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6M100 MH99719 6m100contl
6M100 MH99719 6m100contl
1. Outline...................................................................................................... 4-1
2. Main Functions........................................................................................ 4-2
2.1 Instrument Panel ..................................................................................................... 4-3
2.2 VCM (Vehicle Control Module)-1M.......................................................................... 4-3
2.3 ECM (Gasoline Engine Control Module) ................................................................. 4-3
2.4 DCM (Diesel Engine Control Module) ..................................................................... 4-3
2.5 Remote Input/Output Units ...................................................................................... 4-3
2.6 GSE Connector ....................................................................................................... 4-4
3. Service Tool Functions........................................................................... 4-5
3.1 Service Tool Menus................................................................................................. 4-5
3.2 Service Tool Box ..................................................................................................... 4-7
4. Mast Interlock System .......................................................................... 4-18
4.1 Function................................................................................................................. 4-18
4
4.2 VCM-1M Controller, Mast Interlock System Checking Procedure......................... 4-19
4.3 Active Test Inspection Procedure.......................................................................... 4-22
5. Powershift Transmission Driving Interlock System .......................... 4-25
5.1 Function................................................................................................................. 4-25
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks ............ 4-26
5.3 Active Test Inspection Procedure.......................................................................... 4-29
6. Seat Belt Warning Lamp....................................................................... 4-31
6.1 Function................................................................................................................. 4-31
6.2 Seat Belt Warning Lamp Checking Procedure ...................................................... 4-31
7. Parking Brake Warning Buzzer and Lamp.......................................... 4-32
7.1 Function................................................................................................................. 4-32
7.2 Parking Brake Warning Buzzer/Lamp Checking Procedure.................................. 4-33
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure
with Key in OFF Position ....................................................................................... 4-35
8. Harness Codes ...................................................................................... 4-36
9. Controller Details .................................................................................. 4-37
9.1 VCM-1M Controller................................................................................................ 4-37
9.2 Seat Switch/Seat Belt Switch ................................................................................ 4-38
9.3 Parking Brake Switch ............................................................................................ 4-38
9.4 Direction Lever ...................................................................................................... 4-38
9.5 Speed Sensor........................................................................................................ 4-39
9.6 T/M Solenoid ......................................................................................................... 4-40
9.7 Unload Solenoid .................................................................................................... 4-40
9.8 Lift Lock Solenoid .................................................................................................. 4-40
9.9 Warning Buzzer ..................................................................................................... 4-42
9.10 Warning Buzzer Relay........................................................................................... 4-42
9.11 Warning Buzzer Circuit.......................................................................................... 4-43
9.12 Instrument Panel ................................................................................................... 4-43
10. Error Codes and Troubleshootings..................................................... 4-45
10.1 Error Code Display ................................................................................................ 4-45
10.2 Troubleshooting..................................................................................................... 4-46
10.3 Diagnosis Table (F Code)...................................................................................... 4-46
10.4 Error Codes and Troubleshooting ......................................................................... 4-59
11. Locations of Sensors and Switches.................................................... 4-70
CONTROLLERS
Chapter 4 CONTROLLERS
1. Outline
The controllers control the lift truck body and engine.
Controllers are located as shown below.
Instrument panel
Input unit
VCM-1M
(Vehicle control module)
GSE connector
Consult connector
ECM
(Gasoline engine
Output unit control module)
QGS controller
(Diesel truck only) DCM
(Diesel engine
control module)
213486
4-1
CONTROLLERS
2. Main Functions
The controllers connected by a CAN network pass
information between controllers via the network. The
VCM (vehicle control module) controller controls the
vehicle system, and other controllers control the rele-
vant components.
FC model
Instrument Parking
switch Engine
Seat Warning
215201
4-2
CONTROLLERS
4-3
CONTROLLERS
Direction of force
(2) With the rim of cup holder raised, pull the cup
holder in the direction of mast.
