
lift height Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
: Disconnection, and short cir- lowering to at most up- place the harness
cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-484 1 ELECTRICAL TROUBLESHOOTING

Control category/Tilt control (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the high lift lyzer ▪ Inspect and replace
height : In NL state the switch
The mast forward tilt Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
speed is constantly lowering to at most up- place the harness
slow : Disconnection, and short cir-
cuit (Harness and connector) ward lifting, and check
ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-485

1.5.7 Swing lock (OPT) 1

Control category/Swing lock (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
▪ Inspect and replace
Tire body
tires
: Type, diameter, and air pres- -
▪ Inspect and repair air
sure
pressure
Lock cylinder body
: Leakage, and unable to lock Inspect the lock cylinder ▪ Inspect, repair, and
Lock cylinder installation in the active test replace the lock cylin-
der
: Installed part damaged, and : Force ON the swing
broken solenoid (Release the ▪ Inspect and replace
lock)/Force OFF (Lock), the swing solenoid
Swing solenoid harness
and check the lock cylin- ▪ Check, repair, and re-
: Short circuit and leakage der state place the harness
problem (Harness and con-
nector)
Inspect the load sensor
Load sensor body voltage by using an ana-
: Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Check, repair, and re-
and leakage problem (Harness lowering to at most up- place the harness
and connector) ward lifting (release), and
check the voltage change
Inspect the lift height
No stability during Lift height switch body switch by using an ana-
traveling : Always detect the low lift lyzer ▪ Inspect and replace
(Traveling lock is un- height : In NL state the switch
likely to happen or Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
does not happen)
: Disconnection, and short cir- lowering to at most up- place the harness
cuit (Harness and connector) ward lifting, and check
ON/OFF
Yaw rate sensor body
Inspect the yaw rate
: Lowered sensitivity, and
sensor by using an ana- ▪ Inspect and replace
voltage fixation (Internal dam-
lyzer the sensor
age)
: Truck in stopped state ▪ Check, repair, and re-
Yaw rate sensor harness
Check the sensor voltage place the harness
: Leakage problem (Harness is approx. 2.5 V
and connector)
Traveling motor rotation sensor
body
: Internal failure
Drive motor rotation sensor har-
ness
- ▪
: Disconnection, short circuit,
and leakage problem (Harness
and connector)
Drive motor driver
: Internal failure
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-486 1 ELECTRICAL TROUBLESHOOTING

Control category/Swing lock (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Lock cylinder body Inspect the lock cylinder ▪ Inspect, repair, and
in the active test replace the lock cylin-
: Lock fixation der
: Force ON the swing
Swing solenoid harness ▪ Inspect, and replace
solenoid (Release the
: Disconnection, short circuit, lock)/Force OFF (Lock), the solenoid
and leakage problem (Harness and check the lock cylin- ▪ Check, repair, and re-
and connector) der state place the harness
Inspect the load sensor
Load sensor body voltage by using an ana-
: Internal damage lyzer ▪ Inspect and replace
Load sensor harness : In NL state the sensor

: Disconnection, short circuit, Operate the lift at lowest ▪ Check, repair, and re-
and leakage problem (Harness lowering to at most up- place the harness
and connector) ward lifting (release), and
check the voltage change
Inspect the lift height
Lift height switch body switch by using an ana-
: Always detect the high lift lyzer ▪ Inspect and replace
height : In NL state the switch
Always swing locked Lift height switch harness Operate the lift at lowest ▪ Check, repair, and re-
during traveling and : Disconnection, and short cir- lowering to at most up- place the harness
load handing opera- cuit (Harness and connector) ward lifting, and check
tion, or swing locked ON/OFF
frequently Yaw rate sensor body Inspect the yaw rate
: Lowered sensitivity, and sensor by using an ana- ▪ Inspect and replace
voltage fixation lyzer the sensor
Yaw rate sensor harness : Truck in stopped state ▪ Check, repair, and re-
: Leakage problem (Harness Check the sensor voltage place the harness
and connector) is approx. 2.5 V
Traveling motor rotation sensor
body
: Internal failure ▪ Inspect and replace
Drive motor rotation sensor har- the sensor
ness ▪ Check, repair, and re-
-
: Disconnection, short circuit, place the harness
and leakage problem (Harness ▪ Replace the traveling
and connector) motor driver
Drive motor driver
: Internal failure
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-487

1.5.8 Knob compensation control (OPT) 1

Control category/Knob compensation control (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Tire angle sensor body
: Internal failure
Inspect the sensor voltage
Tire angle sensor installation
by using an analyzer ▪ Inspect and replace
: Installed part damage, and the sensor
: Direction neutral, accel-
damage
erator full-closed state ▪ Check, repair, and re-
Tire angle sensor harness Steer and check the place the harness
: Disconnection, short circuit, voltage change.
and leakage problem (Harness
and connector)
Matching value of the tire
sensor at the straight traveling
angle Check the matching value
▪ Re-matching
in the matching screen
: Does not match with the truck
state
Steering-wheel angle sensor
body
: Internal damage
Inspect the steering-wheel
Steering-wheel angle sensor at-
angle sensor by using an ▪ Inspect and replace
tachment
analyzer the sensor
: Cam or steering wheel failure
: Check the input single ▪ Check, repair, and re-
A knob position Steering-wheel angle sensor by conducting steering place the harness
shifts to a specific harness operation
position : Disconnection, short circuit,
(10ํํ° or more and leakage problem (Harness
from the straight and connector)
traveling position) Check the knob compens-
ation valve with the active
test
Knob compensation valve body
: In the tire end state ▪ Inspect, repair, and
: Leakage, and fixation (Internal replace the knob com-
Force ON the knob com-
damage) pensation valve
pensation solenoid (By-
Knob compensation solenoid pass)/Force OFF ▪ Inspect, repair and re-
harness (Bypass stop), and check place the solenoid
: Disconnection, short circuit, operation at steering
▪ Check, repair, and re-
and leakage problem (Harness Force ON ... Steering place the harness
and connector) spins (Light)
Force OFF ... Steering
does not spin (Heavy)
When traveling on a road
surface that is tilted to
right and left for the mov-
ing direction of a truck,
The road has slope -
the knob position required
for traveling straight dif-
fers when traveling on a
horizontal road surface.
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-488 1 ELECTRICAL TROUBLESHOOTING

Control category/Knob compensation control (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Tire angle sensor body
: Internal failure
Inspect the sensor voltage
Tire angle sensor installation
by using an analyzer ▪ Inspect and replace
: Installed part damage, and the sensor
: Direction neutral, accel-
damage
erator full-closed state ▪ Check, repair, and re-
Tire angle sensor harness Steer and check the place the harness
: Disconnection, short circuit, voltage change.
and leakage problem (Harness
and connector)
Matching value of the tire
sensor at the straight traveling
angle Check the matching value
▪ Re-matching
in the matching screen
: Does not match with the truck
state
Steering-wheel angle sensor
body
: Internal damage
Inspect the steering-wheel
Steering-wheel angle sensor at-
angle sensor by using an ▪ Inspect and replace
tachment
analyzer the sensor
Knob position shifts : Cam or steering wheel failure : Check the input single ▪ Check, repair, and re-
(The knob position Steering-wheel angle sensor by conducting steering place the harness
at traveling straight harness operation
is not stable) : Disconnection, short circuit,
and leakage problem (Harness
and connector)
Check the knob compens-
ation valve with the active
test
Knob compensation valve body : In the tire end state ▪ Inspect, repair, and
: Leakage and fixation Force ON the knob com- replace the knob com-
pensation solenoid (By- pensation valve
Knob compensation solenoid
harness pass)/Force OFF ▪ Inspect, repair and re-
(Bypass stop), and check place the solenoid
: Disconnection, short circuit, operation at steering
and leakage problem (Harness ▪ Check, repair, and re-
and connector) Force ON ... Steering place the harness
spins (Light)
Force OFF ... Steering
does not spin (Heavy)
PS cylinder system link failure
▪ Inspect, repair, and
: Eccentric pin and king pin fail- - replace the cylinder
ure
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-489

