BEFORE TROUBLESHOOTING19-2 0 CONNECTOR …dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · 11 htt 2007-12 12 htt 2008-01 13 htt 2008-02 14 htt 2008-03 15 htt 2008-04

19-1

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ELECTRICAL SYSTEM TROUBLESHOOTINGPage

BEFORE TROUBLESHOOTING..........................19-2CONNECTOR HANDLING.......................................19-2WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE ..................................19-2TROUBLESHOOTING..........................................19-4

BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y-E ENGINE........................................19-4

DIAGNOSIS (SELF DIAGNOSIS FUNCTION) ............19-5DIAGNOSIS DISPLAY METHOD..............................19-5LIST OF DIAGNOSIS CODES..................................19-6WARNING LIST ...................................................19-12VIEWING RELATED PORTIONS............................19-13ERROR CONFIRMATION DRIVE MODE.................19-13TROUBLESHOOTING BY ERROR CODE...............19-14TROUBLESHOOTING WHEN THERE IS

NO ERROR CODE ...........................................19-156

kalstatt

Text Box

8FG(D)U15-32, 8FGCU20-32

Description Page # Date

1Revised error code for change in terminal esignation on seat switch from X1-1, X1-2 to 05- 19-111 12/15/09

2Page not required foerror code A5-1 and turned into memo page 19-112 12/15/09

3 Added bookmarks all 3/31/134 Added SIB CE07-008 197 3/31/135 Added SIB CE08-005 195, 196 3/31/136 Added SIB CE09-004 199 3/31/137 Added SIB CE10-005 198 3/31/13

Service Manual Change History

Service Information Buletin1 SIB CC08-005 4Y ECS Controller Programming Change Chapter 192 SIB CE07-008 Error Code AD-1 and AD-7 Chapter 193 SIB CE09-004 A5, A5-1 or 1-1 Error Codes For OPSS Chapter 194 SIB CE10-003 Horn Relocation Chapter E25 SIB CE10-005 Main Wiring Harness Change (Error Code 73-1) Chapter 196 SIB CE11-001R Clamp Release Interlock (Mini Lever Units) Chapter 19, 14, E37 SIB CE11-003 Clamp Release Interlock (Standard Lever Units) Chapter 14, E38 SIB EN07-001 4Y Engine Ignition Timing Procedure Chapter 1.3-109 SIB EN08-001 Repair Manual (00700-X8880-71) Revision Embedded

10 SIB EN08-002 Repair Manual (00700-X8880-71) Revision Embedded11 SIB EN09-001 Repair Manual (00700-X8880-71) Revision Embedded12 SIB EN09-002 Repair Manual (00700-X8880-71) Revision Embedded13 SIB EN10-001 Engine Block Heaters Chapter 1.2-414 SIB FS08-001 LPG Regulator Chapter 1.3-215 SIB HS07-003 Flow Regulator Replacement Parts Chapter 1416 SIB MA07-001 Hourmeter Fuse Installation Chapter 017 SIB MA07-003 Transmission Oil Level Inspection Chapter 2 & 2.118 SIB MA07-004R Grease Specifications Chapter 019 SIB MA10-001 Overhead Guard Mounting Bolt Torque Chapter 920 SIB MA10-007 Oil Pressure Switch Chpater 0 & E321 SIB MA11-001 Service Hint For Greasing Rear Axle Beam Pivot Pin Chapter 022 SIB MA13-001 Exhaust Mounting Clamp with Rubber Bushing Inspection Chapter 023 SIB RA08-001 Updated Horn Pad Chapter 724 SIB ST07-001 Special Service Tools Chapter 1725 SIB TR07-001 Transmission Control Valve Identification Chapter 2 & 2.126 SIB TR07-002 Propeller Shaft Cover Chapter 2 & 2.1

Technical News Brief1 TNB 2007-03R1 Hydraulic Oil Change2 TNB 2007-05 Transmission Knocking Noise At Idle3 TNB 2007-06 LPG Regualtor Slow Path Tamper Resistant Cap4 TNB 2007-11 Torque Specificaion Of Outer Mast Support Bolts5 TNB 2008-07 Fuel Mixture Adjustment Procedure For The 4Y ECS Engine6 TNB 2008-20 Gasoline Fuel System7 TNB 2008-12 Installation of Fuel Line Fittings8 TNB 2009-03 Suppliment to TNB 2008-07 For Adjusting VF (Voltage Fuel)

Hotline Tech Tips1 HTT 2007-022 HTT 2007-033 HTT 2007-044 HTT 2007-055 HTT 2007-066 HTT 2007-077 HTT 2007-088 HTT 2007-099 HTT 2007-10

10 HTT 2007-11

Transmission Control Valve Identification; Proper Chasis LubricationIdle Surge/Hunt; Quick Facts; Rotten Egg/Ammonia SmellLimiting Travel Speed; A5-1 CodeLPG Regulator Adjustment; Engine/Transmission "Knocking" ComplaintTroubleshooting Diesel Smoke; Multifunction DisplayLPG Regulator MaintenanceEngine SurgePropshaft CoverError Code 68-3; Flow Regulator Valve Parts ReplacementWet Brake Option Hydraulic Oil; Error Code AD-1 And AD-7

11 HTT 2007-1212 HTT 2008-0113 HTT 2008-0214 HTT 2008-0315 HTT 2008-0416 HTT 2008-0517 HTT 2008-0618 HTT 2008-0719 HTT 2008-0820 HTT 2008-0921 HTT 2008-1022 HTT 2008-1123 HTT 2008-1224 HTT 2009-0125 HTT 2009-0326 HTT 2009-0627 HTT 2009-0728 HTT 2009-0829 HTT 2009-0930 HTT 2009-1031 HTT 2009-1132 HTT 2010-0133 HTT 2010-0234 HTT 2010-0335 HTT 2010-0436 HTT 2010-0537 HTT 2010-0638 HTT 2010-0739 HTT 2010-0840 HTT 2010-0941 HTT 2010-1042 HTT 2010-1143 HTT 2010-1244 HTT 2011-0145 HTT 2011-0246 HTT 2011-0347 HTT 2011-0448 HTT 2011-0549 HTT 2011-0650 HTT 2011-0751 HTT 2011-0852 HTT 2011-0953 HTT 2011-1054 HTT 2011-1155 HTT 2011-1256 HTT 2012-01

Engine Analyzer Screen 10/10Error Code 09-1; LPG Filter Kit; Cold Soak Lack Of Travel

Engine Analyzer Screen 4/10Engine Analyzer Screen 5/10Engine Analyzer Screen 6/10Engine Analyzer Screen 7/10Engine Analyzer Screen 8/10Engine Analyzer Screen 9/10

Engine Analyzer Screen 3/10

SAS Manual Lowering Valve Location; Flow Regulator W/ Part NumbersSAS Code History Check Without The AnalyzerClearing 01-1, 01-2, 01-3, 01-4, 01-5, 01-6 Codes After Making The Repair Error Code 73-1 After Replacing The Main HarnessHour Meter Diagnostics & MemoryDiagnosing Diesel SmokeLPG Regulator Adjustment & Tar Draining: Idle Speed AdjustmentHow To Read An O2 SensorRequired Adjustments For New LP Regulator, And Installation Of Anti-Tamper CapsEngine Analyzer Screen 1/10; Throttle Body CleaningEngine Analyzer Screen 2/10; Analyzer Speed Versus Displayed Speed

Error Code AD-7 After Replacing The Main Harness

Load Sensor Wire Breakage; Dual Brake Pedal "Low Pedal" ComplaintError Code OB-1 Horn Pad Improvements; Flow Regulator Update; Overheat DiagnosticsEngine Controller Version IdentificationIdentifying LPG Regulator 1st Valve Material; High Engine Idle IssuesUsing the Engine Analyzer To Check The Engine FunctionError Codes Without An Hour Meter Reading; LPG Filter Kit PNReverse Polarity Damage IssuesIgnition Timing Value (IGT) Shown On AnalyzerError Code 06-3; Error Code 01-5To Throttle Valve Actuation And Error Code 06-3 E-THRO Fuse Location

Error Code 73-1, Or Missing Plug On New Harness

Error Code List; Rear Pillar Assist Relay Location; New CabCarriage Roller ReplacementFuel Shut Off Valve Orientation On Gasoline And Dual Fuel TrucksDriveability Issues Due To Dirty Throttle BodyShift Interlock (Intelli-Shift) Adjustments; Overheat Trouble ShootingLPG Tamper Resistant CapCam Positions SensorSAS Matching; Transmission RepairSeatbelt Interlock; Function Menu w/ Travel & Load Handling Option; Gas Tank PressureAccelerator Sensor Codes; LPG Filter Kit Service PartsCNG Trucks Using The Analyzer; Extra Long Feeler Gauges for Mast Shimming Checks

"L-OFF" ComplaintHorn Pad Improvements; Correct Timing Mark On Crank Pulley

19-219-2

BEFORE TROUBLESHOOTING

CONNECTOR HANDLING1. Disconnect the battery plug before connecting or

disconnecting each connector or terminal.

2. When disconnecting a connector, do not pull the wire harnessbut hold the connector itself and pull it after unlocking it.To connect, push the connector fully until it is locked inposition.

3. Bring a tester probe into contact with a connector terminal fromthe rear side of the connector (harness side).

4. If insertion from the rear side is impossible, as in the case of awaterproof connector, bring the tester probe carefully intocontact with the terminal so as not to cause deformation of theconnector terminal.

5. Do not touch connector terminals directly with your hand.

6. When bringing tester probes into contact with terminals thatvoltage is applied to prevent two tester probes from cominginto contact with each other.

WIRE HARNESS AND CONNECTOR INSPECTION PROCEDUREWhen any trouble occurs, first inspect the connectors and wireharness of the related circuit according to the following procedure:

Continuity Inspection

1. Disconnect the connectors at both ends of the correspondingharness.

2. Measure the resistance between corresponding terminals ofthe connectors at both ends.

Standard: 10 Ω or less

Note:• Measure while jiggling the wire harness up and down and

sideways.• Open circuit at the wire harness occurs rarely partway

through a vehicle wiring but mostly at connectors. Inspectespecially the sensor connectors with sufficient care.

Electrical System Troubleshooting

Section 19

19-3

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Short Circuit Check1. Disconnect the connectors at both ends of the corresponding

harness.

2. Measure the resistance between the corresponding connectorterminal and frame. Be sure to inspect the connectors at bothends.

Standard: 1 MΩ or above

Note:Measure while jiggling the wire harness up and down andsideways.

3. Measure the resistance between terminals of thecorresponding connector. Be sure to inspect the connectors atboth ends.

Standard: 1 MΩ or above

Note:The wiring may short-circuit due to pinching by the body ordefective clamping.

Visual and Contact Pressure Checks1. Disconnect the connectors at both ends of the corresponding

harness.

2. Visually inspect that there is neither rust nor foreign mattertrapped at connector terminals.

3. Inspect that there is no looseness or damage at the crimpedportion. Also, lightly pull the wire harness from the connector tocheck that it does not come off.

4. Insert a male terminal same as that of the connector terminalto a female connector and check the drawing force.Defective contact may exist at a terminal where the drawingforce is less than that of other terminals.

Note:Even if there is rust or foreign matter trapped at the terminal,or the contact pressure between male and female terminals islow, abnormal contact condition may be changed to normal bydisconnecting and reconnecting the connector. In this case,disconnect and reconnect the connector several times, and ifa fault occurs even once, then consider the terminal may havea defective contact.


Section 19

19-419-4

TROUBLESHOOTING

BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y-E ENGINEIt is extremely risky to begin troubleshooting for the 4Y engine on the basis of results only. It can lead to mistakencorrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, ask the customer aboutdetailed information on conditions around the time a problem occurred, based on the following.

Diagnostic ProcedureFirst, it is necessary to be informed of the "fault history and service history" for the vehicle, and then to gather definiteinformation about the fault occurence such as "when", "at what times", "in what places", "during what operations oractions", "what happened afterwards", and “frequency of occurrence”.Also, try to recreate the conditions for the fault occurence. (a. Recreation impossible b. Recreation possible: in whatcondition?)

• General items

• Condition of the defect (Tick the items that apply)

Customer name Date of delivery Date fault occurred / hour meter reading

Vehicle model Frame No. Engine No. (punched)

Fuel type

Gasoline LPG Gasoline - LPG combination (Note LPG fuel company name: )

Defect phenomena

1. Cannot start a. Does not crank b. Combustion does not start c. Incomplete combustion

2. Does not start well Poor cranking (when cold - when warm - at all times)

3. Poor idle a. Poor idle speed b. Unstable idle speed c. Hunting (regular fluctuation in speed)

4. Engine stallinga. Immediately after start-up (when cold - when warm) b. During deceleration c. After decelerationd. Without sign e. After the engine has been running rough f. When steering g. When handling materials h. Can be re-started immediately

5. Defect operational status

a. Insufficient power output b. Hesitation c. Surging (swaying forward and backward during acceleration) d. Knocking e. Backfiring f. After firing

6. Other a. Excessive fuel consumption b. Excessive oil consumption c. Overheating d. Water or oil leakse. Abnormal noise f. Other ( )

Environment at the time of the defect's occurrence

The time when the fault began to occur

a. Since the vehicle was new b. Recently (from around the following date (month and year): ) c. After being serviced

Frequency of occurence a. Always b. Under certain conditions c. Sometimes

Weather Sunny - cloudy - rain - snow - thunderstorm Temperature Approximately

°C Humidity Approximately%

Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: °C

Operation conditions

a. No relation b. When idling c. When revving d. When acceleratinge. When traveling at constant speed f. When decelerating g. When climbing a slopeh. During material handling operations When not loaded (when steering - when lifting - when tilting) When loaded (load: appox. kg) (when steering - when lifting - when tilting)i. Other (when using the inching brake - when steering - other)

Lamps a. Lights constantly b. Lights occaisonally c. Does not light


Section 19

19-5

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DIAGNOSIS (SELF DIAGNOSIS FUNCTION)GeneralWhen the computer detects a problem in the system, the fault is indicated by lighting a warning lamp on thecombination meter and displaying an error code. And fail-safe functions are started automatically to stop the engineor control the engine to a low speed.

DIAGNOSIS DISPLAY METHOD1. Diagnosis display method

The diagnosis is displayed by means of an error code asshown in the illustration to the left, and by the lights turning on.When the ignition key switch is turned ON, the lamp lightsonce to allow checking for the bulb, and then turns off again ifthe status is normal.With the ignition key switch ON, if an abnormality is detectedwhen the vehicle is stopped, travelling or performing meterialshandling operations, an error code is displayed and the lampsturn on as a warning. When this happens, stop the vehicle immediately and checkthe error code.

2. Diagnosis memory display methodTo display the diagnosis memory display, there are a method using the hour meter and tilt lever, a method usingthe optional display, and a method using a plug-in analyzer. Here the display method using the hour meter and tilt lever is described.

(1) From the main menu, display the diagnosis memory menu. For how to display the main menu, refer to page18-30.

(2) A diagnosis No. and error code are displayed each time the knob switch is pressed and released. Eacherror code and the time at which it occurred are displayed alternately at 2 second intervals.

Note:• The maximum number of error codes that can be stored is 10. The smaller the diagnosis No., the more

recent the error is. • The stored time of an error code appearing just when the ignition key switch is turned ON may be stored

as 0.0.

(3) Connect the matching connector and turn the ignition key switch OFF.

Error code display

An orange colored lamp lights(Engine ECU only)

Lamp blinks

Knob switch

Diagnosis memory menu

Press the knob switch to return it.

Switches automatically every 2 seconds


Section 19

19-6

LIST

OF

DIA

GN

OSI

S C

OD

ES

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age

01-1

01-1

Blin

king

4Y-E

CS

Fuel

feed

back

con

trol e

rror (

gaso

line)

rich

The

engi

ne s

peed

is u

nsta

ble

and

it m

ay s

top.

19-1

401

-201

-2Bl

inki

ng4Y

-EC

SFu

el fe

edba

ck c

ontro

l erro

r (ga

solin

e) le

an

01-3

01-3

Blin

king

4Y-E

CS

Fuel

feed

back

con

trol e

rror (

LPG

/CN

G) r

ich

19-1

801

-401

-4B

linki

ng4Y

-EC

SFu

el fe

edba

ck c

ontro

l erro

r (LP

G/C

NG

) lea

n

01-5

01-5

Blin

king

4Y-E

CS

O2

sens

or o

pen

abno

rmal

ityTh

e en

gine

spe

ed is

uns

tabl

e an

d it

may

sto

p.19

-23

01-6

01-6

Blin

king

4Y-E

CS

O2

sens

or h

eate

r ope

n ab

norm

ality

Dis

play

onl

y19

-25

02-1

02-1

Blin

king

4Y-E

CS

Inta

ke te

mpe

ratu

re s

enso

r ope

n ab

norm

ality

The

engi

ne m

ay h

ave

a pr

oble

m a

t low

te

mpe

ratu

res.

19

-27

02-2

02-2

Blin

king

4Y-E

CS

Inta

ke te

mpe

ratu

re s

enso

r sho

rt ab

norm

ality

03-1

03-1

Blin

king

4Y-E

CS

Inta

ke p

ipe

pres

sure

sen

sor o

pen

abno

rmal

ityTh

e en

gine

may

hav

e a

prob

lem

19-2

903

-203

-2B

linki

ng4Y

-EC

SIn

take

pip

e pr

essu

re s

enso

r sho

rt ab

norm

ality

04-1

04-1

Blin

king

4Y-E

CS

Coo

lant

tem

pera

ture

sen

sor o

pen

abno

rmal

ityTh

e en

gine

may

hav

e a

prob

lem

at l

ow

tem

pera

ture

s.19

-31

04-2

04-2

Blin

king

4Y-E

CS

Coo

lant

tem

pera

ture

sen

sor s

hort

abno

rmal

ity

05-1

05-1

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or 1

ope

n ab

norm

ality

Lim

ting

spee

d of

trav

elin

g an

d m

ater

ials

ha

ndlin

g du

e to

lim

ited

engi

ne p

ower

out

put

19-3

3

05-2

05-2

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or 1

sho

rt ab

norm

ality

05-3

05-3

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or 2

ope

n ab

norm

ality

05-4

05-4

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or 2

sho

rt ab

norm

ality

05-5

05-5

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or o

ffset

abn

orm

ality

05-6

05-6

Blin

king

4Y-E

CS

Thro

ttle

posi

tion

sens

or o

ut o

f ran

ge e

rror

06-1

06-1

Blin

king

4Y-E

CS

Thro

ttle

mot

or d

rive

circ

uit o

pen

abno

rmal

ity

Lim

ting

spee

d of

trav

elin

g an

d m

ater

ials

ha

ndlin

g du

e to

lim

ited

engi

ne p

ower

out

put

19-3

506

-206

-2B

linki

ng4Y

-EC

STh

rottl

e m

otor

driv

e ci

rcui

t sho

rt ab

norm

ality

06-3

06-3

Blin

king

4Y-E

CS

Thro

ttle

mot

or p

ower

sup

ply

circ

uit o

pen

abno

rmal

ity19

-37

06-4

06-4

Blin

king

4Y-E

CS

Thro

ttle

mot

or p

ower

sup

ply

circ

uit s

hort

abno

rmal

ity

06-5

06-5

Blin

king

4Y-E

CS

Thro

ttle

mot

or s

eizi

ng a

bnor

mal

ity19

-38

06-6

06-6

Blin

king

4Y-E

CS

Ele

ctro

nic

thro

ttle

syst

em e

rror

19-4

0

07-1

07-1

Blin

king

4Y-E

CS

Air-f

uel r

atio

mot

or o

pen

abno

rmal

ityTh

e en

gine

spe

ed is

uns

tabl

e an

d it

may

sto

p.19

-41

08-1

08-1

Blin

king

4Y-E

CS

Low

vol

tage

(bat

tery

line

ope

n) e

rror

Dis

play

onl

y19

-43

09-1

09-1

Blin

king

4Y-E

CS

Igni

tion

sign

al e

rror

The

engi

ne s

peed

is u

nsta

ble

and

it m

ay s

top.

19-4

4

0A-1

0A-1

Blin

king

4Y-E

CS

Fuel

spe

cific

atio

n de

term

inat

ion

sign

al e

rror

Dis

play

onl

y

19-4

70A

-20A

-2Bl

inki

ng4Y

-EC

SFu

el s

peci

ficat

ion

chan

geov

er s

witc

h er

ror

Dis

play

onl

y

0A-3

0A-3

Blin

king

4Y-E

CS

Fuel

spe

cific

atio

n ty

pe u

nmat

chEn

gine

may

sto

p


Section 19

19-7

0A-4

0A-4

Blin

king

4Y-E

CS

Engi

ne s

peci

ficat

ion

dete

rmin

atio

n er

ror

Lim

ting

spee

d of

trav

elin

g an

d m

ater

ials

ha

ndlin

g du

e to

lim

ited

engi

ne p

ower

out

put

19-4

9

13-1

13-1

Blin

king

AS

CM

otor

rela

y co

ntac

t poi

nt o

pen

abno

rmal

ityC

ontin

uatio

n of

eng

ine

idlin

g st

atus

19-5

013

-213

-2B

linki

ngA

SC

Mot

or re

lay

cont

act p

oint

sho

rt ab

norm

ality

Dis

play

onl

y

13-3

13-3

Blin

king

AS

CM

otor

rela

y op

en c

ircui

t or l

oad

shor

t abn

orm

ality

Con

tinua

tion

of e

ngin

e id

ling

stat

us

15-1

15-1

Blin

king

ASC

NM

R s

witc

h op

en a

bnor

mal

ityTh

e en

gine

may

idle

dur

ing

full

acce

lera

tion.

19-5

215

-215

-2B

linki

ngA

SC

NM

R s

witc

h sh

ort a

bnor

mal

ityC

ontin

uatio

n of

eng

ine

idlin

g st

atus

15-3

15-3

Blin

king

AS

CId

le /

NM

R s

witc

h si

mul

tane

ousl

y O

N e

rror

Con

tinua

tion

of e

ngin

e id

ling

stat

us a

fter

acce

lera

tion

off.

19-5

5

16-1

16-1

Blin

king

AS

CId

le s

witc

h op

en a

bnor

mal

ityC

ontin

uatio

n of

eng

ine

idlin

g st

atus

19-5

816

-216

-2B

linki

ngA

SC

Idle

sw

itch

shor

t abn

orm

ality

18-1

18-1

Blin

king

4Y-E

CS

Cam

ang

le s

enso

r ope

n ab

norm

ality

Engi

ne s

top

19-6

1

ASC

Engi

ne s

peed

sen

sor o

pen

abno

rmal

ityP

artia

l lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

n.19

-65

18-2

18-2

Blin

king

4Y-E

CS

Cam

ang

le s

enso

r ope

n ab

norm

ality

(on

star

t up)

Engi

ne w

ill no

t sta

rt19

-61

ASC

Engi

ne s

peed

sen

sor G

ND

sho

rt ab

norm

ality

Parti

al li

mita

tion

of th

e dr

ive

cont

rol f

unct

ion.

19-6

5

18-3

18-3

Blin

king

4Y-E

CS

Cra

nk a

ngle

sen

sor o

pen

abno

rmal

ityD

ispl

ay o

nly

19-6

3

1F-1

~ 8

1F-1

~ 8

Blin

king

ASC

CPU

erro

r

Con

tinua

tion

of e

ngin

e id

ling

stat

usM

axim

um s

peed

may

be

limite

dFu

nctio

n of

aut

omat

ic id

le s

peed

incr

ese

durin

g lif

ting

limite

d

19-6

7

41-1

41-1

Blin

king

SA

S/O

PS

Mat

chin

g co

nnec

tor o

pen

abno

rmal

ityD

ispl

ay o

nly

19-6

8

51-1

51-1

Blin

king

SA

S/O

PS

Spee

d se

nsor

ope

n ab

norm

ality

The

vehi

cle

spee

d in

dica

tor s

how

s 0

km/h

Parti

al li

mita

tion

of th

e re

ar w

heel

sw

ing

cont

rol

func

tion.

