‘TROUBLESHOOTING ‘TROUBLESHOOTING TROUBLESHOOTING 1. PRECAUTIONS TO TAKE WHEN FAILURE CODE IS DISPLAYED (1) When resetting a displayed failure code by turning the key switch OFF, wait at least 3 seconds before turning the key switch ON again (since it takes 3 scones to tum the CPU OFF after the key switch is turned OFF). (2) When checking the main controller, disconnect the battery plug and wait for atleast 2 minutes. (3) The following codes are displayed when mistakes are made in operation (Note) When the operation is repeated, if the same trouble occurs, see TROUBLESHOOTING. + E-23: Travel neutral is detected + E60: Work neutral is detected + E-68: Mistakes in operation of automatic ling stopper device and automatic fork leveling device are displayed + Abnormal operation LED in automatic lifting height indicator panel: A mistake in automatic lifting height indication is displayed (4) Te flowing codes are ceplayed a= wamings for Faure code] Troubled part safety toro tao ast Pt: Adomate fk evelng device does nt OT= 28-1425 Tae | reach level position or exceeds level position | 30 - 38, 55, 56 9 mg ey" ‘o proportional solenoid valve) + E-69: Automatic liting stopper device does not 555; ———T§ system reach set height | |Cargo handling system (related to | + E-70: Automatic lifting stopper device exceeds |60— 89 peional Saeclaatve) set height 3, 0 ‘Charger system 97 ‘Communication between main controller and multi-controller 88 ‘Communication between system controller and multi-controller i ‘Communication between meter panel and multi-controller 2. TROUBLES THAT ARE NOT DISPLAYED Repair method Reset (Execute 1) > 2) —) method 7 |Vehicle cannot oper-|» Control voltage [Check and repair control voltage (Key | — = Jate at all (Travel, | (key switch ine) |switch, EMG switch line. leargo hanging, is not applied EPS, display on meters are Impossi- ble) No. Trouble in vehicle [Contents of trouble| Remarks |» Relay in multi- Check charger interlock relay (eub) in | — 5 controller: Open |muiti-controler, then replace multi-con- troller board if necessary. 2 |Onerations related 7 5 5 = Itomain controller 1) When FR switch |+ Connectors of _ |Check connection of connectors A and [Reset | Take care when replacing (F or R) and ac- | travel speed sen-|B, then connect them correctly. normally. motor. Gelerator are op- | sors A and B are ‘erated, vehicle | connected oppo- does not travel. | sitely |» Accelerator |) Repairor replace wiring harness be-|Reset = ‘switch and its tween CN2-19 (CPU board) and [normaly signal circuit are | travel accelerator. disconnected. |2) Repair or replace wiring hamess be-| tween CN2-8, 9, 20 (CPU board) and travel accelerator. 3) Repair or replace travel accelerator unit [2) Vehicle stops [+ Accelerator and |1) Check and repair brake switch in |Tum _|Vehicle may stop be- traveling brake are operat-| OFF postion. brake |cause of mistake in oper- fed simultaneous-|2) Repair or repiace wiring hamnessbe-|switen ation (Mistake is detected ly too long. tween CN-1-6 (CPU board) and |OFF. {when accelerator and brake switch a |- Overvoltage pro-|1) Check battery connector for defec- |Reset If battery connector has tection works in| tive contact. normally |defective contactor is dis-| regeneration _|2) Repair or replace wiring harness be- ‘connected in regenera: mode, tween CN4-2 (CPU board) and ter- tion mode, protection is minal P3, applied. 13). Repair or replace wiring harness be-| tween CN4-10 (CPU board) and ter minal P13, BE30 Series 70-71TROUBLESHOOTING ‘TROUBLESHOOTING Ropalr method Reset INo.] Trouble in vehicle | Contents of trouble acs neni (Reset | Remarks 7 [(B) Cargo handling sys [Upper FED of eargo — [Check cargo handling power module = = tem chops but does [handing power module |(TMP), ten replace # necessary not have sufficient |(TMP) open power. '4) Vehicle stops travel-|PS motoris shorted, — |Check PS motor and is wiring for short c=) — = ing cul, then replace necessary 3 [Troubles weiated 0 aye = = = = loz} tom controler 4) P motor does not ro- Drive Tr power in sys-|1) Check voltage at system controller = 7 fate lemeontfoleris open. |") CNIS-2,4, 96,17, 18, and 19: itis [Sensor crcut in man | above 8¥V. replace conirlle board lcontoleris defective. |2) itvotage Isbeiow 4 Vin t)above, check Work equipment switch |" voitage at main controler CN1-8, 9, 10, Isignal harness is dofec-| 21, 28, and 25: fits above 4 V, check tive ‘wing hamess for disconnection. 3) Ifvottage fs below 4 Vin2) above, check wiring harness for shor cru lay itwinng harness is found normal in 3) above, feplace main controler Board /P motor DUTY signal |1) Check wiring hamess between system | — = hamess ie shorted contoler CN1S-1 and main controler (Command IC n system | GN28 for short creut controler is detective.” |2) Replace system controler. 2) When levers oper- |P motor DUTY signal _|1) Check wiring hamess between system | — = ated, Pmotorrotates [hamess fs shorted controler CNTS-1 and main controler at full speed Command IC in system |_| GN2-5 for short circu controller is detective.” |2) Replace system controler. 3) When certainleveris Output of lever lst. |Check and repair Pot oflever operating sec-| [Pot ouput operated, vehicle ton, Seemsto be Sbes rot respond keptat2.5V, {and related pro regardless of tional valve col does turning angle. not dtve), 7 [Automatic iting topper Ss = = = ox} function 1) Automate iting |FEP-ROM in system | 1) Setautomatic iting topping distance a | — 5 topping positon fs [controllers detective, |" litle longer and apply automat ing abnormal (Below or stop to see any trouble displayed. If above set positon: any trouble daplayed, see trouble: £69 or E-/8 5 not Shooting fort displayed) 2) Ifany trouble is not displayed, change gutematio ing Sopp Posen tn key switch OFF and ON, apply auiomet- ielting stop. See i iting stops at changed position. 3) iting does not stop normally, replace system contoler board 2) Automatic iting [Following defects in au-|1) If all LED segments of automatic iting | |Memory notdisplayed.”iomatcliing display | display panel ight up after key awitch fs swten pane! turned ON. replace system control. horted under Memory switch ie _|2) Hall LED segments do not ight up n 1), onal cond open above, memory switch of automatic Mt tion + Memory switch wiring | ing display panel is open or is wiring hamese edisconned:| hatness is disconnected. Repar oe 5 [Automatic fork evelng 5 : = : lsen|device 1) Fork cannot be tited [Automatic mode is nat |1) Operate fork leveling display switch to | — | Switch at eft manually, reset (This is nottrou- |" reset automatic mode. isan alternate be} switch, which 2) Fork cannot be tited |Fork leveling daplay — |1) Iffork leveling display switch camotbe | (ness opera- manually (Open), |switch is defective. tuned ON anid OFF, replace i tion, Ea Fork cannot be tited | Wiring harness of fork. |2) I switen is normal, check ts wiing har- ime it oper manually (Shorted). |leveling display switch is ness for disconnection and shor circuit, ed, ts siete |defective. then replace. Is reversec 3)1fresultof above checkis normal, replace system contol. 