Direction of force
GSE connector
215208
4-4
CONTROLLERS
Menu items
Toolbox 214883
4-5
CONTROLLERS
4-6
CONTROLLERS
Discription of a monitor item Start recording button Stop recording button Reset values button
214884
4-7
CONTROLLERS
4-8
CONTROLLERS
214885
4-9
CONTROLLERS
Solenoid output (ATT3 valve) feedback [mA] Tiltlock solenoid feedback [mA]
Solenoid output (ATT3 valve 1) output Parking brake alarm
Solenoid output (ATT3 valve 2) output Over load alarm 1
Solenoid output (ATT3 valve) status Over speed alarm
PWM voltage (RIO1) [V] Angle adjust solenoid
PWM voltage (RIO1) Angle adjust tilt lock current [mA]
OUT-UNIT status (RIO1) Auto light OUT
Unload solenoid AUX out 1
Unload solenoid feedback [mA] AUX out 2
Liftlock solenoid AUX out 3
Liftlock solenoid feedback [mA] Limp home
Tiltlock solenoid
214886
4-10
CONTROLLERS
OK button
214887
Items to add
214888
Added items
214889
4-11
CONTROLLERS
214891
214892
4-12
CONTROLLERS
214893
4-13
CONTROLLERS
214896
4-14
CONTROLLERS
(7) Oscilloscope
Click the oscilloscope button from the menu or toolbox to display the oscilloscope screen in the main window. The
oscilloscope screen shows a graph of the specified input/output values. The user can set up two items (CH1 and
CH2) as input/output values to be expressed in the graph. The time axis of the graph is expressed in seconds. The
user also can store the data of the graph being displayed on the screen, and re-display the graph by reading it from
the memory. The graph screen can be printed out on a printer by clicking the printing screen button. Because the
function of this oscilloscope is simple, there will be some amount of lag in the wave pattern and a margin of error.
For an accurate wave pattern, use a dedicated measuring instrument.
Oscilloscope button
Input/output
Setting buttion of time axis
read setting button
214897
4-15
CONTROLLERS
214900
4-16
CONTROLLERS
214901
4-17
CONTROLLERS
213488
Controller Function
Monitors the seat switch and if the operator is not
seated, locks the lift and tilt motions.
VCM-1M Controller Mast Interlock Function
Interrupts electric current supply to the unload sole-
noid and the lift lock solenoid when the operator is not
seated.
4-18
CONTROLLERS
214156
Fig. 1-2 Output monitor screen
4-19
CONTROLLERS
214157
Fig. 1-3 Input monitor screen
214158
Fig. 1-4 Input monitor screen
(7) Make sure that the mast interlock indicator lamp
on the instrument panel blinks. (Fig. 1-5)
214159
Fig. 1-5 Instrument panel screen
4-20
CONTROLLERS
4-21
CONTROLLERS
Active test
214168
Fig. 1-7 Active test screen
4-22
CONTROLLERS
214169
Fig. 1-8 Active test check screen
(4) Check “OK” when the write completed check box
is displayed. (Fig. 1-9)
214171
Fig. 1-9 Write completed check screen
(5) Put check marks in the check boxes of the unload
solenoid and lift lock valve solenoid, and press
“Write.” (Fig. 1-10)
Write button
Check
(6) Same as above (3), check “YES” when the write
validity check box is displayed, and check “OK”
when the write completed check box is displayed.
214172
Fig. 1-10 Active test check screen
4-23
CONTROLLERS
214173
Fig. 1-11 Output monitor screen
(8) After the verification, return the key to OFF posi-
tion to release the active test. (Be sure to turn the
key to the OFF position whenever proceeding with
next procedure.)
If there is an error, see “Error Codes and
Troubleshootings” of Section 10 and check each
item listed as possible causes of trouble of F-75, F-
77 and F-79.
4-24
CONTROLLERS
Controller Function
The controller monitors the seat switch and if the oper-
ator is not seated, automatically locks the shift position
in “Neutral” when the speed is 4 km/h or less.
4-25
CONTROLLERS
5.2 Driving Interlock System Checking Procedure for Powershift T/M Trucks
Travel interlock system (powershift truck)
(1) Raise the forks slightly from the floor.
(2) With the engine idling (not pressing on the accel-
erator pedal), place the direction lever to the for-
ward or reverse position, and then half rise from
the operator's seat.
(3) In a few seconds, the lift truck should stop with the
driving interlock indicator lamp blinking.
(4) To restore the lift truck to its normal driving condi-
tion, sit properly in the operator's seat and 213489
depress the brake pedal to hold the lift truck.
Return the direction lever to the neutral position,
then place the lever to the forward or reverse
position.