Kno

b of

fest

com

pens

atio

n st

ops

Parti

al li

mita

tion

of th

e dr

ive

cont

rol f

unct

ion.

19-6

951

-251

-2B

linki

ngS

AS

/OP

SSp

eed

sens

or G

ND

sho

rt ab

norm

ality

52-1

52-1

Blin

king

SA

S/O

PS

Yaw

rate

sen

sor o

pen

abno

rmal

ity

Parti

al li

mita

tion

of th

e re

ar w

heel

sw

ing

cont

rol

func

tion

19-7

152

-252

-2B

linki

ngS

AS

/OP

SYa

w ra

te s

enso

r VC

C s

hort

abno

rmal

ity

52-3

52-3

Blin

king

SA

S/O

PS

Yaw

rate

sen

sor n

eutra

l vol

tage

erro

r

54-1

54-1

Blin

king

SAS/

OPS

Sw

ing

lock

sol

enoi

d op

en c

ircui

t or l

oad

shor

t abn

orm

ality

Parti

al li

mita

tion

of th

e re

ar w

heel

sw

ing

cont

rol

func

tion

19-7

3

61-1

61-1

Blin

king

SA

S/O

PS

Load

sen

sor o

pen

abno

rmal

ityP

artia

l lim

itatio

n of

the

rear

whe

el s

win

g co

ntro

l fu

nctio

nPa

rtial

lim

itatio

n of

mas

t con

trol f

unct

ion

Lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

nLo

ad in

dica

tor c

anno

t dis

play

19-7

561

-261

-2B

linki

ngS

AS

/OP

SLo

ad s

enso

r VC

C s

hort

abno

rmal

ity

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age


Section 19

19-8

62-1

62-1

Blin

king

SAS/

OPS

Tilt

angl

e se

nsor

ope

n ab

norm

ality

Parti

al li

mita

tion

of m

ast c

ontro

l fun

ctio

n19

-78

62-2

62-2

Blin

king

SA

S/O

PS

Tilt

angl

e se

nsor

VC

C s

hort

abno

rmal

ity

63-1

63-1

Blin

king

SA

S/O

PS

Tilt

switc

hes

sim

ulta

neou

sly

ON

Parti

al li

mita

tion

of m

ast c

ontro

l fun

ctio

n 19

-81

63-2

63-2

Blin

king

SA

S/O

PS

Tilt

switc

h fo

rwar

d til

t SW

sho

rt

63-3

63-3

Blin

king

SA

S/O

PS

Tilt

switc

h ba

ckw

ard

tilt S

W s

hort

64-1

64-1

Blin

king

SA

S/O

PS

Lift

low

er lo

ck s

olen

oid

open

circ

uit o

r loa

d sh

ort a

bnor

mal

ityLi

ft lo

wer

may

sto

p19

-84

65-1

65-1

Blin

king

SAS/

OPS

Tilt

cont

rol s

olen

oid

open

circ

uit o

r loa

d sh

ort a

bnor

mal

ityFo

rwar

d til

t may

sto

p, b

ackw

ard

tilt m

ay g

o fu

lly

back

19-8

6

66-1

66-1

Blin

king

SAS/

OPS

Out

side

mat

chin

g va

lue

rang

e fo

r tilt

ang

le e

rror

Par

tial l

imita

tion

of m

ast c

ontro

l fun

ctio

n19

-88

67-1

67-1

Blin

king

SA

S/O

PS

Lifti

ng h

eigh

t sw

itch

open

abn

orm

ality

Parti

al li

mita

tion

of th

e re

ar w

heel

sw

ing

cont

rol

func

tion

Parti

al li

mita

tion

of m

ast c

ontro

l fun

ctio

nLi

mita

tion

of th

e dr

ive

cont

rol f

unct

ion

Load

indi

cato

r dis

play

is u

nste

ady

19-8

9

68-1

68-1

Blin

king

SA

S/O

PS

Lift

switc

h ra

ise

and

low

er s

imul

tane

ousl

y O

N e

rror

Low

erin

g m

ay s

top

Func

tion

of a

utom

atic

idle

spe

ed in

cres

e du

ring

liftin

g lim

ited

19-9

268

-268

-2B

linki

ngS

AS

/OP

SLi

ft sw

itch

rais

e S

W s

hort

abno

rmal

ityFu

nctio

n of

aut

omat

ic id

le s

peed

incr

ese

durin

g lif

ting

limite

d

68-3

68-3

Blin

king

SA

S/O

PS

Lift

switc

h lo

wer

SW

sho

rt ab

norm

ality

Low

erin

g m

ay s

top

69-1

69-1

Blin

king

SA

S/O

PS

Back

war

d til

t loc

k so

leno

id o

pen

circ

uit o

r loa

d sh

ort

abno

rmal

ityB

ackw

ard

tilt m

ay s

top

19-9

5

71-1

71-1

Blin

king

SA

S/O

PS

Tire

ang

le s

enso

r ope

n ab

norm

ality

Knob

offe

st c

ompe

nsat

ion

stop

s19

-97

71-2

71-2

Blin

king

SA

S/O

PS

Tire

ang

le s

enso

r VC

C s

hort

abno

rmal

ity

72-1

72-1

Blin

king

SA

S/O

PS

Stee

ring-

whe

el a

ngle

sen

sor S

S1

open

abn

orm

ality

Knob

offe

st c

ompe

nsat

ion

stop

s19

-100

72-2

72-2

Blin

king

SA

S/O

PS

Stee

ring-

whe

el a

ngle

sen

sor S

S2

open

abn

orm

ality

72-3

72-3

Blin

king

SA

S/O

PS

Stee

ring-

whe

el a

ngle

sen

sor S

SC

ope

n ab

norm

ality

72-4

72-4

Blin

king

SAS/

OPS

Stee

ring-

whe

el a

ngle

sen

sors

SS1

and

SS2

ope

n ab

norm

ality

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age


Section 19

19-9

73-1

73-1

Blin

king

SA

S/O

PS

Knob

pos

ition

com

pens

atio

n so

leno

id o

pen

circ

uit o

r loa

d sh

ort

abno

rmal

ityKn

ob o

ffest

com

pens

atio

n st

ops

19-1

08

74-1

74-1

Blin

king

SA

S/O

PS

Out

side

mat

chin

g va

lue

rang

e fo

r tire

ang

le e

rror

Kno

b of

fest

com

pens

atio

n st

ops

19-1

10

A5-

1A

5-1

Blin

king

SA

S/O

PS

Sea

t sw

itch

GN

D s

hort

abno

rmal

ity

Trav

elin

g an

d m

ater

ial h

andl

ing

poss

ible

eve

n af

ter l

eavi

ng th

e se

at.

Park

ing

brak

e re

min

der a

nd re

leas

e re

min

der

alar

m p

artia

lly d

isab

led.

19-1

11

A7-

1A

7-1

Blin

king

SA

S/O

PS

Bra

ke s

witc

h G

ND

sho

rt ab

norm

ality

Par

tial l

imita

tion

of th

e dr

ive

cont

rol f

unct

ion

19-1

13

AD

-1AD

-1B

linki

ngS

AS

/OP

SC

AN

com

mun

icat

ion

4Y-E

CS

or A

SC

dat

a re

cept

ion

erro

rP

artia

l lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

n

19-1

15

AD

-2AD

-2B

linki

ng4Y

-EC

SC

AN

com

mun

icat

ion

SA

S/O

PS

dat

a re

cept

ion

erro

rP

artia

l lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

n

AD

-7AD

-7B

linki

ngS

AS

/OP

SC

AN

com

mun

icat

ion

disp

lay

data

rece

ptio

n er

ror

Lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

nFu

nctio

n of

aut

omat

ic id

le s

peed

incr

ese

durin

g lif

ting

limite

dD

ispl

ay w

arni

ng fu

nctio

n op

erat

ion

failu

re

AD

-8AD

-8–

Dis

play

CA

N c

omm

unic

atio

n S

AS

/OP

S d

ata

rece

ptio

n er

ror

Dis

play

not

sta

ble

AF-

1 ~

3A

F-1

~ 3

On

SA

S/O

PS

CPU

erro

rVa

rious

con

trol o

pera

tions

not

sta

ble

19-1

19A

F-4

~ 8

AF-

4 ~

8B

linki

ngS

AS

/OP

S

C4-

1C

4-1

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor 1

ope

n

Lim

ting

spee

d of

trav

elin

g an

d m

ater

ials

ha

ndlin

g du

e to

lim

ited

engi

ne p

ower

out

put

19-1

23

AS

C

C4-

2C

4-2

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor 1

sho

rtA

SC

C4-

3C

4-3

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor 2

ope

nA

SC

C4-

4C

4-4

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor 2

sho

rtA

SC

C4-

5C

4-5

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor o

ffset

abn

orm

ality

AS

C

C4-

6C

4-6

Blin

king

4Y-E

CS

Acc

eler

ator

sen

sor o

ut o

f ran

ge e

rror

C7-

1C

7-1

Blin

king

SA

S/O

PS

Shi

ft le

ver f

orw

ard

and

reve

rse

trave

l sw

itch

open

abn

orm

ality

Trav

el re

turn

to n

eutra

l ope

ratio

n di

sabl

edPa

rtial

lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

n.19

-126

C7-

2C

7-2

Blin

king

SA

S/O

PS

Shift

leve

r for

war

d an

d re

vers

e tra

vel s

witc

hes

sim

ulta

neou

sly

ON

erro

rTr

avel

ling

may

sto

pPa

rtial

lim

itatio

n of

the

driv

e co

ntro

l fun

ctio

n.

CA

-1C

A-1

Blin

king

SA

S/O

PS

Forw

ard

and

reve

rse

trave

l T/C

rela

y op

en c

ircui

t or l

oad

shor

t ab

norm

ality

Trav

ellin

g an

d m

ater

ial h

andl

ing

enab

led

even

af

ter l

eavi

ng th

e se

at.

19-1

29

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age


Section 19

19-10

EC-1

EC-1

Blin

king

SAS/

OPS

Unl

oad

sole

noid

ope

n ci

rcui

t or l

oad

shor

t abn

orm

ality

Trav

ellin

g an

d m

ater

ial h

andl

ing

enab

led

even

af

ter l

eavi

ng th

e se

at.

19-1

31

F1-1

–B

linki

ngM

eter

SA

S/O

PS

dat

a re

cept

ion

erro

rD

ispl

ay o

nly

19-1

33F2

-1–

Blin

king

F4-1

~ 8

F4-1

~ 8

Blin

king

Dis

play

CPU

erro

rD

ispl

ay n

ot s

tabl

e19

-134

H1-

1H

1-1

Blin

king

SAS/

OPS

Lift

leve

r pot

entio

met

er o

pen

abno

rmal

ity

Lift

stop

19-1

35

H1-

2H

1-2

Blin

king

SA

S/O

PS

Lift

leve

r pot

entio

met

er V

CC

sho

rt ab

norm

ality

H1-

3H

1-3

Blin

king

SA

S/O

PS

Lift

leve

r pot

entio

met

er a

ssem

bly

erro

r

H1-

4H

1-4

Blin

king

SA

S/O

PS

Lift

leve

r pot

entio

met

er n

eutra

l abn

orm

ality

Mat

eria

l han

dlin

g di

sabl

ed

H1-

5H

1-5

Blin

king

SA

S/O

PS

Lift

leve

r pot

entio

met

er m

atch

ing

valu

e ab

norm

ality

Lift

stop

H2-

1H

2-1

Blin

king

SAS/

OPS

Tilt

leve

r pot

entio

met

er o

pen

abno

rmal

ity

Tilt

stop

19-1

38

H2-

2H

2-2

Blin

king

SAS/

OPS

Tilt

leve

r pot

entio

met

er V

CC

sho

rt ab

norm

ality

H2-

3H

2-3

Blin

king

SA

S/O

PS

Tilt

leve

r pot

entio

met

er a

ssem

bly

erro

r

H2-

4H

2-4

Blin

king

SA

S/O

PS

Tilt

leve

r pot

entio

met

er n

eutra

l erro

r abn

orm

ality

Mat

eria

l han

dlin

g di

sabl

ed

H2-

5H

2-5

Blin

king

SA

S/O

PS

Tilt

leve

r pot

entio

met

er m

atch

ing

erro

rTi

lt st

op

H3-

1H

3-1

Blin

king

SA

S/O

PS

Atta

chm

ent 1

leve

r pot

entio

met

er o

pen

abno

rmal

ity

Atta

chm

ent 1

sto

p

19-1

41

H3-

2H

3-2

Blin

king

SA

S/O

PS

Atta

chm

ent 1

leve

r pot

entio

met

er V

CC

sho

rt ab

norm

ality

H3-

3H

3-3

Blin

king

SA

S/O

PS

Atta

chm

ent 1

leve

r pot

entio

met

er c

ombi

natio

n er

ror

H3-

4H

3-4

Blin

king

SA

S/O

PS

Atta

chm

ent 1

leve

r pot

entio

met

er n

eutra

l abn

orm

ality

Mat

eria

l han

dlin

g di

sabl

ed

H3-

5H

3-5

Blin

king

SA

S/O

PS

Atta

chm

ent 1

leve

r pot

entio

met

er m

atch

ing

valu

e ab

norm

ality

Atta

chm

ent 1

sto

p

H4-

1H

4-1

Blin

king

SA

S/O

PS

Atta

chm

ent 2

leve

r pot

entio

met

er o

pen

abno

rmal

ity

Leve

r 2 s

top

19-1

44

H4-

2H

4-2

Blin

king

SA

S/O

PS

Atta

chm

ent 2

leve

r pot

entio

met

er V

CC

sho

rt ab

norm

ality

H4-

3H

4-3

Blin

king

SA

S/O

PS

Atta

chm

ent 2

leve

r pot

entio

met

er c

ombi

natio

n er

ror

H4-

4H

4-4

Blin

king

SA

S/O

PS

Atta

chm

ent 2

leve

r pot

entio

met

er n

eutra

l abn

orm

ality

Mat

eria

l han

dlin

g di

sabl

ed

H4-

5H

4-5

Blin

king

SA

S/O

PS

Atta

chm

ent 2

leve

r pot

entio

met

er m

atch

ing

valu

e ab

norm

ality

Leve

r 2 s

top

H5-

1H

5-1

Blin

king

SAS/

OPS

Lift

PUSH

sol

enoi

d op

en a

bnor

mal

ityLi

ft m

ay s

top

19-1

47H

5-2

H5-

2Bl

inki

ngSA

S/O

PSLi

ft PU

LL s

olen

oid

open

abn

orm

ality

H6-

1H

6-1

Blin

king

SAS/

OPS

Tilt

PUSH

sol

enoi

d op

en a

bnor

mal

ityTi

lt m

ay s

top

19-1

49H

6-2

H6-

2Bl

inki

ngSA

S/O

PSTi

lt PU

LL s

olen

oid

open

abn

orm

ality

H7-

1H

7-1

Blin

king

SAS/

OPS

Atta

chm

ent 1

PU

SH s

olen

oid

open

abn

orm

ality

Atta

chm

ent 1

may

sto

p19

-151

H7-

2H

7-2

Blin

king

SA

S/O

PS

Atta

chm

ent 1

PU

LL s

olen

oid

open

abn

orm

ality

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age


Section 19

19-11

H8-

1H

8-1

Blin

king

SAS/

OPS

Atta

chm

ent 2

PU

SH s

olen

oid

open

abn

orm

ality

Atta

chm

ent 2

may

sto

p19

-153

H8-

2H

8-2

Blin

king

SA

S/O

PS

Atta

chm

ent 2

PU

LL s

olen

oid

open

abn

orm

ality

HA

-1H

A-1

Blin

king

SAS/

OPS

3/4

way

cha

nge

rela

y G

ND

sho

rt ab

norm

ality

Atta

chm

ent s

witc

hing

dis

able

d19

-155

Indi

catio

nW

renc

h la

mp

Span

ner

Det

ectio

n E

CU

Erro

r mod

ePh

enom

enon

on

vehi

cle

Des

crib

ed

on p

age


Section 19

19-12

WA

RN

ING

LIS

TC

autio

n:If

the

wre

nch

lam

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angl

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disa

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with

the

knob

sw

itch

in th

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posi

tion

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leve

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angl

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oper

ates

to fo

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chin

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Lift

stop

Lift

leve

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mat

chin

g

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Tilt

stop

Tilt

leve

r not

mat

chin

g

––

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SA

S/O

PS

Atta

chm

ent 1

sto

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ttach

men

t 1 n

ot m

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SA

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PS

Atta

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pA

ttach

men

t 2 n

ot m

atch

ing


Section 19

19-13

VIEWING RELATED PORTIONSIn the wiring diagrams for related portions, there are cases in which the parts are connected directly, and caseswhere they are connected via a junction block or similar. Refer below for how to identify wiring configuartions.

Example of a Related Portion

ERROR CONFIRMATION DRIVE MODE Turn the ignition key switch ON, start and completely warm up the engine. Fully depress the accelerator pedal for 3 to 5 minutes with the direction neutral. Release and leave the accelerator pedal (run the engine at idle) for 2 minutes. Repeat steps and 3 times. Turn the ignition key switch OFF (for 1 minute). Repeat steps to 3 times.

Enginecontroller

SAS/OPScontroller

8 (BATT)A21

1 (IG1)

28 (CAN+)29 (CAN-)

A36

Multifunction display

3 (BATT)

9 (IGSW)

2 (IG)

5 (CANH)

Q2

6 (CANL)3 (E1)

2 (IG2)

12 (CANH)13 (CANL)

: Direct connection: Connection via a junction

ECU-B

ECU-IG

EFI

IGN

A20

Engine speed

Idle

3 ~ 5 minutes 3 ~ 5 minutes 3 ~ 5 minutes

2 minutes 2 minutes 2 minutes

Warmed up

time

NMR

IGOFF

IGOFF


Section 19

19-1419-14

TROUBLESHOOTING BY ERROR CODE Error codes 01-1, 01-2 (Fuel feedback control abnormality) (Gasoline)

Related portion

Probable cause Intake system defect Fuel system defect Exhaust system defect Harness defect Sensor defect Engine controller defect Ignition defect

Caution:When another error code is present repair the related parts first before carrying out the following.

Error codes 01-1 and 01-2

TA

B

RE

CEnginecontroller O2 sensor

C120 (OX) 3 (OX)21 (E11) 4 (E1)

A3520 (OX) 4

7

AC2

Disconnect the battery negative terminal, disconnect TC terminal - E1 terminal, connect the battery negative terminal, start the engine, and check whether the error occurs after performing error confirmation drive mode (see 19-13).

No error

Error

NGInspection 1:Inspect the air intake

OK

Intake system defectIntake system connection defect

A

Disconnect the battery negative terminal (for more than 10 seconds). Check the connection status of C1, disconnect C1 and perform a visual and contact pressure inspection of the connector. Short circuit the service connector TC terminal with the E1 terminal, and after connecting C1 and the battery negative terminal (on a combination vehicle, switch the fuel changeover switch to gasoline), turn the ignition key switch ON (engine stopped), depress the accelerator pedal 5 times within 30 seconds (fully open to fully closed), then start the engine and check that the error has been cleared.

Service connector

Connector contact defect


Section 19

19-15

NGIntake pipe pressure sensor defect

Pressure regulator defectFuel filter defectFuel pump defect

NGInspection 4:Fuel pressure inspection

OK

NGInspection 5:Spark plug individual inspection

OK

Spark plug defect

NGInspection 6:Injector individual inspection

OK

Injector defect

OK

Inspection 7:Intake pipe pressure sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

NG

OK

Intake temperature sensor defectInspection 8:Intake temperature sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

A

NG

OK

Coolant temperature sensor defectInspection 9:Coolant temperature sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

NGInspection 10:Harness continuity and short circuit inspection

OK

Harness defect

NGInspection 3:Fuel leakage inspection

OK

Fuel system defectFuel system connection defect

NGInspection 2:Exhaust gas leakage inspection

Exhaust system defectExhaust system

OK

B


Section 19

19-1619-16

Inspection 1: Inspect for air suction.

Start the engine and check whether air is being sucked in from the engine oil level gauge, oil filler cap, or PCVhose etc.

Standard: There is no air being sucked in.Check if there is air being sucked in from the intake system parts and connections between the air cleaner andthe cylinder head.

Standard: There is no air being sucked in.

Inspection 2: Inspect for exhaust gas leakage.

Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connectionsbetween the cylinder head and the catalytic muffler.

Standard: There is no exhaust gas leakage.

Inspection 3: Inspect for fuel leakage.

Start the engine and check if there is any fuel leakage from the fuel system parts and connections between thefuel pump and the injectors.

Standard: There is no fuel leakage.

Inspection 4: Inspect the fuel pressure.

For the fuel pressure inspection, refer to the repair manual for the 4Y engine.

Inspection 5: Carry out a spark plug individual inspection.

For the spark plug individual inspection, refer to the repair manual for the 4Y engine.

Inspection 6: Carry out an injector individual inspection.

For the individual injector inspection, refer to the repair manual for the 4Y engine.

NG

OK

Engine controller defectInspection 12:O2 sensor voltage inspectionANL.:I/O ENGINE CTRL 9/10

O2 sensor defect

B

OK

NG

Connector contact defectInspection 11:O2 sensor voltage inspectionANL.:I/O ENGINE CTRL 9/10


Section 19

19-17

Inspection 7: Inspect the intake pipe pressure sensor voltage.

Ignition key switch ON, engine stoppedIntake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:

Inspection 8: Inspect the intake temperature sensor voltage.Ignition key switch ON, engine stopped

Intake temperature sensor voltage (I/O monitor: THA)

Standard:

Inspection 9: Inspect the coolant temperature sensor voltage.Start the engine, warm up completely (coolant temperature gauge: at 5-6 bars)

Coolant temperature sensor voltage (I/O monitor: THW)

Standard:

Inspection 10: Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect battery negative terminal, disconnect A35 and C1.

Standard:

Inspection 11: Inspect the O2 sensor output.

Connect A35 and C1, start the engine, warm up completely, set direction in neutral, fully open the acceleratorpedalO2 sensor voltage (I/O monitor: OX)

Standard:


Disconnect C1, connect A35, start the engine, warm up completely, set direction in neutral, fully open theaccelerator pedalO2 sensor voltage (I/O monitor: OX)

Standard:

PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])

THA2.4 ± 0.6 V (20 ± 10°C)

0.55 ± 0.15 V (80 ± 10°C) (reference value)

THW0.55 ± 0.15 V (80 ± 10°C)


A35-20 ~ C1-3 Continuity


A35-20 ~ Frame No continuity

OX 0.4 V or less and 0.5 V or more alternately output

OX 0.2 V or less


Section 19

19-1819-18

Error codes 01-3, 01-4 (Fuel feedback control abnormality) (LPG/CNG)Related portion

Probable cause Intake system defect Fuel system defect Exhaust system defect Harness defect Sensor defect Engine controller defect Ignition defect

Caution:When another error code is occuring, repair the related parts first before carrying out the following.

Error codes 01-3 and 01-4TA

B

RE


C120 (OX) 3 (OX)21 (E11) 4 (E1)

A3520 (OX) 4

7

AC2


No error

Error

NGInspection 1:Inspect the air intake

OK

Intake system defectIntake system connection defect

A



Service connector


Section 19

19-19


OK

Harness defect

Regulator defectNGInspection 4:

Regulator primary pressure inspection

OK

NGInspection 5:Spark plug individual inspection

OK

Spark plug defect

NGInspection 6:Injector individual inspection

OK

Injector defect

NG

OK

Intake pipe pressure sensor defectInspection 8:Intake pipe pressure sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

NG

OK

Intake temperature sensor defectInspection 9:Intake temperature sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

A

NG

OK

Water temperature sensor defectInspection 10:Water temperature sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10

NGInspection 3:Fuel leakage inspection

OK

Fuel system defectFuel system connection defect

NGInspection 2:Exhaust gas leakage inspection

Exhaust system defectExhaust system connection defect

OK

B

NGInspection 7:Air-fuel ratio motor individual inspection

OK

Air-fuel ratio motor defect


Section 19

19-2019-20

Inspection 1: Inspect for air suction.

