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• Edin Raul Yalle Rafael

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CONTROLLER 1. Outline.......................................................................................................................... 4-2 1.1 System Configuration............................................................................................................................ 4-2 1.2 External View ........................................................................................................................................ 4-4 1.2.1 VCM-3 ......................................................................................................................................................... 4-4 1.2.2 VCM-3OP.................................................................................................................................................... 4-5 1.2.3 ECU............................................................................................................................................................. 4-6 1.2.4 Meter panel ................................................................................................................................................. 4-7 1.2.5 Input unit ..................................................................................................................................................... 4-8 1.2.6 Output unit................................................................................................................................................... 4-9

2. Service Tool Functions............................................................................................... 4-10 2.1 Menu ................................................................................................................................................... 4-10 2.2 Input Monitor and Output Monitor ....................................................................................................... 4-11 2.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)................................................................... 4-11 2.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP) ........................................................ 4-13 2.2.3 MP input monitor (VCM-3 → MP) ............................................................................................................. 4-14 2.2.4 ECU input monitor and output monitor (VCM-3 → ECU) .......................................................................... 4-15

2.3 Fault Status......................................................................................................................................... 4-16 2.4 Fault History........................................................................................................................................ 4-17

3. Chassis Error Code List ............................................................................................. 4-18 4. Troubleshooting ......................................................................................................... 4-19 4.1 General Information ............................................................................................................................ 4-19 4.1.1 Before replacing controllers ...................................................................................................................... 4-19 4.1.2 Connection of service tool......................................................................................................................... 4-19 4.1.3 How to clean harness connectors and system components ..................................................................... 4-20

4.2 Troubleshooting .................................................................................................................................. 4-21

4-1

4

CONTROLLER

1. Outline 1.1 System Configuration The controller system consists of the vehicle control controllers (VCM-3 and VCM-3OP), engine control controller (ECU), meter panel, input unit and output unit.

The controllers are connected on the Controller Area Network (CAN) and communicate mutually to control the lift truck.

Gateway

ECU VCM-3OP

Input unit

Meter panel

N 1

VCM-3 Output unit

212331

4-2

CONTROLLER

CAN connection

Harness A

CAB harness

Harness B

Connector

201

Connector

Harness C

Connector

201

205

205

200

204

204

200

Meter panel

201

200

396 396

395 395

396

395

205

204

VCM-3OP

VCM-3 Input unit

286 285

288 287

VCM-3 GSE

VCM-3OP GSE

Output unit

Gateway

394 393

209 208 858 857

857

ECU 858

212332

4-3

CONTROLLER

1.2 External View 1.2.1 VCM-3

A A'

B

B'

SECTION A 㧙 A'

Connector pin number (from view B')

Connector pin number (from view B) CN1

1

2

10 11 18

19

3

4

CN2

5

12 13 14

6

7

8

9

15 16 17

20 21 22 23 24

25

26 27 28 29 30 31 32 33 34

1

2

10 11 18

19

3

4

5

12 13 14

6

7

8

9

15 16 17

20 21 22 23 24

25

26 27 28 29 30 31 32 33 34

212333

4-4

CONTROLLER

1.2.2 VCM-3OP

A A'

B

B'

SECTION A 㧙 A'

Connector pin number (from view B')

Connector pin number (from view B) CN1

1

2

10 11 18

19

3

4

CN2

5

12 13 14

6

7

8

9

15 16 17

20 21 22 23 24

25

26 27 28 29 30 31 32 33 34

1

2

10 11 18

19

3

4

5

12 13 14

6

7

8

9

15 16 17

20 21 22 23 24

25

26 27 28 29 30 31 32 33 34

212333

4-5

CONTROLLER

1.2.3 ECU

A

B C D

E

Connector pin number A: GF34A

B: GF35A

C: GF32A

D: GF35B

E: GF31A

212334

4-6

CONTROLLER

1.2.4 Meter panel

CN2

CN1

Connector pin number

13 14 11 12 15 16 17 18 19 20

CN2

1 6

2 7

3

4

8

9 10

5

CN1 212335

4-7

CONTROLLER

1.2.5 Input unit

A

Connector pin number (from view A)

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

212336

4-8

CONTROLLER

1.2.6 Output unit

A

Connector pin number (from view A) 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

212337

4-9

CONTROLLER

2. Service Tool Functions 2.1 Menu Monitor menu

Tool menu

• Input Monitor

• Set-up Option

Indicates the input values of the controllers. • Output Monitor Indicates the output values of the controllers. • Custom Monitor Indicates the input/output values of the item selected. • Fault Status Indicates all error codes occurring. • Fault History Indicates the fault data, such as the error codes and hour meter data, stored in the controller.

Indicates or sets the Setup Option data. • Oscilloscope Graphs the input/output values. The oscillograph can be stored as data. • Active Test Outputs the signal forcibly to check the operation of the equipment selected. • Connection Change Designates the controller operated by the service tool and the controller connected to it. • Firmware Update Updates the firmware of the controller connected.

212338

4-10

CONTROLLER

2.2 Input Monitor and Output Monitor These screens indicate the input and output values of each controller. 2.2.1 VCM-3 input monitor and output monitor (VCM3 → VCM-3)

(InputUnit)

212339

4-11

CONTROLLER

(OutputUnit ) [ V ] (OutputUnit ) (OutputUnit )

212340

4-12

CONTROLLER

2.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP)

212341

4-13

CONTROLLER

2.2.3 MP input monitor (VCM-3 → MP)

212342

4-14

CONTROLLER

2.2.4 ECU input monitor and output monitor (VCM-3

→ ECU)

Accel pedal position (unfiltered) Accel pedal position (filtered)

Reference injection quantity

212343

4-15

CONTROLLER

2.3 Fault Status This screen indicates all error codes occurring.

OutputUnit Communication error InputUnit Communication error

212344

4-16

CONTROLLER

2.4 Fault History This screen indicates the fault data, such as the error codes and hour meter data, stored in the controller.

OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error

212345

4-17

CONTROLLER

3. Chassis Error Code List Error Code

Description

Page No.

Error Code

Description

Page No.

F01

VCM-3 Memory Check Error

4-21

F54

Lift Solenoid Leak

4-90

F02

VCM-3 Battery Voltage Error

4-22

F55

Tilt Forward Solenoid Error

4-94

F03

VCM-3 Communication Error

4-24

F57

Tilt Backward Solenoid Error

4-96

F04

ECM Communication Error

4-26

F59

Tilt Solenoid Leak

4-98

F07

MP Communication Error

4-27

F60

Attachment 1A Solenoid Error

4-102

F10

Lift Lever Neutral Error

4-29

F62

Attachment 1B Solenoid Error

4-104

F11

Tilt Lever Neutral Error

4-31

F64

Attachment 1 Solenoid Leak

4-106

F12

Attachment 1 Lever Neutral Error

4-33

F65

Attachment 2A Solenoid Error

4-110

F13

Attachment 2 Lever Neutral Error

4-35

F67

Attachment 2B Solenoid Error

4-112

F14

Attachment 3 Lever Neutral Error

4-37

F69

Attachment 2 Solenoid Leak

4-114

F15

ECU Communication Error

4-39

F70

Attachment 3A Solenoid Error

4-118

F16

Shift Lever Error

4-41

F72

Attachment 3B Solenoid Error

4-120

F17

Vehicle Speed Error

4-43

F74

Attachment 3 Solenoid Leak

4-122

F18

ECU KWP2000 Communication Error

4-45

F75

Unload Solenoid Error

4-126

F19

ECU Speed Sensor Error

4-47

F79

Unload Solenoid Leak

4-128

F20

Lift Lever Error

4-49

F80

Knob Position Solenoid Error

4-131

F22

Tilt Lever Error

4-51

F84

Knob Position Solenoid Leak

4-133

F24

Attachment 1 Lever Neutral Error

4-53

F85

Transmission Forward Solenoid Error

4-136

F26

Attachment 2 Lever Neutral Error

4-55

F87

Transmission Backward Solenoid Error

4-138

F28

Attachment 3 Lever Neutral Error

4-57

F89

Transmission Solenoid Leak

4-140

F29

Joystick Lever Error

4-59

F90

VCM-3OP Sensor Voltage Error

4-143

F31

VCM-3 Sensor Voltage Error

4-61

F91

VCM-3OP Memory Check Error

4-146

F33

VCM-3OP Lift Oil Pressure Sensor Error

4-63

F92

VCM-3OP Battery Voltage Error

4-147

F34

Vehicle Speed Sensor Error

4-65

F93

VCM-3OP Speed Change Solenoid 1 Error

4-149

F36

Tire Angle Sensor Error

4-67

F94

VCM-3OP Speed Change Solenoid 2 Error

4-151

F39

VCM-3OP Tilt Angle Sensor Error

4-69

F95

VCM-3OP Speed Change Solenoid Leak

4-153

F40

Steering Error

4-71

F96

VCM-3OP EAT Setting Error

4-155

F41

Output Unit Error

4-73

F97

VCM-3OP Communication Error

4-156

F42

Output Unit Life Control Signal

4-74

L03

VCM3 Communication Error

F43

Output Unit Memory Check Error

4-75

L04

ECM/ECU Communication Error

F44

Output Unit PWM Voltage Error

4-76

L07

MP Communication Error

F45

Output Unit Communication Error

4-79

L08

TMS Communication Error

F46

Input Unit Error

4-81

P03

VCM3 Communication Error

F47

Input Unit Life Control Signal

4-82

P04

ECM/ECU Communication Error

F48

Input Unit Memory Check Error

4-83

P07

MP Communication Error

F49

Input Unit Communication Error

4-84

P08

TMS Communication Error

F50

Lift Up Solenoid Error

4-86

P22

Shift Lever Error Signal

F52

Lift Down Solenoid Error

4-88

4-18

CONTROLLER

4. Troubleshooting 4.1 General Information 4.1.1 Before replacing controllers Do not replace controllers casually even if replacement is required as a result of troubleshooting. Be sure to check the following items before replacing controllers. • Loose battery connectors • Abnormal wire harness connections • Loose connectors • Broken, bent or loose connector pins • Dirty connectors If connectors are dirty, remove the connector and clean connectors. See “How to clean harness connectors and system components” on the next page. • Ensure that the main harness is not short-circuited to the truck body. If any of these items (above items) is a source of the trouble, the controller will be damaged even if it is replaced with a new one. Be sure to check the above items and replace carefully. 4.1.2 Connection of service tool

(1) (2) (3) (4) (5)

Turn off the truck power. Find the service tool connector in the CAB harness. Remove the cover and connect the PC as shown. Turn on the truck power. Start the service tool software.