1.5.9 OPS 1
Control category/OPS
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Seat switch body Inspect the seat switch by
using an analyzer ▪ Inspect and replace
: Short failure
: Direction neutral, accel- the switch
Both traveling OPS Seat switch harness erator all-closed state ▪ Check, repair, and re-
and load handling : Short circuit (Harness and Sit on the seat and leave place the harness
OPS do not operate connector) the seat to check ON/OFF
Main controller ▪ Replace the main con-
-
: Internal failure troller
Drive motor driver ▪ Replace the traveling
The traveling OPS -
: Internal failure motor driver
only does not oper-
ate Main controller ▪ Replace the main con-
-
: Internal failure troller
Oil control valve Check the tilt forwarding ▪ Replace, repair, and
lock valve with the active replace the oil control
: Tilt forward tilt lock valve fixa-
test valve
tion and leakage
: Force OFF the forward ▪ Inspect, repair and re-
Tilt control solenoid harness
tilt solenoid (Forward tilt place the solenoid
: Short circuit and leakage stop) state
problem (Harness and con- Conduct \forward tilt, and ▪ Check, repair, and re-
nector) check the operation place the harness
Oil control valve Check the tilt rear tilting ▪ Replace, repair, and
lock valve with the active replace the oil control
: Tilt rear tilting lock valve fixa-
test valve
tion and leakage
: Force OFF the backward ▪ Inspect, repair and re-
Tilt rear solenoid harness
tilt solenoid (Backward tilt place the solenoid
: Short circuit and leakage stop) state
problem (Harness and con- Conduct backward tilt, ▪ Check, repair, and re-
nector) and check the operation place the harness
The load handling Oil control valve Check the lift lowering ▪ Replace, repair, and
OPS only does not lock valve with the active replace the oil control
: Lift descent lock valve fixation,
operate test valve
and leakage
: Force OFF the lift lock ▪ Inspect, repair and re-
Lift lock solenoid harness
solenoid (Lift lock) state place the solenoid
: Short circuit and leakage Conduct lowering lift oper-
problem (Harness and con- ation, and check the oper- ▪ Check, repair, and re-
nector) ation place the harness
Oil control valve (Standard
lever truck) Check the unload valve ▪ Replace, repair, and
with the active test replace the oil control
: Unload valve fixation, and valve
leakage : Force ON the unload
solenoid (Lift lock) state ▪ Inspect, repair and re-
Unload solenoid harness place the solenoid
Conduct lowering lift oper-
: Disconnection, short circuit, ation, and check the oper- ▪ Check, repair, and re-
and leakage problem (Harness ation place the harness
and connector)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-490 1 ELECTRICAL TROUBLESHOOTING

1.5.10 Multifunction display

Control category/Multifunction display
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Some of the following matching
items are not conducted.
▪ Tire straight traveling angle
matching
▪ Forward tilt regulation angle ▪ Change settings
matching
*The full-opened matching
▪ Tilt horizontal angle match- value is cleared once for
ing the accelerator pedal full-
▪ Tilt no load cargo matching closed and full-open
matching if conducted in
▪ Mast type data matching
(Spanner Indicator) the full-closed position
▪ Accelerator pedal full- matching; therefore, make
An error code is not closed matching Check the matching value sure to conduct both.
displayed; however,
▪ Accelerator pedal full-open in the matching screen *The operation point
the spanner indic-
matching matching value is cleared
ator remains ON.
▪ Brake pedal full-closed once for the brake pedal
matching full-closed and the opera-
tion point matching if con-
▪ Brake pedal full-open
ducted in the full-closed
matching
position matching; there-
▪ Each load handling lever fore, make sure to con-
neutral voltage matching duct both.
▪ Swing angle matching
▪ Slope angle matching (For
slope assist (OPT) only)
▪ Tire diameter data

1.5.11 Buzzer related

Control category/Buzzer related
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Display settings
: OPS operation notification
Check the setting values
buzzer settings disabled ▪ Change settings
in the Option Set screen
OPS operation noti- (Option set BUZZER SPEC and
fication does not SEAT BUZZER)
sound
When the display switch
Display ▪ When no sound is
(micro switch) is pushed,
heard, replace the dis-
: Built-in buzzer damage check the built-in buzzer
play
responds with a beep
Display settings
: Disable the return-to-neutral Check the setting values
▪ Change settings
warning buzzer setting in the Option Set screen
Traveling OPS re-
(Option set BUZZER SPEC)
turn-to-neutral warn-
ing does not sound When the display switch
Display ▪ When no sound is
(micro switch) is pushed,
heard, replace the dis-
: Built-in buzzer damage check the built-in buzzer
play
responds with a beep
1 ELECTRICAL TROUBLESHOOTING 1-491

Control category/Buzzer related

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Load handling OPS Display settings
return-to-neutral : Disable the return-to-neutral Check the setting values
▪ Change settings
warning does not warning buzzer setting in the Option Set screen
sound (Option set BUZZER SPEC)
(Exporting specifica- When the display switch
tion trucks excluding Display ▪ When no sound is
(micro switch) is pushed,
the OPS buzzer-less : Built-in buzzer damage heard, replace the dis-
check the built-in buzzer
specification) play
responds with a beep
Using an analyzer, in-
Parking brake switch body spect the parking brake
switch
: Short failure (Can be checked also
▪ Inspect, adjust, and
Parking brake switch assembly from the ON/OFF of the
replace the switch
: Pushed state of the switch parking indicator on the
display) ▪ Check, repair, and re-
Parking brake switch harness place the harness
Parking brake non- : Direction neutral state
: Short circuit problem (Harness Operate the parking
pulling warning does
and connector) brake, and check ON/
not sound
OFF.
When the display switch
Display ▪ When no sound is
(micro switch) is pushed,
heard, replace the dis-
: Built-in buzzer damage check the built-in buzzer
play
responds with a beep
Main controller ▪ Replace the main con-
-
: Internal failure troller
Using an analyzer, in-
Parking brake switch body spect the parking brake
switch
: Open failure (Can be checked also
▪ Inspect, adjust, and
Parking brake switch assembly from the ON/OFF of the
When traveling with replace the switch
: Switch off state parking indicator on the
released parking ▪ Check, repair, and re-
display)
brake, the parking Parking brake switch harness place the harness
brake non-returning : Direction neutral state
warning sounds : Disconnection problem (Har- Operate the parking
ness and connector) brake, and check ON/
OFF.
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-492 1 ELECTRICAL TROUBLESHOOTING