214176
Fig. 2-1 Input monitor screen
4-26
CONTROLLERS
214177
Fig. 2-2 Input/output monitor screen
(7) Leave the operator's seat. Make sure that seat
switch is turned OFF. Then, by the function of the
seat delay counter, Seating flag turns OFF in a
few seconds after seat switch indicates OFF.
(Fig. 2-3 and Fig 2-4)
214178
Fig. 2-3 Input monitor screen
214179
Fig. 2-4 Input monitor screen
4-27
CONTROLLERS
214180
Fig. 2-5 Instrument panel screen
(9) When the driving interlock is activated, T/M con-
trol valve (F) output does not indicate ON even if
the status of the direction lever (F) input is ON.
(Fig. 2-6)
214181
Fig. 2-6 Input/output monitor screen
If Seat SW does not indicate ON
Check seat SW for operation, wiring, etc. according to
“Harness codes” of section 8, “VCM-1M controller” of
section 9.1, and “Seat switch/Seat belt switch” of sec-
tion 9.2.
4-28
CONTROLLERS
(1) Connect the service tool and turn the key to the
ON position. (DO NOT start the engine.)
Active test
214168
Fig. 2-7 Active test screen
(3) Put a check mark in the check box of the active
test flag, and press “Write.” (Fig. 2-8) Write button
Check
214169
Fig. 2-8 Active test check screen
(4) When the write validity check box is displayed,
check “YES” (Fig. 2-8), and check “OK” when the
write completed check box is displayed. (Fig. 2-9)
214171
Fig. 2-9 Write completed check screen
4-29
CONTROLLERS
(5) Put a check mark in the check box in the T/M (F)
or T/M (R) solenoid, and press “Write.” (Fig. 2-10)
214182
Fig. 2-10 Active test check screen
(7) Press the output monitor button in the service tool
screen to display the output monitor screen (Fig.
2-11), and make sure that the T/M control valve
current is 2 (A) or around on the screen.
214183
Fig. 2-11 Output monitor screen
(8) After the verification, return the key to OFF posi-
tion to release the active test. (Be sure to turn the
key to the OFF position whenever proceeding with
next procedure.)
If there is a error, see “Error codes and
troubleshootings” of section 10 and check each
item listed as possible causes of trouble of F-85, F-
87 and F-89.
4-30
CONTROLLERS
Controller Function
Sends the warning signal to the instrument panel if the
seat belt is not worn.
215106
214187
Fig. 3-1 Input monitor screen
(5) Check that the Seat Belt Switch turns ON and the
seat belt warning lamp on the instrument panel
goes out when the seat belt is correctly buckled.
If Seat belt SW does not indicate ON
Check seat belt SW for operation, wiring, etc.
according to “Harness codes” of section 8, “VCM-
1M controller” of section 9.1, and “Seat switch/seat
belt switch” of section 9.2.
Glow
214188
Fig. 3-2 Input monitor screen
215107
Fig. 3-3 Instrument panel screen
4-31
CONTROLLERS
4-32
CONTROLLERS
214191
Fig. 4-2 Input monitor screen
Light
215108
Fig. 4-3 Instrument panel screen
4-33
CONTROLLERS
(8) Apply the parking brake. Make sure that the park-
ing brake warning lamp in the instrument panel
glows and the buzzer stops.
214158
Fig. 4-4 Input monitor screen
214194
Fig. 4-5 Input monitor screen
Turn off
215109
Fig. 4-6 Instrument panel screen
4-34
CONTROLLERS
7.3 Parking Brake Warning Buzzer/Lamp Checking Procedure with Key in OFF Position
(1) Place and keep the parking brake lever in lock
position.
Set the direction lever (shift lever) in the neutral
position. Stop the engine and place the key in Release
OFF position. Then, power for VCM-1M controller
and instrument panel is stopped. (Inoperable)
Lock
(2) Make sure that the parking brake warning buzzer
is activated when the parking brake is released.
(This function is not affected by the status of Seat
Switch.)