CAB harness VCM-3OP GSE

GSE cable

VCM-3 GSE

212346

4.1.3 Diagnostic Precautions

(4) When performing measurement with the tester, handle

(1) Before measuring voltage, check the battery for

the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in connector or between connector and truck body. (5) Resistance is affected by temperature. Determine the necessity of resistance measurement following given temperature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.

charged condition and specific gravity. If system inspection is performed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. (2) To avoid having electrical parts damaged, set the starter switch to OFF before disconnecting and reconnecting battery cables. (3) Before disconnecting connectors, set the starter switch to OFF then allow at least 20 seconds. Voltage may remain in electric parts or connected circuit.

4-19

CONTROLLER

4.1.4 How to clean harness connectors and system components

(1) Open-circuits are often caused by dirty harness connectors and components. Dust, together with greasy matter, forms grime which, in time, penetrates electrical connections, resulting in loose metal-to-metal contact or, for worse, electrical separation of surfaces in contact. For this reason, it is essential that the connectors and components be cleaned at each periodic inspection and when servicing the truck. Instead of a commonly used solvent, use the electronic parts cleaner (in the manner illustrated on the right). Electronic parts cleaner

Electronic parts cleaner 212347

Three Bond 29D or Pow-R-Wash CZ*

NOTE The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime. No need to wipe off the sprayed liquid.

(2) After checking the connector for continuity, wash it as shown. Then, uncouple the connector and spray the contact surface activator onto contact surfaces. Install and remove the connector several times to wet the surfaces thoroughly with the activator liquid. After coupling up the connector, check to be sure that it is in locked state. Contact surface activator

Electronic parts cleaner

Three Bond 2501S (aerosol) or Nyogel 760G*

NOTE Do not spray too much liquid into the connector. Cleaner liquid reacts differently with some resins (plastic materials). *: Products contained in Terminal Maintenance kit (SE000003)

Contact surface activator 212348

4-20

CONTROLLER

4.2 Troubleshooting

Problem: VCM-3 Memory Check Error (F01) (1) Situation Indication: "F01" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty truck type setting data in VCM-3.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Check truck type setting data. Normal

Abnormal

(5) Enter truck type setting data again.

(6) Enter shipment default value into VCM-3. Abnormal

Normal

(7) Perform standard setting, then enter truck type setting data again.

(8) Write updated software into VCM-3. Abnormal

Normal

(9) Faulty software writing.

(10) Replace VCM-3.

4-21

CONTROLLER

Problem: VCM-3 Battery Voltage Error (F02) (1) Situation Indication: "F02" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Poor battery charge, faulty battery, faulty VCM-3, faulty harness, faulty DC-DC converter.

(3) How the error code is triggered When VCM-3 input voltage is less than 7V or more than 21V.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

32V or more

7V or less (5) Charge battery.

Error remains (6) Replace battery.

(7) Measure output voltage and input voltage of DC-DC converter. 1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). Normal

Input voltage abnormal

Output voltage abnormal

(9) Replace DC-DC converter.

(8) Replace harness.

(10) Measure input voltage of VCM-3. 1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25). 2. Between 41(VCM-3: CN1-26) and 131(VCM-3: CN1-34). 7V or less

(11) Replace harness.

4-22

12V 24V

(12) Replace VCM-3.

7V to 21V

CONTROLLER

DC-DC CONVERTER

VCM-3 CN1 0.85B/L 131 0.85B/L 130 1.25R/Y 41 1.25R/Y 40

107 1.25B/L 2R/Y 40 1.25B 104

105 40

F7 8R

245

1 224 223

10

218 217 216132 215 40

10A

18

㧗

BATTERY

㧙

105

60B

2B/L

60B

㧙

2R/W

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

41 26

100

211

8

2B

130

34 131 229 411

FLW 0.85R

25

2R/W

4

17

5

9

8

15R

1

CN1

107 40 104 94 49 8 62 301

㧗

BATTERY 212349

4-23

CONTROLLER

Problem: VCM-3 Communication Error (F03) (1) Situation Indication: "F03" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication of VCM-3 is interrupted.

(4) Checks Check to see if other errors occur simultaneously. F03 only

Other errors occur (5) See troubleshooting for errors occurred.

(6) Check continuity of CAN communication cables. 1. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32) and 200(Meter panel: 19) 2. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and 200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31). 3. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32) and 393(Output unit: 14). 4. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32) and 395(Input unit: 8). ࡮In case of diesel engine 5. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and 200(VCM-3: CN2-32) and 208(Gateway: A24). ࡮In case of Iasoline engine 6. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM: 86). Continuity

(7) Replace VCM-3.

4-24

No continuity

(8) Replace faulty harness.

CONTROLLER

CN2 9 277

VCM-3 CN2

254 273 253

10

25

258

18

34

0.85L/R

CAN H 201 0.85B/W CAN L 200

201 200

1

279 281

17

205 204 295 294 293 292

VCM-OP CN2

26

0.85B/W

204 205

CAN L

204 205

0.85L/R

CAN H

CN2

25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

METER PANEL

10 18 26

201 200

0.85L/R

CAN H

201

0.85B/W

CAN L

200

OUTPUT UNIT 0.85L/R 0.85B/W

393

394 13 CAN H 14 CAN L

INPUT UNIT (HARNESS, IN FC) 0.85L/R

0.85B/W

396 395

0.5B 0.5B/W

396 395

7 CAN H 8 CAN L

GATEWAY (Diesel engine)

208 209

9 17

0.85B/W 0.85L/R

94 86

ECM (Gasoline engine)

212350

4-25

CONTROLLER

Problem: ECM Communication Error (F04) (1) Situation Indication: "F04" flickering.

(2) Possible cause Faulty VCM-3, faulty harness, faulty ECM.

(3) How the error code is triggered When CAN communication from ECM to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM:86).

Continuity

(6) Replace harness.

(5) Replace VCM-3. Error remains (7) Replace ECM.

4-26

No continuity

CONTROLLER

Problem: MP Communication Error (F07) (1) Situation Indication: "F07" flickering. Drive operations disabled.

(2) Possible cause Faulty meter panel, faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication from meter panel to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32) and 200(Meter panel: 19). Continuity

No continuity (6) Replace harness.

(5) Replace meter panel. Error remains (7) Replace VCM-3.

4-27

CONTROLLER

78 77 79 83 82 80 81

VCM-3

BRAKE F FUEL PKB OIL TEMP R N F

CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

201 200

201 200

0.85L/R 0.85B/W

48 201 200 45 49 46 102

GLOW CAN H CAN L 12V LAMP ALT R ALT L GND

SIGNAL PROCESSOR

METER PANEL

FUEL GAGE WATER TEMP GAGE BRAKE LAMP OIL PRESSURE LAMP TORQ CONV OIL TEMP LAMP INTERLOCK LAMP MULTIPURPOSE WARNING LAMP GLOW LAMP (LPG) MAST INTERLOCK LAMP SEAT BELT LAMP

CHARGE LAMP

10 18 26

212351

4-28

CONTROLLER

Problem: Lift Lever Neutral Error (F10) (1) Situation Indication: "F10" flickering. Hydraulic operations disabled.

(2) Possible cause Lift lever operated when turning on key switch, faulty lift lever, faulty input unit, faulty harness.

(3) How the error code is triggered Lift lever is not in neutral when turning on key switch.

(4) Checks Shift lift lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between lift lever and input unit. 1. Between 468(Input unit: CN1-25) and 468(Lift lever). 2. Between 469(Input unit: CN1-26) and 468(Lift lever). 3. Between 460(Input unit: CN1-23) and 460(Lift lever). 4. Between 464(Input unit: CN1-24) and 464(Lift lever). Continuity

No continuity

(6) Replace harness.

(7) Replace lift lever with another section lever. Error transition

(8) Replace lift lever.

Error remains

(9) Replace input unit.

4-29

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-30

CONTROLLER

Problem: Tilt Lever Neutral Error (F11) (1) Situation Indication: "F11" flickering. Hydraulic operations disabled.