Control category/Buzzer related

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Display settings
: Disable the parking brake Check the setting values
non-pulling warning buzzer set- in the Option Set screen ▪ Change settings
ting
(Option set PKB BUZZER)
Using an analyzer, in-
Parking brake switch body spect the parking brake
switch
: Open failure (Can be checked also
▪ Inspect, adjust, and
Parking brake switch assembly from the ON/OFF of the
replace the switch
: Switch off state parking indicator on the
display) ▪ Check, repair, and re-
Parking brake switch harness place the harness
: Direction neutral state
Parking brake non- : Disconnection problem (Har- Operate the parking
pulling warning does ness and connector) brake, and check ON/
not sound OFF.
Seat switch body
Inspect the seat switch by ▪ Inspect and replace
: Short failure
using an analyzer the seat
Seat switch harness
: Sit on the seat and leave ▪ Check, repair, and re-
: Short circuit (Harness and the seat to check ON/OFF place the harness
connector)
When the display switch
Display ▪ When no sound is
(micro switch) is pushed,
heard, replace the dis-
: Built-in buzzer damage check the built-in buzzer
play
responds with a beep
Main controller ▪ Replace the main con-
-
: Internal failure troller
Parking brake switch body
Inspect the parking brake
: Short failure switch by using an ana-
▪ Inspect, adjust, and
Parking brake switch assembly lyzer
Parking brake non- replace the switch
pulling warning keep : Switch on state : Direction neutral state
▪ Check, repair, and re-
sounding even when Parking brake switch harness Operate the parking place the harness
the parking brake is brake, and check ON/
pulled : Short circuit (Harness and OFF.
connector)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-493

1.5.12 Battery protecting function (optional) 1

Control category/Battery protecting function (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Change the setting ac-
cording to the battery
Display settings “B” the current model
Check the setting values
: Incorrect battery setting in the Option Set screen (fluid-level unit with LED
(Optional set B UNIT) display)
”C” with fluid-level/fluid
Battery fluid-level temperature unit
warning indicator re-
Fluid-level/fluid temperature ▪ Check the CN35 con-
mains ON
unit - nector (If disconnec-
(Battery fluid is filled) ted, connect)
: Disconnected connector
Fluid-level/fluid temperature
unit ▪ Replace the fluid-
Internal failure (Inside fluid level - level/fluid temperature
harness disconnection, and unit
fluid level sensor failure)

1.5.13 Simple damage detection (OPT)

Control category/Simple damage detection (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Display settings
The settings screen
of the simple dam- : Simple damage detection Check the setting values
▪ Change settings
age detection func- function disabled in the Option Set screen
tion is not displayed. (Optional set SHOCK
SENSOR)
1-494 1 ELECTRICAL TROUBLESHOOTING

Control category/Simple damage detection (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Truck collision method
: Depending on a collision
method, direction, and target it
collides, the collision value de- - -
tected by the collision sensor
changes. It does not detect all
collisions.
▪ Change settings
Display settings (When a large shock is
generated in normal oper-
: The collision detection setting -
ation, and the value is set
value is too large (Not ad-
When a shock is ap- equate) to large to avoid it, the
plied, the shock de- possibility for not detect-
tection alarm does ing becomes higher)
not function Shock sensor body Inspect each voltage of
: Lowered sensitivity the shock sensor 1 and 2
by using an analyzer
Shock sensor installation
: Truck stopped state ▪ Inspect and replace
: Installation failure (Loose), the sensor
2.0±0.21 V
and interference
Apply a shock on the ▪ Check, repair, and re-
Shock sensor harness sensor, and check there is place the harness
: Disconnection, short circuit, a voltage change
and leakage problem (Harness (Compare between the
and connector) sensor 1 and 2)
Main controller ▪ Replace the main con-
-
: Internal failure troller
Display settings ▪ Change settings
: The collision detection setting - (Set to a shock value that
value is too small (Not ad- does not generate in nor-
equate) mal operation)
Shock sensor body
: Internal damage (Excessive Inspect each voltage of
response) the shock sensor 1 and 2
Shock sensor installation by using an analyzer
When a shock is not
applied, the shock : Installation failure (Loose), : Truck stopped state ▪ Inspect and replace
detection alarm and interference 2.0±0.21 V the sensor
functions Shock sensor harness Apply a shock on the
▪ Check, repair, and re-
sensor, and check the
: Disconnection, short, and place the harness
voltage change is not too
leakage problem (Harness and sensitive
connector) (Compare between the
(When a slit exists in the har- sensor 1 and 2)
ness, a shock may be detected
in high frequency)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-495

1.5.14 PIN code entry system (OPT) 1

Control category/Operator authentication system (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Authentication can-
not be done by nu- Log in with the initially re-
meric key. gistered number, and ▪ Register PIN from the
Display check if PIN is registered operator authentica-
(The operation from the operator authen- tion menu of the ad-
: PIN not registered
sound of numeric tication menu of the ad- ministrator function
key sounds, but lo- ministrator function
gin fails)
Display Check the meter starts is
▪ Execute the meter
Authentication is conducted in the service
: Meter start not set start
possible without en- function
tering PIN. Display
- ▪ Replace the display.
: Internal failure

1.5.15 Slope assist (OPT)

Control category/Slope assist (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Display settings
Check the setting values
: Slope assist settings ▪ Change settings
in the Option Set screen
(Optional set SLOPE ASSIST)
Slope angle sensor body
: Internal failure
Slope angle sensor installation
The slope assist Inspect the sensor voltage ▪ Inspect and replace
function does not : Installed part damage, and by using an analyzer the sensor
work damage
: Check voltage change ▪ Check, repair, and re-
Slope angle sensor harness while the truck is tilted place the harness
: Disconnection, short circuit,
and leakage problem (Harness
and connector)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-496 1 ELECTRICAL TROUBLESHOOTING

1.5.16 Laser marker (OPT)

Control category/Laser marker (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Changing switch body
▪ Inspect, adjust, and
: Open failure
replace the switch
Changing switch harness -
▪ Check, repair, and re-
: Disconnection problem (Har- place the harness
ness and connector)
Laser marker body
: Internal failure
Not output from the Laser marker installation
laser marker ▪ Inspect and replace
: Installed part damage, and the laser marker
damage -
▪ Check, repair, and re-
Laser marker harness place the harness
: Disconnection, short circuit,
and leakage problem (Harness
and connector)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-497