(3) Make sure that the parking brake warning buzzer
stops when the parking brake lever is shifted to
the lock position. 214196
Fig 4-7 Parking brake lever
214197
Fig. 4-8 Active test screen
4-35
CONTROLLERS
8. Harness Codes
Explanation Wire number Remark
1 Seat Switch 610 0.5 L/Y
2 Seat Belt Switch 609 0.5 G/W
3 Seat Switch GND 966 0.5 B
4 Parking Brake Switch N.O 373 0.5 W/L
5 Parking Brake Switch N.O 349 0.5 L
6 Parking Brake Switch GND 949 0.5 B
9 FNR Direction Lever 1 125 0.5 G/W
10 FNR Direction Lever 2 921 0.5 B
11 FNR Direction Lever 3 611 0.5 BR
12 FNR Direction Lever 4 922 0.5 B
13 FNR Direction Lever 5 461 0.5 L/W
14 Speed Sensor + 702 0.5 G
15 Speed Sensor – 703 0.5 G/B
16 Forward Solenoid 670 0.5 W
17 Forward Solenoid RET 672 0.5 R/B
18 Backward Solenoid 671 0.5 Y
19 Backward Solenoid RET 673 0.5 G
20 Unload Solenoid 630 0.5 R/W
21 Unload Solenoid RET 631 0.5 G/W
22 Lift lock Solenoid 628 0.5 L/Y
23 Lift Lock Solenoid RET 629 0.5 G/W
24 Warning Buzzer 371(625) 0.5 Y
25 Warning Buzzer + 12V 370 0.5 G
26 Warning Buzzer Relay Contact a 373 0.5 W/L
27 Warning Buzzer Relay Contact c 371 0.5 Y
28 Warning Buzzer Relay + 12V 372 0.5 L/Y
29 Warning Buzzer Relay 0V 906 0.5 B
30 Fuel Gauge FUEL 302 0.5 BR
31 Brake Lamp PKB 349 0.5 L
32 Oil Pressure OIL 342 0.5 W/Y
33 Water Temperature TEMP 301 0.5 Y/R
37 CAN 717(715) 0.5 W/B
38 CAN 718(716) 0.5 L/R
39 12V 300 1.25 Y
Instrument panel
40 ALT 341 0.5G
41 GND 920 0.5B
42 Speedometer SP 303 0.5 Y/G
43 Speed alarm RL1 308 0.5 GY
44 Speed alarm RL2 309 0.5 Y/L
45 Continuous Power BAT 360 0.5 W/L
46 Brake Fluid Level Sensor BFS 348 0.5 G
4-36
CONTROLLERS
9. Controller Details
9.1 VCM-1M Controller
VCM-1M
Controller CN2
CN1
(RIGHT SIDE)
Name plate
214198
Fig. 7-1 Controller location
(1) VCM-1M Controller
*1
9 374 343 346 345 642 623 612 609 610 1 9 611 722 723 677 676 1
*1:A028 FC *4:A087 FC
*2:716 Diesel engine truck *5:A086 FC
*3:715 Diesel engine truck 213503
Fig. 7-2 Controller code allocation (VCM-1M)
4-37
CONTROLLERS
(White)
213505
Fig. 7-3 Seat switch
0.5 W/L
(Release) 373
0.5 B
949
349 0.5 L
(Lock)
(Black)
213506
Fig 7-4 Parking brake switch
(White)
921 922
Reverse
0.5 G/W
125
5 4 3 2 1
0.5 B
921
0.5 BR
611
0.5 B
922
0.5 L/ W
461
4-38
CONTROLLERS
Light switch/
turn signal lever
Direction lever
Front
Light switch/
turn signal switch
Shift change switch
Horn contact
214199
Fig. 7-6 Direction lever
Speed sensor
0.5 G
702
0.5 G / B
703
(Black)
702 703
Speed sensor
213509
Fig. 7-7 Speed sensor
4-39
CONTROLLERS
T/M solenoid
0.5 W
( L.H )
670
Forward 0.5 R/B
672
0.5 Y
671
0.5 G
673
( R.H )
Reverse
671 670
673 672
(Gray)
213510
Fig. 7-8 T/M solenoid
Unload solenoid
0.5 R/W
630
0.5 G/W
631
630 631
(Black)
213511
Fig. 7-9 Unload solenoid
0.5 L/Y
628
0.5 G/W
629
628 629
(Black)
213512
Fig. 7-10 Lift lock solenoid
4-40
CONTROLLERS
214200
Fig. 7-11 MC valve unit (with lift lock valve)
B2 B3
A2 A3
From
hydraulic tank
(oil intake port) To hydraulic tank
a3 SOL
(oil return port)
(To lift cylinder) a2 SOL
a1 SOL
4-41
CONTROLLERS
Warning buzzer
371 0.5 Y
0.5 G
370
213515
Fig. 7-13 Warning buzzer
0.5 B
906
0.5 L / Y
372
(Black)
(Blue) Relay box 1
* : 122 Gasoline
: 124 Diesel
213516
Fig. 7-14 Warning buzzer relay
4-42
CONTROLLERS
Fuse box
+ 12 V (Continuous)
5 W/R
115 Key switch (Relay ON with key
5 W/L
116 in ON position)
F13 10A 1.25 L / Y Warning buzzer ( + 12 V )
130
F2 10A 0.85 G Warning buzzer ( + 12 V )
430
Warning buzzer
VCM Controller
371 0.5 Y 625
0.5 G
370
372 0.5 L / Y
0.5 B
906 * Buzzer activates with
(0V) parking brake released
Parking brake switch
(Release) and key in OFF position.