(2) Possible cause Tilt lever operated when turning on key switch, faulty tilt lever, faulty input unit, faulty harness.

(3) How the error code is triggered Tilt lever is not in neutral when turning on key switch.

(4) Checks Shift tilt lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between tilt lever and input unit. 1. Between 470(Input unit: CN1-27) and 470(Tilt lever). 2. Between 471(Input unit: CN1-28) and 471(Tilt lever). 3. Between 460(Input unit: CN1-23) and 461(Tilt lever). 4. Between 464(Input unit: CN1-24) and 465(Tilt lever). Continuity

No continuity

(6) Replace harness.

(7) Replace tilt lever with another section lever. Error transition

(8) Replace tilt lever.

Error remains

(9) Replace input unit.

4-31

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-32

CONTROLLER

Problem: Attachment 1 Lever Neutral Error (F12) (1) Situation Indication: "F12" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 1 lever operated when turning on key switch, faulty attachment 1 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 1 lever is not in neutral when turning on key switch.

(4) Checks Shift attachment 1 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 1 lever and input unit. 1. Between 472(Input unit: CN1-29) and 472(ATT1 lever). 2. Between 473(Input unit: CN1-30) and 473(ATT1 lever). 3. Between 460(Input unit: CN1-23) and 462(ATT1 lever). 4. Between 464(Input unit: CN1-24) and 466(ATT1 lever). Continuity

No continuity (6) Replace harness.

(7) Replace attachment 1 lever with another section lever. Error transition

(8) Replace attachment 1 lever.

Error remains

(9) Replace input unit.

4-33

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-34

CONTROLLER

Problem: Attachment 2 Lever Neutral Error (F13) (1) Situation Indication: "F13" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 2 lever operated when turning on key switch, faulty attachment 2 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 2 lever is not in neutral when turning on key switch.

(4) Checks Shift attachment 2 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 2 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). No continuity

Continuity

(6) Replace harness.

(7) Replace attachment 2 lever with another section lever. Error transition

(8) Replace attachment 2 lever.

Error remains

(9) Replace input unit.

4-35

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-36

CONTROLLER

Problem: Attachment 3 Lever Neutral Error (F14) (1) Situation Indication: "F14" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 3 lever operated when turning on key switch, faulty attachment 3 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 3 lever is not in neutral when turning on key switch.

(4) Checks Shifts attachment 3 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 3 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). Continuity

No continuity

(6) Replace harness. (7) Replace attachment 3 lever with another section lever. Error remains

Error transition

(8) Replace attachment 3 lever.

(9) Replace input unit.

4-37

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-38

CONTROLLER

Problem: ECU Communication Error (F15) (1) Situation Indication: "F15" flickering. Drive operations restricted.

(2) Possible cause Faulty ECU, faulty VCM-3, faulty gateway, faulty harness.

(3) How the error code is triggered When CAN communication from ECU(gateway) to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and 200(VCM-3: CN2-32) and 208(Gateway: A24). Gateway to ECU:

Between 857(Gateway: A26) and 857(ECU: 157), and 858(Gateway: A27) and 858(ECU: 158).

Continuity

No continuity (6) Replace harness.

(5) Replace gateway. Error remains (7) Replace VCM-3. Error remains (8) Replace ECU.

4-39

VCM-3 CN2

17

25 9

34

4-40 234 235 233 232 231 230 221 220

384 222 238

200 201 299 298 297 296 237

CAN H 201 0.85B/W CAN L 200 0.85L/R 0.85R

0.85W

0.85L/R

0.85B/W

0.85Lg

0.85V

0.85W

0.85R

0.85R/B

0.85G/W

0.85Y/B

SVC POWER - 1

WATER TEMP. SENSOR CAN - 1(H) 858 CAN - 1(L) 862 FUEL TEMP. SENSOR - 1(LEAK) 863 FUEL TEMP. SENSOR - 2

855 857

SVC POWER - 2 854 AIR TEMP. SENSOR

847

846

GATEWAY

0.85Or

858 857

208 209

162 163

158

157

154 155

146 147

CONTROLLER

CONTROL UNIT, ECG (e e)

201 200

CN2 227228 1

10 18

26

212353

CONTROLLER

Problem: Shift Lever Error (F16) (1) Situation Indication: "F16" flickering. Drive operations disabled.

(2) Possible cause Faulty meter panel, faulty VCM-3, faulty harness.

(3) How the error code is triggered When F, N and R signals of shift lever are inputted simultaneously.

(4) Checks Check continuity between meter panel and shift lever. 1. N: Between 272(Shift lever: 1) and 80 (Meter panel). 2. F: Between 81(Shift lever: 3) and 81(Meter panel). 3. R: Between 62(Shift lever: 5) and 82 (Meter panel). 4. GND: Between 126(Shift lever: 2) and 102(Meter panel), and 127(Shift lever: 4) and 102(Meter panel). Continuity

No continuity

(6) Replace harness.

(5) Replace meter panel. Error remains (7) Replace VCM-3.

4-41

CONTROLLER

METER PANEL

DIODE

127 126 81 272 62

80

0.85L/G 0.85L/W

62

0.85G/L 272 0.85B 127 0.85G/R 81 0.85B 126 0.85L/G

82

80

272

0.85G/L 0.85Y/L 272

62

62 82

1 2 34 5 F1 N R1

0.85L/W

0.85Y/L 0.85G/R

78 77 79 83 82 80 81 48 201 200 45 49

1.25B

46 102

BRAKE F FUEL PKB OIL TEMP R N F GLOW CAN H CAN L 12V LAMP ALT R ALT L GND

SIGNAL PROCESSOR

DIODE

FNR LEVER

FUEL GAGE WATER TEMP GAGE BRAKE LAMP OIL PRESSURE LAMP TORQ CONV OIL TEMP LAMP INTERLOCK LAMP MULTIPURPOSE WARNING LAMP GLOW LAMP (LPG) MAST INTERLOCK LAMP SEAT BELT LAMP

CHARGE LAMP

212354

4-42

CONTROLLER

Problem: Vehicle Speed Error (F17) (1) Situation Indication: "F17" flickering.

(2) Possible cause Vehicle speed over limit, Faulty VCM-3, faulty harness.

(3) How the error code is triggered When vehicle speed is 35 km/h or more.

(4) Checks Check continuity between VCM-3 and vehicle speed sensor connectors. 1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +). 2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -). Continuity

(5) Replace VCM-3.

No continuity (6) Replace harness.

4-43

CONTROLLER

VCM-3

Harness B

Harness A

SPEED METER

384

0.85R/G 0.85G/B 0.85Y/G

220 221

Harness C 220 221

0.85W/L

220 221

9 17 25 34

220 221

CN2

0.85G/B

220 221 222

0.85R/G

SPEED SENSOR SPEED SENSOR AUTO LIGHT OUT

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

SPEED SENSOR 212355

4-44

CONTROLLER

Problem: ECU KWP2000 Communication Error (F18) (1) Situation Indication: "F18" flickering. Drive operations disabled.

(2) Possible cause Faulty ECU, faulty gateway, faulty harness.

(3) How the error code is triggered When KWP2000 communication from ECU to gateway is interrupted.

(4) Checks Check continuity of KWP2000 communication cable. 1. Between 719(Gateway) and 719(ECU). Continuity

(5) Replace gateway.

No continuity

(6) Replace harness. Error remains

(7) Replace ECU.

4-45

4-46 2Y/R

0.85G/Y

PTO MAX. REV. SET (SIG) VEHICLE SPEED SENSOR (SIG) 730 IDLE VOLUME (SIG) 731 PTO ACCEL SENSOR (SIG) 734 EGR TEMP. SENSOR

726 727

0.85G/B

CASE GND MUT-3 (KWP2000) ACCEL SENSOR-1 (SIG) ACCEL SENSOR-2 (SIG)

TACHO OUT (SIG)

721 722

0.85G/L

0.85L/R

+VB-3(ECU POWER) 708 718 719

+VB-2(ECU POWER)

+VB-1(ECU POWER) 707

705 706

719

34

30 31

27

22 26

19 21

18

7 8

5 6

GATEWAY

1.25B

1.25Y/R

1.25Y/R

0.85L/R

CONTROLLER

CONTROL UNIT, ECG (ea)

212356

CONTROLLER

Problem: ECU Speed Sensor Error (F19) (1) Situation Indication: "F19" flickering. Drive operations restricted.

(2) Possible cause Faulty gateway, faulty VCM-3, faulty ECU, faulty harness.

(3) How the error code is triggered When vehicle speed pulse signal to ECU is interrupted. Abnormal signal is sent from ECU.

(4) Checks Check continuity between ECU and gateway. 1. Between 727(ECU) and 727(Gateway). Continuity

(5) Replace gateway.

No continuity

(6) Replace harness. Error remains

(7) Replace VCM-3. Error remains (8) Replace ECU.