37. For proportional solendid valve apes 70-72 BE3O Series‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) FAILURE CODES LIST (1.0 - 2.5 TON MODELS) Faure] Contents of code trouble Trouble ih vehicle Repair method (Exeoute 1) 2) —) Reset method Remarks ‘Ot [Travel power mod- ule is shorted (Upper and lower FET's are short: ed). Vehicle cannot travel |1) lor handle cargo (MD lconnectoris not |2) Iclosea), This trouble is also ldetected when failure code dSisdsplayes.) 4) 5) 6) Tushile can wave, check code 45 Check travel power modules (TMDU, TMDV, and TMDW) and replace them if necessary. (Ifa power mod Ue is defective, be sure fo replace it and power supply board as a set.) ) Check wiring hamess between CNSR (Power supply board) and each pow ‘er module, then repair oF replace tt. Check wiring hamess between CN4- 2 (CPU board) and terminal P3, then Tepair or replace it. Check wiring harness between CN4- 8 (CPU board) and terminal P1, then repair or replace it. If result of above check is normal, re- place power supply board Tur key switch OFF. 03 [Main contactor (MD) is shorted or ‘open or its sensor lrcuit hamess is, defective IVeniele cannot ravel |1) lor handle cargo. 2) 3) ‘Cheok main contactor (MD) (for mere ing, mechanical hitching, etc. of con-| tacls), then repair or replace it. Check wiring harness between CNS- 11 (CPU board) and terminal P2, then fepair or replace it Check wiring harness between CN4-| 8 (CPU board) and terminal P', then repair or replace it Fram key sulteh OFF. 05 | Travel power mod- 11 |ules are shorted (Upper and lower ‘modules are shor led separately). Vehicle cannot travel [1] lor handle cargo. 2) 3) 4) 5) 6) ‘Check travel power modules (TMDU, ‘TMDV, TMDW) and replace them i Sure epiate thom aoa ot ogeth er with power supply board) Check wiring harness between CNSR (Power supply board) and teach power module, then repait or replace t Check wiring harness between CN 3 (CPU board) and terminal P4, then iepair or replace it Check wiring harness between CN 2 (CPU board) and terminal PS, then repair or repace it Check wiring harness between CN 8 (CPUboats) and terminal P1, then repair o replace i ifresul of above check is normal, e- place power supply board Tarn key suttch OFF. Faire code 05: Detected when key switch is turned OF Failure code 11 Detected after key Iswiteh and MD are turned ON. 06 | Travel power mod- 08 |ule is open. 09 |U., V., or W-phase is disconnection, Vehicle cannot favel [1] lor handle cargo. 2) 3) 4) ‘Check travel power modules (TMDU TMDV, TMDW) and replace them if necessary. (When replacing, be sure to repiace them as a set, togeth- fer with power supply board.) Check wiring harness between ENGR (Power supply board) and each power module, then repair or replace it Check output terminals of U-, V-, and We phase for sisconnecton énd If result of above check is normal, re Tur key switch OFF. place power supply board Failure code 06: \U-phase is open disconnected) Failure code 08: \V-phase is open \isconnected) Failure code 09: ‘W-phase is open disconnected) BE20 Series 70-73FAILURE CODES LIST (1.0 - 2.5 TON MODELS) ‘TROUBLESHOOTING Talus | — Contents of Towler Repair method Reset code| “trouble vehicle (Execute 1) 2) method] Remarks 07 ain contactor Venice cannot wavel[) Check main contactor (Mb) col for [Tum = [td) Grve'Ta de-|or hance cago. Gaconnecton of connector and Cl, Key fectve (in cPU then reparor replace ewtch tarde) >) Checking hatness between [OFF ain contactor co contactor cal ana CN&-3. 13 (CPU (Sopen Beard). then rat or replace Seto creut har a) Replat CPU pour ste Sve Tris ness of main Estee). Goncactor cl is Sefecive 5 |F or swich s de Venice cannot Wavel| 1) Check withg Namnews bowser CNT Reset [Tum Fawteh and R fectve S1°53 (CBU boar) and Fi ston |normal-|arton ON smut focshowtereut then replace fnes: |. neously, 2) Repat or replace FIR ovitch 7” [Travel accsleraior | Vehjcle can Tavelat 1)” Check wing iamess between CRE-|Reset_| Nompal source aTageoT output defecve, 40% of maximum |” 8,9, 20(CRU board) and travel c- |nonmat-|sccaeraor $V (Ge speed celerater ten repair orrepiace tly." |teen NE Sand 2) 2) Check rave accelerator unt, then uta votage fae repair or eplace ata weer oes detected Max 02 V, Win #8 (eteen Che and20) 5 |Sumpator pring —|VeTice cannot wavel 7] -Check wing hamess betwen CPU Tarn — | Normal sensor ouiput Ratnoss often Soaid and cunartconeote hone [toy | 'Burng navel so earentsareor par or repace wen | OH’ (E380 SS5%y is ESbUERSSS, 4 14 15, OFE” | when PR owich is Serecive ESDW-ENSS, 6, 46, 17 Whoural am accel 2) Check source volags of curent sen caer OE AE Sor power supply of CPU board prox 7 BBoU Bonen NS Sand 1h 15, ES6U; Boween GSM Between CNS 8 and 16, 17 ENS and ts 13 fr eource yottage is abnormal, r= Sov Betwsen place cPU bosra ENS ana 16.17 a) Beck curtnt seneors (CSU, CS- Novel source vo BW then replace tf cesta Dyoot sensor power oe supply 15. sensor eutpt when sonore ie detec earhox 13. Mn ev | Travel mam tse —| Vee cannot rave [1)- Check Travel fuse (FTyand replace [Tum — [Check voage on 366 (Eabrokenoris|iBeosacers. | necessary. Key", ondary ie of fuse Servor cheuk nar: |cosenh 2) Chese wing harness between CNS-|swrch (F3). ese 6 dofoctve, SNebU besrdjand teminel 2. [ORE then repar or replace a) Check rg hamness between CNS- STEAL boats) and terminal 95, hen repair or replace ZT [Undewaage = — [Venice cannot ral |) Charge bate Turn [This rouble dete elected (atery |{MDIMPS connector [2) Check winng famess between CNé- key" [ed when ater vote Notage s ower). |enorciosed) When |” 8(CPUboars) and terminal, then [such |age'stelow 28.2\/for Keyawteh wiumed | fepar orropace t Ore” |e seconds, ON again venice can ve 2 |Ouiput oT ravel —|Vehice can Wavel 1) Check temperature sensor (THD), [Reset Votage of empare- controler tempere-/normaly (assuming |” snd replace t necessary Tonal ure spnoor CTD) fre sensor (HD) [temperature so 