1.5.17 Telematics equipped type (OPT) 1

Control category/Telematics equipped type (OPT)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
Numeric key harness ▪ Check, repair, and re-
-
: Open failure place the harness
Check operation of each
Numeric key body switch
: Check all or only a spe- ▪ Replace the numeric
: Internal failure
cific switch do not re- key body
: Failure of each switch spond (Green LED or
RED LED ON)
▪ Using TruckCom,
switch the operator
authentication function
Numeric key body of the numeric key
-
: Not server management body to server man-
agement. Refer to
cautions when repla-
cing the numeric key.
Operation management system Check PIN code is re- ▪ Register PIN code in
: PIN code not registered gistered in the Web site the Web site
▪ From the Truck Man-
agement screen in the
Web site, start com-
Authentication can- Operation management system munication forcibly us-
not be done by the - ing “Start communica-
: PIN code cannot be down-
numeric key. tion” (Permission to
loaded
manage the truck is
required) or using
TruckCom
Display power and grand har-
ness
: Disconnection, short circuit,
and leakage problem (Harness ▪ Check, repair, and re-
and connector) place the harness
Display ▪ Replace the display.
: Internal failure - ▪ Replace the main con-
troller
Main controller
▪ Replace the CAN
: Internal failure (D7V and
bridge controller
DGND)
CAN bridge controller
: Internal failure
Left the seat for three minutes *Not an error
or more after turning the key ▪ Try authentication op-
-
switch ON, authentication oper- eration again after tak-
ation was conducted ing the seat
Without authentica-
tion, the power is ap- Display settings ▪ Change settings
plied with key ON : Operation management Check the setting values : Operation manage-
(the display is dis- device “NO” setting (Optional in the Option Set screen ment device “YES”
played, and the truck set D-REC) setting
moves)
1-498 1 ELECTRICAL TROUBLESHOOTING

Control category/Telematics equipped type (OPT)

Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
*Not an error
Check the warning display
Travel control is ap- Truck performance control is ▪ Contact the Adminis-
and warning sound on the
plied applied due to shock detection trator, and request to
display
release the control.
Truck collision method
: Depending on a collision
method, direction, and target it
collides, the collision value de- - -
tected by the collision sensor
changes. It does not detect all
collisions.
▪ Change settings
(When a large shock
Web site settings is generated in normal
: The collision detection setting - operation, and the
value is too large (Not ad- value is set to large to
When a shock is ap- equate) avoid it, the possibility
plied, the shock de- for not detecting be-
tection alarm does comes higher)
not function Shock sensor body
: Lowered sensitivity Using TruckCom (SST),
inspect the output value of
Shock sensor installation
the shock sensor ▪ Inspect and replace
: Installation failure (Loose), the sensor
: Truck stopped state 0 or
and interference
1 ▪ Check, repair, and re-
Shock sensor harness Apply a shock, and check place the harness
: Disconnection, short circuit, there is a value change
and leakage problem (Harness
and connector)
Shock sensor ▪ Replace the shock
-
: Internal failure sensor
Web site settings ▪ Change settings
: The collision detection setting - (Set to a shock value
value is too small (Not ad- that does not generate
equate) in normal operation)
Shock sensor body
: Internal damage (Excessive Using TruckCom (SST),
response) inspect the output value of
When a shock is not Shock sensor installation the shock sensor ▪ Inspect and replace
applied, the speed the sensor
control engages : Installation failure (Loose), : Truck stopped state 0 or
and interference 1 ▪ Check, repair, and re-
Shock sensor harness Apply a shock, and check place the harness
there is a value change
: Disconnection, short circuit,
and leakage problem (Harness
and connector)
Shock sensor ▪ Replace the shock
-
: Internal failure sensor
1 ELECTRICAL TROUBLESHOOTING 1-499

Control category/Telematics equipped type (OPT)

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
Antenna
: Internal failure Check the antenna wire ▪ Replace antenna
Data are not dis-
and connection Use
played on the Web Unable to find radio wave ▪ Move to other loca-
TruckCom to perform tions for better radio
site during operation : Disconnection, short circuit,
GSM/GPRS test wave reception
and leakage problem (Harness
and connector)
Operation management system
The hour meter time settings ▪ Change settings
Using TruckCom (SST),
of the display is not : The hour meter input setting is : Select ‘Hour meters
check the hour meter set-
displayed on the selected to “Hour meters from from truck CAN sys-
ting of DHU2
Web site DHU inputs” in the input port tem’
setting of DHU2

1.5.18 On-truck charger (OPT)

Control category/On-truck charger (OPT)
Phenomena that occur
Faulty part/mode Check method Measures
in the machine stand
Display settings Check the setting values
▪ Change the dis-
: Disabled charge unit in the Option Set screen
play settings
(Optional set CHARGER UNIT) (Should be “YES”)
Check the power voltage
AC power for the charger : Turn the key switch
OFF, disconnect the char- ▪ Inspect and re-
: Power supply problem or pair power
ging plug, and check each
power failure
power terminal voltage is
191 to 220 V
Inspect the charging plug
terminal voltage
Charging cable ▪ Inspect, repair,
: Check the voltage and replace the
: Disconnection, short circuit,
between each terminal of charging cord
and leakage problem
the charging plug is 191
The charging screen is to 220 V
not shown on the display Inspect the connection
even when the charging
plug is connected. : Turn the key switch
Charger connection OFF, disconnect the char- ▪ Inspect, repair,
ging plug, and check the and replace the
: Connection failure connection
connection on the rear
side of the charging plug
outlet
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
and leakage problem (Harness harness
and connector)
Control panel ▪ Replace the con-
-
: Internal failure trol panel
Display ▪ Replace the dis-
-
: Internal failure play
1-500 1 ELECTRICAL TROUBLESHOOTING

Control category/On-truck charger (OPT)

Phenomena that occur
Faulty part/mode Check method Measures
in the machine stand
*Not an error
When the low speed
setting switch of the
display is pushed
Operate the display low speed and hold for two
- seconds while the
setting switch
charging plug is not
connected and the
key switch is OFF,
the charging screen
is displayed.
The charging screen is
displayed on the display Harness between operation
even though the charging panel and display ▪ Check, repair,
plug is not connected : Disconnection, short circuit, and replace the
and leakage problem (Harness harness
and connector)
Remove the harness
between operation panel
Control Panel and display, and check ▪ Replace the con-
: Internal failure the screen trol panel
Display [Charging screen]: Dis- ▪ Replace the dis-
: Internal failure play failure play.
[Others]: Charger opera-
tion panel failure
1 ELECTRICAL TROUBLESHOOTING 1-501

Control category/On-truck charger (OPT)

Phenomena that occur
1
Faulty part/mode Check method Measures
in the machine stand
Display settings Check the setting values
▪ Change the dis-
: Incorrect display setting in the Option Set screen
play settings
(Optional set [Link]) (Shall be “J”)
▪ Inspect, repair,
and replace the
Magnet switch Check the thermal relay magnet switch
: Thermal relay function state ▪ Inspect, repair,
and replace the
transformer
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
and leakage problem (Harness harness
and connector)
Charging does not start
Remove the harness
when the [CHARGE] but-
between operation panel
ton is pushed
and display, and check
(The charging screen is
the operation button
shown on the display)
: For each button, check
Control Panel conduction between the ▪ Replace the con-
: Internal failure button terminal and trol panel
CHGGND
Normal state is: Push the
button: Conduction
Not pushed: No conduc-
tion
Inspect the magnet switch
Magnet switch ▪ Inspect, repair,
: Refer to “MAGNET and replace the
: Internal failure SWITCH ASSY” in magnet switch
CHARGER CHAPTER
Display ▪ Replace the dis-
-
: Internal failure play.
1-502 1 ELECTRICAL TROUBLESHOOTING

Control category/On-truck charger (OPT)