Start the engine and check whether air is being sucked in from the engine oil level gauge, oil filler cap, or PCVhose etc.

Standard: There is no air being sucked in.Check if there is air being sucked in from the intake system parts and connections between the air cleaner andthe regulator.

Standard: There is no air being sucked in.Check if there is air being sucked in from the intake system parts and connections among the air cleaner hose,the resonator, and the regulator.

Standard: There is no air being sucked in.

Inspection 2: Inspect for exhaust gas leakage.

Start the engine and check if there is any exhaust gas leakage from the exhaust system parts and connectionsbetween the cylinder head and the catalytic muffler.

Standard: There is no exhaust gas leakage.

Inspection 3: Inspect for fuel leakage.

Start the engine and check if there is any fuel leakage from the fuel system parts and connections between thefuel tank and the regulator.

Standard: There is no fuel leakage.Check if there is fuel leakage from the fuel system parts and connections between the regulator and the LPGadapter.

Standard: There is no fuel leakage.Check if there is fuel leakage from the fuel system parts and connections between the regulator and the injector.

Standard: There is no fuel leakage.

Inspection 4: Inspect the regulator primary pressure.

For the regulator primary pressure inspection, refer to the LPG repair manual.

NG

OK

Engine controller defectInspection 13:O2 sensor voltage inspectionANL.:I/O ENGINE CTRL 9/10

O2 sensor defect

B

OK

NG

Connector contact defectInspection 12:O2 sensor voltage inspectionANL.:I/O ENGINE CTRL 9/10


Section 19

19-21

Inspection 5: Carry out a spark plug individual inspection.

For the spark plug individual inspection, refer to the repair manual for the 4Y engine.

Inspection 6: Carry out an injector individual inspection.

For the individual injector inspection, refer to the repair manual for the 4Y engine.

Inspection 7: Carry out an individual inspection of the air-fuel ratio motor.

For the individual air-fuel ratio motor inspection, refer to the LPG repair manual.


Ignition key switch ON, engine stoppedIntake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:

Inspection 9: Inspect the intake temperature sensor voltage.

Ignition key switch ON, engine stoppedIntake temperature sensor voltage (I/O monitor: THA)

Standard:

Inspection 10: Inspect the coolant temperature sensor voltage.

Start the engine, warm up completely (coolant temperature gauge: 5-6 bars)Coolant temperature sensor voltage (I/O monitor: THW)

Standard:


Ignition key switch OFF, disconnect A35 and C1

Standard:

PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])

THA2.4 ± 0.6 V (20 ± 10°C)


THW0.55 ± 0.15 V (80 ± 10°C)






Section 19

19-2219-22


Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedalO2 sensor voltage (I/O monitor: OX)

Standard:


Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedalO2 sensor voltage (I/O monitor: OX)

Standard:

OX 0.4 V or less and 0.5 V or more alternately output

OX 0.2 V or less


Section 19

19-23

Error code 01-5 (O2 sensor open abnormality)Related portion

Probable cause O2 Sensor defect Harness defect Engine controller defect

Caution:When another error code is present, repair the related parts first before carrying out the following.

Error code 01-5TA

B

RE


C120 (OX) 3 (OX)21 (E11) 4 (E1)

A3520 (OX) 4

7

AC2


If the error occurs even after replacing the O2 sensor

Harness defect

O2 sensor defect

OK

Engine controller defect


No error

Error



Service connector


Section 19

19-2419-24



Standard:A35-20 ~ C1-3 Continuity




Section 19

19-25

Error code 01-6 (O2 sensor heater open abnormality)Related portion

Probable cause O2 Sensor defect Harness defect Engine controller defect

Error code 01-6

TA

B

RE

C

Enginecontroller

A35

6 (HT)9 O2

sensor

C1

12

R/B EFI Main relay

EFImain relay

AC2

1

No errorConnector contact defect

Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of C1, AC2, reconnect all connectors and battery negative terminal, turn the ignition key switch ON (start the engine), and check whether or not there is an error.

Turn the ignition key switch ON.(Start and run the engine for more than 10 seconds.)

Turn the ignition key switch OFF for more than10 seconds.

Turn the ignition key switch ON.(Start and run the engine for more than 10 seconds.)

Check for errors.

NGInspection 1:O2 sensor individual inspection O2 sensor defect

OK

NGInspection 2:O2 sensor heater power voltage inspection Harness defect

OK

NGInspection 3:Harness continuity and short circuit inspection Harness defect


OK

Error


Section 19

19-2619-26

Inspection 1: Carry out O2 sensor individual inspection.

Ignition key switch OFF, disconnect C1, connect A35

Standard: (Sensor side)

Inspection 2: Carry out O2 sensor heater power voltage inspection.

Ignition key switch OFF, diconnect C1, connect A35, start engine

Standard:



Standard:

C1-2 ~ C1-1 13 ~ 16 Ω (20°C)

C1-2 ~ Frame 8 ~ 16 V



12

34

C1


Section 19

19-27

Error codes 02-1, 02-2 (Intake temperature sensor abnormality)Related portion

Probable cause Intake temperature sensor defect Harness defect Engine controller defect

Inspection 1: Carry out intake temperature sensor individual inspection..

Ignition key switch OFF, disconnect C3, connect A35



C3-1 ~ C3-22.45 ± 0.24 kΩ (20°C)

0.32 ± 0.03 kΩ (80°C)

TA

B

RE

CEnginecontroller

A35 C329 (THA) 2 (THA)28 (E2) 1 (E2)

Intake temperature

sensor

610

AC2

NGInspection 1:Intake temperature sensor individual inspection Intake temperature sensor defect

OK



OK

Error


Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of C3, AC2, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.

12

C3


Section 19

19-2819-28



Standard:A35-29 ~ C3-2 Continuity




Section 19

19-29

Error codes 03-1, 03-2 (Intake pipe negative pressure sensor abnormality)Related portion

Probable cause Intake pipe negative pressure sensor defect Harness defect Engine controller defect


Ignition key switch OFF, disconnect A35 and G12

Standard:


A35-18 ~ G12-2 Continuity


A35-18 ~ A35-17 No continuity




TA

B

RE

C

Enginecontroller

A3517 (VC)18 (PIM)28 (E2)

3 (VC)G12

2 (PIM)1 (E2)

Intake pipe pressure

sensor

158

AG1

Error

Intake pipe pressure sensor defect

Engine controller defectNG

OK

Inspection 2:Intake pipe pressure sensor voltage inspectionANL.: I/O ENGINE CTRL 3/10


OK


Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of G12, AG1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.


Section 19

19-3019-30


Ignition key switch OFF, disconnect G12, connect A35, ignition key switch ON, engine stoppedIntake pipe pressure sensor voltage (I/O monitor: PIM)

Standard:PIM 4.80 V or more


Section 19

19-31

Error codes 04-1, 04-2 (Coolant temperature sensor abnormality)Related portion

Probable cause Coolant temperature sensor defect Harness defect Engine controller defect

Inspection 1: Carry out coolant temperature sensor individual inspection.




G16-1 ~ G16-22.45 ± 0.24 kΩ (20°C)

0.32 ± 0.03 kΩ (80°C)

TA

B

RE

C

Enginecontroller

Coolant temperature

sensor

A35

19 (THW) 2 (THW)

28 (E2) 1 (E2)

G16

1

AG1

Error

NGInspection 1:Water temperature sensor individual inspection Water temperature sensor defect

OK



OK




Section 19

19-3219-32



Standard:A35-19 ~ G16-2 Continuity




Section 19

19-33

Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6 (Throttle position sensor abnormality)Related portion

Probable cause Throttle position sensor defect Harness defect Engine controller defect

Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6

G6

Enginecontroller

G2720 (VC2)21 (VTA)29 (VTA2)28 (E21)

4 (VTA2)3 (E2)

Throttleposition sensor

5 (VC)6 (VTA)

Error

Throttle position sensor defect

NG

OK



OK


Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of G6, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.

Inspection 2:Throttle position sensor voltage inspectionANL.: I/O ENGINE CTRL 5/10


Section 19

19-3419-34


Ignition key switch OFF, disconnect G27 and G6

Standard:

Inspection 2: Inspect the throttle position sensor voltage.

Ignition key switch OFF, disconnect G6, connect G27, ignition key switch ONThrottle position sensor voltage (I/O monitor: VTA1, VTA2)

Standard:

G27-21 ~ G6-6 Continuity


G27-21 ~ G27-20 No continuity


G27-21 ~ Frame No continuity








VTA1, VTA2 4.80 V or more


Section 19

19-35

Error codes 06-1, 06-2 (Throttle motor drive circuit open/short abnormality)Related portion

Probable cause Throttle motor defect Harness defect Engine controller defect

Error codes 06-1 and 06-2R

EC

TAB

2 (M+)1 (M-)

Enginecontroller

Throttlemotor

E-THRO

G277 (+BM)

6 (M+)5 (M-)4 (ME01)

G613

AG1

Error

NGInspection 1:Throttle motor individual inspection Throttle motor defect

OK


OK





Section 19

19-3619-36

Inspection 1: Carry out throttle motor individual inspection.

Ignition key switch OFF, disconnect G6, connect G27

(1) Throttle motor resistance inspection

Standard: (Motor side)

(2) Throttle valve drive condition

Standard:Throttle valve operates smoothly when fully opened.Throttle valve operates smoothly when fully closed.When you remove your hand from the throttle valve, it returns to the opener angle.



Standard:

G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)








123456

G6


Section 19

19-37

Error codes 06-3, 06-4 (Throttle motor power circuit open/short abnormality)Related portion

Probable cause Harness defect Engine controller defect

Inspection 1: Inspect the throttle motor power voltage.

Ignition key switch OFF, disconnect G27

Standard:


G27-7 ~ Frame 8 ~ 16 V

RE

C

TA

BEnginecontroller

E-THRO

G27

7 (+BM)AG1

13

Error

NGInspection 1:Throttle motor power voltage inspection Harness defect

OK





Section 19

19-3819-38

Error code 06-5 (Throttle motor seized abnormality)Related portion

Probable cause Throttle motor defect Harness defect Engine controller defect

Inspection 1: Carry out throttle motor individual inspection.


(1) Throttle motor resistance inspection

Standard: (Motor side)

(2) Throttle valve drive condition

Standard:Throttle valve operates smoothly when fully opened.Throttle valve operates smoothly when fully closed.When you remove your hand from the throttle valve, it returns to the opener angle

Error code 06-5

G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)

RE

CTA

B

2 (M+)1 (M-)

Enginecontroller

Throttlemotor

E-THRO

G277 (+BM)

6 (M+)5 (M-)4 (ME01)

G613

AG1

NGInspection 1:Throttle motor individual inspection Throttle motor defect

OK


OK


Error



123456

G6


Section 19

19-39



Standard:G27-6 ~ G27-5 No continuity




Section 19

19-4019-40

Error code 06-6 (Electronic throttle abnormality)Related portion

Probable cause Engine controller defect

Error code 06-6

Enginecontroller


No errorDisconnect the negative terminal of the battery for 10 seconds or more. Reconnect the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.


Error


Section 19

19-41

Error code 07-1 (Air-fuel ratio motor open abnormality)Related portion

Probable cause Air-fuel ratio motor defect Harness defect Engine controller defect

Error code 07-1

Enginecontroller

Air-fuel ratio

motor

EFImain relay

21 (FCM1)31 (FCM2)20 (FCM3)

30 (FCM4)

3 (FCM1)6 (FCM2)1 (FCM3)

4 (FCM4)

2 (B1)5 (B2)

R/B EFI Main relay

3 (L)

G13

G28

NGInspection 1:Air-fuel ratio motor individual inspection Air-fuel ratio motor defect

OK


OK


Error




Section 19

19-4219-42

Inspection 1: Carry out an individual inspection of the air-fuel ratio motor.

(1) Air-fuel ratio motor resistance inspectionIgnition key switch OFF, disconnect G13, connect G28

Standard: (Air-fuel ratio motor side)

(2) Valve operation checkConnect the battery positive terminal to G13-2 and G13-5 and ground in the following terminal order.

Standard: (Air-fuel ratio motor side)G13-3→G13-6→G13-1→G13-4: Moves to the close sideG13-4→G13-1→G13-6→G13-3: Moves to the open side


Ignition key switch OFF, disconnect G28, G13 and R/B main relay

Standard:

G13-2 ~ G13-1

20 ± 5 Ω (-10 ~ 50°C)25 ± 5 Ω (50 ~ 100°C)

G13-2 ~ G13-3

G13-5 ~ G13-4

G13-5 ~ G13-6





G13-2 ~ R/B main relay terminal 3 Continuity

G13-5 ~ R/B main relay terminal 3 Continuity





3 2 1

6 5 4

G13


Section 19

19-43

Error code 08-1 (Low voltage abnormality)Related portion

Probable cause Harness defect Engine controller defect


Ignition key switch OFF, disconnect A36

Standard:

Error code 08-1

A36-3 ~ EFI Continuity


Enginecontroller

EFI

A36

3 (BATT)


OK


Error


Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of A36, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.


Section 19

19-4419-44

Error code 09-1 (Ignition signal abnormality)Related portion

Probable cause Ignition coil Igniter defect Harness defect Engine controller defect

Enginecontroller

Igniter

Ignition coil

G27

G21

G25

33 (IGT)32 (IGF)

3 (IG2)5 (IG1)

2 (IG-)1 (IG+)

2 (IGT)1 (IGF)

IGN


Section 19

19-45

Inspection 1: Carry out an ignition signal (IGF) inspection.

Ignition key switch OFF, disconnect G25, connect G27, ignition key switch ON, enginestopped

Standard:

Error code 09-1

G25-1 ~ Frame 4.0 ~ 5.5 V

Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection of G21 and G25 and internal leakage, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON to start the engine.

Engine will not start

Enginestarts

Operate the accelerator pedal and check whether there is an error.

Error


OK

Igniter defect

NGInspection 1:Ignition abnormality signal (IGF) inspection

Harness defect

OK



Ignition coil defect

OK

NGInspection 3:Ignition coil individual inspection

Harness defect

OK


Engine controller defectNG

OK

Igniter defect

Inspection 5:Igniter IGT signal inspection

OKOKOK

12345

G25


Section 19

19-4619-46



Standard:

Inspection 3: Carry out distributor individual inspection.

Ignition key switch OFF, disconnect G21 and G25, connect G27

Standard:


Ignition key switch OFF, disconnect G27, G21 and G25

Standard:

Inspection 5: Carry out an igniter (IGT) signal inspection.

Ignition key switch OFF, disconnect G21 and G25, connect G27, ignition key switchON, (cranking)

Standard:



Primary side (G21-1 ~ G21-2) 1.2 ~ 1.5 Ω

Secondary side (IIA inner terminal) 7.7 ~ 10.4 Ω









G25-5 ~ frame No continuity

G25-3 ~ frame No continuity

G25-2 ~ Frame Not 0 V

12

G21

12345

G25


Section 19

19-47

Error code 0A-1, 0A-2, 0A-3 (Fuel specification determination abnormality)Related portion

Probable cause Fuel changeover switch defect Harness defect Engine controller defect

Error codes 0A-1, 0A-2, 0A-3

Enginecontroller

14 (GAS)13 (LPG)

G28

G2715 (SEL1)

14 (SEL2)

13 (SEL3)12 (SEL4)10 (ESEL)

3 (GAS)1 (LPG) Fuel

changeover switch2 (IG)

3 (L) EFImain relay

G88

NGInspection 2:Fuel changeover switch individual inspection Fuel changeover switch defect

OK


OK


Error

No error Connector contact defect


OK

Inspection 1:Switch input signal inspectionANL.: I/O ENGINE CTRL 1/10


Section 19

19-4819-48

Inspection 1: Carry out switch input signal inspection.

Ignition key switch ONSwitch input signal (I/O monitor: G/LP, SEL1-4)

Standard:

Inspection 2: Carry out fuel changeover switch individual inspection.(Carry out only for convertible vehicles, and only when the G/LP input in inspection 1 is outsidethe standard value)

Ignition key switch OFF, disconnect G88, connect G28 and G27

Standard: (Switch side)

Inspection 3: Inspect for continuity and short circuiting of the harness. (Begin with the place that was outside the standardvalue in inspection 1)


Vehicle specification Fuel changeover switch G/LP SEL

Gasoline specification – 10 1100

LPG exclusive – 01 0101

LPG/Gasoline convertible

Gasoline selection 10

0110LPG selection 01

Neutral 00

Gasoline/CNG convertible

Gasoline selection 10

0101CNG selection 01

Neutral 00

Fuel changeover switch

Gasoline LPG/CNG Neutral

G88-2 ~ G88-3 Continuity No continuity No continuity

G88-2 ~ G88-1 No continuity Continuity No continuity

Vehicle specificationHarness

SEL1 SEL2 SEL3 SEL4

Gasoline specificationShort circuit to

ESELShort circuit to

ESEL– –

LPG exclusiveShort circuit to



ESEL–

LPG/Gasoline convertible –Short circuit to


ESEL–

Gasoline/CNG convertible –Short circuit to

ESEL–

Short circuit to ESEL

G88


Section 19

19-49

Error code 0A-4 (Engine specification determination abnormality)Related portion

Probable cause Engine controller defect

Error code 0A-4

Enginecontroller


No errorNormal

Error

Disconnect the battery negative terminal (for 10 seconds or more), reconnect the battery negative terminal, then turn the ignition key switch ON (start the engine) and check whether or not there is an error.


Section 19

19-5019-50

Error codes 13-1, 13-2, 13-3 (Relay abnormality)Related portion

Probable cause Connector contact defect ASC relay defect Harness defect ASC controller defect

Error codes 13-1, 13-2, 13-3R

EC

TA

B

RE

C

TA

B

ASC controller

G385 (SRLY)

13 (E12)

2 (MEN+)

IGN

1

5

3

2ASC relay

Step motor

R/B ASC relay

G373 (B)

AG2

13

AG2

2

NGInspection 1:ASC relay individual inspection ASC relay defect

OK


OK

ASC controller defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of G38, AG2 and the ASC relay, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.

Connector contact defectASC relay not plugged in properly


Section 19

19-51

Inspection 1: Carry out ASC relay individual inspection.

Ignition key switch OFF, remove ASC relay

Standard: (Relay side)


Ignition key switch OFF, disconnect G38, remove ASC relay

Standard:

At all times1 ~ 2 terminals Continuity (approx. 90 Ω)

3 ~ 5 terminals No continuity

When battery voltage is applied

between terminals 1 ~ 23 ~ 5 terminals Continuity

G38-2 ~ ASC relay terminal 5 Continuity

ASC relay terminal 3 ~ IGN Continuity

G38-2 ~ BATT No continuity

G38-5 ~ ASC relay terminal 1 Continuity



G38-5 ~ BATT No continuity

ASC relay terminal 2 ~ Frame Continuity

ASC relay


Section 19

19-5219-52

Error codes 15-1 and 15-2 (NMR switch abnormality)Related portion

Probable cause Connector contact defect NMR switch defect Harness defect ASC controller defect Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)

RE

CTA

B

G39

12 (NMR)

G3621

ASC controller

IGN

NMR switch

Starting motor relay2 (STA) 1

R/B Starting motor relayAG2

3


Section 19

19-53

Inspection 1: Carry out an NMR switch individual inspection.



Error codes 15-1, 15-2

Switch OFF Switch ON

G36-1 ~ G36-2 No continuity Continuity

Reconnect the connectors and the battery negative terminal, then repeat the operations to below several times and check whether an error occurs.

Turn the ignition key switch ON (engine stopped) Operate the accelerator pedal ON/OFF (several

times) Start the engine with the accelerator fully

depressed Release the accelerator pedal and turn the

ignition key switch OFF


NGInspection 1:NMR switch individual inspection NMR switch defect

OK


OK

NGASC controller defect

Inspection 3:Inspection of the status of the NMR switch which is detected by ASC controllerANL.: I/O ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection items such as link catching or switch position adjustment.

Error

Disconnect the battery negative terminal, then inspect and repair disconnection of G36, G39, AG2 and starting motor relay and any water entry.

G36


Section 19

19-5419-54


Ignition key switch OFF, disconnect G36, G39 and starting motor relay

Standard:

Inspection 3: Carry out inspection of the status of the NMR switch in the controller.

Ignition key switch OFF, remove NMR switch so that it can be turned ON and OFF manually,connect G39 and G36, ignition key switch ONNMR switch (I/O monitor: NMR)

Standard:


IGN ~ G36-2 Continuity

G39-2 ~ Starting motor relay terminal 1 Continuity

G39-12 ~ IGN No continuity

Analyzer display Switch OFF Switch ON

NMR 0 1


Section 19

19-55

Error code 15-3 (NMR switch abnormality)Related portion

Probable cause Connector contact defect NMR switch defect Idle switch defect Harness defect ASC controller defect Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)

IGN

G39

12 (NMR)

ASC controller

15 (ZERO)

G36

12

NMR switch

Idle switch34


Section 19

19-5619-56

Inspection 1: Carry out an NMR and idle switch individual inspection.





Standard:

Error code 15-3




G39-12 ~ IG No continuity

G39-15 ~ IG No continuity



times) Turn the ignition key switch OFF


NGInspection 1:NMR and idle switch individual inspection

NMR switch defectIdle switch defect

OK

NGInspection 2:Carry out harness continuity and short circuit inspection

Harness defect

OK


Inspection 3:Inspection of the status of the NMR and idle switches in the controllerANL.: I/O ENGINE CTRL 1/3

OK


Error

Disconnect the battery negative terminal, then inspect and repair disconnection of G39 and G36 and any water entry.

G36


Section 19

19-57

Inspection 3: Carry out inspection of the status of the NMR and idle switches which is detected by controller.

Ignition key switch OFF, remove NMR and idle switches so that they can be turned ON and OFF manually,connect G36 and G39, ignition key switch ONNMR and idle switches (I/O monitor: NMR, IDLE)

Standard:Analyzer display Switch OFF Switch ON

NMR 0 1

IDLE 0 1


Section 19

19-5819-58

Error codes 16-1 and 16-2 (Idle switch abnormality)Related portion

Probable cause Connector contact defect Idle switch defect Harness defect ASC controller defect Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)

Note:In the case where a 13-1 error is present, service that error first before dealing with this one.

IGN

G39

15 (ZERO)

ASC controllerG37

11 (NINA)12 (NINB)3 (INA)4 (INB)

G36

34

Idle switch

Step motor

2 (NIA)1 (NIB)5 (IA)4 (IB)

G38


Section 19

19-59

Inspection 1: Carry out idle switch individual inspection.








times) Turn the ignition key switch OFF

No error

NGInspection 1:Idle switch individual inspection Idle switch defect

OK

NGInspection 2:Carry out harness continuity and short circuit inspection

Harness defect

OK


Inspection 3:Inspection of the status of the idle switch which is detected by controllerANL.: I/O ENGINE CTRL 1/3

OK


Error

Disconnect the battery negative terminal, then inspect and repair disconnection and water entry of G39, G36 and G37.


G36


Section 19

19-6019-60


Ignition key switch OFF, disconnect G36, G37, G38 and G39

Standard:

Inspection 3: Carry out inspection of the status of the idle switch which is detected by controller.