373 0.5 W / L
949 0.5 B
0.5 L (To instrument panel) (0V)
349
(Lock)
213517
Fig. 7-15 Warning buzzer circuit
920
0.85G 0.5Y/G 0.5B
1.25B 0.5B G045 GND
G045 GND 0.5GY 308 RL1
0.5Y/G 0.5GY 308 RL1 0.5Y/L 309 RL2
0.5Y/L 309 RL2 0.5GY
0.5GY 719 0.5Y/L
0.5Y/L 719
1
14
14
360 920
360 920
G045
341
718 717
13
26
13
26
390
215206
214875
CONTROLLERS
Troubleshooting
Press the fault status button from the monitor menu or
toolbox to display the fault status screen, and the
screen is displayed, press the troubleshooting button
on the lower part of screen to display error codes and
their descriptions.
215111
4-45
CONTROLLERS
10.2 Troubleshooting
10.3 Diagnosis Table (F Code)
10.3.1 Error Code Table
Error descriptions
Diagnosis Lift lever neutral error (F10) Error name and error code
A
A F٤٤ F٤٤
B
Error ocurrs with condition A Error ocurrs with condition A
Action
Turn OFF all solenoid outputs of oper-
Actions to be taken when errors occur
ating functions.
LED blink pattern C See “LED light emitting pattern” of “10.3.2 LED blink pattern.”
4-46
CONTROLLERS
4-47
CONTROLLERS
4-48
CONTROLLERS
4-49
CONTROLLERS
4-50
CONTROLLERS
4-51
CONTROLLERS
4-52
CONTROLLERS
4-53
CONTROLLERS
4-54
CONTROLLERS
4-55
CONTROLLERS
4-56
CONTROLLERS
4-57
CONTROLLERS
LED blink
LED blinking
pattern
Lit
F
OFF (LED remains in a solid lit state or OFF.)
4-58
CONTROLLERS
4-59
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-16 Shift lever error
3. Shift lever bad 3. Shift lever check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-17 Speed error
3. Speed sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-20 Lift lever error
3. Lift lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-22 Tilt lever error
3. Tilt lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-24 Att1 lever error
3.Att1 lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-26 Att2 lever neutral error
3.Att2 lever bad 3. Lever connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-28 Att3 lever neutral error
3. Att3 lever bad 3. Lever connection check
4. Controller bad
1. Joystick lever bad 1, Check if any other errors is present
(e.g.: F20, F22, F24, F26, F28)
F-29 Joystick double error
2. Input unit bad 2. Input unit check
3. Harness bad 3. Harness connection check
1. Wheel sensor bad 1. Wheel sensor check
F-31 Sensor voltage error 2. VCM bad 2. VCM check
3. Harness bad 3. Harness connection check
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-34 Speed sensor error
3. Speed sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-36 Wheel sensor error 3. Wheel sensor bad 3. Sensor connection check
4. Joint and link bad 4. Joint and link check
5. Controller bad
4-60
CONTROLLERS
Error
Description Probable cause Check item
code
1. Link connection and damage check
1. Connector contact bad
2. Connector connection check
F-38 Tilt sensor error 2. Harness bad 3. Harness connection check
3. Tilt sensor bad 4. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
F-40 Steering error
3. Wheel sensor bad 3. Sensor connection check
4. Controller bad
F-41 Output unit fault 1. Output unit bad 1. Output unit check
1. Power shortage 1. Battery voltage check
2. Output unit bad 2. Output unit check
F-44 Output unit PWM power error
3. VCM bad 3. VCM check
4. Harness bad 4. Harness check
1. Output unit bad 1. Output unit check
F-45 Output unit communication error 2. VCM bad 2. VCM check
3. Harness bad 3. Harness check
F-46 Input unit fault 1. Input unit bad 1. Input unit check
1. Input unit bad 1. Input unit check
F-49 Input unit communication error 2. VCM bad 2. VCM check
3. Harness bad 3. Harness check
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-50 Lift up solenoid error 3. Harness bad 3. Harness connection check
4. Lift UP solenoid error 4. Lift UP sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-52 Lift down solenoid error 3. Harness bad 3. Harness connection check
4. Lift Down solenoid error 4. Lift Down sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-54 Lift solenoid leak 3. Harness bad 3. Harness connection check
4. Lift solenoid bad 4. Lift solenoid connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-55 Tilt forward solenoid error 3. Harness bad 3. Harness connection check
4. Tilt FW solenoid bad 4. Tilt FW sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-57 Tilt backward solenoid error 3. Harness bad 3. Harness connection check
4. Tilt BW solenoid bad 4. Tilt BW sol connection check
5. Controller bad
4-61
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-59 Tilt solenoid leak 3. Harness bad 3. Harness connection check