2) Ghecewnghamese between ON7-5, |b." |wnen abnormnaly = iSgetoctve. may {NGpU ocaa) ond temperature son: Spleen: Max OV, sor THO), thon reparorepace wine 4.96 V [Neale detect Venice cannot avel |i) Operate accelerator and dresion [Tum When both of acceler a switch normaly accel. latorandrRewtcnare Neutral caused la) Cheskaccelersiorordirectionawih [erator ‘ured ON: ousle = Dyrmstae in op- forshon ercuk then repar ores [ang ER [eset when ether of ator ot pace [Sten them fo tumed OFF trowe 5) Sheek crouit of accelerator or dree- [OFF tion switch for looseness of connec tor and defective wiring hamess, then repair or replace it 70-74 BEQ0 Series‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) Faure] Contents of Trouble Th Repair method Reset code | trouble vehicle (Execute 1) > 2) 9—) method] Remarks 24 [Travel controller |Vehicle can travel |{) Cool controller and stop vehicle. |Con- _|Normal resistance temperature is |(Currentis limited by |2) Check mounting screws of TMDU, _|trolleris | voltage of tempera- high. temperature rise and | TMDV, and TMDW forlooseness.|reset ture sensor Fan drive system output is lowered). |3) Check resistance and voltage of tom-|when _|25°C: 20K0/4.0 V is defective. perature sensor (THD), then replace |temper-|50°C: 7.2k0/3.0 V Iti necessary. ature |B0°C: 2'5kQN1.7 V 4) Check wiring harness between CN7-Jiowers [Tolerance of these 5,11 (CPU board) and temperature |below |values is + 10%. Sensor, then repair or replace it. | 100°C. |1 ton models: fan '5) Check wiring harness between |CN7R-2, 8 CNTR-1, 2,7, 8 (Power supply 12 ton models: 2 fans board) and each fan, then repair or ICN7R-4. 7 added replace it, |Above 100°C: Current 6) Check wiring harness between CN9-| is limited, 6 (CPU board) and CNIR‘6, then re- |Above 103°C: Warn- pair of replace it ings aisplayes. 25 [Travel motortem- |Vehicle can travel [1] Cool travel motor and stop vehicle. |Travel_|Normal resistance peraturarises. |(Current is imited by |2) Check resistance and voltage of trav-|motoris | voltage of travel motor [temperature rise and |" el motor temperature sensor, then reset |temperature sensor loutput is lowered), replace it if necessary lwhen |25"c: 10.7ka/3.5 V 3) Check wiring harness between __|temper-|50°C: 4.4k0v/2.4 V €N17-3,4 (CPU board) and travel ature 100°C: 7.0kQ/0.9 V motor temperature sensor, then re- lowers |150°C: 0.3k0/0.3 V pair or replace it below. |Tolerance of these 160°C, |values is = 10%. |Above 160°C: Current is limited, |Above 163°C: Warn- ing is displayed. 26 [Travel controller |Vehicle cannot travel.[1) Cool controller and stop vehicle. |Con- [Normal resistance temperature is ab- 2) Check mounting screws of TMDU, _|troleris |voltage of tempera- normal, TMDV, and TMDW forlooseness. |reset - |ture sensor Fan drive system 3) Check resistance and voltage of tem-|when _|25°C: 20K14.0V is defective. perature sensor (THD), then replace |temper-|50°C: 7.2k0/3.0 V ‘tif necessary. ature |80°C: 2:5k0/1.7 V 4), Check wiring harness between CN7-liowers [Tolerance of these 5,44 (CPU board) and temperature [below |values is + 10%. Sensor, then repair or replace it. |115°C. |1 ton: 2fans 5) Check wiring harness between lON7R:2, 8 CNTR-1, 2, 7,8 (Power supply 12 ton: 3 fans board) and each fan, then repair or ICN7R-4, 7 added replace it, |Above 115°C: Travel 6) Check wiring harness between CN9-| is stopped, 6 (CPU board) and CNIR-6, then re- pair ot replace it 27 |Outputof travel |Vehicle can travel —_|1) Check voltage of ravel motor tem- [Reset _|Vollage of tempera ‘motor temperature [normally (assuming | perature sensor, then replace sensor |normal- ture sensor when ab- Isensoris defec- |temperature isnor- | ifnecessary ly. [normality is detectes: tive mal). 2). Check wiring harness between Max. 0.2V, Min. 4.95 (€N11-3, 4 (CPU board) and travel lV motor temperature sensor, then re- pair or replace it 2B_|Travel motor tem |Vehicle cannot ravel|[1) Cool travel motor and stop vehicle. |Travel_[Normal resistancel perature is abnor 2) Check resistance and votage of trav-|motoris |voltage of travel motor ral el motor temperature sensor, then reset |temperature sensor replace itif necessary lwhen |25°C: 10.70/35 V '3) Check wiring harness between __|temper- |50°C: 4.4k01/2.4 V GN17-3,4 (CPU board) and travel ature 100°C: 7.0K0/0.9 V motor temperature sensor, then re- lowers |150°C: 03k0/0.3 V pair or replace it. below. |Above 175°C: Travel 475°C. |is stopped. BE20 Series 70-75,FAILURE CODES LIST (1.0 - 2.5 TON MODELS) ‘TROUBLESHOOTING Fal] Contents of Troubles Repar method Reset code | trouble vehicle (Execute 1) > 2) method) __ Remarks 30-_[ Cargo handing —Vetiee can handle i) Trvehicie can handle cargo, check — [Tum = ronermosule’,_|oargo. code Se frst, toy ETMBU}s shortes,| (IB contactoris 2) Check cargo handing power module [such dosed) (TNIPU) and replace tf necessary. [OFF (This tauble's.also | {power module is detectve, be etoctedwnen aiure | Sure to relace t and power Supply code sbisdisplayed|| board as 9 set) a). Gheck wing hamess between NAR (Power supply boerd) and TM- BU. tion epairorreplace t |4) ‘Check winng hamess between CNS 40 (CPU bosrd) and terminal P13. then repair or replace 5). heck ming namess between CN4-| 8 [CPU boars) and terminal P1, then repair or replace lo) Irresuitofabove check is norma, re: Pace power supply boar Gi [Cargo handing —|Vetiee cannot han- ]i) Check eargo handing power module |Tum = owsrmosule™ ale cargo. (IMP) and replace tf nosescary. (key Fri) open. (MIP contactor ie power modules defective, be sureto atch Uppet sige or car. |cosed.) Foplace and power supply board as | OFF 39 handling power act) module (TMP) (Be- 2) Shock wiring harness betwoon ftveenPand OUT) NAR (Power supply board) and car Ig shored o nailing power moaule (TMP). argo handing Rentopairorrepiace moter sorted or 5). Chock wing hamess betwoon CN3- oven S{CPU boars) and CNRS (Power Supply board, ten repaorepisee i 4) Gheck cargo handing motor and its wining, the repatr orteplace 3 [Chassis ENG Vehicle cannotoper- |i) Check chassis EMG awitch. Wikis [Tum [This wouble oomurs Suite e defective |ate work equipment. |.” open, repair or replace ENG [only when CN1-24 is Joris cieuither: |(MP contactors not 2) Checiewinng hartess belween CN1-\swich siseomected (and ness disconnect |elosed) 24(CPU board) and EMG switch, |andkey does not occur while ea then repairor replace Surton’ EMG switch i OFF. _[pressed). 