Phenomena that occur
Faulty part/mode Check method Measures
in the machine stand
1,2t truck:
▪ Perform
Magnet switch troubleshooting
: Unable to shutdown for F7-5 error
-
(The display in stop operation is 3t truck:
in charging stop state) ▪ Perform
troubleshooting
for F8-1 error
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
Cannot stop charging harness
and leakage problem (Harness
after pressing the [STOP]
and connector)
button
(Start charging is pos- Remove the harness
sible) between operation panel
and display, and check
the operation button
Control Panel : Check conduction
▪ Replace the con-
between the stop button
: Internal failure trol panel
terminal and CHGGND
Normal state is: Push the
button: Conduction
Not pushed: No conduc-
tion
Display ▪ Replace the dis-
-
: Internal failure play.
1 ELECTRICAL TROUBLESHOOTING 1-503

Control category/On-truck charger (OPT)

Phenomena that occur
1
Faulty part/mode Check method Measures
in the machine stand
▪ Inspect, repair,
and replace the
Magnet switch Check the thermal relay magnet switch
: Thermal relay function state ▪ Inspect, repair,
and replace the
transformer
▪ Use a battery
compatible with
Transformer Check compatibility the transformer
between battery capacity capacity
: Capacity incompatible and transformer capacity
▪ Replace the
transformer
(3t truck only)
Check the power voltage
Tap changer ▪ Tap adjustment
and tap
: Tap adjustment failure
Charging completes nor-
(1.2t truck only) Check the capacity dis-
mally but the charge is in-
sufficient Display settings played in the matching
▪ Change settings
: Battery capacity setting in- screen or the charger
compatible start screen
Inspect the transformer.
Transformer Refer to “TRANS- ▪ Replace the
: Internal failure FORMER ASSY” in transformer
CHARGER CHAPTER
▪ Conduct even
Inspect the battery
Battery charging
: Refer to BATTERY
: Battery failure ▪ Replace the bat-
CHAPTER
tery
Measure the battery
Main controller voltage value, and com-
▪ Replace the
pare with the battery
: Internal failure main controller
voltage value of the ana-
lyzer
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
The indicator on the char- harness
and leakage problem (Harness
ger operation panel does
and connector)
not become ON
(Start charging is pos- Control Panel ▪ Replace the con-
-
sible) : LED bulb out trol panel
Display ▪ Replace the dis-
-
: Internal failure play.
1-504 1 ELECTRICAL TROUBLESHOOTING

Control category/On-truck charger (OPT)

Phenomena that occur
Faulty part/mode Check method Measures
in the machine stand
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
and leakage problem (Harness harness
and connector)
Inspect the magnet switch
Magnet switch ▪ Inspect, repair,
: Refer to “MAGNET and replace the
The magnet switch oper- : Internal failure SWITCH ASSY” in magnet switch
ates though the CHARGER CHAPTER
[CHARGE] button is not
Remove the harness
pressed
between operation panel
Control Panel and display, and check
▪ Replace the con-
the conduction of display
: Internal failure trol panel
connector pin
Display ▪ Replace the dis-
[With short]: Display fail-
: Internal failure play.
ure
[No short]: Charger opera-
tion panel failure
*Not an error
Press the [STOP]
button to turn the
display OFF, and
use it as usual. After
Charging completed Check the display screen charging is com-
(Only when the completed LED [“Charging completed” pleted, if the char-
is ON) screen]: No problem ging plug is extrac-
ted without pushing
any buttons/
switches, the com-
pleted LED remains
ON.
Inspect the error
: Turn the key switch ▪ Perform
The operation panel LED Error generated OFF, connect the char- troubleshooting
comes ON/flashes though (Only when the completed LED ging plug, and check the for the applic-
the charging plug is not is flashing)
error code shown on the able error code
connected. display
Harness between operation
panel and display ▪ Check, repair,
: Disconnection, short circuit, - and replace the
and leakage problem (Harness harness
and connector)
Remove the harness
between operation panel
Control Panel and display, and check
▪ Replace the con-
the voltage of each LED
: Internal failure trol panel
terminal on the display
Display side ▪ Replace the dis-
: Internal failure play
[0 V]: Charger operation
panel failure
[Others]: Display failure
1 ELECTRICAL TROUBLESHOOTING 1-505

Control category/On-truck charger (OPT)

Phenomena that occur
1
Faulty part/mode Check method Measures
in the machine stand
Display settings
: Incorrect clock setting Check the clock and re- ▪ Change the dis-
: Incorrect reserved charging served charging setting play settings
setting
*Not an error
When power outage
Power outage occurred - occurs after starting
charging, it may not
Cannot start or finish the function according to
reserved charging at the the set time.
setting time
*Not an error
When the time from
the start charging
In sufficient charging time time to the set time
- is shorter than the
(End reserved charging only)
time required for full
charging, charging is
continued after
passing the set time.
Display settings
: Operating day settings Check the operating day ▪ Change the dis-
(Administrator function Operat- settings play settings
ing day/OPERATION DAYS)
Display settings ▪ Change the dis-
Check the time settings
Even charging is per- : Incorrect clock setting play settings
formed on an operating
*Not an error
day though the operating
days are set Depending on the
user's charging fre-
Charging frequency - quency. the auto-
matic even charging
may be conducted
on the operating
days.

1.5.19 Australian Specifications (OPT)

When an error is displayed or the wrench mark is ON, always give a priority to the
error or the mark.
In this section, the items related to the Australian specifications (OPT) are described. Any items besides be-
low, refer to the general items.
1-506 1 ELECTRICAL TROUBLESHOOTING

[Link] Traveling
Control category/Australian specifications
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
(Seatbelt reminder alarm OPT)
Seatbelt switch body
: Open failure (Internal dam- Inspect the seat switch by
age) using an analyzer ▪ Inspect and replace
: Short failure (Internal damage) the seatbelt (buckle)
: Direction neutral, accel-
Unable to travel (the Seatbelt switch line (Signal and erator all-closed state ▪ Check, repair, and re-
travel motor does ground) Put the seatbelt ON/OFF, place the harness
not rotate) or cannot : Disconnection failure (Har- and check ON/OFF
climb a slope sud- ness and connector)
denly : Short and leakage failure
(Harness and connector)
(Seatbelt reminder alarm OPT) Return the direction lever
to neutral, remove the
Incorrect operating procedure
seatbelt once, and while -
(The seatbelt is not put on after seated, put the seatbelt
seated) on to start traveling
(V mast only)
Inspect the lift height 800
Fork height 800 mm switch mm switch by using an
body analyzer ▪ Inspect, adjust, and
: Open failure : In NL state replace the switch
Lift height 800 mm switch har- Operate the lift at lowest ▪ Check, repair, and re-
ness lowering to at most up- place the harness
ward lifting, and check
3 km/h is the max- : Disconnection problem (Har-
ON/OFF
imum speed ness and connector)
Display settings
: Mast type setting is not Check the setting value in
▪ Change settings
matched the matching screen
(The wrench mark ON)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1 ELECTRICAL TROUBLESHOOTING 1-507