4. Tilt solenoid bad 4. Tilt sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-60 Att1A solenoid error 3. Harness bad 3. Harness connection check
4. Att1A sol bad 4. Att1A sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-62 Att1B solenoid error 3. Harness bad 3. Harness connection check
4. Att1B sol bad 4. Att1B sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-64 Att1 solenoid leak 3. Harness bad 3. Harness connection check
4. Att1 sol bad 4. Att1 sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-65 Att2A solenoid error 3. Harness bad 3. Harness connection check
4. Att2A sol bad 4. Att2A sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-67 Att2B solenoid error 3. Harness bad 3. Harness connection check
4. Att2B sol bad 4. Att2B sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-69 Att2 solenoid leak 3. Harness bad 3. Harness connection check
4. Att2 sol bad 4. Att2 sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-70 Att3A solenoid error 3. Harness bad 3. Harness connection check
4. Att3A sol bad 4. Att3A sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-72 Att3b solenoid error 3. Harness bad 3. Harness connection check
4.Att3B sd bad 4. Att3B sol connection check
5. Controller bad
4-62
CONTROLLERS
Error
Description Probable cause Check item
code
1. Hour meter time difference between 1. Connect service tool and #252.
F-73 Hour meter gap error
VCM and instrument panel Hour meter update.
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-74 Att3 solenoid leak 3. Harness bad 3. Harness connection check
4. Att3 sol bad 4. Att3 sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-75 Unload solenoid error 3. Harness bad 3. Harness connection check
4. Unload solenoid error 4. Unload sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-77 Lift lock solenoid error 3. Harness bad 3. Harness connection check
4. Lift lock sol bad 4. Lift lock sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-79 Unload solenoid leak 3. Harness bad 3. Harness connection check
4. Unload solenoid error 4. Unload sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
F-80 Knob position solenoid error
4. Knob position solenoid bad 4. Knob position solenoid connection
check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-82 Tilt lock solenoid error 3. Harness bad 3. Harness connection check
4. Tilt lock sol bad 4. Tilt sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
F-84 Knob position solenoid leak
4. Knob position solenoid bad 4. Knob position solenoid connection
check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-85 T/M FW solenoid error 3. Harness bad 3. Harness connection check
4. T/M FW sol bad 4. T/M FW sol connection check
5. Controller bad
4-63
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-87 T/M BW solenoid error 3. Harness bad 3. Harness connection check
4. T/M BW sol bad 4. T/M BW sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
F-89 T/M solenoid leak 3. Harness bad 3. Harness connection check
4. T/M sol bad 4. T/M sol connection check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-61 Engine overrun
3. Engine revolution sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-62 Engine revolution pulse error
3. Engine revolution sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-63 Over heat (STEP 1)
3. Temp sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-64 Over heat (STEP 2)
3. Temp sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-71 Accelerator sensor error
3. Accelerator sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-73 Engine revolution sensor error
3. Engine revolution sensor bad 3. Sensor connection check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-75 Idle switch fault
3. Idle switch bad 3. Idle switch check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-76 Throttle min position error
3. Throttle min switch bad 3. Throttle min switch check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-77 Throttle max position error
3. Throttle max switch bad 3. Throttle max switch check
4. Controller bad
4-64
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
D-78 Throttle origin position error 2. Harness bad 2. Harness connection check
3. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-79 Throttle min switch fault
3. Throttle min switch bad 3. Throttle min switch check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
D-91 Throttle motor fault
3. Throttle motor bad 3. Throttle motor check
4. Controller bad
1. When air flow meter output current of
0.5V or less (break or short) continues
for a length of time while engine is run-
ning.