35 [Cargo handing —Veticle cannothan- 1) Check cargo handling use (F2)and [Turn — Check vollage on se main fuse (F2)is_ {dle cargo (MP » enlace t Pnecossaty, o |hay”londary See Ot fuse Droken ts sensor contactors closed). |2) Check wing hamess between CNS-|awtch |(F2) ereut harness $2 (GPU board) and terminal P12.” [OFF aetectve then repair or replace it 3). heck tring hamess between CN4-| $0 (CPU board) and terminal P13, then reparror replace J4) Check wining hamess between CNS- ST (GPU bokrc) and terminal P2, then repair or replace 3B [Cargo handing It [Vehicle cparateswih }1)-Gheck wiring harness between CNZ-|Reset Ths code i appledto [ia shoned Sr" [eargonancing On" |” $0'14,21 (GPU board) end cargo [noma ony venice equiped open Perodrato at 100%. | hanaiig MI VR, theneparorro= |i.” |wit mancal valve nace 2). heck cargo handing it VR, then -| Output oft VR when place if necessary abnormality is ostece fc: Max 0.2 V. Min £5V Getween NE, tOand21) 36 [Oubputof cargo — [Vehicle can handle 1) Check votageoftemperature sensor [Reset Volage of tempera: andiing convaer |cargo normaly (as- |.” (TH), thenteplace Sensor f neves-|normal- ture sensor when ab- Remperature cen. [suming temperature | Say. ty |normaity is detected sor (TH) is detec nora. 2). heck wing harness between CN7-| Niaxc2 v Min 48 ive 6.12 (CPU Boars) and temperature ViGetween N76 Sensor (THE) then ropa oF enlace and 13) i 1 |Outoatoftavel — |Vehice cannot ravel| 7) Chock wing hammess botweon CNZ-[Resot = speed sensor Ais $18 (CPU Beard) and travel speed normal aetoctve. Sencor A, en repairorreplace i. |. 2) Check travel speed sensor A. then repair or replace a). Replace evel moir. (Combination of gencor and it panel in motor ls deteatve) 70-76 BE30 Series,‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) place it i necessary. (Note) Be sure to replace following pars, if necessary. * Replace setof main Tr(TMPS1, 2) + Replace EPS boars Faure] Contents of Trowle Tr Repair method Reset al code trouble. vehicle (Execute 1) 2) > —) method 42 [Output oftevel |Vericlecannottravel/ 1) Check wfing harness between [Reset Si speed sensor B is CN11-5, 6 (CPU board) and travel |normal- defective Speed sensor then repirorre- Jy 2) Check travel speed sensor B, then repair or replace it 8). Replace travel motor. (Combination Of sensor and sit panel in motor is, defective.) | Capacitor of wavel [Vehicle can travel _|1) If vehicle cannot ravel, cheok code [Tum — |Note) this trouble is capacitor port normally. Whenmain | 01 first key left as itis, travel (CBD) is charged contactor (MD) is |2) Replace CPU board (Resistance of |switen contactor (MD) is fabnormally lturned ON, arc is boosting charge drive Tris defec- OFF. |wom quickly by arcs. Igenerated. (This. te). Repair it immediately. rouble is also detect- led when failure code [01 is displayed.) 30 [PS main Trorits [Steering wheel is |1) Check PS motor and is wiring for [Tum Si ‘ive circuithar-_|heavy. ning, then repair or replace it, |key ness are defective.| «If short circuit is {Take care of defective contact ot switch IEPS board is de- |made. this trouble is | brush, too.) OFF. lective. [detected before MPS |2) Check connectors and wiring har- [PS motor is open. |contactor is turned ness between terminals G, E of main [ON. Tr(TMPS1, 2) and CNAR (Power supply board) for short circuit, then repair or replace them. 3) Check connectors and wiring hat- ness between CNER (Power supply board) and CN2E (EPS board), then repair or replace them. 4) Check connectors and witing har- ness between CNER (CPU board) and CNtE (EPS board), then repair tr replace them. 5) Check main Tr (TMPS1, 2), then re- 6) Ifresult of above check is normal, place EPS board. ‘ST [PS contactor |Vehicle operates nor-|1)_ Check PS contactor (MPS), then re- [Tum _ |Timing of displaying (MPS) is shorted |mally place it if necessary, key trouble lorits sensor circuit |(Error is kept dis- | 2) Check wiring hamess between CNé-|switch |When key is turned hhamess is defec- |played.) 9(CPU board) and terminal P21, |OFF. JON and when MPS. tive. then repair or replace it \drive is turned OFF 3) Check wiring hamess between CN4-| 4 (CPU board) and terminal P22, then repair or replace it. ‘82 [PS main fuse (F3) |Steering wheelis__|1) Check PS main fuse (F3), then re [Tum 7 is open. heavy. place it if necessary. key PS contactor __|(PS contactor (MPS) |2) Check PS contactor (MPS), then re- }switch (MPS) is open or |is not closed.) pai or replace it. OFF. its sensor circuit 8) Check wiring hamess between CN4-| harness is defeo- 9 (CPU board) and terminal P21, tive. then repair or replace it. 4) Check wiring hamess between CN4-| 1 (CPU board) and terminal P22, then repair or replace it. 5) Check wiring hamess between CN4-| 8 (CPU board) and terminal P1, then repair or replace it, 53 [PS contactor __|Steering wheelis | 1) Check PS contactor (MPS) coilfor_ [Turn = (MPS) coil drive Tr heavy. disconnection of connector and coil, |key lorits sensor circuit then repair or replace it switch harness is defec- 2) Check wiring hamess between OFF. tive. ‘contactor coll connector and CN4-6, (in CPU board: 14 (CPU board), then repair or re- 18) place it. 3) Replace CPU board (since drive Tris defective). BE30 Series 70-77FAILURE CODES LIST (1.0 - 2.5 TON MODELS) ‘TROUBLESHOOTING Fae cade Contents oF trouble Trouble im Vehicle Repair method (Execute 1) > 2) 9 —) Reset La Remarks 54 |Output of PS torque sensor is ‘Steering wheel is heavy. ‘Check and repair connectors and wiring harass between torque sen- Tum |Output wokage of key |torque sensor when defective, ‘sor and CN2-6, 7, 18 (CPU board). |switch | abnormality is detect- }2) Check PS torque sensor, then repair |OFF.|ed: Max. 0:2 V, Min. cor replace it 4.8V (Between CN2-6 ‘and CN1-14) 5 [Cargo handing __|Vehicle can handle |) Cool controller and stop vehicle, |Con-__| Normal resistance controller tempera-|cargo ("ON" period _|2) Check mounting screws of TMP for |trolleris | voltage of tempera- ture is high: ratio i limited by ter looseness, reset |ture sensor Fan drive system |perature rise). 