4-47

4-48 2Y/R

0.85G/Y

0.85G/B

0.85G/L

CASE GND

31 731 PTO ACCEL SENSOR (SIG) 734 EGR TEMP. SENSOR

34

27 30

727 730

726

26

21 22

19

VEHICLE SPEED SENSOR (SIG) IDLE VOLUME (SIG)

MUT-3 (KWP2000) ACCEL SENSOR-1 (SIG) ACCEL SENSOR-2 (SIG) PTO MAX. REV. SET (SIG) 722

721

719

7 8 18

TACHO OUT (SIG) 708 718

5 6 +VB-3 (ECU POWER)

+VB-1 (ECU POWER) +VB-2 (ECU POWER) 707

705 706

727

GATEWAY

0.85L/R

1.25B

1.25Y/R

1.25Y/R

0.85G/Y

CONTROLLER

CONTROL UNIT, ECG

(ea)

212357

CONTROLLER

Problem: Lift Lever Error (F20) (1) Situation Indication: "F20" flickering. Lift up and lift down operations disabled.

(2) Possible cause Faulty lift lever, faulty input unit, faulty harness.

(3) How the error code is triggered When lift lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between lift lever and input unit. 1. Between 468(Input unit: CN1-25) and 468(Lift lever). 2. Between 469(Input unit: CN1-26) and 469(Lift lever). 3. Between 460(Input unit: CN1-23) and 460(Lift lever). 4. Between 464(Input unit: CN1-24) and 464(Lift lever). Continuity

No continuity

(5) Replace harness.

(6) Replace lift lever with another section lever. Error transition

(7) Replace lift lever.

Error remains

(8) Replace input unit.

4-49

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-50

CONTROLLER

Problem: Tilt Lever Error (F22) (1) Situation Indication: "F22" flickering. Tilt forward and tilt backward operations disabled.

(2) Possible cause Faulty tilt lever, faulty input unit, faulty harness.

(3) How the error code is triggered When tilt lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between tilt lever and input unit. 1. Between 470(Input unit: CN1-27) and 470(Tilt lever). 2. Between 471(Input unit: CN1-28) and 471(Tilt lever). 3. Between 460(Input unit: CN1-23) and 461(Tilt lever). 4. Between 464(Input unit: CN1-24) and 465(Tilt lever). No continuity

Continuity

(5) Replace harness. (6) Replace tilt lever with another section lever. Error transition

(7) Replace tilt lever.

Error remains

(8) Replace input unit.

4-51

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-52

CONTROLLER

Problem: Attachment 1 Lever Error (F24) (1) Situation Indication: "F24" flickering. Attachment 1 operation disabled.

(2) Possible cause Faulty attachment 1 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 1 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 1 lever and input unit. 1. Between 472(Input unit: CN1-29) and 472(ATT1 lever). 2. Between 473(Input unit: CN1-30) and 473(ATT1 lever). 3. Between 460(Input unit: CN1-23) and 462(ATT1 lever). 4. Between 464(Input unit: CN1-24) and 466(ATT1 lever). No continuity

Continuity

(5) Replace harness.

(6) Replace attachment 1 lever with another section lever. Error transition

(7) Replace attachment 1 lever.

Error remains (8) Replace input unit.

4-53

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-54

CONTROLLER

Problem: Attachment 2 Lever Error (F26) (1) Situation Indication: "F26" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty attachment 2 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 2 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 2 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). Continuity

No continuity

(5) Replace harness.

(6) Replace attachment 2 lever with another section lever. Error transition

(7) Replace attachment 2 lever.

Error remains

(8) Replace input unit.

4-55

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-56

CONTROLLER

Problem: Attachment 3 Lever Error (F28) (1) Situation Indication: "F28" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty attachment 3 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 3 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 3 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). No continuity

Continuity

(5) Replace harness.

(6) Replace attachment 3 lever with another section lever. Error transition

(7) Replace attachment 3 lever.

Error remains

(8) Replace input unit.

4-57

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-58

CONTROLLER

Problem: Joystick Lever Error (F29) (1) Situation Indication: "F29" flickering. Corresponding hydraulic operation disabled.

(2) Possible cause Faulty FC lever, faulty input unit, faulty harness.

(3) How the error code is triggered Voltage data between main signal and sub-signal is different when FC lever is not operated.

(4) Checks Check to see if other FC lever errors occur. F20

F22

F24

F26

F28

To (5)

To (6)

To (7)

To (8)

To (9)

(5) Replace lift lever.

(6) Replace tilt lever.

(7) Replace attachment 1 lever.

(8) Replace attachment 2 lever.

(9) Replace attachment 3 lever.

4-59

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-60

CONTROLLER

Problem: VCM-3 Sensor Voltage Error (F31) (1) Situation Indication: "F31" flickering.

(2) Possible cause Faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When VCM-3 sensor power voltage is 3.85V or less.

(4) Checks Check continuity between sensor and VCM-3. 1. Between 231(Tire angle sensor: +5V) and 231(VCM-3: CN2-13: +5V). 2. Between 232(Tire angle sensor: GND) and 232(VCM-3: CN2-14: GND).

Continuity

No continuity

(5) Replace harness. (6) Check short circuit between sensor power and GND in sensor terminal. Not shorted

Shorted

(7) Replace tire angle sensor.

(8) Check short circuit between sensor and VCM-3 1. Between 231(Tire angle sensor: +5V) and 232(VCM-3: CN2-14: GND). 2. Between 232(Tire angle sensor: GND) and 231(VCM-3: CN2-13: +5V). Shorted

(9) Replace harness.

Not shorted

(10) Replace VCM-3.

4-61

CONTROLLER

VCM-3

0.85Y 1.25G/Y

230 231 232

230 231 232

9 17 25 34

231 232 230

232

CN2

0.85Br/Y

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

TIRE ANGLE SENSOR 212358

4-62

CONTROLLER

Problem: VCM-3OP Lift Oil Pressure Sensor Error (F33) (1) Situation Indication: "F33" flickering. Tilt horizontal function operation disabled.

(2) Possible cause Faulty lift oil pressure sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When lift oil pressure sensor signal voltage is out of range of 0.5V to 4.5V.

(4) Checks Check continuity between lift oil pressure sensor and VCM-3OP. 1. Between 267(VCM-3OP: CN1-14: +5V) and 267(Lift oil pressure sensor: Vcc). 2. Between 268(VCM-3OP: CN1-15: SIG) and 268(Lift oil pressure sensor: SIG). 3. Between 269(VCM-3OP: CN1-17: GND) and 269(Lift oil pressure sensor: GND). Continuity No continuity

(5) Replace harness. (6) Turn on key switch, then measure lift oil pressure sensor signal voltage between VCM-3OP connector terminals. 1. Between 268(Lift oil pressure sensor: SIG) and 269(Lift oil pressure sensor: GND). Normal (0.5V to 4.5V)

(7) Replace VCM-3OP.

Abnormal (out of 0.5V to 4.5V)

(8) Replace lift oil pressure sensor.

4-63

CONTROLLER

VCM-OP

250 252 267 268 269 264 265 266 290 257 42 43 135 136

0.85B/W

269 268 267

269

0.85Lg/B

0.85Lg

267

P. SOURCE 1 P. SOURCE 2 GND1 GND2

267 268 269

268

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN. SPEED PULSE CAB OPEN IND1

CN1 9

252 250

17

269

25

135

34 136 257

1

268 267

10

42

18

266 265 264 43 26

LIFT OIL PRESSURE SENSOR (OP) 212359

4-64

CONTROLLER

Problem: Vehicle Speed Sensor Error (F34) (1) Situation Indication: "F34" flickering. Drive speed change operation disabled.

(2) Possible cause Faulty vehicle speed sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When vehicle speed sensor signal voltage is out of range of 1.3V to 4.9V.

(4) Checks Check continuity between VCM-3 and vehicle speed sensor. 1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +). 2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).

Continuity

No continuity

(5) Replace harness. (6) Measure resistance between vehicle speed sensor terminals. 220(Speed sensor: +) and 221(Speed sensor: -). Normal [2kǡto 3kǡ at 25 °C (77 °F)]

(7) Replace VCM-3.

Abnormal

(8) Replace vehicle speed sensor.

4-65

CONTROLLER

VCM-3

Harness B

Harness A

SPEED METER

384

0.85R/G 0.85G/B 0.85Y/G

220 221

Harness C 220 221

0.85W/L

220 221

9 17 25 34

220 221

CN2

0.85G/B

220 221 222

0.85R/G

SPEED SENSOR SPEED SENSOR AUTO LIGHT OUT

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

SPEED SENSOR 212355

4-66

CONTROLLER

Problem: Tire Angle Sensor Error (F36) (1) Situation Indication: "F36" flickering. Knob position control disabled.

(2) Possible cause Faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When tire angle sensor signal voltage is out of range of 0.27V to 4.72V.

(4) Checks Check continuity between VCM-3 and tire angle sensor. 1. Between 231(VCM-3: CN2-13) and 231(Tire angle sensor: SIG). 2. Between 230(VCM-3: CN2-12) and 230(Tire angle sensor: Vcc). 3. Between 232(VCM-3: CN2-14) and 232(Tire angle sensor: GND). Normal

Abnormal

(5) Replace harness. (6) Measure resistance between tire angle sensor terminals. (Place tires in straight-ahead position.) 1. Between 230(Tire angle sensor: Vcc) and 231(Tire angle sensor: SIG). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F) 2. Between 231(Tire angle sensor: SIG) and 232(Tire angle sensor: GND). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F) 3. Between 230(Tire angle sensor: Vcc) and 232(Tire angle sensor: GND). ࡮࡮࡮1.6kǡ to 2.4kǡ‫ޓ‬at 25͠ (77 ˚F) Normal

(7) Replace VCM-3.

