21-1

ELECTRICAL SYSTEM TROUBLESHOOTING

Page Page
BEFORE TROUBLESHOOTING 0
TROUBLESHOOTING.........21-2 (OPT EQUIPPED
VEHICLE*) ......................... 21-65 1
CONNECTOR HANDLING ........21-2
BEFORE BEGINNING 2
WIRE HARNESS AND
CONNECTOR INSPECTION TROUBLESHOOTING
FOR THE 4Y-E ENGINE ....... 21-65 3
PROCEDURE .......................21-2
TROUBLESHOOTING DIAGNOSIS (SELF 4
DIAGNOSIS FUNCTION) ..... 21-66
(SAS-LESS MODEL) ...........21-4 5
DIAGNOSIS DISPLAY
OPS PLUG-IN ANALYZER....21-6 METHOD............................ 21-66 6
SCREEN CONFIGURATION .....21-6 LIST OF DIAGNOSIS
CODES .............................. 21-67
7
BASIC OPERATION ................21-7
WARNING LIST .................... 21-73 8
ANALYZER.............................21-9
TROUBLESHOOTING ...........21-13
VIEWING RELATED 9
PORTIONS ......................... 21-74
OPS 10
ERROR CONFIRMATION
TROUBLESHOOTING.......21-15 DRIVE MODE ..................... 21-74 11
DIAGNOSIS ..........................21-15 TROUBLESHOOTING
BY ERROR CODE ............... 21-75
12
DIAGNOSIS ERROR
CODE LIST .........................21-16 TROUBLESHOOTING 13
TROUBLESHOOTING WHEN THERE IS NO
ERROR CODE .................. 21-217 14
BY ERROR CODE ...............21-19
TROUBLESHOOTING 15
BY PHENOMENON .............21-34 16
17
*: An OPT equipped vehicle means vehicles that are equipped with the following options:
4Y engine with electronic control, mini lever, joystick, 3-way catalytic converter system,
travel and load handling control, multifunction display, and deluxe multifunction display.
18
19
20
21
E
21-2

BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
2. When disconnecting a connector, do not pull the wire harness
but hold the connector itself and pull it after unlocking it.
To connect, push the connector fully until it is locked in
position.

3. Bring a tester probe into contact with a connector terminal from

the rear side of the connector (harness side).
4. If insertion from the rear side is impossible, as in the case of a
waterproof connector, bring the tester probe carefully into
contact with the terminal so as not to cause deformation of the
connector terminal.
5. Do not touch connector terminals directly with your hand.
6. When bringing tester probes into contact with terminals that
voltage is applied to prevent two tester probes from coming
into contact with each other.

WIRE HARNESS AND CONNECTOR

INSPECTION PROCEDURE
When any trouble occurs, first inspect the connectors and wire
harness of the related circuit according to the following procedure:
Continuity Inspection
1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between corresponding terminals of
the 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. Inspect
especially the sensor connectors with sufficient care.
 21-3

Short Circuit Check

1. Disconnect the connectors at both ends of the corresponding
harness.
2. Measure the resistance between the corresponding connector
terminal and frame. Be sure to inspect the connectors at both 0
ends.
Standard: 1 MΩ or above 1
Note:
Measure while jiggling the wire harness up and down and 2
sideways.

3. Measure the resistance between terminals of the

3
corresponding connector. Be sure to inspect the connectors at
both ends. 4
Standard: 1 MΩ or above
5
Note:
The wiring may short-circuit due to pinching by the body or
defective clamping.
6
7