13) Check resistance and voltage of tem-|when | 25°C: 20k 214.0 V is defective. perature sensor (THP), then replace /temper-|50°C: 7.240/3.0 V itif necessary. lature | 80°C: 2'5k0/1.7 V l4) Check wiring hamess between CN7- [lowers | Tolerance of these 6, 12 (CPU board) and temperature |below | values is + 10%, sensor (THP), then repair or replace | 100°C. it 5) Check witing harness between CNTR, 2, 7, 8 (Power supply board) and each fan, then repair or Toplace it |6) Check wiring hamess between CN9- 6 (CPU board) and CNIR‘S, then re- pair or repiace it 36 | Capacitor of cargo |Vehicle can handle |) When driving cargo handing motor [Tum — |Note) this wouble © Randling capacitor |cargo. When main | continuously, check code 30 first. key leftasitis, main por (CBP) is contactor (MD) is |2) Replace CPU board (Resistance of |switch ‘contactor (MD) charged abnormal-|turned ON, arc is boosting charge drive Tris defec- | OFF. is worn quickly ly generated. (This tive) byarcs. Repair trouble is also detect- itimmediately. ‘ed when failure code 30 is displayed.) @0_|* Key switch is |+ Only related opera- |#) Check input signal of work equip- Tum [lf E87 —E89 are also (642) |" tuted ON while |" tons are impassi- |” ment Pot key" |displayed, check them work equipment | ble. Erroris + Measure voltage at system controller |switch first. For repair meth- controlleveris | displayed immedi- | " connector CN4S — Normal: 24-26 V|OFF. _ |od, see each failure rotinneutral. | ately after key |2) Ifresult of check in (1) above is nor- ‘ode section, (Note) This is not | Switchistumed ON.| mal, replace system controller board. rouble. 3) If result of check in (1) above is ab- = Adjustment of normal, disconnect related Pot con- ‘work equipment rector and check its resistance, then Pot is abnormal replace if necessary + Work equipment Normal resistance — Pin No. 1-3: Pot is abnormal 2k) Pin No, 2-3: 0- 2k + Work equipment ]4)_ if result of check in (1) above is ab- Pot circuit hat- rormal but that in (3) is normal, ness is defective. check and repair wining hamess be- tween system controller and work ‘equipment Pot. Gi_|> Adjustment of | Only related opera- |) Check and adjust control ever siop- [Tum |W EG7- E89 and E-60 (6%2)| work equipment | tions are impossi- | per. key |are also displayed Pot is abnormal Work equipment Pot is abnormal, Work equipment Pot circuit har- ness is defective. ble. Error is displayed when le- ver is operated, 2) 3) 4) Measure voltage at work equipment control lever Pot connector CN4S, ‘When lever is fully tited 9-43 When lever i fly ites back: 0.7 — If result of (1) above is normal, re- place system controller board. Ifresul of (1) above is abnormal, dis- connect related Pot connector and check its resistance, then repair it Normal resistance ~- Pin No. 1-3: 2k0 Pin No, 2-3: 0 ~ 2k If result of check in (1) above is ab- normal but that in (3) is normal check and repair wiring harness be- tween system controller and work ‘equipment Pot. sawtteh [check them first. For OFF. repair method, see each failure code sec- tion 32. Displayed only proportional solencid valve spec. 70-78 BEQ0 Series‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) tinued)| Is abnormal 2 |+ Lit pressure, hamesss defec-| tive. sponse is lowered, however, and hunt- ing prevention func- tion does not work when lit lowers, ‘Automatic iting and ‘automatic fork level- ing (f equipped) ‘cannot be applied Error is displayed immediately after key switch fs turned ON. + Measure voltage at system controler |switch Connector CN&S --- Normal: 0.37— |OFF. 43V 2) IWresultof check in 1) above is nor- imal, replace system controller board, 3) result of check in 1) above is abnor mal, check and repair pressure sen- Sor hamess 4) result of check in. 1) above is ab- ‘normal but that in 3)is normal, repair pressure sensor. Faure] Contents of Trouble Th Repair method Reset code trouble. vehicle (Execute 1)» 2) 9 —) method comes 61 |» Outputof it __|+ Vehicle can do all |1) Check input signal of lit pressure [Tum (Can. |" pressure sensor | operations. Re- sensor. ke Output vottage of Pressure sensor: Out lof0.34-4.8 V) (axiomatic fork Noveling device Is instales) Output of ting ange sensors arora soruithar- ness is defective, I Automatic fork Tev- ling cannot be ap- plied. (Fork can be moves by manual operation.) Error is displayed immediately after key switch is turned ON. 1) Check and repair mechanical opera- [Set tt tion of titing angle sensor. lever in 2) Check that mast does not stop me- neutral chanically during automatic fork lev- tling operation, then repair mast necessary. 3) Check input signa from sling angle sen Sor and adjust installation of sensor. Measure voltage at system controller Connector CNSS, Normal voltage: 0.4 — 4.6 V (Back Ward tiking end - Forward titing end) 4) result of 3) above is normal, re- place system controller board. '5) result of 3) above is abnormal, ‘check and repair iting angle sensor. Disconnect ting angie sensor and measure resistance of sensor. (Output voitage of tit: ing angle sensor: Out ‘344.7 V) | Output of sensor |does not change dur- ing fork leveling oper- lation.) |: Proporional a2) | vate col sis connected Wiring hamess Between propor- {onal valve and System controler fas touble of s- conection, leak. age, or defective coniace > Relay fuse, ENS Site, or ii hamessis dis? connected + Ee relay in ayo tem controler Battery vot Battery voltage fowerowl lever operated. <1 (Note) This is no! lier. EMG siitch is operated white leveris operated, then only propor: tional valve pow- ce supply circuit is broken. 32 (Note) This is not. rouble in. system” controler, + Proportional valve drive cireuit in system con- troller is open, Only related opera: tions are impossi- ble. Error is displayed when le- ver is operated (Pump motor ro- tates fora moment.) / Vehicle cannot op- erate at al Error is displayed when lever is Oper- fated. (Pump motor rotates for a mo: ment.) \ Oniy related opera- tions are imposs- ble. Error is displayed when le- ver is operated. (Pump motor ro- tates fora moment.) T) Check resistance of proportional [Turn valve coil, then repair coilifnneces- key say. sutch Normal resistance: 17 ~ 18 OFF. 2) If result of above check is normal, ‘check and repair proportional valve reuit hamess, 3) fresults of 1) and 2) are normal, go te PROPORTIONAL VALVE DRIVE CIRCUIT IS OPEN, 1) Check proportional valve power sup-|Turn py key + Check voltage between pins No. 8 |switch ‘and No. 21 of system controller con- |OFF. hector CN1S — Normal voltage: Bat- tery voltage 2) If result oF 1) above is normal, re- place system controller board. '3) result of 1) above is abnormal, ‘check proportional valve power Sup: ply circuit hamess, CH interlock (main) relay, fuse, and EMG switch between battery and system control- ler for disconnection and leakage, then repair 1), Replace system controller board. If E87 E89, E60, land E-61 are also dis- played, check them first. For repair meth- lod, see each failure [code section ‘1 — Example: Main transistor of main