Abnormal (8) Replace tire angle sensor.

4-67

CONTROLLER

VCM-3

0.85Y 1.25G/Y

230 231 232

230 231 232

9 17 25 34

231 232 230

232

CN2

0.85Br/Y

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

TIRE ANGLE SENSOR 212358

4-68

CONTROLLER

Problem: VCM-3OP Tilt Angle Sensor Error (F39) (1) Situation Indication: "F39" flickering. Tilt auto stop control function operation disabled.

(2) Possible cause Faulty tilt angle sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When tilt angle sensor signal voltage is out of range of 0.1V to 4.9V.

(4) Checks Check continuity between VCM-3OP and tilt angle sensor. 1. Between 264(VCM-3OP: CN1-27: +5V) and 264(Tilt angle sensor: +5V). 2. Between 265(VCM-3OP: CN1-28: SIG) and 265(Tilt angle sensor: SIG). 3. Between 266(VCM-3OP: CN1-29: GND) and 266(Tilt angle sensor: GND). Continuity

(6) Replace tilt angle sensor.

No continuity

(5) Replace harness. Error remains

(8) Replace VCM-3OP.

4-69

CONTROLLER

VCM-OP

269 264

264 265 266

SPEED PULSE CAB OPEN IND1

0.85R/B

265 266 290 257 42 43 135

266 265 264

264 265

P. SOURCE 1 P. SOURCE 2 GND1 GND2

0.85B/Y

HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN.

136

266

250 252 267 268

0.85Y/B

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE

CN1 9 17 25

252 250 269 135

34 136 257

1

268 267

10

42

18

266 265 264 43 26

TILT ANGLE SENSOR (OP) 212360

4-70

CONTROLLER

Problem: Steering Error (F40) (1) Situation Indication: "F40" flickering. Knob position control disabled.

(2) Possible cause Faulty steering sensor, faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered Steering angle is changed when tire angle remains unchanged. Tire angle is changed when steering angle remains unchanged.

(4) Checks Check to see if tire angle sensor error (F36) occurs. F36 occurs

Not occurs

(5) See F36 troubleshooting. (6) Check continuity between VCM-3 and steering sensor. 1. Between 132(VCM-3: CN1-20: GND) and 132(Steering angle sensor: +5V). 2. Between 218(VCM-3: CN1-23: NT) and 218(Steering angle sensor: NT). 3. Between 217(VCM-3: CN1-22: ST2) and 217(Steering angle sensor: ST2). 4. Between 216(VCM-3: CN1-21: ST1) and 216(Steering angle sensor: ST1). 5. Between 215(VCM-3: CN1-19: +12V) and 215(Steering angle sensor: +12V). Continuity

No continuity

(7) Replace harness.

(8) Confirm tire angle with service tool when steering wheel is operated. Change

(9) Replace VCM-3.

Not change

(10) Replace steering sensor.

4-71

CONTROLLER

VCM-3

215 216 217 218 132

0.85Y 1.25G/Y

230 231 232

230 231 232

0.85Br 0.85Br/Y

CN2

9 25

1

9

10 18

17

41 26

34

245 224 223

17 130

218 217 216132 215 40

34 131 229 411

211

25

227228 1 234 235 233 232 231 230 221 220 384

222 238

0.85G/Y

0.85Br

217 215 218 216 132

237

200 201 299 298 297 296

132 218 217 216 215

CN1

0.85W/G

0.85B/G

0.85Br/Y

217 218 132

0.85W/G

0.85B/G

ST. ANGLE SEN ST. ANGLE SEN

231 232 230

215 216

232

Harness A 0.85G/Y

0.85Br/Y

ST. ANGLE SEN ST. ANGLE SEN ST. ANGLE SEN

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

10

TIRE ANGLE SENSOR

18 26

R/E STEERING ANGLE SENSOR 212361

4-72

CONTROLLER

Problem: Output Unit Controller Error (F41) (1) Situation Indication: "F41" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Write updated software into output unit. Normal Faulty software writing

Error remains

(5) Replace output unit.

4-73

CONTROLLER

Problem: Output Unit Life Control Signal (F42) (1) Situation Indication: "F42" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered When output unit is being initialized.

(4) Checks Write updated software into output unit. Normal Faulty software writing

4-74

Error remains

(5) Replace output unit.

CONTROLLER

Problem: Output Unit Memory Error (F43) (1) Situation Indication: "F43" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Write updated software into output unit. Normal Faulty software writing

Error remains

(5) Replace output unit.

4-75

CONTROLLER

Problem: Output Unit PWM Voltage Error (F44) (1) Situation Indication: "F44" flickering. Hydraulic operations disabled.

(2) Possible cause Poor battery charge, faulty VCM-3, faulty DC-DC converter, faulty harness.

(3) How the error code is triggered When output unit PWM voltage is 7V or less.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

7V or less

(5) Charge battery. Error remains (6) Replace battery.

4-76

CONTROLLER

(7) Measure DC-DC converter output voltage and input voltage. 1. Output voltage: Between 40(DC-DC converter: +12V) and 107(DC-DC converter: GND). ࡮࡮࡮ (12V) 2. Input voltage: Between 8(DC-DC converter: +24V) and 104(DC-DC converter: GND). ࡮࡮࡮࡮ (24V) Normal Input voltage abnormal Output voltage abnormal (8) Replace harness.

(9) Replace DC-DC converter.

(10) Measure VCM-3 input voltage. 1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25). 2. Between 41(VCM-3: CN1-26) and 131(VCM-3: CN1-34). 7V to 21V

7V or less (11) Replace harness.

(12) Replace VCM-3.

4-77

CONTROLLER

DC-DC CONVERTER

VCM-3 CN1 0.85B/L 131 0.85B/L 130 1.25R/Y 41 1.25R/Y 40

107 1.25B/L 2R/Y 40 1.25B 104

105 40

F7 8R

245

1 224 223

10

218 217 216132 215 40 211

10A

18

41 26

60B

60B

2B

4

5 㧙

2R/W

㧗

BATTERY

㧙

105

130

34 131 229 411

8

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

2B/L

25

2R/W

100

17

FLW 0.85R

9

8

15R

1

CN1

107 40 104 94 49 8 62 301

㧗

BATTERY 212349

4-78

CONTROLLER

Problem: Output Unit Communication Error (F45) (1) Situation Indication: "F45" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness, faulty output unit.

(3) How the error code is triggered When CAN communication from output unit to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32) and 393(Output unit: 14).

Continuity

No continuity (6) Replace harness.

(5) Replace output unit. Error remains (7) Replace VCM-3.

4-79

CONTROLLER

OUTPUT UNIT

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

0.85L/R 0.85B/W

1 2 3 4 5 6 7 8 9 10 11 12 394 13 393 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GND GND +VE +VE N.C. N.C. SWITCH IN GND SWITCH IN GND SWITCH IN GND RS-232 Tx RS-232 Rx RS-232 GND CAN H CAN L N.C. N.C. BOOT FWE 0V DC 12V PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM4PWM 5+ PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

212362

4-80

CONTROLLER

Problem: Input Unit Controller Error (F46) (1) Situation Indication: "F46" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered Software checks sum value of ROM in CPU, and detects fault.

(4) Checks Write updated software into input unit. Normal Faulty software writing

Error remains

(5) Replace input unit.

4-81

CONTROLLER

Problem: Input Unit Life Control Signal (F47) (1) Situation Indication: "F47" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered When input unit is being initialized.

(4) Checks Write updated software into input unit. Normal Faulty software writing

4-82

Error remains

(5) Replace input unit.

CONTROLLER

Problem: Input Unit Memory Error (F48) (1) Situation Indication: "F48" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered Software checks sum value of ROM in CPU, and detects fault.

(4) Checks Write updated software into input unit. Normal Faulty software writing

Error remains

(5) Replace input unit.

4-83

CONTROLLER

Problem: Input Unit Communication Error (F49) (1) Situation Indication: "F49" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness, faulty input unit.

(3) How the error code is triggered When CAN communication from input unit to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32) and 395(Input unit: 8).

Continuity (5) Replace input unit.

(6) Replace harness. Error remains

(7) Replace VCM-3.

4-84

No continuity

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

0.85L/R

0.85B/W

396 395

1 2 3 4 5 6 0.5B 396 7 0.5B/W 395 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

GND Vcc 19V FWE RS-232 Tx RS-232 Rx RS-232 GND CAN H CAN L CAN R+ CAN RBOOT SEL0 SEL1 SW GND SW INPUT 1 SW INPUT 2(SPEED SEL) SW INPUT 3(4V/5V) SW INPUT 4(F) SW INPUT 5(N) SW INPUT 6(R) SW INPUT 7 SW INPUT 8 5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

212363

4-85

CONTROLLER

Problem: Lift Up Solenoid Error (F50) (1) Situation Indication: "F50" flickering. Lift operation disabled.

(2) Possible cause Faulty output unit, faulty lift up solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when lift up solenoid signal is outputted.

(4) Checks Check continuity between output unit and lift up solenoid. 1. Lift up: Between 480(Output unit: CN1-21) and 480(Lift A solenoid). 2. Lift return: Between 482(Output unit: CN1-23) and 482(Lift A solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of lift up solenoid. 1. Lift up: Between 480(Lift A solenoid) and 482(Lift A solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)?