Control category/Australian specifications

Phenomena that
1
occur in the ma- Faulty part/mode Check method Measures
chine stand
(V mast only)
Fork height 800 mm switch Inspect the lift height 800
body mm switch by using an
analyzer ▪ Inspect, adjust, and
: Short failure replace the switch
: In NL state
Lift height 800 mm switch har- Operate the lift at lowest ▪ Check, repair, and re-
ness lowering to at most up- place the harness
: Short circuit and leakage ward lifting, and check
problem (Harness and con- ON/OFF
nector)
The speed is not Display settings
controlled when the : The settings are not in Aus-
mast is raised Check the setting value in
tralian specification ▪ Change settings
the matching screen
(No match with the machine
stand specification)
Display settings
: Mast type setting is not Check the setting value in
▪ Change settings
matched, and the hour meter is the matching screen
▪ Hour meter start
not started Check the hour meter
(The wrench mark ON)
Main controller ▪ Replace the main con-
-
: Internal failure troller
Display settings
: The mast type setting does Check the setting value in
The lift height that not match ▪ Change settings
the matching screen
speed is controlled (No match with the machine
is different stand specification)
Main controller ▪ Replace the main con-
-
: Internal failure troller
1-508 1 ELECTRICAL TROUBLESHOOTING

[Link] Load handling & power steering

Control category/Load handling & power steering (Australian specification)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
(Seatbelt reminder alarm OPT)
Seatbelt switch body
: Open failure (Internal dam- Inspect the seat switch by
age) using an analyzer ▪ Inspect and replace
: Short failure (Internal damage) the seatbelt (buckle)
Load handling only : Load handling lever in
Seatbelt switch line (Signal and the neutral state ▪ Check, repair, and re-
is not possible ground) Put the seatbelt ON/OFF, place the harness
(In steering, and dir- : Disconnection failure (Har- and check ON/OFF
ection operation, ro- ness and connector): Short and
tate the pump motor leakage failure (Harness and
with the direction op- connector)
eration)
Return the load handling
(Seatbelt reminder alarm OPT) lever to neutral, remove
Incorrect operation procedure the seatbelt once, and -
(The seatbelt is not put on after while seated, put the seat-
seated) belt on to start load hand-
ling operation

[Link] OPS
Control category/OPS (Australian specifications)
Phenomena that
occur in the ma- Faulty part/mode Check method Measures
chine stand
(Seatbelt reminder alarm OPT)
Inspect the seat switch by
Seatbelt switch body using an analyzer
: Short failure (Internal damage) : Direction neutral, accel- ▪ Inspect and replace
Both traveling OPS the seatbelt (buckle)
and load handling Seatbelt switch line (Signal and erator all-closed state,
OPS do not operate ground) load handling lever neut- ▪ Check, repair, and re-
ral state place the harness
: Short circuit and leakage
Put the seatbelt ON/OFF,
problem (Harness and con-
and check ON/OFF
nector)
2 APPENDIX 2-509

2 APPENDIX
2
2.1 SST LIST ............................................................................................... 509
2.2 CONNECTOR DRAWING ..................................................................... 510
2.3 CONNECTOR LOCATION .................................................................... 532
2.4 CONNECTING DIAGRAM..................................................................... 544
2.5 SEQUENCE DIAGRAM......................................................................... 545

2.1 SST LIST

SECTION
ILLUST PART NUMBER PART NAME
TROUBLESHOOTING
Sub harness for AC
09240-13240-71 ○
Driver

09230-13700-71 IC check pin ○

09232-13130-71 Sub harness ○

Sub harness(For
09238-13130-71 ○
CN124)

Sub harness(For
09236-13900-71 ○
CN92, CN93, CN99)

09250-82110-71 Castor-USB ○

09561-12640-71 PC-CAN Cable ○

2-510 2 APPENDIX

2.2 CONNECTOR DRAWING

2 APPENDIX 2-511

OPT LAMP
STD

VOLUME
SWITCH

STD
2-512 2 APPENDIX

STD

STD
LED

LED
2 APPENDIX 2-513

2
2-514 2 APPENDIX
2 APPENDIX 2-515

STD

HEIGHT
SELECTOR*

STD

HEIGHT
SELECTOR*

* : “HEIGHT SELECTOR” is only JAPAN model.

2-516 2 APPENDIX
2 APPENDIX 2-517

2
2-518 2 APPENDIX
2 APPENDIX 2-519

2
2-520 2 APPENDIX
2 APPENDIX 2-521

11-- 2t 系
2 ton
series

33t
ton系
series
2-522 2 APPENDIX
2 APPENDIX 2-523

2
2-524 2 APPENDIX
2 APPENDIX 2-525

2
2-526 2 APPENDIX
2 APPENDIX 2-527

2
2-528 2 APPENDIX
2 APPENDIX 2-529

BODY MAIN WIRE

2
2-530 2 APPENDIX

PUSH-PULL(ATTACHMENT) SUB WIRE PUMP MOTOR SUB WIRE

WIPER SUB WIRE

REAR UPPER WIRE

2 APPENDIX 2-531

REAR UPPER SUB WIRE REAR LOWER WIRE

CLAMP INTERLOCK WIRE

TELEMATICS SUB WIRE

MAST SUB WIRE

2-532 2 APPENDIX

2.3 CONNECTOR LOCATION

CONTENTS
▪ MAST
▪ INSTRUMENT PANEL
▪ CABLES
▪ REAR BODY No.1
▪ REAR BODY No.2
▪ REAR UPPER
SYMBOLS WIRE NAME
A BODY MAIN WIRE
B FRONT STAY WIRE
C MAST SENSOR WIRE
D MAST SENSOR SUB WIRE
E WIPER SUB WIRE NO.1
F WIPER SUB WIRE NO.2
G INSTRUMENT PANEL SUB WIRE
H REAR UPPER WIRE
I TEN KEY SUB WIRE
J DRIVE MOTOR SUB WIRE
K PUMP MOTOR SUB WIRE
L REAR UPPER SUB WIRE
M HOOD WIRE
N HOOD SUB WIRE
O TELEMATICS SUB WIRE NO.1
P TELEMATICS SUB WIRE NO.2
Q TELEMATICS SUB WIRE NO.3
R REAR LOWER WIRE
S FAN SUB WIRE
T HORN SUB WIRE
U ACCEL SENSOR SUB WIRE
V CLAMP INTERLOCK WIRE
W CLAMP INTERLOCK SWITCH WIRE
X BUZZER WIRE
Y HEADLIGHT OFF WIRE
Z LASER MARKER CABLE
a HEIGHT SELECTOR WIRE
b MAST CLAMP INTERLOCK WIRE
c DIODE HARNESS
d STOP LAMP SWITCH SUB WIRE
2 APPENDIX 2-533

2.3.1 MAST
B FRONT STAY WIRE *1: V MAST 2
C MAST SENSOR WIRE *2: FV MAST
*3: FSV MAST
D MAST SENSOR SUB WIRE *4: LAMP W/ HEAD GUARD (RH)
*5: LAMP W/ HEAD GUARD (LH)
Z LASER MARKER CABLE *6: LAMP W/ MAST (RH)
a HEIGHT SELECTOR WIRE *7: LAMP W/ MAST (LH)

b MAST CLAMP INTERLOCK WIRE

CN92 *3 CN92 *2 CN14 *5 CN16 *5

CN260

CN16 *4
B [LAMP W/ MAST] CN16 *7

CN14 *7
CN16 *6

CN14 *4 D B

CN93 CN14 *6 B
C
B
CN189
b
CN99 a
c

CN92
*1

a b
CN261
b
CN124
a
CN188

CN226
*3
CN226
*1
2-534 2 APPENDIX

CN14 COMBINATION HEAD LAMP

CN14 FRONT COMBINATION LAMP
CN16 HEAD LAMP
CN92 HEIGHT SWITCH NO.1 (V)
CN92 HEIGHT SWITCH (FSV, FV)
CN93 HEIGHT SWITCH NO.2
CN99 ULTRA SONIC SENSOR
CN124 HEIGHT SENSOR
CN188 CLAMP INTER LOCK VALVE
CN189 BALE CLAMP INTER LOCK VALVE
CN226 LASER MARKER
CN260 HEIGHT SWITCH
CN261 MAST SENSOR SUB WIRE
2 APPENDIX 2-535