con- rollers shorted, 2--- Example: EMG [switch is operated mo- meniaily or pushed alway, 3X2, Displayed only proportional solenoid valve spec. BE20 Series 70-79FAILURE CODES LIST (1.0 - 2.5 TON MODELS) ‘TROUBLESHOOTING low. (Note) This is not lwoubie in system controler (Examole: Main tran- sistor of main con. lroler is shorted) Error is displayed immediately after key switch is turned ON. Fale] — Contents of Trouble im Repair method Reset coce| “trouble vehicle (Execute 1)>2) 9 —) mmethoa| Remarks 2_|+ Proportional | Vehidle cannot op- |1) Check resistance of proporional [Turn | EB7—E69, E60, (Con-|"vave cols |" erate atal Valve coil then repair col tneces- |key" and E-64 are also cs- inued)| Shorted Erroris displayed | sary. lsuitch_|played, check them 2) when fevers oper. | Normal resistance: 17 ~ 180 OFF.” frst: For repair math- ated. (Pump motor |2) If result of above check is normal, go ‘od, see each failure fotates foramo- |” to PROPORTIONAL VALVE DRIVE ode seston, ment) CIRCUIT IS OPEN. ‘Example Main transistor of main con- troler is shorted 2~- Example: EMG switch is operated mo: mentanily or pushed halfway Proportional |= Vehicle cannot op- |) Replace system controller board (Check output oorre- valve drive circuit | erate at al ‘sponding to input.) ineystem con. | Eror ie displayed troleris shorted, | when lever is oper- ated. (Pump motor fotates for'a mo- ment) ‘Gi_|iFautomatie fork |» Automatic fork ev- |i) This phenomenon i not rouble. Fit [Leave —| Forks notin level po (642) leveling device s | eling device does ‘occurs frequently, however, check » {lever in |sition.) insted} not each evel posi-| for mechanical factor such as hiteh- neutral Automatic fork | ton or exceeds lev-| ing, then repai teveling device | elpositon does not reach (+ Fork can be tilted tevel positon or | manually) exczeds level po- Stton rouble @E_|[ir automate ing |» Automatic Wing —]1) Check input signal for automate [Tum (642) |device installed] | cannotbe applied. |" ing operation. key Aubomalietting | (-Litcan be raised | « Measure input voltage for switches |swtch control pane!” | manually.) ‘ther than memory switch at connec-| OFF Switch ig shorted | Erroris displayed | tor CNGS of system controller, beforekeyeniteh | immediately ater_| Normalvottage: When switch is OFF: istumed ON. | Keyswitch turned | Mina V ON. When switch is ON: 0 V 2) result of 3} above Is normal, re- place system controler board 3). resuf of 1) above fs abnormal measure res/stance of &-pin connec- toref iting display panel Normal resistance: When snitch is OFF When switch is ON: 09 (when key switch is (Exeluding memory switch) Aimed ON, unloading, |4) Ifresult of 3) above s abnormal, re loading, or aumber-of pair lifting display panel. layer setting (1 - 5 lay-| 5) Wrresult of 1) above is abnormal but ere) switeh vs tured that (3) @ normal replace stem ON) controler 67_|[rautomatie ing |= Automate iin 7) Check encoder power supply arout, [Turn (Source vovage: Be (32) [sevice 8 nstaled} | cannotbe applied. |'* Disconnect system controler con. |key" |low 4.77 ¥) Automatic fing. |+Ifhistrouble ocsurs | " nector CNBS and check votage be- |swtch fencoder power’ | inautomatcifting | tween Pin No. tand No. 4 OFF. Supply in system | mode, vehicle Wren normal: 10'7 controler is de" | Stops l2) Itresul of above check is abnormal, fective (-Littcan be raised |" replace system controller board Battery voltages | manually.) 3X2, Displayed only proportional solenoid valve spec. 70-80 BEQ0 Series‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) + Lifting encoder Grout is detec- tive [If automatic itn device is install [When 2 encoders are installed] sist and 2nd en- coders are con- nected wrong (when 2 encod. ers are installed). [If automatic iting device is installed} [When 2 encoders are installed] * Lifting 2) refer- fence switch is defective + Circuitharness of ling (2) refer fence switch is defective [Faviomate iting fevice is installed) Acphase and B- hase of iting Encoder are con- fected opposite: ly. tion any more, (¢Lit'can be raised manvelly.) Vehicle stops iting operation, hen chnnot lant auto- male iting opera. toneny more (Lit can be raised franvally) \ Vehicle stops lifting operation, then it cannot start auto- matic lifting opera- tion any more, (¢Lift can be raised manually.) /- Vehicle stops liking operation, then it ‘cannot start auto- matic lifting opera- tion any more. (¢Lift can be raised manually.) ically during automatic liting opere- tion, then repair lit f necessary. 8) Check input signal from lifting encod.| cer while itis ring, + Check voltage at system controller Connector CNS. Voltage under abnormal condition (Note 1): 5V oro V (Note 2): Check A-phase and B> phase with encoders 1 and 2 respec-| tively 14) If result of 3) above is normal, replace ‘system controller board. 5) I result of 3) above is abnormal, check lifting encoder harness, then repair t if necessary. 6) I result of 3) above is abnormal but that of 5) is normal, repair Iiting en- coder. 1) Check that ist and 2nd encoders are connected correctly, then repair them if necessary. 7), Disconnect connector of iting 2) ref [Turn erence switch and measure voltage. |ke\ If voltage is above 4 V, check iting | switch 2) reference switch, then repair tif |OFF. necessary, 2) If voltage measured in 1) above is below 4 V, check wiring hamess be- tween sysiem controller and lfting 2) reference switch, then repair it nec- essary. 3) If result of 2) above is normal, re- place system contraller board. 1) Turn key switch ON and pass refer- |Turn ence switch. See f trouble occurs |key (buzzer sounds) 1 second after fst | switch Titing operation is performed. OFF. 2) If trouble occurs by operation in 1) above, check and repair connections of A-phase and B-phase. Faure] Contents of Trouble Th Repair method Reset code. trouble vehicle (Execute 1)» 2) 9 —) method eomete 67 _|[ifautomaticifing |* Vehicle stops iting |1) Check that iting encoder is operat- [Tum |(Note 7) (Con. |device is instaled] | operation, then it ing (wire is coming out or going in), |key |Encoderoutputpulses inued)|» Lifting encoderis | cannot start auto- | then repair it necessary. switch of OV and $V. IFitis (042) | defective matic lifting opera- |2) Check that lit does not stop mechan-|OFF. |abnormal, is output lonly 0 V or 5V. Note 2) heck encoder (2) lonly when itis in= stalled Note 3) Inspectfication shown in standard connec tion diagram, iting lencoder wire is pulled loutwhen lit is raised, In specification where lwire is pulled in when itis raised, A-phases land B-phase are on lopposite sides. Ac- lcordingly, phases must be confirmed. If E87 — E69, E60 and E61 are also dis- played, check them first. For repair meth- lod, see each failure Icode section. (Pulses lare not output from lencoder during lifting loperation.) (Operating direction [does not conform to loutput direction of en- looder.) [automate iting device is installed} + Lifting encoder input circuit in system control- leris abnormal / Vehicle cannot op- erate automatic It- ing work. Vehicle strs iting operation. T] trouble is not repaired by above — [Turn methods, replace system controller |key board. sutch OFF. [Pulses are rotoutput Irom encoder during iting operation.) 