E-21 Air flow meter fault
2. When air flow meter output current of
4.9V or more (break or short) continues
for a length of time with the engine
stopped (key SW in ON position)
1. When water temperature sensor out-
put voltage of 0.06V or less (break or
short) continues for a length of time.
E-22 Water temperature sensor fault
2. When water temperature sensor out-
put voltage of 4.8V or more (break or
short) continues for a length of time.
1. When throttle sensor 2 output voltage
of 0.3V or less (break) continues for a
length of time.
2. When throttle sensor 2 output voltage
of 4.8V or more (short) continues for a
length of time.
3. When throttle sensor 1 output voltage
of 0.3V or less (break) continues for a
length of time.
E-23 Throttle sensor fault
4. When throttle sensor 1 output voltage
of 4.8V or more (short) continues for a
length of time.
5. When throttle min position learning is
abnormally small.
6. When throttle valve closed position
learning is impossible
7. When there is an error on correlation
between throttle sensors 1 and 2.
4-65
CONTROLLERS
Error
Description Probable cause Check item
code
1. When accelerator sensor 1 output
voltage of 0.15V or less (break) contin-
ues for a length of time.
2. When accelerator sensor 1 output
voltage of 5V or more (short) continues
for a length of time.
3. When accelerator sensor 2 output
E-24 Accelerator sensor fault
voltage of 0.15V or less (break) contin-
ues for a length of time
4. When accelerator sensor 2 output
voltage of 5V or more (short) continues
for a length of time.
5. When there is an error on correlation
between accelerator sensors 1 and 2.
1. When O2 sensor output voltage is
higher than the normal voltage (1.4V or
E-25 O2 sensor fault more).
2. When break of O2 sensor signal line
occurs.
1. When O2 sensor heater control volt-
age of 0.12V or less (break or short)
continues for a length of time.
E-26 O2 sensor heater fault
2. When O2 sensor heater control volt-
age of 4.7V or more (short) continues
for a length of time.
1. When POS signal is not detected for
a length of time when the engine being
started or running (during PHASE sig-
nal input).
E-27 POS sensor fault
2. When abnormal POS signal wave is
detected for a length of time when the
engine is running (during PHASE signal
input)
1. When PHASE signal is not detected
for a length of time when the engine is
being started.
2. When PHASE signal is not detected
for a length of time when the engine is
E-28 Phase sensor fault
running (during POS signal input).
3. When abnormal PHASE signal wave
is detected for a length of time when the
engine is running (during POS signal
input)
1. ECCS C/U self shutoff does not acti-
E-29 Self shutdown system fault
vate properly.
1. CPU or circuit of ECCS C/U has
problem.
2. ECCS C/U are not supplied with
E-30 ECCS C/U system fault power.
3. When sensor battery of 5.6V or
more, or 4.6V or less continues for a
length of time.
4-66
CONTROLLERS
Error
Description Probable cause Check item
code
1. When a short-circuit fault in throttle
motor power system occurs.
2. When a break fault in throttle motor
power system occurs.
3. When a short-circuit fault in throttle
motor signal system.
4. When target throttle valve open angle
E-31 Throttle control fault is abnormal.
5. When electronic control throttle valve
does not function properly due to
mechanical malfunction.
1. When there is an error on correlation
between target throttle open angle and
actual angle.