(7) Replace output unit.

4-86

Abnormal

(8) Replace lift up solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-87

CONTROLLER

Problem: Lift Down Solenoid Error (F52) (1) Situation Indication: "F52" flickering. Lift operation disabled.

(2) Possible cause Faulty output unit, faulty lift down solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when lift down solenoid signal is outputted.

(4) Checks Check continuity between output unit and lift down solenoid. 1. Lift down: Between 481(Output unit: CN1-22) and 481(Lift B solenoid). 2. Lift return: Between 482(Output unit: CN1-23) and 495(Lift B solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of lift down solenoid. 1. Lift down: Between 481(Lift B solenoid) and 495(Lift B solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(7) Replace output unit.

4-88

Abnormal

(8) Replace lift down solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-89

CONTROLLER

Problem: Lift Solenoid Leak (F54) (1) Situation Indication: "F54" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty lift solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when lift lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Tilt operation (5) Not operate

(7) Attachment 1 operation

(8) Attachment 2 operation

Forward

Backward

A

B

A

B

A

B

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-90

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between lift section and tilt section. Between 483(Output unit: CN1-24) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between lift section and tilt section. Between 484(Output unit: CN1-25) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between lift section and attachment 1 section. Between 486(Output unit: CN1-27) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between lift section and attachment 1 section. Between 487(Output unit: CN1-28) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-91

CONTROLLER

(25) Check continuity between lift section and attachment 2 section. Between 489(Output unit: CN1-30) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between lift section and attachment 2 section. Between 490(Output unit: CN1-31) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between lift section and attachment 3 section. Between 492(Output unit: CN1-33) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between lift section and attachment 3 section. Between 493(Output unit: CN1-34) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less)

(35) Insulate wires in harness or replace harness.

4-92

No continuity (Several Mǡ) (15) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-93

CONTROLLER

Problem: Tilt Forward Solenoid Error (F55) (1) Situation Indication: "F55" flickering. Tilt operation disabled.

(2) Possible cause Faulty output unit, faulty tilt forward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when tilt forward solenoid signal is outputted.

(4) Checks Check continuity between output unit and tilt forward solenoid. 1. Tilt forward: Between 483(Output unit: CN1-24) and 483(Tilt A solenoid). 2. Tilt return: Between 485(Output unit: CN1-26) and 485(Tilt A solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of tilt forward solenoid. 1. Lift up: Between 483(Tilt A solenoid) and 485(Tilt A solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(7) Replace output unit.

4-94

Abnormal

(8) Replace tilt forward solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-95

CONTROLLER

Problem: Tilt Backward Solenoid Error (F57) (1) Situation Indication: "F57" flickering. Tilt operation disabled.

(2) Possible cause Faulty output unit, faulty tilt backward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when tilt backward solenoid signal is outputted.

(4) Checks Check continuity between output unit and tilt backward solenoid. 1. Tilt backward: Between 484(Output unit: CN1-25) and 484(Tilt B solenoid). 2. Tilt return: Between 485(Output unit: CN1-26) and 496(Tilt B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of tilt backward solenoid. 1. Tilt backward: Between 484(Tilt B solenoid) and 496(Tilt B solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(7) Replace output unit.

4-96

Abnormal (8) Replace tilt backward solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-97

CONTROLLER

Problem: Tilt Solenoid Leak (F59) (1) Situation Indication: "F59" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty tilt solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when tilt lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation (5) Not operate

(7) Attachment 1 operation

(8) Attachment 2 operation

Up

Down

A

B

A

B

A

B

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-98

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between tilt section and lift section. Between 480(Output unit: CN1-21) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between tilt section and lift section. Between 481(Output unit: CN1-22) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between tilt section and attachment 1 section. Between 486(Output unit: CN1-27) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between tilt section and attachment 1 section. Between 487(Output unit: CN1-28) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-99

CONTROLLER

(25) Check continuity between tilt section and attachment 2 section. Between 489(Output unit: CN1-30) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between tilt section and attachment 2 section. Between 490(Output unit: CN1-31) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between tilt section and attachment 3 section. Between 492(Output unit: CN1-33) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between tilt section and attachment 3 section. Between 493(Output unit: CN1-34) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less)

(35) Insulate wires in harness or replace harness.

4-100

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-101

CONTROLLER

Problem: Attachment 1A Solenoid Error (F60) (1) Situation Indication: "F60" flickering. Attachment operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 1A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 1A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 1A solenoid. 1. Attachment 1 A: Between 486(Output unit: CN1-27) and 486(ATT1 A solenoid). 2. Attachment 1 return: Between 488(Output unit: CN1-29) and 488(ATT1 A solenoid). No continuity

Continuity

(5) Replace harness.

(6) Measure resistance of attachment 1A solenoid. 1. Attachment 1A: Between 486(ATT1 A solenoid) and 488(ATT1 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (9) Replace output unit.

4-102

Abnormal

(8) Replace attachment 1A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-103

CONTROLLER

Problem: Attachment 1B Solenoid Error (F62) (1) Situation Indication: "F62" flickering. Attachment operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 1B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 1B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 1B solenoid. 1. Attachment 1B: Between 487(Output unit: CN1-28) and 486(ATT1 B solenoid). 2. Attachment 1 return: Between 488(Output unit: CN1-29) and 497(ATT1 B solenoid). No continuity

Continuity

(5) Replace harness.

(6) Measure resistance of attachment 1B solenoid. 1. Attachment 1B: Between 487(ATT1 B solenoid) and 497(ATT1 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (9) Replace output unit.

4-104

Abnormal

(8) Replace attachment 1B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-105

CONTROLLER

Problem: Attachment 1 Solenoid Leak (F64) (1) Situation Indication: "F64" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 1 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 1 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 2 operation

Up

Down

Forward

Backward

A

B

A

B

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-106

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 1 section and lift section. Between 480(Output unit: CN1-21) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 1 section and lift section. Between 481(Output unit: CN1-22) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 1 section and tilt section. Between 483(Output unit: CN1-24) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 1 section and tilt section. Between 484(Output unit: CN1-25) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-107

CONTROLLER

(25) Check continuity between attachment 1 section and attachment 2 section. Between 489(Output unit: CN1-30) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 1 section and attachment 2 section. Between 490(Output unit: CN1-31) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 1 section and attachment 3 section. Between 492(Output unit: CN1-33) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 1 section and attachment 3 section. Between 493(Output unit: CN1-34) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less)

(35) Insulate wires in harness or replace harness.

4-108

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-109

CONTROLLER

Problem: Attachment 2A Solenoid Error (F65) (1) Situation Indication: "F65" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 2A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 2A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 2A solenoid. 1. Attachment 2A: Between 489(Output unit: CN1-30) and 489(ATT2 A solenoid). 2. Attachment 2 return: Between 491(Output unit: CN1-32) and 491(ATT2 A solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 2A solenoid. 1. Attachment 2A: Between 489(ATT2 A solenoid) and 491(ATT2 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-110

Abnormal (8) Replace attachment 2A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-111

CONTROLLER

Problem: Attachment 2B Solenoid Error (F67) (1) Situation Indication: "F67" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 2B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 2B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 2B solenoid. 1. Attachment 2B: Between 490(Output unit: CN1-31) and 490(ATT2 B solenoid). 2. Attachment 2 return: Between 491(Output unit: CN1-32) and 498(ATT2 B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 2B solenoid. 1. Attachment 2B: Between 490(ATT2 B solenoid) and 498(ATT2 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-112

Abnormal (8) Replace attachment 2B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-113

CONTROLLER

Problem: Attachment 2 Solenoid Leak (F69) (1) Situation Indication: "F69" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 2 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 2 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 1 operation

Up

Down

Forward

Backward

A

B

A

B

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-114

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 2 section and lift section. Between 480(Output unit: CN1-21) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 2 section and lift section. Between 481(Output unit: CN1-22) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 2 section and tilt section. Between 483(Output unit: CN1-24) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 2 section and tilt section. Between 484(Output unit: CN1-25) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-115

CONTROLLER

(25) Check continuity between attachment 2 section and attachment 1 section. Between 486(Output unit: CN1-27) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 2 section and attachment 1 section. Between 487(Output unit: CN1-28) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 2 section and attachment 3 section. Between 492(Output unit: CN1-33) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 2 section and attachment 3 section. Between 493(Output unit: CN1-34) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less)

(35) Insulate wires in harness or replace harness.