342, Displayed only proportional solenoid valve spec. BE20 Series 70-81FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING Faure] Contents of Trouble mh Repair method Reset code | “trouble Vehicle (Execute 1) 2) method} __ Remarks €8_|[rautomatic iting |= Vehicle cannot op- [1) Repeat operation correctly Set |[Fork leveling opera (642) [device s installed) | erate automatic lit lever in | ion is abnormal) lor{Mautomaticfork | ing work. neutral. |+Operation isin re- leveling device is |+ Vehicle cannot op- verse direction installed) erate fork leveling (Automatic iting oper- Automatic iting | work ation is abnormal] ‘operation and” | (+ Fork can be lev- *Reference switch is forkleveling op- | sled manually.) not detected or num eration are de ber of layers is not fective set Tf automatic ifing |= Vehicle cannot op- |) Disconnect reference switch connec-|Set__|*Number of layers is ldevice is installed) | erate automatic lit-| torand measure voltage. If voltage |iever in | Changed during op- lor{ifautomatictork | ing work. isabove4 V, checkreference switch, |neutral.| eration or automatic leveling device is |(-Forkcanbeleveled| then repair tit necessar operation is started installed) manually.) 2) Ifvoltage measured in 1} above is in manual operation Automatic itn below 4 V. check wiring haress be- mode, reference switl ‘tween system controller CNBS-9 and + Operation isin re- is detective. reference switch, then repairit if nec- yorse direction or it + Wining hamess of ‘essary. is performed at short automatic itn 3) IF resutt of 2) above is normal, re- distance. reference switl place system controller board is defective. Tf automatic fork |» Fork cannot be tt- |) fork leveling display switch cannot [Set leveling device is |” ed manually. be tumed ON and OFF, replace it. lever in installed) 2) iewitch is normal, check its wiring |neutral Tiltdisplay switch harness for shor crcut, then repair. is shorted. 3). Ifresult of above check is normal, re- + Titdisplay switch place system controler. harness shot 8 | {iF automatic Ming |» Fork stops before [1) This phenomenon s not rouble, Wit [Set [After ork stops before (642) |Sevice is installed) | set stop position in | "occurs frequently, however, check lever in |set stop position, itis Automatic iting | automate iting {or mechanical factor such as hitch- | neutral. (moved to set stop po- device does not | mode. ing, then repair. sition manually, Buzz- each set stop fer sounds position Note) This is not rouble 76_|[If automatic ling |> Fork stops afler set |7) This phenomenon s not rouble, [Fit [Sel | After fork stops ox: (642) |Gevice is installed] | stop position in au- | "occurs frequently, however, check »|lever in |ceeding set stop post Automatic iting | tomaticliting mode.| for mechanical factor such as mal-_|neutal ton, itis moved to device exceeds fancion of proportona solenoid set sp poston mar- set siop position valve, ete, then repair, tally, Buzzer sounds, Note) Tiss not 7 rouble, B7_|+ Sensor power —|+ Vehicle cannot op- |) Disconnect connectors CNIS, 48, [Turn (642) | supply in system | erate at al 58, and 65 of the system controller |key controler is ab- | Erroris displayed | and check voltage between pins No. |switch normal immediately after_| 26 and 28 of CN&S. When tis nor. |OFF. + Battery voltageis | key witch isturned| mal, itis 5V. low. ON. J2) If resut of 1) above is abnormal, re Note) This is not, place system controller board lroubie in sysiem 3) FFresultof 1} above is normal, check (Squce vetoae: lgontoler, SENSSV circuit harness and sensor jelow 4.5 V}) (Example: Main for short circuit and leakage, then re- transistor of main pa. controller is short led.) 342. Displayed only proportional solenoid valve spec. 70-82 BE3O Series‘TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS) Faure] Contents of Trouble Th Repair method Reset code | trouble vehicle (Execute 1) > 2) 9—) ethos] Remarks 9 | Work equipment |+ Pump motor rotates |1) Check work equipment switch signal [Tum 6«2)| switch signals |” at low speed output key shorted fo GND |+ Vehicle cannot op- | + Measured voltage between pins No. | switch oritis leaking. |” erate at al, 4and 2, Sand 2, 5 and 2, 6.and 2, |OFF- + Work equipment | Erroris displayed | and 17 and 2 of system controller switch circuit of | immediately after | connector CN1S. "fits normal, itis main controlleris | key switch stuned | above 4 V. abnormal ON. 2) I result of 1) above is normal, re- place system controler. '3) if result of 1) above is abnormal, check work equipment switch signal harness for leakage ana short circut to GND, then repair. 4) result of 1) above is abnormal, ‘measure voltage between pins No. 8 and 14, 10.and 14,21 and 14, 22.and 44, 23 and 14 of rain contraller con When key switch is nector CN. Ifitis normal, tis 4V- turned ON, hydraulic BV. [chopper starts without 5) If result of 4) above is abnormal, re- ecelving operation in-| place main controller board, put) Proporional. | Ertoris displayed |1) Replace system controler boaré. Turn When Keyswitch is valve EMG relay |" immediately ater key |tumed ON, EMG relay insystem con- | key switch is turned switch |in Board is closed.) trolleris shorted. |_ON, OFF. 5 |Mul-controller is |+ Erroris displayed |1) Replace mult-controller board. [Tum = defective immediately after batter key switch is turned Joon ON. Inector (Vehicle operates OFF. hormally.). 