Ignition key switch OFF, remove idle switch so that it can be turned ON and OFF manually, connect G36 andG39, ignition key switch ONIdle switch (I/O monitor: IDLE)

Standard:


IGN ~ G36-4 Continuity






G38-11 ~G38-12 No continuity














Analyzer display Switch OFF Switch ON

IDLE 0 1


Section 19

19-61

Error codes 18-1, 18-2 (4Y engine: Cam angle sensor abnormality)Related portion

Probable cause Distributor (cam angle sensor) defect Starter defect Defect in the part connecting the starter and engine Harness defect Engine controller defect

Caution:If the engine does not crank, troubleshoot "Does not crank (see 19-156)" first.


Engine controller

Igniter

Distributor

IGN

G27

G25

31 (NE+)30 (NE-)

3 (IG2)5 (IG1)

2 (IG-)1 (IG+)

G21

G191 (NE)2 (NE-)

NGInspection 1:Distributor individual inspection Distributor (cam angle sensor) defect

OK

NGInspection 2:Timing rotor operation inspection

Starter defectDefect in the part connecting the starter and engine

OK


Error


OK

No error




Section 19

19-6219-62

Inspection 1: Carry out distributor individual inspection.

Ignition key switch OFF, disconnect G19 and G21, connect G27

(1) Pickup coil (2 in series) resistance measurement

Standard: (Distributor side)

(2) Inspection of the air gap between the pickup coils and the timing rotor

Standard: 0.2 ~ 0.4 mm (0.008 ~ 0.016 in)

Inspection 2: Inspect the timing rotor operation.

Disconnect G19 and G21, connect G27, ignition key switch ON

Standard: Timing rotor rotates during cranking



Standard:

G19-1 ~ G19-2 460 ± 50 Ω

12

G19





Section 19

19-63

Error code 18-3 (4Y engine: Crank angle sensor abnormality)Related portion

Probable cause Crank angle sensor defect Harness defect Engine controller defect

Error code 18-3

Engine controller

Crank anglesensor

G2711 (G2) 1 (G2)22 (G-) 2 (G-)

G18


OK

NGInspection 2:Crank angle sensor individual inspection Crank angle sensor defect

OK


No error Normal(Entry of foreign matter etc.)

Error

Inspection 3:Crank angle sensor installation inspection

Install the crank angle sensor, connect G27, G18 and battery negative terminal, start the engine.Check whether an error occurs.

Error

No error




Section 19

19-6419-64



Standard:

Inspection 2: Carry out crank angle sensor individual inspection.



Inspection 3: Carry out crank angle sensor installation inspection.


Standard:Remove the crank angle sensor, ensure that there is no foreign matter etc. adhereing to the sensor part.If there is remove it.




G18-1 ~ G18-2 1100 ± 150 Ω

12

G18


Section 19

19-65

Error codes 18-1, 18-2 (1DZ-II, 2Z engines: NE sensor abnormality)Related portion

Probable cause Connector contact defect Engine speed sensor defect Harness defect ASC controller defect

Caution:In the event that the engine stops while traveling, when the ignition key switch is turned from OFF to ON, an18-2 error may be detected, however this is not a fault.Stop the vehicle, turn the ignition key switch OFF and restart the engine.



Standard:





ASC controllerEngine speedsensor (NE sensor)

G399 (NE+) 2 (NE)22 (NE-) 1 (NE-)

G31


OK

NGInspection 2:Engine speed sensor individual inspection Engine speed sensor defect

OK

Error


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of G31 and G39, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.



Section 19

19-6619-66

Inspection 2: Carry out engine speed sensor individual inspection.


Standard: (Sensor side)G31-1 ~ G31-2 Approx. 1 kΩ

2 13

G31


Section 19

19-67

Error codes 1F-1, 1F-2, 1F-3, 1F-4, 1F-5, 1F-6, 1F-7, 1F-8 (CPU abnormality)Related portion

Probable cause ASC controller defect

ASC controller


Section 19

19-6819-68

Error code 41-1 (Matching connector abnormality)Related portion

Probable cause Connector contact defect Matching connector harness defect SAS/OPS controller defect

Inspection 1: Inspect for continuity of the harness.

Ignition key switch OFF, disconnect A20, A45 and A46

Standard:

Error code 41-1

A20-24 ~ A45-1 Continuity


SAS/OPS controller

Matchingconnector

A2024 (MAT)

1 (E3)

1

1

A45

A46

NG

OK

Inspection 1:Harness continuity check Harness defect

SAS/OPS controller defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection of A20 and A45 internal moisture, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.



Section 19

19-69

Error codes 51-1, 51-2 (Speed sensor abnormality)Related portion

Probable cause Connector contact defect Harness defect Speed sensor defect SAS/OPS controller defect

Inspection 1: Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,engine stopped

51-1 displayed → to inspection 2No error displayed → Speed sensor error

Error code 51-1

SAS/OPScontroller

Speedsensor

A2122 (SP1+)23 (SP1-)

12

A19

Speed sensor defectInspection 1:Speed sensor inspection

Error

No error

Harness defectInspection 2:Harness continuity and short circuit inspection

OK

NG


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A19 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.



Section 19

19-7019-70


Ignition key switch OFF, disconnect A19 and A21

Standard:

Inspection 1: Ignition key switch OFF, disconnect A19, ignition key switch ON, engine stopped

51-2 displayed → to next inspection51-1 displayed → Speed sensor defect



Standard:





Error code 51-2





Sensor defectInspection 1:Speed sensor inspection

51-2 is displayed

51-1 is displayed

OK



Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection of A19 and A21 and internal moisture, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.


Harness defect


Section 19

19-71

Error codes 52-1, 52-2, 52-3 (Yaw rate sensor abnormality)Related portion

Probable cause Connector contact defect Yaw rate sensor harness defect Yaw rate sensor defect SAS/OPS controller defect

Inspection 1: Ignition key switch OFF, disconnect O1, use SST 09232-13130-71 to short circuit O1-1 and O1-3, ignition keyswitch ON, engine stopped

52-1 displayed → to inspection 252-2 displayed → Yaw rate sensor defect

Error code 52-1

TA

B

RE

C

26 (YRS-)SAS/OPScontroller

Yaw-ratesensor

A2124 (YRS+)25 (YRS)

1O1

32

465

AO1

Yaw rate sensor defectInspection 1:Yaw rate sensor inspection

52-1 is displayed

52-2 is displayed


OK

NG


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of O1, AO1 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.



Section 19

19-7219-72

Inspection 2: Inspect for continuity and short circuiting of the harness.Ignition key switch OFF, disconnect O1 and A21Standard:

Inspection 1: Inspect for continuity and short circuiting of the harness.Ignition key switch OFF, disconnect O1 and A21Standard:

Inspection 2: Yaw-rate sensor inspectionIgnition key switch OFF, disconnect A21 and O1, use SST 09232-13130-71 to short circuit O1-2 to O1-3 (mainharness side)Standard:

A21-25 ~ O1-3 ContinuityA21-26 ~ O1-2 ContinuityA21-24 ~ O1-1 Continuity

A21-24 ~ Frame No continuityA21-25 ~ Frame No continuityA21-26 ~ Frame No continuity


A21-25 ~ O1-3 ContinuityA21-26 ~ O1-2 ContinuityA21-24 ~ O1-1 Continuity

A21-24 ~ Frame No continuityA21-25 ~ Frame No continuityA21-26 ~ Frame No continuity

A21-25 ~ A21-26 ContinuityA21-25 ~ Frame No continuityA21-26 ~ Frame No continuity


OK

NG


Turn the ignition key switch OFF, disconnect the battery negative terminal, disconnect O1, connect the battery negative terminal, turn the ignition key switch ON (engine stopped), check whether the error changes.

52-2 or 52-3

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of O1, AO1 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.


Inspection 2:Yaw-rate sensor inspection

Yaw-rate sensor defect

Continuity

No continuity

52-1


Section 19

19-73

Error code 54-1 (Swing lock solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Swing lock solenoid defect SAS/OPS controller defect

*: Make sure that no error is displayed when driving in a circle or during repeated left and right turns.

Inspection 1: Carry out swing lock solenoid individual inspection.

Ignition key switch OFF, disconnect Z1

Standard: (Solenoid side)

Error code 54-1

Z1-1 ~ Z1-2 Approx. 6 Ω (20°C)

TA

B

RE

C

RE

C

TA

B

SAS/OPS controller

Swing lock solenoid

A20

8 (E01)

1

9 (E02)

22 (SWN-)3 (SWN+)

Z172

ZO11213

AO1

NGInspection 1:Swing lock solenoid individual inspection

OK


OK


Swing lock solenoid defect

Harness defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A20, AO1, ZO1 and Z1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.


2 1

Z1


Section 19

19-7419-74


Ignition key switch OFF, disconnect Z1 and A20

Standard:A20-3 ~ Z1-1 Continuity

A20-2 ~ Z1-2 Continuity




Section 19

19-75

Error codes 61-1, 61-2 (Load sensor abnormality)Related portion

Probable cause Connector contact defect Load sensor defect Harness defect SAS/OPS controller defect

Inspection 1: Carry out load sensor individual inspection.

Ignition key switch OFF, disconnect A18, use SST 09230-13700-71 to short circuit A18-1 and A18-2 (main harness side), ignitionkey switch ON, engine stopped61-1 displayed → to inspection 261-2 displayed → load sensor defect

Error code 61-1

5 (E2)SAS/OPS controller Load sensor

A2119 (5PRS)27 (PRES)

1 (B)A18

2 (P)3 (E)

No continuityInspection 2:Harness continuity and short circuit inspection

Continuity

61-2 is displayedInspection 1:Load sensor individual inspection

61-1 is displayed

Main harness defect

Main harness defect

Load sensor defect


Continuity


Error

No error



SST


Section 19

19-7619-76


Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)

Standard:


In the same state as for inspection 2

Standard:



Standard:





Error code 61-2




Disconnect A18, ignition key switch ON (engine stopped), inspect the diplayed error code.

61-2


Continuity

61-1

Main harness defect

SAS/OPScontroller defect

· Sub harness defect· Load sensor defect

Inspection 2:Load sensor individual inspection

Continuity

No continuityMain harness defect

Continuity

No continuity

Error

No error




Section 19

19-77

Inspection 2: Carry out load sensor individual inspection.

Ignition key switch OFF, disconnect the battery negative terminal, disconnect A18 and A21, use SST 09230-13700-71 to short circuit A18-2 to A18-3 (main harness side)

Standard:A21-27 ~ A21-5 Continuity


Section 19

19-7819-78

Error codes 62-1, 62-2 (Tilt angle sensor abnormality)Related portion

Probable cause Connector contact defect Tilt angle sensor harness defect Tilt angle sensor defect SAS/OPS controller defect

Inspection 1: Carry out tilt angle sensor individual inspection.

Ignition key switch OFF, disconnect A42, use SST 09232-13130-71 to short circuit A42-1 and A42-2 (mainharness side), ignition key switch ON (engine stopped)62-1 displayed → to inspection 262-2 displayed → tilt angle sensor defect

Error code 62-1

5 (E2)SAS/OPS controller

Tilt angle sensor

A2128 (5MA)32 (MA)

1A42

23


Continuity

Inspection 1:Tilt angle sensor individual inspection

62-1 is displayed

Main harness defect

Main harness defect

Tilt angle sensor defect


Continuity


Error

No error



62-2 is displayed


Section 19

19-79


Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)

Standard:



Standard:


Ignition key switch OFF, disconnect A42, ignition key switch ON, engine stopped62-1 displayed → to inspection 362-2 displayed → to inspection 2



Standard:





Error code 62-2



Continuity

62-1 is displayedInspection 1:Tilt angle sensor individual inspection

62-2 is displayed

Main harness defect


Tilt angle sensor defect

Error

No error



Inspection 3:Tilt angle sensor individual inspection

Continuity

No continuity


Section 19

19-8019-80


Ignition key switch OFF, disconnect A21 and A42, use SST 09232-13130-71 to short circuit A21-2 and A42-3(main harness side)



Section 19

19-81

Error codes 63-1, 63-2, 63-3 (Tilt lever switch abnormality)Related portion

Probable cause Connector contact defect Harness defect Forward tilt switch defect Tilt switch installation defect Backward tilt switch defect SAS/OPS controller defect

21 (MR)SAS/OPScontroller

Backward tiltswitch

A20

20 (MF)1 (E3)

1

A13

3

Forward tiltswitch

4

2


Section 19

19-8219-82

*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the tilt lever forward andbackward. Also, make sure that no error is displayed when the tilt lever is left standing in neutral position for 2minutes.

Inspection 1: Check the condition of the switch.

Ignition key switch ON, engine stoppedTilt switch (I/O monitor: MF·MR)

Standard:

Error codes 63-1, 63-2, 63-3

Lever in neutral position

Lever in forward tilt position

Lever in backward tilt position

MF (Forward tilt switch) 0 1 0

MR (Backward tilt switch) 0 0 1

OK

OKInspection 2:Individual continuity inspection of the tilt lever switch(es) that was abnormal in inspection 1 (while still installed on the vehicle).

NG

No error

Error


Tilt switch defect

Inspection 3:Individual continuity inspection of the tilt lever switch (removed from the vehicle).

OK

NG

Inspection 4:Harness continuity and short circuit inspection

OK

NG

Tilt switch installation defect

Harness defect



NG

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A13 and A20, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.*

Inspection 1:Check the condition of the switchANL.: I/O M.HANDLING 1/6


Section 19

19-83

Inspection 2: Individual continuity inspection of the tilt lever switch (still installed on the vehicle).



Inspection 3: Carry out individual continuity inspection of the tilt lever switch (removed from the vehicle).





Standard:


Lever in forward tilt position

Lever in backward tilt position

A13-1 ~ A13-2 No continuity Continuity No continuity

A13-3 ~ A13-4 No continuity No continuity Continuity


A13-1 ~ A13-2 No continuity Continuity

A13-3 ~ A13-4 No continuity No continuity






21

3 4

A13


Section 19

19-8419-84

Error code 64-1 (Lift lock solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Lift lock solenoid defect SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is lowered.



Standard:

Error code 64-1


A11-2 ~ Frame Continuity




8 (E01)

Lift locksolenoid

A207 (LSOL)9 (E02)

A1112SAS/OPS

controller


OK

Harness defect

NGInspection 2:Lift lock solenoid individual inspection

OK

Solenoid defect


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A11 and A20, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.*



Section 19

19-85

Inspection 2: Carry out lift lock solenoid individual inspection.


Standard: (Solenoid side)A11-1 ~ A11-2 9.9 ± 0.5 Ω (20°C)

21

A11


Section 19

19-8619-86

Error code 65-1 (Tilt control solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Tilt control solenoid defect SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is operated to tilt forward.



Standard:

Error code 65-1






8 (E01)

Tilt controlsolenoid

A204 (TSOL)9 (E02)

A1012SAS/OPS

controller


OK

Harness defect

NGInspection 2:Tilt control solenoid individual inspection

OK

Solenoid defect


Error

No error




Section 19

19-87

Inspection 2: Carry out tilt control solenoid individual inspection.



21

A10


Section 19

19-8819-88

Error code 66-1 (Outside matching value range abnormality)Related portion

Probable cause Tilt horizontal angle matching value is outside the specified range for matching. Tilt forward tilt angle matching value is outside the specified range for matching. Load sensor matching value is outside the specified range for matching.

Error code 66-1

SAS/OPScontroller

Error

Controller defect

Carry out tilt horizontal angle matching, tilt forward tilt angle matching, and load sensor matching. (Refer to section 18)


Section 19

19-89

Error code 67-1 (Lifting height switch abnormality)Related portion

Probable cause Connector contact defect Harness defect Lifting height switch defect SAS/OPS controller defect IG fuse defect

TA

B

RE

C

A20 b1

Except mast lifting height H2000

11 (E3)31 (MH1)

3SAS/OPScontroller 32 (MH21)

Lifting height switch

2

A61435


Section 19

19-9019-90

Error code 67-1

Lifting height switch defect

MH:000

ErrorNone

Error


Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A20, A61 and b1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.*

Inspection 1:Lifting height switch input value inspectionANL.: I/O M.HANDLING 2/6

MH:000

Except MH000

Inspection 2:Harness continuity and short circuit inspectionANL.: I/O M.HANDLING 2/6

Except MH:000

OK SAS/OPScontroller defect


NG

Main harness defect

Inspection 4:Lifting height switch individual inspection

OK

Lifting height switch defectNG


NG

OK

Main harness defect


*: Raise the lift lever from the fully lowered position until an error is detected.


Section 19

19-91


Maintain the error status and check the display.Lifting height switch (I/O monitor: MH)MH: 000 displayed → to checking the mast height at the time of error detectionMH: Except 000 → to inspection 2


Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1, ignition key switch ON, stop theengine, check the displayMH: 000 displayed → sub harness defect or lifting height switch defectMH: Except 000 → to inspection 3


Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1

Standard:

Inspection 4: Carry out lifting height switch individual inspection.

Maintain the error status, ignition key switch OFF, disconnect b1



Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 adn b1, use SST 09236-13900-71 toshort circuit the terminals

Standard:










b1-1 ~ b1-2 No continuity

b1-1 ~ b1-3 Continuity

Inspection terminal Short circuit terminals Continuity

A20-1 ~ A20-31 b1-1 ~ b1-2 Continuity

A20-1 ~ A20-32 b1-1 ~ b1-3 Continuity

b1

1 2 3


Section 19

19-9219-92

Error codes 68-1, 68-2, 68-3 (Lift switch abnormality)Related portion

Probable cause Connector contact defect Harness defect Raising lift switch defect Lift switch installation defect Lowering lift switch defect SAS/OPS controller defect

23 (MD)SAS/OPScontroller

Lowering lift switch

A20

22 (MU)1 (E3)

3

A14

1

Raising lift switch

2

4


Section 19

19-93

*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the lift lever upward anddownward. Also, make sure that no error is displayed when the lift lever is left standing in neutral position for 2minutes.

Error codes 68-1, 68-2, 68-3

OK

OKInspection 2:Individual continuity inspection of the lift lever switch(es) that was abnormal in inspection 1 (while still installed on the vehicle).

NG

Inspection 1:Lift switch condition checkANL.: I/O M.HANDLING 1/6

Lift switch defect

Inspection 3:Individual continuity inspection of the lift lever switch (removed from the vehicle).

OK

NG


OK

NG

Lift switch installation defect

Harness defect



NG

ErrorNone

Error




Section 19

19-9419-94


Ignition key switch ON (engine stopped)Lift switch (I/O monitor: MU·MD)

Standard:

Inspection 2: Carry out individual continuity inspection of the lift lever switch (still installed on the vehicle).



Inspection 3: Carry out individual continuity inspection of the lift lever switch (removed from the vehicle).



Inspection 4: Harness continuity and short circuit inspection


Standard:


Lever in raised position

Lever in lowered position

MU (Raising switch) 0 1 0

MD (Lowering switch) 0 0 1


Lever in raised position

Lever in lowered position



Switch ON Switch OFF

A14-3 ~ A14-4 Continuity No continuity

A14-1 ~ A14-2 Continuity No continuity






3

12

4

A14


Section 19

19-95

Error code 69-1 (Backward tilt lock solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Backward tilt lock solenoid defect SAS/OPS controller defect

*: Make sure that no error is displayed when the material handling lever is operated to tilt backward.

Inspection 1: Carry out harness continuity and short circuit inspection.


Standard:

Error code 69-1






8 (E01)

Backward tilt lock solenoid

A2010 (BSO+)9 (E02)

A5612SAS/OPS

controller


OK

Harness defect

NGInspection 2:Backward tilt lock solenoid individual inspection

OK

Solenoid defect


Error

No error




Section 19

19-9619-96

Inspection 2: Carry out tilt backward tilt lock solenoid individual inspection.



21

A56


Section 19

19-97

Error codes 71-1 and 71-2 (Tire angle sensor abnormality)Related portion

Probable cause Connector contact defect Tire angle sensor harness defect Tire angle sensor defect Tire angle sensor joint, rear axle link system defect SAS/OPS controller defect

Inspection 1: Carry out tire angle sensor individual inspection.

Ignition key switch OFF, disconnect Z3, use SST 09232-13130-71 to short circuit Z3-2 and Z3-3, ignition keyswitch ON, engine stopped71-1 displayed → to inspection 271-2 displayed → Tire angle sensor defect

Error code 71-1

TA

B

RE

C

RE

C

TA

B

5 (E2)SAS/OPScontroller

Tire anglesensor

A2130 (5T)34 (T)

3Z3

2111

AO128

1

ZO143

5 (E2)


OK

71-2 is displayedInspection 1:Tire angle sensor individual inspection

71-1 is displayed

Harness defect

Harness defect

OKInspection 3:Harness continuity and short circuit inspection

NG


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of Z3, AO1, ZO1 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.


Tire angle sensor defect


Section 19

19-9819-98


Ignition key switch OFF, disconnect A21(With the SST used in inspection 1 still connected)

Standard:



Standard:

Inspection 1: Carry out tire angle sensor individual inspection.Ignition key switch OFF, disconnect Z3, ignition key switch ON, engine stopped71-1 displayed → to inspection 371-2 displayed → to inspection 2





Error code 71-2


NG

71-1 is displayedInspection 1:Tire angle sensor individual inspection

71-2 is displayed

Main harness defect


Tire angle sensor defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of Z3, AO1, ZO1 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (engine stopped) and check whether or not there is an error.


Inspection 3:Tire angle sensor individual inspection

Continuity

No continuity


Section 19

19-99



Standard:

Inspection 3: Carry out tire angle sensor individual inspection.

Ignition key switch OFF, disconnect Z3 and A21, use SST 09232-13130-71 to short circuit Z3-1 to Z3-2 (mainharness side)

Standard:


A21-34~ A21-5 Continuity


Section 19

19-10019-100

Error codes 72-1, 72-2, 72-3, 72-4 (Steering angle sensor abnormality)Related portion

Probable cause Connector contact defect SAS/OPS controller defect Steering angle sensor harness defect Steering angle sensor defect

Note:If only the steering angle sensor is turned, not with the steering wheel, error code 72-4 may be output.

SAS/OPScontroller

14 (SS1)15 (SS2)16 (SSC)5 (E2)

Steering anglesensor

A31

3452

1 (IG1)A21

2 (IG2)

ECU-IG


Section 19

19-101

Error code 72-1

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A3 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate (rotate) the steering and check whether or not there is an error.


Check the STS value with an analyzer while operating the steering.ANL.: I/O STEERING 1/1

1**

0**(* is 0 or 1)

Disconnect the battery negative terminal and A3, short circuit A3-2 to A3-3 (main harness side) using SST 09232-13130-71, reconnect the battery negative terminal, and turn the ignition key switch ON.

1**

0**


Steering angle sensor defect


OK

Main harness defect


Disconnect the battery negative terminal and A3, reconnect the battery negative terminal, and turn the ignition key switch ON.

0**

1**




OK

Main harness defect



Section 19

19-10219-102



Standard:



Standard:





Section 19

19-103

Error code 72-2

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A3 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate (rotate) the steering and check whether or not there is an error.



*1*

*0*(* is 0 or 1)


*1*

*0*




OK

Main harness defect



*0*

*1*



OK

Main harness defect




Section 19

19-10419-104



Standard:



Standard:





Section 19

19-105

Error code 72-3

Error



**1

**0(* is 0 or 1)


**1

**0




OK

Main harness defect



**0

**1




OK

Main harness defect


Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A3 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate the steering (one or more rotations) and check whether or not there is an error.

No error


Section 19

19-10619-106



Standard:



Standard:

Inspection 1: Carry out steering angle sensor supply voltage inspection.

Standard:




Error code 72-4

A3-1 ~ A3-2 Battery voltage (approx. 12 V)

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection of A3 and A21 and internal moisture, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate (rotate) the steering and check whether or not there is an error.