2. When overcurrent flows in the throttle
motor control system.
1. When water sensor output voltage of
0.6V or less continues for a length of
E-32 Over heat (STEP 1) time
(when water temperature sensor is nor-
mal).
1. When water sensor output voltage of
0.35V or less continues for a length of
E-33 Over heat (STEP 2) time
(when water temperature sensor is nor-
mal).
1. When there is no generation of igni-
E-34 Ignition system fault tion signal continuously when the
engine is running.
1. When abnormal current is applied to
the LPG injector 1 (within injection
E-35 LPG Injector system fault range)
2. When abnormal current is applied to
the LPG injector 1 (non injection range)
1.When a short-circuit of LPG fuel pres-
E-36 Fuel pressure sensor fault
sure sensor occurs.
E-37 LPG fuel temperature sensor fault
1. When a short-circuit of LPG fuel
pressure sensor occurs.
E-38 LPG vaporizer fuel pressure 2. When abnormal rise of LPG fuel
pressure in fuel pipe from LPG VAPO to
injector continues a length of time.
E-39 Mast height switch fault
E-40 Oil pressure sensor fault
1. When break or short-circuit of stop
E-41 Stop lamp switch fault
lamp occurs.
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
P-03 VCM communication error
3. VCM Controller bad 3. Communication line check
4. Controller bad
1. Controller bad
S-01 VCM communication error
2. Setting data bad 2. Setting data check
4-67
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-02 OCM battery error
3. Battery voltage decrease 3. Battery check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-03 VCM communication error
3. VCM Controller bad 3. Communication line check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-04 ECM communication error
3. ECM Controller bad 3. Communication line check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-05 DCM communication error
3. DCM Controller bad 3. Communication line check
4. Controller bad
1. Connector contact bad 1. Connector connection check
S-06 OCM communication error 2. Harness bad 2. Harness connection check
3. OCM Controller bad 3. Communication line check
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-07 MP communication error
3. Instrument panel bad 3. Communication line check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-10 APS1 input error
3. Accelerator position sensor bad 3. Accelerator position sensor check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-11 APS2 input error
3. Accelerator position sensor bad 3. Accelerator position sensor check
4. Controller bad
1. Connector contact bad 1. Connector connection check
2. Harness bad 2. Harness connection check
S-13 APS1/APS2 correlation error
3. Accelerator position sensor bad 3. Accelerator position sensor check
4. Controller bad
1. Connector contact bad 1. Connector connection check
S-14 Idle switch error 2. Harness bad 2. Harness connection check
3. Idle switch bad 3. Idle switch check
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
S-40 Service brake solenoid error
4. Service brake solenoid bad 4. Service brake solenoid connection
check
5. Controller bad
4-68
CONTROLLERS
Error
Description Probable cause Check item
code
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
S-41 Service brake solenoid leak error
4. Service brake solenoid bad 4. Service brake solenoid connection
check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
S-42 Parking brake solenoid error
4. Parking brake solenoid bad 4. Parking brake solenoid connection
check
5. Controller bad
1. Connector contact bad 1. Connector connection check
2. Diode bad 2. Diode connection check
3. Harness bad 3. Harness connection check
S-43 Parking brake solenoid leak error
4. Parking brake solenoid bad 4. Parking brake solenoid connection
check
5. Controller bad
4-69
CONTROLLERS
Up-and-down adjustment
Attachment stopper knob
Lift lever
2 lever
Tilt lever
Attachment 1 lever
VCM-1M
(body right side) FC Lever box
Shift lever
Shift lever
connector Oil temperature sensor
Shift lever Transmission
(for powershift truck) (right side)
213520
4-70
CONTROLLERS
Attachment 1B
Tilt, Forward
Lift, Lowering Attachment 2B
Attachment 3B
Attachment 3A
Tilt, Backward Attachment 2A
Lift, Lifting Attachment 1A
Control valve (for FC truck)
Solenoid valves
Control valve
(for MC truck)
213524
4-71
CONTROLLERS
Transmission
(for Powershift truck) 213527
Others (option)
Lift pressure sensor and
Sensor name Tilt angle sensor and connector Tiltlock solenoid and connector
connector
Between control valve and tilt Between control valve and lift
Location Tilt cylinder pin
cylinder cylinder
4-72