37 [Communication |Erroris displayed __|1) Check continuity ofwinng hamesses [Per |Occasional occur- between main con-|when abnormality is | of CN1-5, CN1-6, CN1-13, and CN1-lform au-|rence ofthis trouble is. lroler and mult- |detected, {ot muticontoler, then repair fiomatc |caused by defectve Controller is abnor-| Main controller can-| them if necessary, reset. contact. In this case, ral not be adjusted. |2) Replace mult-controller board. __|ting nor-|connect and discon- |-Iteannot display fai-|3) Replace main controller board. mal. {nect connector. ure codes. (Vehicle operates normally.) ‘98 [Communication |Etroris displayed _ |1) Check continuity of winng hamesses [Per Occasional occur- (2) [Between system |when abnormality is | "of CN4-5, CN4-6, CN4-7, and CN4-9 |form au-|rence ofthis trouble is controller and |detected, ‘of mult-controller, then répair them i tomatic |caused by defective ‘multscontroller is. [System controller necessary. reset. contact. In this case, jebnormal Icannot display failure |2) Replace mult-controller board. _|ting nor- [connect and discon- lcodes, (Vehicle oper-|3) Replace system controller board, _|maly. . \nect connector. lates normally.) 38 [Communication |Erroris displayed __|1) Check continuity of winng harnesses [Per |Occasional occur- between meter when abnormality is | of CN3-1 and CN3-2 of multi-control- form au-|rence ofthis trouble is jpaneland mult. |detected, ler, then repair them if necessary. tomatic |caused by defective ‘controller is abnor-|+ Main controller can-|2) Replace multi-controler board. |reset-_|contact. In this case, ral not be adjusted. |3) Replace meter panel ting nor-|connect and discon- |. Main controller, sys- mally. |nect connector. tem controler, and multi-controller can- not display failure codes. (Vehicle op- fates normally.) 3X2, Displayed only proportional solenoid valve spec. BE30 Series 70-83FAILURE CODES LIST (3.0 TON MODEL) FAILURE CODES LIST (3.0 TON MODEL) ‘TROUBLESHOOTING Fae cade Contents of Trouble in ‘rouble Vehicle Repair method (Execute 1) 2) > Reset method Remarks of Travel power mod-| Vehicle cannot travel lule's shorted |or handle cargo (MD (Upper and lower |connector is not FETs ere shor |closed), ed). (This trouble is also detected when failure ‘code 45 is displayed.) ay 2) 3) 4) 5) 6) Typhi can travel, check code a5 ist Check travel power modules (TMDU, TMDV, and TMDW) and replace them if necessary. (Ifa power mod- Ule is defective, be sure to replace t ‘and power supply board as a set.) Check witing harness between CNSR (Power supply board) and each pow ler module, then repair or replace it Check wiring hamess between CN4- 2 (CPU board) and terminal P3, then Tepair of replace it Check wiring hamess between CN4- 8 (CPU boar) and terminal Pt then repair of replace it, It result of above check is normal, re-| place power supply board Turn key switch OFF. ci Main contactor __| Vehicle cannot travel (MD) is shorted or |or handle cargo. lopen or its sensor rout harness is \defective, 2) 3) ‘Check main contactor (MD) (for melt ing, mechanical itching, et. of con tacis), then repair or replace it. Check wiring harness between CNS. ‘11 (CPU board) and terminal P2, then repait or replace it ‘Check wiring harness between CN4- 8 (CPU board) and terminal P1, then Fepair of replace tt Turn key switch OFF. i Travel power mod-| Vehicle cannot travel lules are shorted |or handle cargo. (Upper and lower Modules are short led separately) 2) 3) 4) 5) 6) ‘Check travel power modules (TMDU, TMDV, TMDW) and repiace them if necessary. (When replacing, be Sure to repiace them as a set, ogeth- ‘er with power supply board.) Check wiring harness between CNSR (Power supply board) and ‘each power module, then repair or Teplace it Check wiring harness between CN4- 3 (CPU boat) and terminal P4, then Tepair or replace tt Check wiring harness between CN4- 2 (CPU board) and terminal P3, then Tepair or replace it. Check wiring harness between CN4- 8 (CPU board) and terminal P1, then Fepair or replace tt If result of above check is normal, re- place power supply board Tam rey rich Orr. Faiure code OF Detected when key Swish tumed ON (Upper Pour Sode 05: Detected when key Swish tumed ON Lower) Fare code 11 Detected afer k Switch and MD ate fumed ON (Upper) Fare code 10 Detected after k Suite and MD ate fled ON (Lower) 0 0 Travel power mod- | Vehicle cannot travel ule is open. or handle cargo. Us, Vo, or Wephase is disconnection 2) 3) la) ‘Check travel power modules (TMDU, TMDV, TMDW) and replace them if necessary. (When repiacing, be sure to repiace them as.a set, togeth- ‘er with power supply board.) Check wiring harness between CNSR (Power supply board) and ‘each power module, then repair or replace it Check oulput terminals of U-, V-, and Wphase or cisconnecton and If result of above check is normal, re Tor key switch OFF. place power supply board, Failure code 06: U-phase is open (disconnected) Failure coe 08: Vephase is open (disconnectes) Failure code 09: W-phase is open (disconnected) 70-84 BEQ0 Series‘TROUBLESHOOTING FAILURE CODES LIST (3.0 TON MODEL) Fare] —Conians of Trowiiom Repar method Rese] panera cole | ‘rouble vehicle (Excaite a> —) [method G7 Wan contactor Versi cannot Wavel 7) Check main contactor (VD) color [Tum = [Mo ine Fear cao Gheonroion el conneeto na ea, [ey ave in CPU then repair or replace sich tarde) 2) Check wig hafvess between [OEE Main constr ei contactor cal ang CN4-3, 3 (CPU nope Sear hn ropar os frlace Seto circuit her 2) Replave CPU boar sine sve Tris ness of main Sebo eontator co is Selective 6 |For switch de Vetice cannot wavel [7] Check wing hamess baween CNT-|Reset_[Tum F swish and R feelve “hts (CPU boars) and Fm ste [norma awrteh ON simulta forshor eeu, then replace nee: |i. (neously, 2) Repalt or replace F/R switch, 7 [Travel accelerator [Vehicle cannot travel) Check wring namess beween CNZ-|Reset_Nonnalsouce vatagedh ut s detective, 19.20 (CPU board) and travel ae (normal [accverator 9 Ve Eelerator ten repr or repace |." [tween GNZ9 and 2) 2) Cheek travel acaleetor unt then Supt vote of set repair orreplace er noc oboe ceteced Nox 0.2 V, Tin 48° (Geteen ne 3 and 0) 19” |Outpatorwirng — Vehicle cannatwavel/1) Check wing hamess between CPU [Tur [Normal sersor oput ares of travel foard ang cuen sensors:then e-(key" |e burg travel 3.0 rent sensor gator replace © puten | oan (CS0U, C80¥) is ROUEN, 14,15 OPE | When FR switenis etectve ESDW:CNSS, 6, "6,17 ‘neutral and accel 2), heck souree volags of curent ser raters OFF: A= Ser sewer supol 01 CPU board. prox 7 BASU" Seaveen NS-3 ana 18 15 ES5u Bemeen ESbWBeween CNS-S and 1, 7 ENS and ta, 18 IFsource voltage is abnormal, f= ESbwv Betncen place CPU bosra ENS and 16,17 2) heck current sensors (CSDU, CS- Somat source vot DW then replace t ecessary Sooo! sensor poner Sippy 13 [sensor output when abnormality detec eo Max. 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