OK

Main harness defect


Battery voltage (approx. 12 V)Inspection 1:

Steering angle sensor supply voltage inspection

Approx. 0 V

To troubleshooting for 72-1 and 72-2


Section 19

19-107







Section 19

19-10819-108

Error code 73-1 (Knob position compensation solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Knob position compensation solenoid defect SAS/OPS controller defect

*: Make sure that no error is displayed when turning the knob position compensation solenoid ON/OFF using theactive test function.


Ignition key switch OFF, disconnect O4 and A20

Standard:

Error code 73-1

A20-6 ~ O4-1 Continuity

O4-2 ~ Frame Continuity




TA

B

RE

C

SAS/OPScontroller

Knob position compensationsolenoid

O4A206 (STRG)9 (E02)8 (E01)

12

AO12019


OK

Harness defect

NGInspection 2:Knob position compensation solenoid individual inspection

OK

Knob position compensation solenoid defect


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of O4, AO1 and A20, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.*



Section 19

sheath

Text Box

Click here for more info on 73-1 code

19-109

Inspection 2: Carry out knob position compensation solenoid individual inspection.

Ignition key switch OFF, disconnect O4

Standard: (Solenoid side)O4-1 ~ O4-2 Approx.10 Ω (20°C)

2 1

O4


Section 19

19-11019-110

Error code 74-1 (Outside matching value range abnormality)Related portion

Probable cause Tire alignment value is outside the specified range for matching.

Error code 74-1

SAS/OPS controller

Perform tire alignment.(Refer to section 18)

Error

Controller defect


Section 19

19-111

Error code A5-1 (Seat switch abnormality)

ry negative terminal, then inspect and repair disconnection and water entry of A20, AO1, XO4 and X1.*


Related Portion

Inspection 1:

Check the condition of the switch.

Disconnect O5, ignition key switch ON, engine stopped

Seat switch (I/O monitor: SEAT)

Standard:

SEAT 0

Inspection 2:

Inspect for continuity and short circuiting of the harness.

Ignition key switch OFF, disconnect A20 and O5

Standard:

A20-35～A20-1 No continuity

A20-35～Frame No continuity

Error code A5-1

Disconnect the battery negative terminal, then inspect and repair disconnection of A20, AO1 and O5 and any internal moisture.

No error

Error

SAS/OPS

controller

A20

35 (DMS)

1 (E3)

AO1

1

O5

2

1 Seat switch


Section 19Revised December 15, 2009

sheath

Text Box

Click here for info on A5-1 code

19-11219-112 Memo

Section 19Revised December 15, 2009

19-113

Error code A7-1 (Brake switch abnormality)Related portion

Probable cause Connector contact defect Brake switch defect Harness defect SAS/OPS controller defect

*: After correcting, connect the connector and turn the ignition key switch OFF → ON (at least 2 seconds) → OFF.Make sure that no error is displayed when the ignition key is turned ON after leaving the vehicle with the seatempty for 15 minutes.


Disconnect A6, ignition key switch ON, engine stoppedBrake switch (I/O monitor: BRKSW)

Standard:

Error code A7-1

BRKSW 0

SAS/OPScontroller 17 (BSW)

A201

A6

2

STOP

Brake switch

OKOK

No error

Error

Brake switch installation defect

Inspection 3:Individual continuity inspection of the brake switch (removed from the vehicle)

OK

NG



NGInspection 1:Check the condition of the switchANL.: I/O TRAVELING 1/3

NG Harness defect

Brake switch defect

Disconnect the battery negative terminal, then inspect and repair disconnection and water entry of A20 and A6.*



Section 19

19-11419-114



Standard:

Inspection 3: Carry out individual continuity inspection of the brake switch (removed from the vehicle).



A20-17 ~ BATT No continuity


A6-1 ~ A6-2 No continuity Continuity

1 2

A6


Section 19

19-115

Error codes AD-1, AD-2, AD-7, AD-8 (4Y-E spec.) (CAN communication abnormality)Related portion

Probable cause Connector contact defect Engine controller defect Engine controller harness defect Multifunction display defect Multifunction display harness defect SAS/OPS controller defect Fuse defect

Caution:When the controller or optional display is replaced into another vehicle with different specifications, AD-1and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".

Error codes AD-1, AD-2, AD-7, AD-8

TA

B

RE

C

SAS/OPS controller

8 (BATT)A21

1 (IG1)

28 (CAN+)29 (CAN-)

A36

Multi-function display

Engine controller

3 (BATT)

9 (IGSW)

2 (IG)

5 (CANH)

Q2

6 (CANL)3 (E1)

2 (IG2)

12 (CANH)13 (CANL)

A20

ECU-B

ECU-IG

EFI

IGN

AQ12

143

NGDisconnect the negative terminal of the battery and inspect the fuses.

OK

Fuse defect

No error

Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of A20, A21, A36, AQ1 and Q2, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.*

Error



OK

Harness defect

Engine controller defect (AD-1)Multifunction display defect (AD-7)SAS/OPS controller defect (AD-8)

SAS/OPS controller orengine controller defect (AD-2)


Section 19

sheath

Text Box

For more info on AD-1 and AD-7 code click here to go to SIB

19-11619-116

*: It is not necessary to inspect A36 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD-8 have notoccurred.


Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21 and A36(unnecessary if AD-1 and AD-2 have not occured)

Standard:A21-8 ~ ECU-B Continuity

A21-1 ~ ECU-IG Continuity


Q2-2 ~ ECU-IG Continuity

A20-12 ~ Q2-5 Continuity






A36-3 ~ EFI Continuity

A36-9 ~ IGN Continuity


Section 19

19-117

Error codes AD-1, AD-2, AD-7, AD-8 (ASC spec.) (CAN communication abnormality)Related portion

Probable cause Connector contact defect Engine controller defect Engine controller harness defect Multifunction display defect Multifunction display harness defect SAS/OPS controller defect Fuse defect

Caution:When the controller or optional display is replaced into another vehicle with different specifications, AD-1and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".

Error codes AD-1, AD-2, AD-7, AD-8

TA

B

RE

C

TA

B

RE

C

SAS/OPS controller

8 (BATT)A21

1 (IG1)

13 (CANH)26 (CANL)

G39


ASC controller

G38

25 (IGSW)

2 (IG)

5 (CANH)

Q2

6 (CANL)3 (E1)

2 (IG2)

12 (CANH)13 (CANL)

A20

ECU-B

ECU-IG

ECU-B2

IGN

AQ12

143

AG245

1

1

NGDisconnect the negative terminal of the battery and inspect the fuses.

OK

Fuse defect

No error

Disconnect the battery negative terminal (for more than 10 seconds), after inspecting and correcting disconnection and water entry of A20, A21, G38, G39, AQ1, AG2 and Q2, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.*

Error



OK

Harness defect

Engine controller defect (AD-1)Multifunction display defect (AD-7)SAS/OPS controller defect (AD-8)

SAS/OPS controller orengine controller defect (AD-2)


Section 19

19-11819-118

*: It is not necessary to inspect G38 when AD-1 and AD-2 have not occurred, and Q2 when AD-7 and AD-8 have notoccurred.


Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21, G38 andG39 (unnecessary if AD-1 and AD-2 have not occured)

Standard:A20-12 ~ Q2-5 Continuity






A21-8 ~ ECU-B Continuity



Q2-2 ~ ECU-IG Continuity

G38-1 ~ ECU-B2 Continuity

G39-25 ~ IGN Continuity


Section 19

19-119

Error codes AF-1, AF-2, AF-3, AF-4, AF-5, AF-6, AF-7, AF-8 (CPU abnormality)Related portion

Probable cause SAS/OPS controller defect

Note:When AF is displayed, the SAS/OPS controller is defective and must be replaced.

SAS/OPS controller


Section 19

19-12019-120

Error codes C4-1, C4-2, C4-3, C4-4, C4-5, C4-6 (4Y-E spec.) (Accelerator sensor abnormality)Related portion

Probable cause Connector contact defect Accelerator sensor defect Harness defect Engine controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated.

Error codes C4-1, C4-2, C4-3, C4-4, C4-5

TA

B

RE

CEngine controller

Accelerator sensor

A35 a125 (VCPA)26 (VPA)27 (EPA)33 (VCP2)34 (VPA2)35 (EPA2)

5 (VCP1)4 (VPA1)6 (EP1)1 (VCP2)3 (VPA2)2 (EPA2)

Aa148237

1

NGInspection 1:Accelerator sensor individual inspection Accelerator sensor defect

OK


OK


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A35, Aa1 and a1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine), and check whether or not there is an error.*

Error



Section 19

19-121


Inspection 1: Carry out accelerator sensor individual inspection.

Ignition key switch OFF, disconnect a1, conenct A35(1) Accelerator sensor resistance measurement


(2) Accelerator sensor output circuit resistance measurement


Error code C4-5

a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ (released)a1-1 ~ a1-2

a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the rotation of the potentiometer when the potentiometer section is rotated.a1-3 ~ a1-2


OK


OK

NG

OK

Accelerator sensor defectInspection 3:Accelerator sensor voltage inspectionANL.: I/O ENGINE CTRL 4/10


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A35, Aa1 and a1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.*

Error


123456

a1


Section 19

19-12219-122


Ignition key switch OFF, disconnect A35 and a1

Standard:

Inspection 3: Inspect the accelerator sensor voltage.

Ignition key switch OFF, disconnect a1, connect A35, ignition key switch ONAccelerator sensor (I/O monitor: VPA1, VPA2)

Standard:

A35-26 ~ a1-4 Continuity












VPA1 0.20 V or less

VPA2 0.20 V or less


Section 19

19-123

Error codes C4-1, C4-2, C4-3, C4-4, C4-5 (ASC spec.) (Accelerator sensor abnormality)Related portion

Probable cause Connector contact defect Accelerator sensor defect Harness defect ASC controller defect


Error codes C4-1, C4-2, C4-3, C4-4, C4-5

TA

B

RE

C

RE

C

TA

BASC controller Accelerator sensor

G39 a119 (VCPA)6 (VPA)7 (EPA)18 (VCP2)5 (VPA2)17 (EPA2)

5 (VCP1)4 (VPA1)6 (EP1)1 (VCP2)3 (VPA2)2 (EPA2)

Aa148237

1

AG2678910

11


OK


OK


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of G39, AG2, Aa1 and a1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine), and check whether or not there is an error.*

Error


NGInspection 3:Accelerator sensor voltage inspectionANL: I/O ENGINE CTRL 1/3

Accelerator sensor defect

OK


Section 19

19-12419-124

Inspection 1: Carry out accelerator sensor individual inspection.

Ignition key switch OFF, disconnect a1, conenct G39(1) Accelerator sensor resistance measurement


(2) Accelerator sensor output circuit resistance measurement


a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ (released)a1-1 ~ a1-2

a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the rotation of the potentiometer when the potentiometer section is rotated.a1-3 ~ a1-2

123456

a1


Section 19

19-125


Ignition key switch OFF, disconnect G39 and a1

Standard:

Inspection 3: Inspect the accelerator sensor voltage.

Ignition key switch OFF, disconnect a1, connect G39, ignition key switch ONAccelerator sensor (I/O monitor: VPA1, VPA2)

Standard:

G39-6 ~ a1-4 Continuity












VPA1 0.20 V or less

VPA2 0.20 V or less


Section 19

19-12619-126

Error codes C7-1 and C7-2 (Shift lever switch abnormality)Related portion

The above chart is for vehicles of the left shift lever column specification.For vehicles of the right shift lever column specification, A43-4, A43-5 and A43-9 should be used.For vehicles of the armrest specification, Y4-7, Y4-6 and Y4-1 should be used.

Probable cause Connector contact defect Harness defect Forward travel shift switch defect Shift switch installation defect Reverse travel shift switch defect SAS/OPS controller defect

Note:In the event that the engine stops while travelling, when the ignition key switch is turned from OFF to ON, anC7-1 error may be detected, however this is not a fault.Stop the vehicle, turn the ignition key switch OFF and restart the engine.

SAS/OPScontroller Shift switch18 (DRF)

19 (DRR)

SFT

A41

51

A206


Section 19

19-127

*: Check if an error occurs after turning the ignition key switch ON, moving the shift lever and traveling from stoppedstate to more than 10 km/h (6.2 mph) within 3 seconds.

*: Make sure there is no error after turning the ignition key switch ON, and move the shift lever to forward and reversetravel.

Error code C7-1

Error code C7-2

NG

Inspection 1:Check the condition of the switchANL.: I/O TRAVELING 2/3


OK

Harness defect


NGInspection 2:Individual continuity inspection of the direction lever switch that was abnormal in inspection 1 (while still installed on the vehicle).

Shift switch defect

OK

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection of A20 and A41 and internal moisture, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.*

Error


NG

Inspection 4:Check the condition of the switchANL.: I/O TRAVELING 2/3


NG

Harness defect


OKShift switch defect

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection of A20 and A41 and internal moisture, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.*

Error



Section 19

19-12819-128


Ignition key switch ONDirection switch (I/O monitor: DRF - DRR)

Standard:

Inspection 2: Individual continuity inspection of the direction lever switch(es) (still installed on thevehicle).





Standard:


Disconnect A41, ignition key switch ON (engine stopped), direction switch (I/O monitor: DRF·DRR)

Standard:


Lever in forward travel position

Lever in reverse travel position

DRF (for forward travel) 0 1 0

DRR (for reverse travel) 0 0 1


Lever in forward travel position

Lever in reverse travel position










Analyzer display

DRF (for forward travel) 0

DRR (for reverse travel) 0

123456789

101112131415161718

A41


Section 19

19-129

Error code CA-1 (Forward-reverse travel lever abnormality)Related portion

Probable cause Connector contact defect Reverse travel relay harness defect Forward travel relay harness defect Reverse travel relay defect Forward travel relay defect SAS/OPS controller defect


Ignition key switch OFF, disconnect A20, A21 and forward/reverse relay

Standard:

Error code CA-1

A21-17 ~ R/B forward relay terminal 1 Continuity

R/B reverse relay terminal 2 ~ Frame Continuity




A21

SAS/OPScontroller

17 (RYF)

8 (E01)

12

Forward travel relay

Reverse travel relay

12

9 (E02)

A20

OK

NGInspection 2:Relay individual inspection

OK

Relay defect


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A20 and A21, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.

Error




Section 19

19-13019-130

Inspection 2: Carry out relay individual inspection.

Standard: (Relay side)Forward relay terminal 1 ~ Forward relay terminal 2

Approx. 90 Ω (20°C)Reverse relay terminal 1 ~ Reverse relay terminal 2

Forward/reverse relay


Section 19

19-131

Error code EC-1 (Unload solenoid abnormality)Related portion

Probable cause Connector contact defect Harness defect Unload solenoid defect SAS/OPS controller defect

*: Check whether an error occurs after turning the ignition key switch ON and leaving the seat (for at least 2seconds).

Inspection 1: Carry out unload solenoid individual inspection.



Error code EC-1

A12-1 ~ A12-2 Approx. 10 Ω (20°C)

8 (E01)

Unloadsolenoid

A205 (USOL)9 (E02)

A1212SAS/OPS

controller

NGInspection 1:Unload solenoid individual inspection

OK

Unload solenoid defect


OK

Harness defect


No error

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A12 and A20, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON (start the engine) and check whether or not there is an error.*

Error


1 2

A12


Section 19

19-13219-132









Section 19

19-133

Error codes F1-1, F2-1 (Controller to combination meter communication abnormality)Related portion

Probable cause Connector contact defect Hour meter harness defect Hour meter defect SAS/OPS controller defect


Ignition key switch OFF, disconnect A20 and Q1

Standard:

Error codes F1-1, F2-1

Q1-3 ~ Frame No continuity


RE

C

TA

B

A20

14 (SIL) Combination meter

SAS/OPS controller

Q1

3 (SIL2)

QA1

10

Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A20, QA1 and Q1, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON and check whether or not there is an error.


OK

Harness defect

F1-1

Combination meter defect

F2-1


SAS/OPS controller orcombination meter defect


Section 19

19-13419-134

Error codes F4-1, F4-2, F4-3, F4-4, F4-5, F4-7, F4-8 (CPU abnormality)Related portion

Probable cause Multi-function display board defect



Section 19

19-135

Error codes H1-1, H1-2, H1-3, H1-4, H1-5 (Lift lever potentiometer abnormality)Related portion

Probable cause Connector contact defect Lift lever potentiometer harness defect Lift lever potentiometer defect SAS/OPS controller defect Fuse defect

RE

C

TA

B

RE

C

TA

B

TA

B

RE

C

RE

C

TA

B Lift leverpotentiometer

A237 (IG)

8 (IG2)

29 (LIF+)27 (LIF1)28 (LIF2)

26 (E1)9 (E43)10 (E44)

9 (E41)10 (E42)3 (E11)

4 (E12)

Y6

SAS/OPS/mini levercontroller

4 (LIF+)3 (LIF1)2 (LIF2)

1 (LIF)

A21

ECU-IG

AO3 YX131214

7

141213

1

1465

3

7XO3

XO2


Section 19

19-13619-136

Note:If the lever has been removed, be sure to perform matching after the lever is reinstalled.

Inspection 1: Carry out lift lever potentiometer inspection.

Ignition key switch OFF, return the lift lever potentiometer and tilt lever potentiometer to their original positions,check lift lever potentiometer installation (refer to section 18), ignition key switch ON, match lift leverpotentiometer

Error codes H1-1, H1-2, H1-3, H1-4

Turn the ignition key switch OFF, disconnect the battery negative terminal, replace the lift lever potentiometer with the tilt lever potentiometer, and check if there is any change in the error.

H1-*

H2-4 OKInspection 1:Lift lever potentiometer inspection

NG

Installation defect

Lift lever potentiometer abnormalityH2-1·H2-2·H2-3


NG

OK

Harness defect

Fuse inspection

OK

Replace fuseNG

SAS/OPS/mini levercontroller defect

No error

Error


Disconnect the battery negative terminal, after inspecting and correcting disconnection and water entry of A21, A23, AO3, XO3, YX1 and Y6, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, and check whether or not there is an error.


Section 19

19-137


Ignition key switch OFF, disconnect A21, A23 and Y6

Standard:A23-29 ~ Y6-4 Continuity

A23-27 ~ Y6-3 Continuity






Error code H1-5

OKMatching value misalignmentMatch lift lever potentiometer

NG



Section 19

19-13819-138

Error codes H2-1, H2-2, H2-3, H2-4, H2-5 (Tilt lever potentiometer abnormality)Related portion

Probable cause Connector contact defect Tilt lever potentiometer harness defect Tilt lever potentiometer defect SAS/OPS controller defect Fuse defect

RE

C

TA

B

TA

B

RE

C

RE

C

TA

B Tilt leverpotentiometer

A237 (IG)

8 (IG2)

30 (TIL+)11 (TIL1)12 (TIL2)26 (E1)

9 (E43)10 (E44)

9 (E41)10 (E42)3 (E11)4 (E12)

Y5


4 (TIL+)3 (TIL1)2 (TIL2)1 (TIL-)

A21

ECU-IG

AO3 YX161087

15981

243

1XO2


Section 19

19-139


Inspection 1: Carry out tilt lever potentiometer inspection.

Ignition key switch OFF, return the tilt lever potentiometer and lift lever potentiometer to their original positions,check tilt lever potentiometer installation (refer to section 18), ignition key switch ON, match tilt leverpotentiometer


Turn the ignition key switch OFF, disconnect the battery negative terminal, replace the lift lever potentiometer with the tilt lever potentiometer, and check if there is any change in the error.

H2-*

H1-4 OKInspection 1:Tilt lever potentiometer inspection

NG

Installation defect

Tilt lever potentiometer abnormalityH1-1·H1-2·H1-3


NG

OK

Harness defect

Fuse inspection

OK

Replace fuseNG


No error

Error


Disconnect the battery negative terminal, after inspecting and correcting disconnect and water entry of A21, A23, AO3, XO2, YX1 and Y5, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, and check whether or not there is an error.


Section 19

19-14019-140










Error code H2-5

OKMatching value misalignmentMatch tilt lever potentiometer

NG



Section 19

19-141

Error codes H3-1, H3-2, H3-3, H3-4, H3-5 (Attachment 1 lever potentiometer abnormality)Related portion

Probable cause Connector contact defect Attachment 1 lever potentiometer harness defect Attachment 1 lever potentiometer defect SAS/OPS controller defect Fuse defect

RE

C

TA

B

TA

B

RE

C

RE

C

TA

B Attachment 1 lever potentiometer

A237 (IG)

8 (IG2)

31 (AT1+)13 (AT11)14 (AT12)26 (E1)

9 (E43)10 (E44)

9 (E41)10 (E42)3 (E11)4 (E12)

Y2


4 (AT1+)3 (AT11)2 (AT12)1 (AT1-)

A21

ECU-IG

AO3 YX11315167

7651

563

10XO2


Section 19

19-14219-142


Inspection 1: Carry out attachment 1 lever potentiometer inspection.

Ignition key switch OFF, return the attachment 1 lever potentiometer and tilt lever potentiometer to their originalpositionsCheck attachment 1 lever potentiometer installation (refer to section 18), ignition key switch ON, matchattachment 1 lever potentiometer


Turn the ignition key switch OFF, disconnect the battery negative terminal, replace the attachment 1 lever potentiometer with the tilt lever potentiometer, and check if there is any change in the error.

H3-*

H2-4Installation defect

Attachment 1lever potentiometer abnormality

H2-1·H2-2·H2-3


NG

OK

Harness defect

Fuse inspection

OK

Replace fuseNG


Inspection 1:Attachment 1 lever potentiometer inspection

NG

OK

ErrorNone

Error




Section 19

19-143


Ignition key switch OFF, disconnect A21, A23 and Y2Standard:








Error code H3-5

Match attachment 1 lever potentiometerOK

Matching value misalignment

NG



Section 19

19-14419-144

Error codes H4-1, H4-2, H4-3, H4-4, H4-5 (Attachment 2 lever potentiometer abnormality)Related portion

Probable cause Connector contact defect Attachment 2 lever potentiometer harness defect Attachment 2 lever potentiometer defect SAS/OPS controller defect Fuse defect

RE

C

TA

B

TA

B

RE

C

RE

C

TA

B Attachment 2 leverpotentiometer

A237 (IG)

8 (IG2)

32 (AT2+)15 (AT21)16 (AT22)26 (E1)

9 (E43)10 (E44)

9 (E41)10 (E42)3 (E11)4 (E12)

Y3


4 (AT2+)3 (AT21)2 (AT22)1 (AT2-)

A21

ECU-IG

AO3 YX12457

4321

793

8XO2


Section 19

19-145


Inspection 1: Carry out attachment 2 lever potentiometer inspection.

Ignition key switch OFF, return the attachment 2 lever potentiometer and tilt lever potentiometer to their originalpositionsCheck attachment 2 lever potentiometer installation (refer to section 18), ignition key switch ON, matchattachment 2 lever potentiometer


Turn the ignition key switch OFF, disconnect the battery negative terminal, replace the attachment 1 lever potentiometer with the attachment 2 lever potentiometer, and check if there is any change in the error.

H4-*

H3-4Installation defect

Attachment 2lever potentiometer abnormality

H3-1·H3-2·H3-3


NG

OK

Harness defect

Fuse inspection

OK

Replace fuseNG

SAS/OPS/mini lever

Inspection 1:Attachment 2 lever potentiometer inspection

NG

OK

No error

Error




Section 19

19-14619-146










Error code H4-5

Attachment 2 lever potentiometer matchingOK

Matching value misalignment

NG



Section 19

19-147

Error codes H5-1 and H5-2 (Lift solenoid abnormality)Related portion

Probable cause Connector contact defect Lift PULL solenoid harness defect Lift PUSH solenoid harness defect Lift PULL solenoid defect Lift PUSH solenoid defect SAS/OPS/mini lever controller defect

H5-1 is now described. For H5-2, substitute A52 for A51 and PULL for PUSH in the following.