4-116

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-117

CONTROLLER

Problem: Attachment 3A Solenoid Error (F70) (1) Situation Indication: "F70" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 3A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 3A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 3A solenoid. 1. Attachment 3A: Between 492(Output unit: CN1-33) and 492(ATT3 A solenoid). 2. Attachment 3 return: Between 494(Output unit: CN1-34) and 494(ATT3 A solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 3A solenoid. 1. Attachment 3A: Between 492(ATT3 A solenoid) and 494(ATT3 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-118

Abnormal (8) Replace attachment 3A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-119

CONTROLLER

Problem: Attachment 3B Solenoid Error (F72) (1) Situation Indication: "F72" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 3B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 3B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 3B solenoid. 1. Attachment 3B: Between 493(Output unit: CN1-34) and 493(ATT3 B solenoid). 2. Attachment 3 return: Between 494(Output unit: CN1-32) and 499(ATT3 B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 3B solenoid. 1. Attachment 3B: Between 493(ATT3 B solenoid) and 499(ATT3 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-120

Abnormal (8) Replace attachment 3B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-121

CONTROLLER

Problem: Attachment 3 Solenoid Leak (F74) (1) Situation Indication: "F74" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 3 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 3 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 1 operation

Up

Down

Forward

Backward

A

B

A

B

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-122

(9) Attachment 2 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 3 section and lift section. Between 480(Output unit: CN1-21) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 3 section and lift section. Between 481(Output unit: CN1-22) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 3 section and tilt section. Between 483(Output unit: CN1-24) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 3 section and tilt section. Between 484(Output unit: CN1-25) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-123

CONTROLLER

(25) Check continuity between attachment 3 section and attachment 1 section. Between 486(Output unit: CN1-27) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 3 section and attachment 1 section. Between 487(Output unit: CN1-28) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 3 section and attachment 2 section. Between 489(Output unit: CN1-30) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 3 section and attachment 2 section. Between 490(Output unit: CN1-31) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less)

(35) Insulate wires in harness or replace harness.

4-124

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-125

CONTROLLER

Problem: Unload Solenoid Error (F75) (1) Situation Indication: "F75" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty unload solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 2.4A or more, when unload solenoid signal is outputted.

(4) Checks Check to see if emergency button is pushed. Pushed

Not pushed

(5) Release emergency button and restart. Error remains

(6) Check continuity between VCM-3 and unload solenoid. 1. Between 211(VCM-3: CN1-30) and 211(Unload solenoid). 2. Between 411(VCM-3: CN1-32) and 411(Input unit). 3. Between 212(Input unit) and 212(Unload solenoid). No continuity

Continuity

(7) Replace harness.

(8) Measure resistance of unload solenoid. 1. Between 211(Unload solenoid) and 212(Unload solenoid). Normal [6.9ǡ to 10.3ǡ at 25͠ (77˚F)]

(9) Replace VCM-3.

4-126

Abnormal (10) Replace unload solenoid.

CONTROLLER

VCM-3

UNLOAD SOL UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41

0.85G/B

Harness A 211

Harness B

Harness C 211

Harness B

0.85B/W

212

0.85L/R 0.85Lg/B 1.25R/Y 1.25R/Y

EMERGENCY SW Harness A

0.85B/L

130 131

212

0.85B/L

245

1 224 223

130

218 217 216132 215 40

34 131 229 411

211

10 18

41 26

212

937

396

397

395 411

0.85G/B

0.85Lg/R 0.85Br/B

25

211

211 212

211 212

9 17

937 397 396 395 212 411

INPUT UNIT

CN1

0.85Br/B

Harness C

212

(BLACK)

UNLOAD 212365

4-127

CONTROLLER

Problem: Unload Solenoid Leak (F79) (1) Situation Indication: "F79" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty unload solenoid, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when hydraulic operation signal is not outputted.

(4) Checks Check operating condition when error occurred.

(7) When knob position control function is installed

(6) Drive operation (5) Not operate. Forward

Reverse

To (11)

To (14)

During steering operation

To (17)

(8) Measure resistance of unload solenoid. Normal [6.9ǡ to 10.3ǡ at 25͠ (77˚F)]

(9) Replace VCM-3.

4-128

Abnormal

(10) Replace unload solenoid.

CONTROLLER

(11) Check continuity between transmission section and unload section. Between 233(VCM-3: CN2-15) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less)

(12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between transmission section and unload section. Between 235(VCM-3: CN2-16) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less)

(15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

(17) Check continuity between knob position solenoid and unload section. Between 237(VCM-3: CN2-18) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less)

(18) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (19) Replace VCM-3.

4-129

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

1.25B/L

234 242

1.25G/L

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

SF

SR

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

9

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-130

CONTROLLER

Problem: Knob Position Solenoid Error (F80) (1) Situation Indication: "F80" flickering. Knob position control fuunction disabled.

(2) Possible cause Faulty VCM-3, faulty knob position solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 3.54A or more, when knob position solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and knob position solenoid. 1. Between 237(VCM-3: CN2-18) and 237(PS CARIB solenoid). 2. Between 238(VCM-3: CN2-20) and 238(PS CARIB solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of knob position solenoid. 1. Between 237(PS CARIB solenoid) and 238(PS CARIB solenoid). Normal [6.9ǡ to 10.3ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

Abnormal (8) Replace knob position solenoid.

4-131

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg/R 0.85Y 1.25G/Y 1.25B/L 1.25G/L

0.85W

Harness A

237 238

Harness B

237 238

237

0.85Lg

0.85B/G

0.85Lg/B

0.85Lg 0.85Lg/B

238

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

(BLACK)

237 238

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

PS CARIB (OP) 212367

4-132

CONTROLLER

Problem: Knob Position Solenoid Leak (F84) (1) Situation Indication: "F84" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty knob position solenoid, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when steering wheel is not operated.

(4) Checks Check operating condition when error occurred.

(6) Drive operation (7) During hydraulic operation

(5) Not operate. Forward

Reverse

To (11)

To (14)

To (17)

(8) Measure resistance of knob position solenoid. Normal [6.9

(9) Replace VCM-3.

to 10.3

at 25

(77˚F)]

Abnormal

(10) Replace knob position solenoid.

4-133

CONTROLLER

(11) Check continuity between transmission section and knob position solenoid. Between 233(VCM-3: CN2-15) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less)

(12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between transmission section and knob position solenoid. Between 235(VCM-3: CN2-16) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less)

(15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

(17) Check continuity between unload section and knob position solenoid. Between 211(VCM-3: CN1-30) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less)

(18) Insulate wires in harness or replace harness.

4-134

No continuity (Several Mǡ) (19) Replace VCM-3.

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

1.25B/L

234 242

1.25G/L

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

SF

SR

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

9

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-135

CONTROLLER

Problem: Transmission Forward Solenoid Error (F85) (1) Situation Indication: "F85" flickering. Drive operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission forward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when transmission forward solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and transmission forward solenoid. 1. Between 233(VCM-3: CN2-15) and 233(Solenoid F: +). 2. Between 234(VCM-3: CN2-17) and 234(Solenoid F: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of transmission forward solenoid. 1. Between 233(Solenoid F: +) and 234(Solenoid F: -). Normal [6.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

4-136

Abnormal (8) Replace transmission forward solenoid.

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg/R 0.85Y 1.25B/L 1.25G/L 0.85Lg

Harness A

233 234 235

Harness B

233 234

Harness C 1.25B/L

1.25B/L

0.85Lg/B 0.85W 0.85B/G

235

1.25G/Y

234 242

1.25G/L

233

1.25G/Y

235

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

SF

SR SOLENOID(F - R)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

212368

4-137

CONTROLLER

Problem: Transmission Backward Solenoid Error (F87) (1) Situation Indication: "F87" flickering. Drive operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission backward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when transmission backward solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and transmission backward solenoid. 1. Between 235(VCM-3: CN2-16) and 235(Solenoid R: +). 2. Between 234(VCM-3: CN2-17) and 242(Solenoid R: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of transmission backward solenoid. Between 235(Solenoid R: +) and 242(Solenoid R: -). Normal [6.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

4-138

Abnormal (8) Replace transmission backward solenoid.

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg/R 0.85Y 1.25B/L 1.25G/L 0.85Lg

Harness A

233 234 235

Harness B

233 234

Harness C 1.25B/L

1.25B/L

0.85Lg/B 0.85W 0.85B/G

235

1.25G/Y

234 242

1.25G/L

233

1.25G/Y

235

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

SF

SR SOLENOID(F - R)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

212368

4-139

CONTROLLER

Problem: Transmission Solenoid Leak (F89) (1) Situation Indication: "F89" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when transmission solenoid is in neutral position.

(4) Checks Check operating condition when error occurred.

(5) Not operate.

(6) During hydraulic operation.

(7) When knob position control function is installed During steering operation

To (11)

To (14)

(10) Measure resistance of transmission forward/backward solenoid. Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)]

(11) Replace VCM-3.

4-140

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(11) Check continuity between unload section and transmission section. Between 211(VCM-3: CN1-30) and 234(VCM-3: CN2-17). Continuity (Several tenǡ or less)

(12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between knob position solenoid and transmission section. Between 237(VCM-3: CN2-18) and 234(VCM-3: CN2-17). Continuity (Several tenǡ or less)

(15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

4-141

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

1.25B/L

234 242

1.25G/L

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

SF

SR

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

9

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-142

CONTROLLER

Problem: VCM-3OP Sensor Voltage Error (F90) (1) Situation Indication: "F90" flickering.

(2) Possible cause Faulty lift oil pressure/tilt angle sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When VCM-3OP sensor 5V power voltage is 3.85V or less.

(4) Checks Check continuity between sensor and VCM-3OP. 1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 267(VCM-3OP: CN1-14: +5V), and 269(Lift oil pressure sensor: GND) and 269(VCM-3OP: CN1-17: GND). 2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 264(VCM-3OP: CN1-27: +5V), and 266(Tilt angle sensor: GND) and 266(VCM-3OP: CN1-29: GND). Continuity

No continuity

(5) Replace harness. (6) Check short circuit between sensor power and GND in sensor connector side. Shorted

Not shorted

(7) Replace faulty sensor(lift oil pressure/tilt angle).