2.3.2 INSTRUMENT PANEL

A BODY MAIN WIRE I TEN KEY SUB WIRE Y HEADLIGHT OFF WIRE 2
B FRONT STAY WIRE J DRIVE MOTOR SUB WIRE Z LASER MARKER CABLE
C MAST SENSOR WIRE T HORN SUB WIRE a HEIGHT SELECTOR WIRE
E WIPER SUB WIRE NO.1 U ACCEL SENSOR SUB WIRE b MAST CLAMP INTERLOCK WIRE
F WIPER SUB WIRE NO.2 V CLAMP INTERLOCK WIRE d STOP LAMP SWITCH SUB WIRE
G INSTRUMENT PANEL SUB WIRE W CLAMP INTERLOCK SWITCH WIRE
*1: RH DIRECTION LEVER
*2: LH DIRECTION LEVER
*3: w/ ATTACHMENT
*4: w/o ATTACHMENT

CN9 *1 CN4
CN8 *1 CN19 CN7 *2

CN10 *2
CN85 CN154 CN327 CN118 CN33
CN3 CN126 CN11 CN326 CN70 CN180
I
CN227 *3
B
CN15 E
CN5
W F CN227 *4
CN215 T G T CN155
CN69
G CN604 CN178
CN176
CN175 CN241
CN98
CN174 CN214
B d CN164
CN162 CN86
CN163
CN73 CN49
CN6 CN173
CN219 CN21
CN172
CN47 CN146
CN150
CN25
CN89 CN22
CN404
CN81 CN88
CN213
CN117
CN212
V CN115 CN119
Z CN46
CN220 CN91 CN26 CN120
CN210
CN90
CN290
CN279
U C a b
CN179
CN254
CN253 CN129
J

[KEY OFF HEADLIGHT OFF] CN121 CN123 [HEIGHT SELECTOR]

CN6
CN401 CN122
CN87
A CN402
CN47 CN78
CN403
CN88
CN210
CN46 Y A
CN212
2-536 2 APPENDIX

CN3 HORN SWITCH CN164 ATT 1 LEVER SENSOR

CN4 KEY SWITCH CN172 FRONT STAY WIRE RH 1
CN5 STOP LAMP SWITCH CN173 FRONT STAY WIRE RH 2
CN6 BRAKE SENSOR CN174 FRONT STAY WIRE LH 1
CN7 TURN SIGNAL & LIGHT SWITCH CN175 FRONT STAY WIRE LH 2
CN8 TURN SIGNAL & LIGHT SWITCH CN176 EMERGENCY SWITCH
CN9 DIRECTION SWITCH CN178 TEN KEY SUB WIRE
CN10 DIRECTION SWITCH CN179 CLAMP INTERLOCK WIRE
CN11 HEIGHT SELECTOR SWITCH CN180 WASHER MOTOR
CN15 PARKING BRAKE SWITCH CN210 HEAD LAMP RELAY
CN19 STEERING SENSOR CN212 ACCESSORY RELAY
CN21 HORN CN213 CLAMP INTER LOCK RELAY
CN22 HORN CN214 HORN SUB WIRE (RH)
CN25 ACCEL SENSOR SUB WIRE CN215 HORN SUB WIRE (LH)
CN26 ACCEL SENSOR CN219 LASER MARKER SWITCH
CN33 TEN KEY CN220 LASER MARKER CABLE
CN46 TAIL LAMP RELAY CN227 HORN
CN47 DIAGNOSIS CONNECTOR CN241 INSTRUMENT PANEL SUB WIRE
CN49 WIPER SUB WIRE NO.1 CN253 DRIVE MOTOR SUB WIRE 1
CN69 CHARGER SWITCH BOX CN254 DRIVE MOTOR SUB WIRE 2
CN70 DISPLAY CN279 CLAMP INTERLOCK WIRE
CN73 WORKING LAMP SWITCH CN290 HEIGHT SELECTOR WIRE
CN78 OIL CONTROL VALVE PULL SORENOID CN326 ATT 1 LEVER SWITCH
CN81 ONRYO-KIRIKAE BACK-UP BUZZER SWITCH CN327 ATT 2 LEVER SWITCH
CN85 TILT NEUTRAL SWITCH CN401 TAIL LAMP RELAY
CN86 TILT ANGLE SENSOR CN402 HEAD LAMP RELAY
CN87 OIL CONTROL VALVE PUSH SORENOID CN403 ACCESSORY RELAY
CN88 OIL CONTROL VALVE SORENOID CN404 CLAMP INTER LOCK RELAY
CN89 TILT SWITCH CN604 WORKING LAMP JUNCTION CONNECTOR
CN90 MAST SENSOR WIRE
CN91 PRESSURE SENSOR
CN98 STEERING SORENOID
CN115 LIFT LEVER SENSOR
CN117 OIL CONTROL VALVE SENSOR SUB WIRE
CN118 HEIGHT LIMIT SWITCH
CN119 ATT1 LEVER SENSOR
CN120 ATT2 LEVER SENSOR
CN121 DRIVE MOTOR TEMPERATURE SENSOR
CN122 DRIVE MOTOR SPEED SENSOR 1
CN123 DRIVE MOTOR SPEED SENSOR 2
CN126 ATT LEVER SWITCH
CN129 IMPACT SENSOR
CN146 12V POWER SUPPLY
CN150 WIPER & WASHER SWITCH
CN154 WIPER MOTOR
CN155 WIPER & WASHER RESISTOR
CN162 LIFT LEVER SENSOR
CN163 TILT LEVER SENSOR
2 APPENDIX 2-537

2.3.3 CABLES
2

CONNECTOR CABLE

Refer to RR BODY NO.2

VIEW A VIEW B

U V W PUMP MOTOR CABLE

U
2-538 2 APPENDIX

2.3.4 REAR BODY No.1

A BODY MAIN WIRE O TELEMATICS SUB WIRE NO.1
H REAR UPPER WIRE P TELEMATICS SUB WIRE NO.2

K PUMP MOTOR SUB WIRE R REAR LOWER WIRE

L REAR UPPER SUB WIRE S FAN SUB WIRE

M HOOD WIRE X BUZZER WIRE

c DIODE HARNESS

CN112
S

CN35 CN101
CN20
CN113 CN110
CN102
CN190 CN148
CN103 CN145
CN128
CN137 CN56 CN12

CN233 CN111
CN136
CN104
H CN361
CN232 CN55 CN605
K CN40
CN200
CN231
M
CN68
R CN95 CN43
CN37
CN94 CN195
CN217
CN201
CN601 CN132
P CN24
CN602
CN97 CN79 CN48 CN80
CN96 CN281
X
CN291
CN127 CN23
CN183 CN38
CN209
CN186
CN294
CN229