Inspection 1: Carry out lift solenoid individual inspection.

Ignition key switch OFF, disconnect battery negative terminal, disconnect A51


Error codes H5-1, H5-2

A51-5 ~ A51-1 Approx. 7 Ω (20°C)


A2317 (LSO+)18 (LPSH)

19 (LPLL)

A515 (LDS+)1 (LDS-)

A525 (LUS+)1 (LUS-)

Lift PUSHsolenoid

Lift PULLsolenoid

NGInspection 1:Lift solenoid individual inspection Lift PUSH solenoid defect

OK


OK

SAS/OPS mini lever controller defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnect and water entry of A23 and A51, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate the lift lever and check whether or not there is an error.


4321

8765

A51


Section 19

19-14819-148


Ignition key switch OFF, disconnect battery negative terminal, disconnect A23 and A51








4321

8765

A52


Section 19

19-149

Error codes H6-1 and H6-2 (Tilt solenoid abnormality)Related portion

Probable cause Connector contact defect Tilt PULL solenoid harness defect Tilt PUSH solenoid harness defect Tilt PULL solenoid defect Tilt PUSH solenoid defect SAS/OPS/mini lever controller defect

H6-1 is now described. For H6-2, substitute A52 for A51 and PULL for PUSH in the following

Inspection 1: Carry out tilt solenoid individual inspection.



Error codes H6-1 and H6-2

A51-6 ~ A51-2 Approx. 7 Ω (20°C)


A231 (TSO+)2 (TPSH)

3 (TPLL)

A516 (TFS+)2 (TFS-)

A526 (TRS+)2 (TRS-)

Tilt PUSHsolenoid

Tilt PULLsolenoid

NGInspection 1:Tilt solenoid individual inspection Tilt PUSH solenoid defect

OK


OK


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnect A23 and A51 and water entry, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate the tilt lever and check whether or not there is an error.


4321

8765

A51


Section 19

19-15019-150










4321

8765

A52


Section 19

19-151

Error codes H7-1, H7-2 (Attachment 1 solenoid abnormality)Related portion

Probable cause Connector contact defect Attachment 1 PUSH solenoid harness defect Attachment 1 PUSH solenoid defect Attachment 1 PULL solenoid harness defect Attachment 1 PULL solenoid defect SAS/OPS/ mini lever controller defect

H7-1 is now described. For H7-2, substitute A52 for A51 and PULL for PUSH in the following



A2320 (3SO+)21 (3PSH)

22 (3PLL)

A517 (3FS+)3 (3FS-)

A527 (3RS+)3 (3RS-)

Attachment 1PUSH solenoid

Attachment 1PULL solenoid

NGInspection 1:Attachment 1 solenoid individual inspection

Attachment 1 PUSHsolenoid defect

OK


OK


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnect and water entry of A23 and A51, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate attachment lever 1 and check whether or not there is an error.



Section 19

19-15219-152

Inspection 1: Carry out attachment 1 solenoid individual inspection.





Standard:

A51-7 ~ A51-3 Approx. 7 Ω (20°C)



A23-20~ A23-21 No continuity





4321

8765

A51

4321

8765

A52


Section 19

19-153

Error codes H8-1, H8-2 (Attachment 2 solenoid abnormality)Related portion

Probable cause Connector contact defect Attachment 2 PUSH solenoid harness defect Attachment 2 PUSH solenoid defect Attachment 2 PULL solenoid harness defect Attachment 2 PULL solenoid defect SAS/OPS/ mini lever controller defect

H8-1 is now described. For H8-2, substitute A52 for A51 and PULL for PUSH in the following.



A234 (4SO+)5 (4PSH)

6 (4PLL)

A518 (B)4 (L)

A528 (B)4 (L)

Attachment 2PUSH solenoid

Attachment 2PULL solenoid

NGInspection 1:Attachment 2 solenoid individual inspection

Attachment 2 PUSHsolenoid defect

OK


OK


Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnect and water entry of A23 and A51, reconnect all connectors and the battery negative terminal, turn the ignition key switch ON, operate attachment lever 2 and check whether or not there is an error.



Section 19

19-15419-154

Inspection 1: Carry out attachment 2 solenoid individual inspection.

Ignition key switch OFF, disconnect battery negative terminal and A51




Standard:

A51-8 ~ A51-4 Approx. 7 Ω (20°C)








4321

8765

A51

4321

8765

A52


Section 19

19-155

Error code HA-1 (3/4-way change relay abnormality)Related portion

Probable cause Connector contact defect 3/4-way change relay 1 harness defect 3/4-way change relay 1 defect 3/4-way change relay 2 harness defect 3/4-way change relay 2 defect SAS/OPS controller defect


Ignition key switch OFF, disconnect A21 and each relay

Standard:

Error code HA-1

A21-12 ~ Relay terminal 2 Continuity

A21-12 ~ Relay terminal 4 Continuity


IG

SAS/OPS/Mini lever controller

3/4-way change relay 1

3/4-way change relay 2

1 2

3 4

A21

12 (ATSO)


OK

SAS/OPS/mini lever controller defect

Error

No error

Disconnect the battery negative terminal, after inspecting and correcting disconnect and water entry of A21, reconnect A21 and the battery negative terminal (leave relay disconnected), turn the changeover switch to the 3-way side, turn the ignition key switch ON, and check whether or not there is an error.

3/4-way change relay defect


Section 19

19-15619-156

TROUBLESHOOTING WHEN THERE IS NO ERROR CODE4Y-E Engine List by Symptom

Symptom Portion to be inspected Page for reference

Does not crank1. Starter relay and starter 19-157

2. Neutral start switch –

Cannot start (no starting combustion)

1. ECU power supply system 19-159

2. Igniter system 19-44

3. Fuel pump circuit 19-161

4. Fuel injector Refer to engine repair manual

Cannot start (no complete combustion)




Does not start well

1. Electronic throttle Refer to engine repair manual



4. Spark plugs Refer to engine repair manual


6. Compression Refer to engine repair manual

Fast idling rough 1. Electronic throttle Refer to engine repair manual

Idle speed high



3. Neutral start switch –

Idle speed low




4. Compression Refer to engine repair manual


Idle unstable




Hunting




Hesitation, poor acceleration




After fire




Engine stalling (immediately after start up)


Engine stalling (immediately after deceleration)


2. Engine control computer –


Section 19

19-157

Starter relay and starterRelated portion

Probable cause Neutral switch defect Starter relay defect Starter defect Wire harness, connector defect

Inspection 1: Carry out starter signal inspection.

Ignition key switch ONStarter signal (I/O motor: STA)

Standard:Starter stopped Starter in operation

STA 0 1

Ignition switch

to meter-related circuit Starter relay

Engine controller

Starter

Neutral switch

STA

G27-24 (STA)

51

32

AM1

OK

NG

Neutral switch defectStarter relay defect

Inspection 1:Starter signal inspectionANL.: I/O ENGINE CTRL 1/10

OKStarter defect

Inspection 2:Wire harness and connector inspection

NG

Wire harness, connector defect


Section 19

19-15819-158

Inspection 2: Carry out wire harness inspection.

Ignition key switch OFF, remove the starter relay, crank the engine and check voltage

Standard:Relay terminal 1 ~ frame 9 ~ 14 V

Relay terminal 2 ~ frame 0 V

Relay terminal 3 ~ frame 0 V

Relay terminal 5 ~ frame 9 ~ 14 V


Section 19

19-159

ECU power supply systemRelated portion

Probable cause Blown fuse EFI main relay defect Wire harness, connector defect

Inspection 1: Carry out a fuse continuity inspection.

Remove the EFI fuse and IGN fuse.

Standard: Continuity exists.

Engine controller

EFI

EFI main relay

1 (+B)2 (+B1)

19 (MREL)

2 13

3 (BATT)A36

G281 (E02)2 (E01)

3 (E1)

G27

5

NGInspection 2:EFI main relay operation and continuity inspection

EFI main relay defect

OK

NGInspection 3:Harness continuity inspection Wire harness, connector defect

OK


NGInspection 1:EFI and IGN fuse inspection Replace fuse

OK


Section 19

19-16019-160

Inspection 2: Inspect the EFI main relay.

(1) Inspect the EFI main relay operation.Ignition key switch ON, operate the EFI main relay

Standard: The EFI main relay makes an operating sound in coordination with the ignition key switch.

(2) Inspect for continuity between each of the terminals of the relay.

Ignition key switch OFF, remove the EFI main relay

Standard:

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is appliedaccross terminals 1 to 2.


Inspection 3: Inspect for continuity of the wire harness.

Ignition key switch OFF

Standard:

Relay terminals 1 ~ 2 Continuity

Relay terminals 3 ~ 5 No continuity

IGN ~ IG switch Continuity

MREL ~ EFI main relay (N18) Continuity

EFI main relay (Z23) ~ frame Continuity

EFI ~ +B Continuity

EFI ~ +B1 Continuity

EFI ~ BATT Continuity

E01 ~ frame Continuity



EFI relay


Section 19

19-161

Fuel pump control systemRelated portion

Probable cause Blown fuse EFI main relay defect Wire harness, connector defect Fuel pump defect

Inspection 1: Carry out a fuse continuity inspection.

Remove the EFI fuse and IGN fuse.


TAB

RE

C

Enginecontroller

3 (GAS)Fuel changeover switch

1 (SOL)

EFI main relay

Fuel pump

22 (FC)

Circuit opening relay

1 25 3

2 (IG)

16

4

5

AO1

G28

2 13 5

G38

NGInspection 2:EFI main relay operation and continuity inspection EFI main relay defect

OK

NGInspection 3:Harness continuity inspection Wire harness, connector defect

OK

Fuel pump defect

NGInspection 1:Fuse inspection Replace fuse

OK


Section 19

19-16219-162

Inspection 2: Inspect the EFI main relay.

(1) Inspect the EFI main relay operation.Ignition key switch ON, inspect the operation of the EFI main relay

Standard: The EFI main relay makes an operating sound in coordination with the ignition key switch

(2) Inspect for continuity between each of the terminals of the relay

Ignition key switch OFF, remove EFI main relay

Standard:

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is appliedaccross terminals 1 to 2.

Standard: Continuity exists

Inspection 3: Inspect for continuity of the wire harness.

Ignition key switch OFF

Standard:

Relay terminals 1 ~ 2 Continuity

Relay terminals 3 ~ 5 No continuity

Main relay ~ fuel changeover switch Continuity

Fuel changeover switch ~ GAS Continuity

FC ~ Circuit opening relay Continuity

Circuit opening relay ~ GND Continuity

Fuel changeover switch ~ Circuit opening relay Continuity

Circuit opening relay ~ Fuel pump Continuity

Fuel pump ~ GND Continuity

EFI relay


Section 19

19-163

Def

ect C

ause

s W

hen

Ther

e is

No

SAS/

OPS

Err

or D

ispl

ay

Not

e:If

an e

rror

cod

e or

wre

nch

lam

p is

flas

hing

, rep

air i

t firs

t.C

ontro

l typ

ePh

enom

enon

on

vehi

cle

Mal

func

tion

area

· m

ode

Che

ckin

g m

etho

dC

orre

ctiv

e ac

tion

Trav

el a

nd lo

ad

hand

ling

cont

rol

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Engi

ne is

alw

ays

slow

to re

v up

.(E

ven

with

the

dire

ctio

n le

ver l

eft i

n F

or R

pos

ition

and

the

brak

e ap

plie

d,

the

engi

ne is

stil

l slo

w to

rev

up)

Bra

ke s

witc

h un

it:

Ope

n fa

ult

(Stu

ck in

dep

ress

ed s

tate

, or

inte

rnal

dam

age)

Brak

e sw

itch

line:

D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

, fus

e)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Acc

eler

ator

sen

sor u

nit:

Inte

rnal

dam

age

Acce

lera

tor s

enso

r ins

talla

tion:

Li

nk, i

nsta

llatio

n pa

rt de

stro

yed,

da

mag

ed

Acce

lera

tor p

edal

pos

ition

che

ck:

Che

ck th

e op

enin

g de

gree

of t

he

acce

lera

tor p

edal

whe

n no

t ope

rate

d.

If no

t clo

se to

0%

, ins

talla

tion

chec

k or

re

plac

e se

nsor

.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Eve

n if

the

lift i

s ra

ised

, the

idle

sp

eed

does

not

rise

.

Lift

rais

e sw

itch

unit:

Ope

n fa

ult

(Sw

itch

mou

nted

inco

rrect

ly,

inte

rnal

dam

age,

stu

ck)

Lift

rais

e sw

itch

line:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Switc

h gr

ound

line

: D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Dis

play

set

ting:

Lift

idle

up

disa

bled

, Id

le u

p sp

eed

tuni

ng v

alue

low

Che

ck s

ettin

gs w

ith o

ptio

n se

t and

tu

ning

Cha

nge

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce


Section 19

19-164

Trav

el a

nd lo

ad

hand

ling

cont

rol

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Spee

d lim

it ap

plie

s at

hig

h lif

ting

heig

ht d

espi

te n

ot b

eing

load

ed

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Shor

t or l

ink

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:M

ount

a lo

ad, g

roun

d th

e fo

rks

and

chec

k th

e ch

ange

in v

olta

ge.

If th

ere

is n

o ch

ange

, per

form

a

harn

ess

chec

k or

repl

ace

the

sens

or.

Dis

play

set

ting:

Max

imum

spe

ed li

mite

r,Sp

eed

limit

setti

ng e

nabl

ed

Che

ck th

e se

tting

con

tent

of t

he

max

imum

spe

ed li

mite

r, ch

eck

the

setti

ng c

onte

nt o

f the

spe

ed li

mit

setti

ng.

Cha

nge

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Des

pite

bei

ng lo

aded

at

hig

h lif

ting

heig

ht th

e sp

eed

limit

does

not

ope

rate

.

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Sho

rt or

link

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:M

ount

a lo

ad, g

roun

d th

e fo

rks

and

chec

k th

e ch

ange

in v

olta

ge.

If th

ere

is n

o ch

ange

, per

form

a

harn

ess

chec

k or

repl

ace

the

sens

or.

Lifti

ng h

eigh

t sw

itch

unit:

D

isco

nnec

tion

faul

t (in

tern

al d

amag

e,

stuc

k)O

N/O

FF c

heck

with

ana

lyze

rH

arne

ss c

heck

or r

epla

ce s

enso

r

Dis

play

set

ting:

Trav

elin

g lim

it se

tting

dis

able

dLo

ad s

ensi

ng s

peed

lim

it di

sabl

edC

heck

set

ting

valu

es w

ith o

ptio

n se

tC

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-165

Trav

el a

nd lo

ad

hand

ling

cont

rol

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Spee

d lim

it ap

plie

s w

hen

load

ed

desp

ite b

eing

at a

low

lifti

ng h

eigh

t

Lifti

ng h

eigh

t sw

itch

unit:

Dis

conn

ectio

n fa

ult

(Inte

rnal

dam

age,

stu

ck)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Dis

play

set

ting:

Max

imum

spe

ed li

mite

r, sp

eed

limite

r se

tting

ena

bled

Che

ck th

e se

tting

con

tent

of t

he

max

imum

spe

ed li

mite

r, ch

eck

the

setti

ng c

onte

nt o

f the

spe

ed li

mit

setti

ng.

Cha

nge

SAS

/OP

S/m

ini l

ever

con

trolle

r:C

ontro

ller d

efec

t–

Rep

lace

For v

ehic

les

with

trav

el a

nd lo

ad

hand

ling

cont

rol:

Spee

d lim

it ap

plie

s at

all

times

re

gard

less

of l

iftin

g he

ight

or l

oad

Dis

play

set

ting:

Max

imum

spe

ed li

mite

r, sp

eed

limite

r se

tting

ena

bled

Che

ck th

e se

tting

con

tent

of t

he

max

imum

spe

ed li

mite

r, ch

eck

the

setti

ng c

onte

nt o

f the

spe

ed li

mit

setti

ng.

Cha

nge

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Buz

zer r

elat

ed

(*)

Buzz

er s

ound

s co

nsta

ntly

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Lea

d-in

sid

e):

Gro

und

shor

t or l

ink

faul

t (H

arne

ss, c

onne

ctor

)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

OPS

leav

ing

seat

war

ning

doe

s no

t so

und.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

Dis

play

set

ting:

OPS

leav

ing

seat

not

ifica

tion

buzz

er

setti

ng d

isab

led

Che

ck s

ettin

g va

lues

with

opt

ion

set

Cha

nge

SAS

/OP

S co

ntro

ller,

OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

*: O

nly

expo

rt m

odel

exc

ept “

WIT

HO

UT

OP

S B

UZZ

ER

” spe

cific

atio

n

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-166

Buz

zer r

elat

ed

Trav

elin

g O

PS

retu

rn to

neu

tral a

larm

do

es n

ot s

ound

.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

Dire

ctio

n le

ver u

nit:

Leve

r def

ect

Dire

ctio

n le

ver s

igna

l: D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

Ref

er to

"Tra

velin

g O

PS d

oes

not

oper

ate,

can

not t

rave

l".R

efer

to "T

rave

ling

OP

S d

oes

not

oper

ate,

can

not t

rave

l".

Dis

play

set

ting:

USA

spe

cific

atio

n en

able

dC

heck

set

ting

valu

es w

ith o

ptio

n se

t.C

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

For c

owl l

ever

veh

icle

s:

Mat

eria

l han

dlin

g O

PS re

turn

to

neut

ral a

larm

doe

s no

t sou

nd.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

– H

arne

ss c

heck

or r

epla

ce b

uzze

r

Low

erin

g le

ver s

witc

h:

Leve

r def

ect

Low

erin

g le

ver s

igna

l: D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

Ref

er to

“Cow

l lev

er v

ehic

les:

can

not

low

er li

ft”.

*: Th

e m

ater

ial h

andl

ing

OPS

retu

rn to

ne

utra

l is

only

a fu

nctio

n fo

r the

lo

wer

ing

leve

r on

cow

l lev

er v

ehic

les.

Ref

er to

“Cow

l lev

er v

ehic

les:

can

not

low

er li

ft”.

Dis

play

set

ting:

USA

spe

cific

atio

n en

able

dC

heck

set

ting

valu

es w

ith o

ptio

n se

t.C

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-167

Buz

zer r

elat

ed

For m

ini l

ever

veh

icle

s:M

ater

ial h

andl

ing

OPS

retu

rn to

ne

utra

l ala

rm d

oes

not s

ound

.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

Mat

eria

l han

dlin

g le

ver p

oten

tiom

eter

un

it: Leve

r def

ect

Mat

eria

l han

dlin

g le

ver l

ine

(Pow

er s

uppl

y, s

igna

l, gr

ound

):D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)Sh

ort o

r lin

k fa

ult

(Har

ness

, con

nect

or)

Mat

eria

l han

dlin

g le

ver p

oten

tiom

eter

vo

ltage

che

ck:

Mov

e th

e le

ver i

nto

forw

ard

and

reve

rse

tilt p

ositi

ons

and

chec

k th

e vo

ltage

cha

nge.

If th

ere

is n

o ch

ange

, per

form

a

harn

ess

chec

k or

repl

ace

the

pote

ntio

met

erIf

none

of t

he m

ater

ial h

andl

ing

leve

rs

mov

e, re

fer t

o “C

owl l

ever

veh

icle

s,

min

i lev

er v

ehic

les:

can

not p

erfo

rm

any

mat

eria

l han

dlin

g”.

Dis

play

set

ting:

USA

spe

cific

atio

n en

able

dC

heck

set

ting

valu

es w

ith o

ptio

n se

tC

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:

Park

ing

brak

e re

min

der a

larm

doe

s no

t sou

nd.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:Fa

ult (

Har

ness

, con

nect

or)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

Park

ing

brak

e sw

itch

unit:

Ope

n fa

ult

(stu

ck in

rele

ased

sta

te, i

nter

nal

dam

age)

Park

ing

brak

e de

tect

ion

mec

hani

sm:

Alw

ays

rele

ased

Park

ing

brak

e lin

e:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k, h

arne

ss c

heck

, or

repl

ace

the

switc

h.

Dis

play

set

ting:

Park

ing

brak

e re

min

der a

larm

set

ting

disa

bled

.U

SA s

peci

ficat

ion

enab

led

Che

ck s

ettin

g va

lues

with

opt

ion

set

Cha

nge

SAS

/OP

S co

ntro

ller s

ettin

g:

Not

mat

ched

–Fo

llow

mat

chin

g pr

oced

ure

to m

atch

.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-168

Buz

zer r

elat

ed

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:P

arki

ng b

rake

rem

inde

r ala

rm

cont

inue

s to

sou

nd e

ven

afte

r the

pa

rkin

g br

ake

has

been

dep

ress

ed

(or p

ulle

d).

Park

ing

brak

e sw

itch

unit:

Gro

und

shor

t fau

lt(S

tuck

in re

leas

ed s

tate

, int

erna

l da

mag

e)Pa

rkin

g br

ake

dete

ctio

n m

echa

nism

:Al

way

s re

leas

edPa

rkin

g br

ake

line:

Gro

und

shor

t fau

lt(H

arne

ss, c

onne

ctor

)

ON

/OFF

che

ck w

ith a

naly

zer

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k, h

arne

ss c

heck

, or

repl

ace

the

switc

h.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:P

arki

ng b

rake

retu

rn re

min

der a

larm

do

es n

ot s

ound

.*

Firs

t per

form

a “P

arki

ng b

rake

re

min

der a

larm

doe

s no

t sou

nd”

chec

k.

Buz

zer u

nit:

Buz

zer d

efec

tB

uzze

r har

ness

line

(Pow

er s

uppl

y si

de, l

ead-

in s

ide)

:Fa

ult (

Har

ness

, con

nect

or)

–H

arne

ss c

heck

or r

epla

ce b

uzze

r

Vehi

cle

spee

d se

nsor

uni

t:C

anno

t det

ect l

ow s

peed

(In

tern

al d

amag

e)Ve

hicl

e sp

eed

sens

or li

ne(S

PD

+ si

de, S

PD- s

ide)

: Li

nk fa

ult

(Har

ness

, con

nect

or)

Che

ck s

enso

r vol

tage

and

veh

icle

sp

eed

with

the

anal

yzer

*With

the

park

ing

brak

e no

t ret

urne

d,

even

whe

n th

e ac

cele

rato

r ped

al is

de

pres

sed,

the

alar

m o

nly

soun

ds a

t sp

eeds

abo

ve 2

km/h

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:P

arki

ng b

rake

retu

rn re

min

der a

larm

so

unds

on

trave

ling.

* Fi

rst p

erfo

rm a

“Par

king

bra

ke

rem

inde

r ala

rm d

oes

not s

ound

” ch

eck.

Met

er u

nit (

with

OK

mon

itor)

:M

eter

def

ect

–R

epla

ce

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-169

Dis

play

fu

nctio

n

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:W

hen

the

load

indi

cato

r sw

itch

is

pres

sed,

the

load

is n

ot d

ispl

ayed

.

Load

indi

cato

r sw

itch

unit:

Ope

n fa

ult (

Inte

rnal

dam

age)

Load

indi

cato

r sw

itch

dete

ctio

n m

echa

nism

(Min

i lev

er, j

oyst

ick)

: D

etec

tion

part

gap

adju

stm

ent d

efec

tLo

ad in

dica

tor s

witc

h lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Ope

n fa

ult

(Pow

er s

uppl

y, h

arne

ss,

conn

ecto

r)

ON

/OFF

che

ck w

ith a

naly

zer

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k, h

arne

ss c

heck

, or

repl

ace

the

switc

h (le

ver).

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:W

hen

the

vehi

cle

is s

topp

ed, t

he

disp

lay

cont

inua

lly s

how

s lo

ad

indi

cato

r.