4-143

CONTROLLER

(8) Check short circuit between sensor and VCM-3OP.

1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 269(VCM-3OP: CN1-17: GND), and 269(Lift oil pressure sensor: GND) and 267(VCM-3OP: CN1-14: +5V). 2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 266(VCM-3OP: CN1-29: GND), and 266(Tilt angle sensor: GND) and 264(VCM-3OP: CN1-27: +5V). Shorted

(9) Replace faulty harness.

4-144

Not shorted

(5) Replace VCM-3OP.

CONTROLLER

43 135

264 265

266 265 264

136

0.85B/W

0.85Lg 269 268 267

269

P. SOURCE 1 P. SOURCE 2 GND1 GND2

266

SPEED PULSE CAB OPEN IND1

0.85R/B

265 266 290 257 42

267

269 264

0.85B/Y

267 268 269 264 265 266

268

250 252 267 268

0.85Y/B

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN.

0.85Lg/B

VCM-OP

CN1 9 17 25

252 250 269 135

34 136 257

1

268 267

10

42

18

266 265 264 43 26

TILT ANGLE SENSOR (OP)

LIFT OIL PRESSURE SENSOR (OP) 212369

4-145

CONTROLLER

Problem: VCM-3OP Memory Check Error (F91) (1) Situation Indication: "F91" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3OP, faulty truck type setting data in VCM-3OP.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Check truck type setting data. Normal

Abnormal

(5) Enter truck type setting data again.

(6) Set shipment default value into VCM-3OP. Normal

Abnormal

(7) Perform standard setting, then enter truck type setting data again.

(8) Write updated software into VCM-3OP. Normal

(9) Faulty software writing.

4-146

Abnormal

(10) Replace VCM-3OP.

CONTROLLER

Problem: VCM-3OP Battery Voltage Error (F92) (1) Situation Indication: "F92" flickering. Tilt horizontal control and speed change control disabled.

(2) Possible cause Poor battery charge, faulty battery, faulty VCM-3OP, faulty harness, faulty DC-DC converter.

(3) How the error code is triggered When VCM-3OP input voltage is less than 7V or more than 21V.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

More than 32V

Less than 7V (5) Charge battery.

Error remains (6) Replace battery.

(7) Measure output voltage and input voltage of DC-DC converter. 1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). Normal

Input voltage abnormal

Output voltage abnormal

(9) Replace DC-DC converter.

(8) Replace harness.

(10) Measure VCM-3OP input voltage. 1. Between 42(VCM-3OP: CN1-18) and 135(VCM-3OP: CN1-25). 2. Between 43(VCM-3OP: CN1-26) and 136(VCM-3OP: CN1-34). Less than 7V

(11) Replace harness.

12V 24V

7V to 21V

(12) Replace VCM-3OP.

4-147

CONTROLLER

DC-DC CONVERTER

VCM-3OP CN1 0.85B/L 136 0.85B/L 135 1.25R/Y 43 1.25R/Y 42

107 1.25B/L 2R/Y 40 1.25B 104

105 42

F7 8R

252 250 268 267

10

42

10A

2R/W

62 301

12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

18

266 265 264 43 26

60B

2B

4

5

60B

㧙

㧗

BATTERY

㧙

105

135

8

12V GND 12V MAIN 24V GND

2B/L

269

25

34 136 257

2R/W

100

17

1

FLW 0.85R

9

8

15R

1

CN1

107 40 104 94 49 8

㧗

BATTERY

212370

4-148

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid 1 Error (F93) (1) Situation Indication: "F93" flickering. EAT control function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty change transmission solenoid 1, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 1 signal is outputted.

(4) Checks Check continuity between VCM-3OP and change transmission solenoid 1. 1. Between 253(VCM-3OP: CN2-15) and 255(Solenoid SH: +). 2. Between 254(VCM-3OP: CN2-17) and 254(Solenoid SH: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of change transmission solenoid 1. 1. Between 255(Solenoid SH: +) and 254(Solenoid SH: -) Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3OP.

Abnormal (8) Replace change transmission solenoid 1.

4-149

CONTROLLER

VCM-OP

CN2

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

281 279 277 253 273 254 258

ECU FUSE 273 204 205

253 255

1.25R/Y

255

253

1.25L/Y 274

273

1.25R/Y 1.25L/Y

205 204 295 294 293 292

26

255

34

1.25L/Y

18

274

1 10

258

254

279 281

254 273 253

25

1.25R/Y

9 277 17

1.25B/W

CN2

246

SH

S2

SOLENOID (SPEED SELECT) 212371

4-150

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid 2 Error (F94) (1) Situation Indication: "F94" flickering. EAT control function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty change transmission solenoid 2, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 2 signal is outputted.

(4) Checks Check continuity between VCM-3OP and change transmission solenoid 2. 1. Between 273(VCM-3OP: CN2-16) and 274(Solenoid S2: +). 2. Between 254(VCM-3OP: CN2-17) and 246(Solenoid S2: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of change transmission solenoid 2. 1. Between 274(Solenoid S2: +) and 246(Solenoid S2: -) Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3OP.

Abnormal (8) Replace change transmission solenoid 2.

4-151

CONTROLLER

VCM-OP

CN2

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

281 279 277 253 273 254 258

ECU FUSE 273 204 205

253 255

1.25R/Y

255

253

1.25L/Y 274

273

1.25R/Y 1.25L/Y

205 204 295 294 293 292

26

255

34

1.25L/Y

18

274

1 10

258

254

279 281

254 273 253

25

1.25R/Y

9 277 17

1.25B/W

CN2

246

SH

S2

SOLENOID (SPEED SELECT) 212371

4-152

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid Leak (F95) (1) Situation Indication: "F95" flickering. EAT control function disabled.

(2) Possible cause Faulty VCM-3OP, faulty corresponding solenoid, faulty harness.

(3) How the error code is triggered Output signal current is 0.18A or more when vehicle is driving at 3rd speed.

(4) Checks Measure resistance of change transmission solenoid 1 and 2. Abnormal

Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)]

(5) Replace faulty solenoid. (6) Check continuity between power source and change transmission section. 1. Between 42(VCM-3OP: CN1-18) and 253(VCM-3OP: CN2-15). 2. Between 42(VCM-3OP: CN1-18) and 273(VCM-3OP:CN2-16). Continuity (Several tenǡ or less)

(7) Insulate wires in harness or replace harness.

No continuity (Several Mǡ)

(8) Replace VCM-3OP.

4-153

CONTROLLER

DC-DC CONVERTER

VCM-3OP CN1 0.85B/L 136 0.85B/L 135 1.25R/Y 43 1.25R/Y 42

107 1.25B/L 2R/Y 40

105 42

CN2

ECU FUSE 273 204 205

253 255

CN2

205 204 295 294 293 292

1.25L/Y 274

273

1.25R/Y 1.25L/Y

CN1 252 250

1

9

10

17

18

25

26

34 136 257

269 135

1

268 267

10

42

18

266 265 264 43 26

1.25L/Y

258

253

255

34

279 281

254 273 253

255

274

25

1.25R/Y

1.25B/W

9 277 17

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

279 277 253 273 254 258

254

CAN H

281

1.25R/Y

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L

107 40 104 94 49 8 62 301

246

SH

S2

SOLENOID (SPEED SELECT) 212372

4-154

CONTROLLER

Problem: VCM-3OP EAT Setting Error (F96) (1) Situation Indication: "F96" flickering. Speed change function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty truck type setting data in VCM-3OP

(3) How the error code is triggered 1 When setting value of speed shift point is not in following relations. 2- speed specification vehicle: (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed) 3- speed specification vehicle: (from 2nd-speed to 3rd-speed) (from 3rd-speed to 2nd-speed) (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed) 2 When setting data for mode selecting decision is in following conditions. Mode selecting decision value is out of setting range (0 to 3). Mode selecting pattern is repeated. Either of mode selector switch SW1 and SW2 is not set. 3 When setting data for speed change solenoid (SH and S2) is in following conditions. Speed change solenoid output decision value is out of setting range (0 to 3). Speed change solenoid output pattern is repeated. Either of SH and S2 is not set.

(4) Checks Check truck type setting data. Normal

Abnormal

(5) Enter truck type setting data again.

(6) Set shipment default value into VCM-3OP. Abnormal

Normal

(7) Perform standard setting, then enter truck type setting data again.

(8) Replace VCM-3OP.

4-155

CONTROLLER

Problem: VCM-3OP Communication Error (F97) (1) Situation Indication: "F97" flickering. Speed change function disabled (current step held).

(2) Possible cause Faulty VCM-3OP, faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication from VCM-3OP to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. 1. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and 200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).

Continuity

No continuity (5) Replace harness.

(6) Replace VCM-3OP. Error remains (7) Replace VCM-3.

4-156

CONTROLLER

VCM-OP CN2 281

CN2 9 277

279 281

1

17

254 273 253

10

25

258

18

34

205 204 295 294 293 292

279 277 253 273 254 258

26

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

204 205

0.85B/W 0.85L/R

204 205 CN1 250 252 267 268 269 264 265 266 290 257 42 43 135 136

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN. SPEED PULSE CAB OPEN IND1 P. SOURCE 1 P. SOURCE 2 GND1 GND2

212373

4-157