CN603 CN82

A
O CN218
CN216

CN100 CN144
[FR & RR CHIME] [LED RR COMBI LAMP]
CN238
CN237

CN240
c CN239
A
A CN24 H
CN23 CN37
L
CN38
2 APPENDIX 2-539

CN12 FLASHER RELAY CN209 SOLID STATE RELAY 2

CN20 N2 CN216 HORN RELAY SUB WIRE
CN23 BACK-UP BUZZER CN217 SURGE KILLER 2
CN23 DIODE HARNESS 1 CN218 SURGE KILLER
CN23 BUZZER WIRE 1 CN229 HORN RELAY
CN24 FORWARD CHIME CN231 PUMP MOTOR SUB WIRE 1
CN24 DIODE HARNESS 2 CN232 PUMP MOTOR SUB WIRE 2
CN35 LIQUID LEVEL SENSOR CN233 PUMP MOTOR SUB WIRE 3
CN37 REAR UPPER WIRE 1 CN237 DC/DC FOR LED REAR COMBINATION LAMP 1
CN37 REAR UPPER SUB WIRE 1 CN238 DC/DC FOR LED REAR COMBINATION LAMP 2
CN38 REAR UPPER WIRE 2 CN239 REAR UPPER WIRE 1
CN38 REAR UPPER SUB WIRE 2 CN240 REAR UPPER WIRE 2
CN40 HORN RELAY CN281 IMPACT SENSOR
CN43 HOOD WIRE 1 CN291 TELEMATICS SUB WIRE NO.2
CN48 REAR WORKING LAMP RELAY CN294 POC
CN55 PUMP MOTOR TEMPERATURE SENSOR CN361 TSDR CONNECTOR
CN56 PUMP MOTOR SPEED SENSOR CN601 N2 JUNCTION CONNECTOR
CN68 THERMO SWITCH CN602 HORN JUNCTION CONNECTOR
CN79 YAW RATE SENSOR CN603 CAN JUNCTION CONNECTOR
CN80 ONRYO-KIRIKAE BACK-UP BUZZER CN605 DRIVE MOTOR SENSOR JUNCTION CONNECTOR
CN82 ONRYO-KIRIKAE BACK-UP BUZZER RELAY
CN94 REAR LOWER SUB WIRE
CN95 SWING SORENOID
CN96 SWING ANGLE SENSOR
CN97 TIRE ANGLE SENSOR
CN100 CAN BRIDGE
CN101 MAIN CONTROLLER 1
CN102 MAIN CONTROLLER 2
CN103 MAIN CONTROLLER 3
CN104 MAIN CONTROLLER 3
CN110 DRIVE MOTOR INVERTER
CN111 PUMP MOTOR INVERTER
CN112 INVERTER FAN 1
CN113 INVERTER FAN 2
CN127 RELAY 1
CN132 SLOPE ANGLE SENSOR
CN136 CONTACTOR 1
CN137 CURRENT SENSOR
CN142 CONTACTOR 2
CN144 DC/DC CONVERTER
CN145 F8 & F9 FUSE
CN148 P4
CN183 TELEMATICS SUB WIRE NO.1
CN186 BUZZER WIRE 2
CN190 FAN SUB WIRE
CN195 HOOD WIRE 2
CN200 CAN JUNCTION CONNECTOR 1
CN201 CAN JUNCTION CONNECTOR 2
2-540 2 APPENDIX

2.3.5 REAR BODY No.2

A BODY MAIN WIRE

CONNECTOR CABLE PUMP MOTOR CABLE TRANS CABLE N2

TRANS CABLE P8

CN110

TRANS CABLE P15

N1 N2

P1 P2 W
W CN111
V

P8 V
U
P15
U
P4 P4

CN602
CN201 CN200 CN601 CN217

DRIVE MOTOR CABLE TRANS CABLE P4

* : This illustration shows "Scott transformer model".

(In case of "Leakage transformer", cable layout is different.)
2 APPENDIX 2-541

CN110 DRIVE MOTOR INVERTER

CN111 PUMP MOTOR INVERTER
CN200 CAN JUNCTION CONNECTOR 1 2
CN201 CAN JUNCTION CONNECTOR 2
CN217 SURGE KILLER
CN601 N2 JUNCTION CONNECTOR
CN602 HORN JUNCTION CONNECTOR
2-542 2 APPENDIX

2.3.6 REAR UPPER

H REAR UPPER WIRE
M HOOD WIRE
N HOOD SUB WIRE
Q TELEMATICS SUB WIRE NO.3
*1: w/ LED REAR COMBINATION LAMP
*2: w/o LED REAR COMBINATION LAMP
*3: w/ EEC SPECIFICATION
*4: w/o EEC SPECIFICATION

CN31 *1 CN31 *2 CN303 CN60 CN285

CN59 *2 CN59 *1 CN34 *2 CN284 CN58

Q CN283

CN607

CN606
CN131

CN185 CN34
CN71 *1 CN286
G CN32

CN331 CN125

CN292

CN334

CN196

CN44
*4

M
CN44
*3
N
2 APPENDIX 2-543

CN31 REAR COMBINATION LAMP LH

CN32 REAR HORN SWITCH
CN34 REAR COMBINATION LAMP RH 2
CN44 SEAT SWITCH
CN58 ROTARY LAMP
CN59 DIODE
CN60 DIODE
CN71 LICENSE LAMP RH
CN125 WORKING LAMP
CN131 LICENSE LAMP LH
CN185 BLUE LIGHT
CN196 SEAT BELT SWITCH
CN283 KEY PAD
CN284 DHU 2
CN285 SERVICE CONNECTOR
CN286 SMART ACCESS
CN292 TELEMATICS SUB WIRE NO.3
CN303 SHORT CONNECTOR
CN331 REAR COMBINATION LAMP (SHAKEN) LH
CN334 REAR COMBINATION LAMP (SHAKEN) RH
CN606 CAN JUNCTION CONNECTOR 1
CN607 CAN JUNCTION CONNECTOR 2
 CONNECTING DIAGRAM

VOLUME SWITCH

(Note)
This connecting diagram shows SAS spec. model.
"HEIGHT SELECTOR" is only JAPAN model.
"SHAKEN" is only JAPAN model.
SEQUENCE DIAGRAM
VOLUME SWITCH

A
B
C

J
K
JAPAN MODEL JAPAN MODEL
JAPAN MODEL
JAPAN MODEL
MODEL

M
N
O
P
Q
R
S
T
U
A
B
C

J
JAPAN MODEL
K

M
N
O
P
Q
R
S
T
U

(Note)
This connecting diagram shows SAS spec. model.
"HEIGHT SELECTOR" is only JAPAN model.
"SHAKEN" is only JAPAN model.
FOR 3 TON (80V) MODEL
 Published by

1st Printing: JAN. 2017

Pub. No. CE210

Printed in JAPAN
 8FBH10, 14, 15, 18, 20, 25 8FBJ35
8FB10, 14, 15, 18, 20, 25, 30
8FB10, 14, 15, 18, 20, 25, 30
8FBH10, 14, 15, 18, 20, 25
8FBJ35

2
TROUBLESHOOTING
2Pub. No. CE210

Pub. No. CE210 Pub. No. CE210