Load

indi

cato

r sw

itch

unit:

Shor

t fau

lt (In

tern

al d

amag

e)Lo

ad in

dica

tor s

witc

h de

tect

ion

mec

hani

sm (M

ini l

ever

, joy

stic

k):

Det

ectio

n pa

rt ga

p ad

just

men

t def

ect

Load

indi

cato

r sw

itch

line

(Sig

nal):

Sh

ort f

ault

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k, h

arne

ss c

heck

, or

repl

ace

the

switc

h (le

ver).

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:Th

e co

rrect

load

is n

ot d

ispl

ayed

.

Dis

play

set

ting:

Cyl

inde

r bor

e, n

umbe

r of c

ylin

ders

, 0

poin

t cor

rect

ion,

cal

ibra

tion

Car

ry o

ut re

mat

chin

g an

d ch

eck

oper

atio

nLo

ad s

enso

r vol

tage

che

ck:

Mou

nt a

load

, gro

und

the

fork

s an

d ch

eck

the

chan

ge in

vol

tage

*At h

igh

liftin

g he

ight

, cor

rect

load

ca

nnot

be

calc

ulat

ed a

nd th

e di

spla

y fla

shes

.

Follo

w th

e pr

oced

ure

for m

atch

ing,

an

d re

mat

ch (c

ylin

der b

ore,

num

ber o

f cy

linde

rs, 0

poi

nt c

orre

ctio

n)In

cas

es w

here

pre

cisi

on is

requ

ired,

ad

just

on

the

load

indi

cato

r mat

chin

g LO

AD

CA

LIB

RAT

ION

scr

een.

If th

ere

is n

o ch

ange

dur

ing

the

volta

ge

chec

k, p

erfo

rm a

har

ness

che

ck o

r re

plac

e th

e se

nsor

.

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-170

Dis

play

fu

nctio

n

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:To

rque

con

verte

r oil

tem

pera

ture

in

dica

tor s

tays

at l

evel

1.

Torq

ue c

onve

rter o

il te

mpe

ratu

re

sens

or u

nit:

Ope

n fa

ult (

Inte

rnal

dam

age)

Torq

ue c

onve

rter o

il te

mpe

ratu

re

sens

or li

ne (S

igna

l, gr

ound

):D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)+B

sho

rt fa

ult

(Har

ness

, con

nect

or)

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

Star

t the

eng

ine

and

afte

r lea

ving

the

vehi

cle

runn

ing

for a

whi

le, c

heck

the

indi

cato

r.

Har

ness

che

ck o

r rep

lace

sen

sor,

or

repl

ace

SA

S/O

PS

con

trolle

r

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:To

rque

con

verte

r oil

tem

pera

ture

in

dica

tor c

ontin

ually

dis

play

s ov

erhe

at w

arni

ng in

dica

tion.

Torq

ue c

onve

rter o

il te

mpe

ratu

re

sens

or u

nit:

Shor

t fau

lt (In

tern

al d

amag

e)To

rque

con

verte

r oil

tem

pera

ture

se

nsor

line

(Sig

nal):

G

roun

d sh

ort f

ault

(Har

ness

, con

nect

or)

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

Stop

the

engi

ne a

nd a

fter l

eavi

ng th

e ve

hicl

e st

oppe

d fo

r a w

hile

, che

ck th

e in

dica

tior.

Har

ness

che

ck o

r rep

lace

sen

sor,

or

repl

ace

SA

S/O

PS

con

trolle

r

Vehi

cles

with

mul

tifun

ctio

n di

spla

y D

X:To

rque

con

verte

r oil

tem

pera

ture

in

dica

tor d

oes

not d

ispl

ay.

Ther

e is

no

disp

lay

on M

T ve

hicl

es.

Dis

play

set

ting:

Torq

ue c

onve

rter o

il te

mpe

ratu

re

emer

genc

y se

tting

ena

bled

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect (

MTC

line

sho

rt)

Che

ck th

at th

e TE

MP

GA

UG

E o

n th

e op

tion

set s

cree

n is

set

to Y

ES

, and

th

at th

e M

TC o

n th

e an

alyz

er I/

O

OTH

ER

S s

cree

n is

set

to 0

.

If th

e TE

MP

GA

UG

E is

set

to N

O o

n th

e op

tion

set s

cree

n, c

hang

e it

to

YE

S, a

nd if

MTC

on

the

anal

yzer

I/O

O

THER

S s

cree

n is

set

to 1

, per

form

a

harn

ess

chec

k or

repl

ace

the

SA

S/

OP

S c

ontro

ller.

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-171

Swin

g lo

ckFe

els

unst

able

whe

n tra

velin

g.(T

rave

ling

lock

has

bec

ome

diffi

cult

or

no lo

nger

pos

sibl

e)

Tire

uni

t:B

urst

, tire

pre

ssur

e ad

just

men

t de

fect

–A

djus

t or r

epla

ce

Lock

cyl

inde

r uni

t:Le

ak, c

anno

t loc

k(In

tern

al d

amag

e)Lo

ck c

ylin

der l

ocke

d st

atus

:In

stal

latio

n pa

rt da

mag

ed o

r de

stro

yed

Che

ck th

e lo

cked

sta

tus

with

an

activ

e te

st.

Rep

lace

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Shor

t or l

eak

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:P

efor

m li

ft re

lief a

nd c

heck

the

chan

ge in

vol

tage

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Lifti

ng h

eigh

t sw

itch

unit:

Dis

conn

ectio

n fa

ult

(Inte

rnal

dam

age,

stu

ck)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Yaw

rate

sen

sor u

nit:

Red

uced

sen

sitiv

ity, v

olta

ge s

tuck

(Inte

rnal

dam

age)

Yaw

rate

sen

sor l

ine

(Sig

nal):

Leak

(Har

ness

, con

nect

or)

Yaw

rate

sen

sor v

olta

ge c

heck

: C

heck

that

the

volta

ge is

ap

prox

imat

ely

2.5

V w

hen

the

vehi

cle

is s

topp

ed.

Inst

alla

tion

chec

k or

repl

ace

sens

or

Vehi

cle

spee

d se

nsor

uni

t:C

anno

t det

ect l

ow s

peed

s (In

tern

al d

amag

e)Ve

hicl

e sp

eed

sens

or li

ne(S

PD

+ si

de, S

PD- s

ide)

:Le

ak fa

ult

(Har

ness

, con

nect

or)

Che

ck s

enso

r vol

tage

and

veh

icle

sp

eed

with

the

anal

yzer

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-172

Swin

g lo

ck

Sw

ing

lock

con

tinua

lly a

ctiv

ates

whi

le

trave

ling

and

mat

eria

l han

dlin

g op

erat

ions

, or s

win

g lo

ck a

ctiv

ates

fre

quen

tly.

Lock

cyl

inde

r uni

t:Lo

ck s

tuck

(int

erna

l dam

age)

Che

ck th

e lo

cked

sta

tus

with

an

activ

e te

st.

Rep

lace

Swin

g lo

ck s

olen

oid

line

(SW

N+,

S

WN

-):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Sole

noid

gro

und

line

(E01

, E02

): D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

Che

ck th

e lo

cked

sta

tus

with

an

activ

e te

st.

Har

ness

che

ck o

r rep

lace

sol

enoi

d

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Shor

t or l

eak

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:P

efor

m li

ft re

lief a

nd c

heck

that

the

volta

ge ri

ses.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Lifti

ng h

eigh

t sw

itch

unit

(220

0H):

Dis

conn

ectio

n fa

ult (

inte

rnal

dam

age,

st

uck)

Lifti

ng h

eigh

t sw

itch

unit

(400

0H):

Dis

conn

ectio

n fa

ult (

inte

rnal

dam

age,

st

uck)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Yaw

rate

sen

sor u

nit:

Red

uced

sen

sitiv

ity, v

olta

ge s

tuck

(Inte

rnal

dam

age)

Yaw

rate

sen

sor v

olta

ge c

heck

:C

heck

that

the

volta

ge is

ap

prox

imat

ely

2.5

V w

hen

the

vehi

cle

is s

topp

ed.

Inst

alla

tion

chec

k or

repl

ace

sens

or

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-173

Tilt

cont

rol

Forw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p.(C

ontin

ues

to ti

lt to

the

forw

ard

mos

t til

t pos

ition

with

out s

topp

ing

at th

e le

vel p

ositi

on)

Tilt

angl

e se

nsor

uni

t:S

enso

r def

ect

Tilt

angl

e se

nsor

inst

alla

tion:

Link

, ins

talla

tion

part

dest

roye

d,

dam

aged

Tilt

angl

e se

nsor

vol

tage

che

ck:

Tilt

to fo

rwar

d an

d ba

ckw

ard

tilt

posi

tions

and

che

ck th

e vo

ltage

ch

ange

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Hor

izon

tal m

atch

ing

valu

e fo

r tilt

ang

le

sens

or:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

Aut

omat

ic fo

rk le

velin

g sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Aut

omat

ic fo

rk le

velin

g sw

itch

dete

ctio

n m

echa

nism

(min

i lev

er,

joys

tick)

:D

etec

tion

part

gap

adju

stm

ent d

efec

tA

utom

atic

fork

leve

ling

switc

h lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer.

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

tilt

cont

rol v

alve

:St

uck

(inte

rnal

dam

age)

Turn

the

tilt s

olen

oid

OFF

and

ope

rate

to

forw

ard

tilt u

sing

an

activ

e te

st.

If fo

rwar

d til

t can

be

perfo

rmed

, re

plac

e th

e C

/V ti

lt co

ntro

l val

ve.

Dis

play

set

ting

(min

i lev

er, j

oy s

tick)

: 3/

4 w

ay c

hang

e ov

er s

peci

ficat

ion

is

set t

o 2/

3 w

ay c

hang

e ov

er s

ettin

gC

heck

the

optio

n se

t con

tent

.C

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-174

Tilt

cont

rol

Forw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p.(S

tops

at a

pos

ition

slig

htly

off

the

leve

l po

sitio

n)

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Shor

t or l

eak

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:P

efor

m li

ft re

lief a

nd c

heck

that

the

volta

ge ri

ses.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Load

sen

sor n

o-lo

ad m

atch

ing

valu

e:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)–

Follo

w m

atch

ing

proc

edur

e to

re

mat

ch.

Tilt

angl

e se

nsor

uni

t:S

enso

r def

ect

Tilt

angl

e se

nsor

inst

alla

tion:

Link

, ins

talla

tion

part

dest

roye

d,

dam

aged

Tilt

angl

e se

nsor

vol

tage

che

ck:

Tilt

to fo

rwar

d an

d ba

ckw

ard

tilt

posi

tions

and

che

ck th

e vo

ltage

ch

ange

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Hor

izon

tal m

atch

ing

valu

e fo

r tilt

ang

le

sens

or:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-175

Tilt

cont

rol

Forw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p.(S

tops

at t

he p

ositi

on w

here

the

auto

mat

ic fo

rk le

velin

g sw

itch

is

pres

sed)

Load

sen

sor u

nit:

Sen

sor d

efec

tLo

ad s

enso

r lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

Shor

t or l

eak

faul

t(H

arne

ss, c

onne

ctor

)

Load

sen

sor v

olta

ge c

heck

:C

heck

that

the

volta

ge ri

ses

on li

ft re

lief.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Load

sen

sor n

o-lo

ad m

atch

ing

valu

e:D

oes

not m

atch

act

ual s

tatu

s (re

mat

ch)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

Tilt

angl

e se

nsor

uni

t:S

enso

r def

ect

Tilt

angl

e se

nsor

inst

alla

tion:

Link

, ins

talla

tion

part

dest

roye

d,

dam

aged

Tilt

angl

e se

nsor

vol

tage

che

ck:

Tilt

to fo

rwar

d an

d ba

ckw

ard

tilt

posi

tions

and

che

ck th

e vo

ltage

ch

ange

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Hor

izon

tal m

atch

ing

valu

e fo

r tilt

ang

le

sens

or:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

Lifti

ng h

eigh

t sw

itch

unit

(220

0H):

Dis

conn

ectio

n fa

ult (

inte

rnal

dam

age,

st

uck)

ON

/OFF

che

ck w

ith a

naly

zer.

Har

ness

che

ck o

r rep

lace

sw

itch

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-176

Tilt

cont

rol

Mas

t bac

kwar

d til

ting

spee

d is

not

lim

ited.

Or,

back

war

d til

ting

spee

d is

alw

ays

slow

.

Aut

omat

ic fo

rk le

velin

g sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Aut

omat

ic fo

rk le

velin

g sw

itch

dete

ctio

n m

echa

nism

(min

i lev

er,

joys

tick)

:D

etec

tion

part

gap

adju

stm

ent d

efec

tA

utom

atic

fork

leve

ling

switc

h lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

tilt

cont

rol v

alve

:St

uck

(inte

rnal

dam

age)

Turn

the

tilt s

olen

oid

ON

/OFF

and

op

erat

e to

bac

kwar

d til

t usi

ng a

n ac

tive

test

.

If th

ere

is n

o ch

ange

in th

e ba

ckw

ard

tiltin

g sp

eed

whe

n O

N/O

FF o

pera

ted,

re

plac

e th

e C

/V ti

lt co

ntro

l val

ve.

Lifti

ng h

eigh

t sw

itch

unit

(220

0H):

Dis

conn

ectio

n fa

ult (

inte

rnal

dam

age,

st

uck)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Dis

play

set

ting

(min

i lev

er, j

oyst

ick)

: 3/

4-w

ay c

hang

e ov

er s

peci

ficat

ion

is

set t

o 2/

3-w

ay c

hang

e ov

er s

ettin

g

Che

ck th

e op

tion

set c

onte

nt.

Cha

nge

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-177

Min

i lev

er

func

tion

Min

i lev

er, j

oyst

ick

vehi

cles

:B

ackw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p. (C

ontin

ues

to ti

lt to

ba

ckw

ard

mos

t tilt

pos

ition

with

out

stop

ping

at t

he le

vel p

ositi

on)

Tilt

angl

e se

nsor

uni

t:S

enso

r def

ect

Tilt

angl

e se

nsor

inst

alla

tion:

Link

, ins

talla

tion

part

dest

roye

d,

dam

aged

Tilt

angl

e se

nsor

vol

tage

che

ck:

Tilt

to fo

rwar

d an

d ba

ckw

ard

tilt

posi

tions

and

che

ck th

e vo

ltage

ch

ange

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Hor

izon

tal m

atch

ing

valu

e fo

r tilt

ang

le

sens

or:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

Aut

omat

ic fo

rk le

velin

g sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Aut

omat

ic fo

rk le

velin

g sw

itch

dete

ctio

n m

echa

nism

(min

i lev

er,

joys

tick)

:D

etec

tion

part

gap

adju

stm

ent d

efec

tA

utom

atic

fork

leve

ling

switc

h lin

e(P

ower

sup

ply,

sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Dis

play

set

ting

(min

i lev

er, j

oy s

tick)

:•

3/4-

way

cha

nge

over

spe

cific

atio

n se

t to

2/3-

way

cha

nge

over

set

ting

•B

ackw

ard

tilt a

utom

atic

fork

leve

ling

is d

eact

ivat

ed

Che

ck th

e op

tion

set c

onte

ntC

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Min

i lev

er, j

oyst

ick

vehi

cles

:B

ackw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p. (S

tops

at a

pos

ition

sl

ight

ly o

ff th

e le

vel p

ositi

on)

Ref

er to

forw

ard

tilt a

utom

atic

fork

le

velin

g do

es n

ot s

top

(sto

ps a

t the

po

sitio

n w

here

the

auto

mat

ic le

velin

g sw

itch

is p

ress

ed).

––

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-178

Min

i lev

er

func

tion

Min

i lev

er, j

oyst

ick

vehi

cles

:B

ackw

ard

tilt a

utom

atic

fork

leve

ling

does

not

sto

p. (S

tops

at t

he p

ositi

on

whe

re th

e au

tom

atic

fork

leve

ling

switc

h is

pre

ssed

)

Tilt

angl

e se

nsor

uni

t:S

enso

r def

ect

Tilt

angl

e se

nsor

inst

alla

tion:

Link

, ins

talla

tion

part

dest

roye

d,

dam

aged

Tilt

angl

e se

nsor

vol

tage

che

ck:

Tilt

to fo

rwar

d an

d ba

ckw

ard

tilt

posi

tions

and

che

ck th

e vo

ltage

ch

ange

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Hor

izon

tal m

atch

ing

valu

e fo

r tilt

ang

le

sens

or:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)

–Fo

llow

mat

chin

g pr

oced

ure

to

rem

atch

.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Min

i lev

er 3

/4-w

ay (2

/3-w

ay) c

hang

e ov

er s

peci

ficat

ion:

3-

way

(2-w

ay) o

pera

tion

even

whe

n th

e le

ver c

hang

e ov

er s

witc

h is

pr

esse

d. (D

oes

not c

hang

e ov

er)

Leve

r cha

nge

over

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Leve

r cha

nge

over

sw

itch

dete

ctio

n m

echa

nism

(min

i lev

er):

Det

ectio

n pa

rt ga

p ad

just

men

t def

ect

Leve

r cha

nge

over

sw

itch

line

(Pow

er s

uppl

y, s

igna

l, gr

ound

):D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Leve

r cha

nge

over

rela

y 1

or 2

uni

t: St

uck,

wel

ding

faul

t (in

tern

al

dam

age)

Leve

r cha

nge

over

rela

y 1

or 2

prim

ary

side

line

:D

isco

nnec

tion

faul

t(w

ire, c

onne

ctor

)

Che

ck th

e ch

ange

over

sta

tus

with

an

activ

e te

st.

Har

ness

che

ck o

r rep

lace

rela

y

SAS

/OP

S/m

ini l

ever

con

trolle

r:C

ontro

ller d

efec

t–

Rep

lace

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-179

Min

i lev

er

func

tion

Min

i lev

er 3

/4-w

ay (2

/3-w

ay) c

hang

e ov

er s

peci

ficat

ion:

4-w

ay (3

-way

) con

tinue

s to

ope

rate

ev

en th

ough

the

leve

r cha

nge

over

sw

itch

has

been

ope

rate

d. (S

tays

ch

ange

d ov

er)

Leve

r cha

nge

over

sw

itch

unit:

Gro

und

shor

t fau

lt (In

tern

al d

amag

e)Le

ver c

hang

e ov

er s

witc

h de

tect

ion

mec

hani

sm (m

ini l

ever

):D

etec

tion

part

gap

adju

stm

ent d

efec

tLe

ver c

hang

e ov

er s

witc

h lin

e(s

igna

l):G

roun

d sh

ort f

ault

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Leve

r cha

nge

over

rela

y 1

or 2

uni

t:St

uck,

wel

ding

faul

t (in

tern

al

dam

age)

Leve

r cha

nge

over

rela

y 1

or 2

prim

ary

side

low

er li

ne:

Gro

und

shor

t fau

lt(w

ire, c

onne

ctor

)

Che

ck th

e ch

ange

over

sta

tus

with

an

activ

e te

st.

Har

ness

che

ck o

r rep

lace

rela

y

Dis

play

set

ting:

Num

ber o

f atta

chm

ent l

ever

s is

not

se

t to

5 w

ayC

heck

the

optio

n se

t con

tent

.C

hang

e

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Min

i lev

er 2

/3-w

ay c

hang

e ov

er

spec

ifica

tion:

Dur

ing

ATT1

ope

ratio

n an

d hi

gh

liftin

g he

ight

, and

whe

n lo

aded

, ATT

1 st

ops

and

pull-

side

ope

ratio

n is

slo

w.

Dis

play

set

ting:

Num

ber o

f atta

chm

ent l

ever

s is

not

se

t to

2/3-

way

Che

ck th

e op

tion

set c

onte

nt.

Cha

nge

3-w

ay (4

-way

) spe

cifc

atio

n:Al

thou

gh A

TT1

(ATT

2) is

ope

rate

d, it

do

es n

ot w

ork.

Dis

play

set

ting:

Num

ber o

f atta

chm

ent l

ever

s is

not

se

t to

3-w

ay (4

-way

)C

heck

the

optio

n se

t con

tent

.C

hang

e

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-180

Knob

co

mpe

nsai

ton

cont

rol

Knob

mov

es o

ut o

f alig

nmen

t int

o a

certa

in p

ositi

on.

(Mor

e th

an 1

0° o

ff th

e st

raig

ht a

head

po

sitio

n)

Tire

ang

le s

enso

r uni

t:S

enso

r def

ect

Tire

ang

le s

enso

r ins

talla

tion:

Loos

enes

s of

the

atta

chm

ent p

art,

dam

age,

bea

ring

hous

ing

dam

age

Tire

ang

le s

enso

r vol

tage

che

ck:

Ope

rate

the

stee

ring

and

chec

k th

e ch

ange

in v

olta

ge.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Tire

ang

le s

enso

r mat

chin

g va

lue:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)–

Follo

w m

atch

ing

proc

edur

e to

re

mat

ch.

Stee

ring

angl

e se

nsor

uni

t:S

enso

r def

ect

Stee

ring

angl

e se

nsor

inst

alla

tion:

Cam

or s

teer

ing

whe

el d

efec

t

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sen

sor

Kno

b co

mpe

nsat

ion

valv

e un

it:

Leak

, stu

ck, (

inte

rnal

dam

age)

Usi

ng a

n ac

tive

test

, tur

n th

e kn

ob

com

pens

atio

n SO

L O

N a

nd O

FF a

nd

oper

ate

the

stee

ring

at th

e tir

e en

d.SO

L O

N: c

heck

that

the

stee

ring

whe

el c

an b

e tu

rned

free

ly.S

OL

OFF

: Che

ck th

at th

e st

eerin

g w

heel

can

not b

e tu

rned

free

ly

(ste

erin

g is

hea

vy).

Rep

lace

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-181

Knob

co

mpe

nsat

ion

cont

rol

Knob

pos

ition

is o

ut o

f alig

nmen

t.(K

nob

posi

tion

is n

ot c

onst

ant w

hen

trave

ling

stra

ight

ahe

ad)

Tire

ang

le s

enso

r uni

t:S

enso

r def

ect

Tire

ang

le s

enso

r ins

talla

tion:

Loos

enes

s of

the

atta

chm

ent p

art,

dam

age,

bea

ring

hous

ing

dam

age

Tire

ang

le s

enso

r vol

tage

che

ck:

Ope

rate

the

stee

ring

and

chec

k th

e ch

ange

in v

olta

ge.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

Tire

ang

le s

enso

r mat

chin

g va

lue:

Doe

s no

t mat

ch a

ctua

l sta

tus

(rem

atch

)–

Follo

w m

atch

ing

proc

edur

e to

re

mat

ch.

Stee

ring

angl

e se

nsor

uni

t:S

enso

r def

ect

Stee

ring

angl

e se

nsor

inst

alla

tion:

Cam

or s

teer

ing

whe

el d

efec

t

Che

ck s

enso

r vol

tage

with

the

anal

yzer

.H

arne

ss c

heck

or r

epla

ce s

enso

r

Knob

com

pens

atio

n va

lve

unit:

Leak

, stu

ck, (

inte

rnal

dam

age)

Usi

ng a

n ac

tive

test

, tur

n th

e kn

ob

com

pens

atio

n SO

L O

N a

nd O

FF a

nd

oper

ate

the

stee

ring

at th

e tir

e en

d.SO

L O

N: C

heck

that

the

stee

ring

whe

el c

an b

e tu

rned

free

ly.S

OL

OFF

: Che

ck th

at th

e st

eerin

g w

heel

can

not b

e tu

rned

free

ly

(ste

erin

g is

hea

vy).

Rep

lace

PS

cylin

der s

yste

m li

nk d

efec

t:Ec

cent

ric p

in, k

ingp

in d

efec

t–

Rep

lace

Vehi

cle

spee

d se

nsor

uni

t:C

anno

t det

ect l

ow s

peed

(int

erna

l da

mag

e)Ve

hicl

e sp

eed

sens

or in

stal

latio

n:H

igh

spee

d no

t det

ecte

d co

rrect

ly(s

enso

r tip

has

met

allic

par

ticle

ad

here

d)Ve

hicl

e sp

eed

sens

or li

ne(S

PD

+ si

de, S

PD- s

ide)

:Le

ak fa

ult

(Har

ness

, con

nect

or)

Che

ck s

enso

r vol

tage

and

veh

icle

sp

eed

with

the

anal

yzer

.

If th

ere

is n

o ch

ange

, per

form

an

inst

alla

tion

chec

k or

repl

ace

the

sens

or.

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-182

Met

er

Wre

nch

lam

p is

lit c

ontin

ually

.

Fuse

:EC

U+B

fuse

blo

wn

EC

U-IG

fuse

blo

wn

–C

heck

for b

low

n fu

se

Met

er c

omm

unic

atio

n lin

e:

Gro

und

shor

t(H

arne

ss, c

onne

ctor

)D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)SA

S/O

PS IG

line

, +B

line

, gro

und

syst

em:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

–H

arne

ss c

heck

Bat

tery

uni

t: Lo

w v

olta

ge, i

ntak

e he

ater

, lar

ge

curre

nt a

uxili

ary

equi

pmen

t ope

ratio

n

Che

ck b

atte

ry v

olta

ge w

ith th

e an

alyz

er.

Keep

the

engi

ne a

t hig

h sp

eed

for a

w

hile

.

SAS

/OP

S co

ntro

ller s

ettin

g:N

ot m

atch

ed–

Follo

w m

atch

ing

proc

edur

e to

re

mat

ch.

Met

er u

nit:

Met

er d

efec

t–

Rep

lace

SAS

/OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

The

wre

nch

lam

p do

es n

ot li

ght e

ven

whe

n th

e ig

nitio

n ke

y sw

itch

is tu

rned

O

N.

Met

er p

ower

sup

ply

line:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

–H

arne

ss c

heck

Met

er u

nit:

Met

er d

efec

t–

Rep

lace

Hou

r met

er is

not

dis

play

ed.

Hou

r met

er s

tart

fuse

: N

ot c

onne

cted

Hou

r met

er s

tart

sign

al li

ne:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

–H

arne

ss c

heck

or r

epla

ce c

onne

ctor

Met

er u

nit:

Met

er d

efec

t–

Rep

lace

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-183

OP

S

For c

owl l

ever

veh

icle

s:C

anno

t low

er th

e lif

t.

Lift

low

er s

witc

h un

it:O

pen

faul

t(S

witc

h m

ount

ed in

corre

ctly,

inte

rnal

dam

age,

stu

ck)

Lift

low

er s

witc

h lin

e:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)Sw

itch

grou

nd li

ne:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

lift

low

er lo

ck v

alve

Stuc

k (in

tern

al d

amag

e)

Usi

ng a

n ac

tive

test

, tur

n th

e lif

t low

er

lock

sol

enoi

d O

N a

nd p

erfo

rm lo

wer

op

erat

ion.

If th

e lif

t can

not l

ower

by

low

er

oper

atio

n, re

plac

e th

e C

/V.

Seat

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

For c

owl l

ever

veh

icle

s:C

anno

t per

form

forw

ard

tilt.

Forw

ard

tilt s

witc

h un

it:O

pen

faul

t(S

witc

h m

ount

ed in

corre

ctly,

inte

rnal

dam

age,

stu

ck)

Forw

ard

tilt s

witc

h lin

e:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)Sw

itch

grou

nd li

ne:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

tilt

cont

rol v

alve

Stuc

k (in

tern

al d

amag

e)Tu

rn th

e til

t sol

enoi

d O

N a

nd o

pera

te

to fo

rwar

d til

t usi

ng a

n ac

tive

test

.If

forw

ard

tilt c

anno

t be

perfo

rmed

, re

plac

e th

e C

/V ti

lt co

ntro

l val

ve.

Seat

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-184

OP

S

For c

owl l

ever

veh

icle

s:C

anno

t per

form

bac

kwar

d til

t.

Bac

kwar

d til

t sw

itch

unit:

Ope

n fa

ult

(Sw

itch

mou

nted

inco

rrect

ly,in

tern

al d

amag

e, s

tuck

)B

ackw

ard

tilt s

witc

h lin

e:D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)Sw

itch

grou

nd li

ne:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

bac

kwar

d til

t loc

k va

lve

Stuc

k (in

tern

al d

amag

e)

Turn

the

back

war

d til

t loc

k so

leno

id

ON

and

ope

rate

to b

ackw

ard

tilt u

sing

an

act

ive

test

.

If ba

ckw

ard

tilt c

anno

t be

perfo

rmed

, re

plac

e th

e C

/V b

ackw

ard

tilt l

ock

valv

e.

Seat

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Can

not p

erfo

rm m

ater

ial h

andl

ing

exce

pt fo

r lift

low

er.

C/V

unl

oad

valv

e:St

uck

(inte

rnal

dam

age)

For c

owl l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

OFF

an

d pe

rform

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

For m

ini l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

ON

an

d pe

rform

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

If ra

isin

g ca

nnot

be

perfo

rmed

, rep

lace

th

e C

/V u

nloa

d va

lve.

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-185

OP

SM

ater

ial h

andl

ing

OPS

doe

s no

t op

erat

e.

C/V

tilt

cont

rol v

alve

:St

uck

(inte

rnal

dam

age)

Turn

the

tilt s

olen

oid

OFF

and

ope

rate

to

forw

ard

tilt u

sing

an

activ

e te

st.

If fo

rwar

d til

t can

be

perfo

rmed

, re

plac

e th

e C

/V ti

lt co

ntro

l val

ve.

C/V

bac

kwar

d til

t loc

k va

lve:

Stuc

k (in

tern

al d

amag

e)

Turn

the

back

war

d til

t loc

k so

leno

id

OFF

and

ope

rate

to b

ackw

ard

tilt u

sing

an

act

ive

test

.

If ba

ckw

ard

tilt c

an b

e pe

rform

ed,

repl

ace

the

C/V

tilt

cont

rol v

alve

.

C/V

lift

low

er lo

ck v

alve

: St

uck

(inte

rnal

dam

age)

Usi

ng a

n ac

tive

test

, tur

n th

e lif

t low

er

lock

sol

enoi

d O

FF a

nd p

erfo

rm lo

wer

op

erat

ion.

If lo

wer

ing

can

be p

erfo

rmed

, rep

lace

th

e C

/V li

ft lo

wer

lock

val

ve.

C/V

unl

oad

valv

e:St

uck

(inte

rnal

dam

age)

For c

owl l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

ON

an

d pe

rform

lift

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

For m

ini l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

OFF

an

d pe

rform

lift

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

If ra

isin

g ca

n be

per

form

ed, r

epla

ce

the

C/V

unl

oad

valv

e.

Seat

sw

itch

unit:

Shor

t fau

lt (in

tern

al d

amag

e)Se

at s

witc

h lin

e (S

igna

l, gr

ound

):D

isco

nnec

tion

faul

t (H

arne

ss, c

onne

ctor

)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

SAS

/OP

S co

ntro

ller,

OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-186

OP

S

Cow

l lev

er, m

ini l

ever

veh

icle

s:N

o m

ater

ial h

andl

ing

can

be

perfo

rmed

.

Seat

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

C/V

unl

oad

valv

e:St

uck

(inte

rnal

dam

age)

For c

owl l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

OFF

an

d pe

rform

lift

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

For m

ini l

ever

veh

icle

s:Tu

rn th

e un

load

val

ve s

olen

oid

ON

an

d pe

rform

lift

rais

ing

oper

atio

n us

ing

an a

ctiv

e te

st.

If ra

isin

g ca

nnot

be

perfo

rmed

, rep

lace

th

e C

/V u

nloa

d va

lve.

SAS

/OP

S co

ntro

ller,

OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Trav

elin

g O

PS d

oes

not o

pera

te.

Forw

ard

trave

l int

erru

pt re

lay

unit:

St

uck

(inte

rnal

dam

age,

wel

ded)

Rev

erse

trav

el in

terru

pt re

lay

unit:

Stuc

k (in

tern

al d

amag

e, w

elde

d)R

elay

sec

onda

ry s

ide

line:

Sh

ort f

ault

(Har

ness

, con

nect

or)

Turn

the

forw

ard

and

reve

rse

trave

l in

terru

pt re

lays

ON

and

ope

rate

fo

rwar

d an

d re

vers

e tra

vel u

sing

an

activ

e te

st.

If fo

rwar

d tra

vel c

an b

e pe

rform

ed,

repl

ace

the

forw

ard

trave

l int

erru

pt

rela

y.If

reve

rse

trave

l can

be

perfo

rmed

, re

plac

e th

e re

vers

e tra

vel i

nter

rupt

re

lay.

Or p

erfo

rm a

har

ness

che

ck.

Sho

rt sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

SAS

/OP

S co

ntro

ller,

OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-187

OPS

Can

not t

rave

l.

Fuse

:S

hift

fuse

blo

wn

–C

heck

for b

low

n fu

se

Forw

ard

trave

l int

erru

pt re

lay

unit:

Ope

n fa

ult

(inte

rnal

dam

age,

wel

ded)

Rev

erse

trav

el in

terru

pt re

lay

unit:

Ope

n fa

ult

(inte

rnal

dam

age,

wel

ded)

Rel

ay s

econ

dary

sid

e lin

e:O

pen

faul

t(H

arne

ss, c

onne

ctor

)

Turn

the

forw

ard

and

reve

rse

trave

l in

terru

pt re

lays

OFF

and

ope

rate

fo

rwar

d an

d re

vers

e tra

vel u

sing

an

activ

e te

st.

If fo

rwar

d tra

vel c

anno

t be

perfo

rmed

, re

plac

e th

e fo

rwar

d tra

vel i

nter

rupt

re

lay.

If re

vers

e tra

vel c

anno

t be

perfo

rmed

, rep

lace

the

reve

rse

trave

l in

terru

pt re

lay.

Or p

erfo

rm a

har

ness

ch

eck.

Seat

sw

itch

unit:

Ope

n fa

ult (

inte

rnal

dam

age)

Seat

sw

itch

line

(Sig

nal,

grou

nd):

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

Dire

ctio

n le

ver u

nit:

Ope

n sy

stem

faul

t (in

tern

al d

amag

e)D

irect

ion

leve

r sig

nal l

ine:

Dis

conn

ectio

n fa

ult

(Har

ness

, con

nect

or)

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

r rep

lace

sw

itch

SAS

/OP

S co

ntro

ller,

OP

S co

ntro

ller:

Con

trolle

r def

ect

–R

epla

ce

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-188

Torq

ue

conv

erte

r in

terlo

ck

The

vehi

cle

cann

ot tr

avel

.

Torq

ue c

onve

rter i

nter

lock

rela

y m

ain

unit

for f

orw

ard

mov

emen

t:An

ope

n ci

rcui

t (in

tern

al d

amag

e)To

rque

con

verte

r int

erlo

ck re

lay

mai

n un

it fo

r bac

kwar

d m

ovem

ent:

An o

pen

circ

uit (

inte

rnal

dam

age)

Rel

ay s

econ

dary

line

:A

n op

en c

ircui

t (h

arne

sses

, con

nect

ors)

–

Che

ck th

e ha

rnes

ses.

If

the

vehi

cle

cann

ot tr

avel

forw

ard,

re

plac

e th

e to

rque

con

verte

r int

erlo

ck

rela

y fo

r for

war

d m

ovem

ent.

If th

e ve

hicl

e ca

nnot

trav

el b

ackw

ard,

re

plac

e th

e to

rque

con

verte

r int

erlo

ck

rela

y fo

r bac

kwar

d m

ovem

ent.

SAS

/OP

S co

ntro

ller:

Inte

rnal

dam

age

–R

epla

ce th

e co

ntro

ller.

The

torq

ue c

onve

rter i

nter

lock

doe

s no

t ope

rate

.

SAS

/OP

S co

ntro

ller i

s se

t:O

ptio

n se

t is

not s

et–

Set t

he c

ontro

ller a

gain

acc

ordi

ng to

th

e op

tion

set p

roce

dure

.

Torq

ue c

onve

rter i

nter

lock

rela

y m

ain

unit

for f

orw

ard

mov

emen

t:An

ope

n ci

rcui

t (in

tern

al d

amag

e)To

rque

con

verte

r int

erlo

ck re

lay

mai

n un

it fo

r bac

kwar

d m

ovem

ent:

An o

pen

circ

uit (

inte

rnal

dam

age)

Rel

ay s

econ

dary

line

:Fr

ame

shor

t (ha

rnes

ses)

–

Che

ck th

e ha

rnes

ses.

If th

e ve

hicl

e ca

nnot

trav

el fo

rwar

d,

repl

ace

the

torq

ue c

onve

rter i

nter

lock

re

lay

for f

orw

ard

mov

emen

t.If

the

vehi

cle

cann

ot tr

avel

bac

kwar

d,

repl

ace

the

torq

ue c

onve

rter i

nter

lock

re

lay

for b

ackw

ard

mov

emen

t.

SAS

/OP

S co

ntro

ller:

Inte

rnal

dam

age

–R

epla

ce th

e co

ntro

ller.

Con

trol t

ype

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n


Section 19

19-189

Def

ect C

ause

s W

hen

Ther

e is

No

ASC

Err

or D

ispl

ay

Not

e:If

an e

rror

cod

e or

wre

nch

lam

p is

flas

hing

, rep

air i

t firs

t.

Phen

omen

on o

n ve

hicl

eM

alfu

nctio

n ar

ea ·

mod

eC

heck

ing

met

hod

Cor

rect

ive

actio

n

Occ

aiso

nally

full

spee

d is

not

reac

hed

even

with

the

acce

lera

tor p

edal

fully

de

pres

sed.

(NM

R s

peed

not

ach

eive

d)

NM

R s

witc

h un

it:Sw

itch

defe

ctN

MR

sw

itch

line:

D

isco

nnec

tion

faul

t(H

arne

ss, c

onne

ctor

)N

MR

sw

itch

adju

stm

ent:

Adju

stm

ent d

efec

t, se

al b

olt p

ositi

on

defe

ct o

r som

e ot

her m

echa

nica

l def

ect

ON

/OFF

che

ck w

ith a

naly

zer

Har

ness

che

ck o

rre

plac

e sw

itch,

or a

djus

t sw

itch,

adj

ust a

nd

repa

ir m

echa

nica

l par

ts.

AS

C c

ontro

ller:

Con

trolle

r def

ect

–R

epla

ce

Idle

spe

ed is

hig

her t

han

spec

ified

spe

ed

even

whe

n th

e ac

cele

rato

r ped

al is

not

de

pres

sed.

Idle

sw

itch

adju

stm

ent:

Adju

stm

ent d

efec

t or m

echa

nica

l def

ect

–S

witc

h ad

just

men

t

Acc

eler

ator

sen

sor:

Sens

or c

atch

ing,

mis

take

in p

roce

dure

du

ring

sens

or re

plac

emen

t (w

hen

the

sens

or is

ben

g re

plac

ed, i

f a C

4 se

ries

erro

r is

not c

reat

ed b

y tu

rnin

g th

e ig

nitio

n ke

y O

N w

hile

the

sens

or c

onne

ctor

is

disc

onne

cted

, the

fully

clo

sed

posi

tion

lear

ning

val

ue is

not

rese

t)

Che

ck a

ccel

erat

or s

enso

r vol

tage

with

the

anal

yzer

.

Acce

lera

tor s

enso

r adj

ustm

ent,

or, i

f a fa

ult

occu

rs a

fter s

enso

r rep

lace

men

t, tu

rn th

e ig

nitio

n ke

y O

N w

ith th

e ac

cele

rato

r sen

sor

conn

ecto

rs re

mov

ed, i

n or

der t

o cr

eate

an

erro

r onc

e.Th

en tu

rn th

e ig

nitio

n ke

y O

FF, c

onne

ct

conn

ecto

rs a

nd tu

rn th

e ig

nitio

n ke

y O

N

AS

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Section 19

…..This Page Intentionally Left Blank…..

Control Circuit

CC08-005 April 15, 2008 Programming Change 8FGU15-32, 8FGCU15-32

SERVICE INFORMATION BULLETIN Subject: 4Y-ECS Controller Programming Change Page 1 of 2 Return To CC Index MODEL APPLICATION:

Return To Main Index 8FGU15-32 and 8FGCU15-32 GENERAL INFORMATION: The 8-Series 4Y-ECS controller programming has been changed to correct the ammonia type odor from the exhaust stream. The controller change has been implemented in production and the controller is now available through Service Parts for repairing forklifts in the field. The part number for the new controller has not changed. The controller with the new programming can be identified by the color of the label. The label on the controller will have a white and orange label. The part number of the ECS controller has stayed the same in past programming versions which can be identified by the black-white, green-white and blue-white labels. Even though the controller may have a different color label, it does not need to be changed if an ammonia odor is not present.

Example of an ECS controller with the white and orange label

The ECS controller does not need to be changed if an ammonia odor is not present.

SIB CC08-005 4Y-ECS Controller Programming Change Page 2 of 2

REPAIR INFORMATION: To change out the ECS controller:

1. Disconnect the battery. 2. Replace the ECS controller. 3. Reconnect the battery. 4. Once the controller is replaced. Verify that the ignition timing and fuel system are

adjusted correctly. Ignition Timing and Fuel System Adjustments: To check and adjust the ignition timing, reference page 2-18 of the 8-Series repair manual, 00700-X8880-71. TNB-2008-07 can be used as a reference and guide line for checking and making the adjustments to the fuel system. The idle mixture adjustment screw can be accessed by piercing the cap and prying it out of the sleeve.

Use a pick to pierce and pry out the cap for the idle

Mixture adjustment screw

Be sure the replace the tamper resistant cap, p/n 21673-13370-71, after making the any adjustments to the regulator. This is an EPA requirement. Frame Number Effective Range: 8FGU15-18 8FGU18-11533 and Higher 8FGU20-25 8FGU25-15748 and Higher 8FGU30-32 8FGU32-12676 and Higher 8FGCU15-S20 8FGCSU20-12589 and Higher 8FGCU20-25 8FGCU25-19092 and Higher 8FGCU30-32 8FGCU32-11833 and Higher

Chassis Electrical

CE07-008 November 30, 2007 Error Codes AD-1 and AD-7 8FG(C)U15-32

SERVICE INFORMATION BULLETIN Subject: Error Codes AD-1 and AD-7 Page 1 of 1 Return To CE Index MODEL APPLICATION:

Return To Main Index 8FGCU15-32 and 8FGU15-32 GENERAL INFORMATION: Error codes AD-1 and AD-7 are CAN Communication Abnormality error codes and can be set by installing a controller or optional display from one unit to another unit with different specifications, or when testing individual components and circuits. In either case, perform the “Engine and Display ECU information clear” procedure to clear the error codes. REPAIR INFORMATION: To perform the “Engine and Display ECU information clear” procedure, follow the instructions for SET 5 in the matching menu on page 16-29 of repair manual 00700-X8880-71.

SERVICE INFORMATION BULLETIN Subject: Main Wiring Harness Change (Error Code 73-1) Page 1 of 1 MODEL APPLICATION: 8FG(D)U15-32, 8FGCU20-32 GENERAL INFORMATION: There has been a main wiring harness change (part # 56011-U2241-71) on the 8-Series I.C trucks with the synchronized steering option (E72A). The connector (O4) for the synchronized steering solenoid has been moved from the left hand side harness to the main wiring harness. If the harness is not installed correctly, then error code 73-1 will become active. REPAIR INFORMATION: The Green and White-Black wires that connect the SAS/OPSS controller to the steering solenoid no longer go through pins 19 and 20 at the brown AO1 connector. The Green and White-Black wires now stop short of the AO1 connector and have their own connector that comes out of the harness just before the junction block connectors. This connector is a black 2-pin connector with a black terminating plug on the end.

When installing the new main harness, the original connector (O4) used on the steer solenoid from the Left Hand wiring harness needs to be disconnected and taped up in the harness. This connector is now inactive, so there is no need to seal the connector. The connector shown above will need to be connected to the steer solenoid in place of the original (O4) connector.

Chassis Electrical CE10-005 August 31, 2010 Main Wiring Harness Change (Error Code 73-1) 8FG(D)U15-32, 8FGCU20-32

New Steering Solenoid Connector Location

AO1 Connector Junction Box Connectors

SERVICE INFORMATION BULLETIN Subject: A5, A5-1, or 1-1 Error Codes for OPSS Page 1 of 1 MODEL APPLICATION: 7FBCU15, 7FBCU18, 7FBCU20, 7FBCU25, 7FBCU30, 7FBCU32 7FBCU35, 7FBCU45, 7FBCU55, 7FBCHU18, 7FBCHU25 7FBEU15, 7FBEU18, 7FBEU20, 7FBEHU18, 7FGU15, 7FGU18 7FGU20, 7FGU25, 7FGU30, 7FGU32, 7FDU15, 7FDU18, 7FDU20 7FDU25, 7FDU30, 7FDU32, 8FGU15, 8FGU18, 8FGU20, 8FGU25 8FGU30, 8FGU32, 8FDU15, 8FDU18, 8FDU20, 8FDU25, 8FDU30 8FDU32, 7FGCU15, 7FGCU18, 7FGCU20, 7FGCSU20, 7FGCU25 7FGCU30, 7FGCU32, 8FGCU18, 8FGCU20, 8FGCSU20, 8FGCU25 8FGCU30, 8FGCU32, 7FGU35, 7FDU35, 7FGKU40, 7FDKU40 7FGU45, 7FDU45, 7FGAU50, 7FDAU50, 7FGU60, 7FDU60, 7FGU70 7FDU70, 7FGU80, 7FDU80, 7FGCU35, 7FGCU45, 7FGCU55 7FGCU60, 7FGCU70 GENERAL INFORMATION: All three error codes are for the same condition.

• A5 is for sit-down electric trucks (Class I) • A5-1 is for 8-Series internal combustion trucks (Class IV & V) • 1-1 is for 7-Series internal combustion trucks (Class IV & V) with OPSS (Operator Presence

Sensing System)

This system was implemented in 2005. The OPSS is required to check for a malfunctioning or bypassed seat switch circuit. To do this, the system stays active even when the key is off and monitors the seat switch. If the seat switch stays closed for more than 15 minutes with the key off, the system assumes that the switch has malfunctioned or been bypassed. The code will stay active until the system sees the seat switch circuit cycle open/closed, then will automatically clear. REPAIR INFORMATION: The most common cause for these seat switch codes is an operator staying in the seat. If an operator stays sitting in the seat with the truck turned off for 15 minutes, they will trip the seat code. Examples have been operators taking a break, lunch period, or filling out paperwork while sitting on the truck with the key off. The dealer has been called for a seat switch code and when the technician arrives, the code has cleared, but is stored in memory. This is because the operator left the truck while waiting for the technician; this cycled the seat switch and cleared the code. In many cases, the seat switch has been replaced unnecessarily due to this occurrence. Further information concerning these codes can be found in the following manuals: 7FBCU15-55 OPSS Manual CU335 page 3-9 7FBEU15-20 OPSS Manual CU341 page 1-10 7FGCU15, 18, S20 OPSS Manual CU042 page 1-19 7FGU15-32, 7FDU15-32, 7FGCU20-32 OPSS Manual CU040 page 1-18 7FGU35-80, 7FDU35-80, 7FGCU35-70 OPSS Manual CU041 page 1-17 8FGCU15, 18, S20 Service manual 00700-X8880-71 page 19.1-82 8FGU15-32, 8FDU15-32, 8FGCU20-32 Service manual 00700-X8880-71 page 19-111

Chassis Electrical CE09-004 October 30, 2009 A5, A5-1, or 1-1 Error Codes for OPSS

Documents

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