Visual and Contact Pressure Checks

8
1. Disconnect the connectors at both ends of the corresponding
harness.
9
2. Visually inspect that there is neither rust nor foreign matter 10
trapped at connector terminals.
3. Inspect that there is no looseness or damage at the crimped 11
portion. Also, lightly pull the wire harness from the connector to
check that it does not come off. 12
13
4. Insert a male terminal same as that of the connector terminal
to a female connector and check the drawing force.
Defective contact may exist at a terminal where the drawing 14
force is less than that of other terminals.
Note:
15
Even if there is rust or foreign matter trapped at the terminal,
or the contact pressure between male and female terminals is 16
low, abnormal contact condition may be changed to normal by
disconnecting and reconnecting the connector. In this case, 17
disconnect and reconnect the connector several times, and if
a fault occurs even once, then consider the terminal may have
a defective contact.
18
19
20
21
E
21-4

TROUBLESHOOTING (SAS-LESS MODEL)

NAME OF EACH PART

(3) (4)
(13)

(2)
(1)

(14)

(7) (8) (9) (10)

(11) (12) (16)

(5) (6)

(15)

(1) OPS controller (9) Backward tilt switch

(2) Seat switch (10) Unload valve
(3) Forward switch (11) Lift lock valve
(4) Reverse switch (12) Tilt control valve
(5) Forward interrupt relay (13) OPS lamp
(6) Reverse interrupt relay (14) OPS buzzer
(7) Lower switch (15) Plug-incanalyzer
(8) Forward tilt switch (16) Backward tilt lock valve
 21-5

FUNCTION OF EACH PART

Input to controller
Name Function
(2) Seat switch Mounted underneath the seat and detects the operator sitting on the seat.

Forward switch
Inputs the voltage branched from the forward drive valve power supply 0
(3) line of the torque converter to the OPS controller for detecting forward
(torque converter vehicle only)
drive operation.
Inputs the voltage branched from the reverse drive valve power supply
1
Reverse switch
(4) line of the torque converter to the OPS controller for detecting reverse
(torque converter vehicle only)
drive operation. 2
Installed at the lift spool of the oil control valve and detects the lowering
(7) Lower switch
operation by the lift lever. 3
Installed at the tilt spool of the oil control valve and detects the forward
(8) Forward tilt switch
operation of the tilt lever. 4
Installed at the tilt spool of the oil control valve and detects the backward
(9) Backward tilt switch
operation of the tilt lever.
5
Output from controller
Name Function
6
(5) Forward interrupt relay
Interrupts the voltage supply to the forward drive valve in the torque
converter according to the instruction from the OPS controller.
7
(6) Reverse interrupt relay
Cuts off the voltage supply to the reverse drive valve in the transmission
according to the instruction from the OPS controller. 8
Provides a bypass to the tank circuit for the hydraulic oil supplied from the
(10) Unload valve
oil pump to the oil control valve. 9
Cuts off the oil flow from the lift cylinder to the oil tank according to the
(11) Lift lock valve
instruction from the OPS controller to disable fork lowering. 10
Changes the oil path to the tilt cylinder according to the instruction from
(12) Tilt control valve the OPS controller to disable forward tilting and to slow down the
backward tilting speed.
11
(13) OPS lamp
Lights while the seat switch is off to indicate the OPS operation.
Furthermore, it blinks when the OPS controller detects any abnormality. 12
Sounds in the predetermined pattern when the seat switch is turned off or
(14) OPS buzzer when the forward/reverse shift lever needs returning to the neutral 13
position (return to neutral warning).
Added with the OPS analyzer functions to the service functions of the 14
conventional SAS analyzer. It is connected to the same service connector.
OPS analyzer functions
• Diagnostic display (More detailed display than OPS lamp blinking 15
(15) Plug-in analyzer
frequency)
• I/O monitor display (Shortening the time required for troubleshooting)
• Output test (Shortening the troubleshooting time by setting each output
16
on and off according to the instruction from the OPS controller)
Cuts off the oil flow from the tilt cylinder bottom side to the oil tank
17
Backward tilt lock valve
(16) according to the instruction from the OPS controller to disable backward
(Standard lever vehicle)
tilt. 18
19
20
21
E
21-6

OPS PLUG-IN ANALYZER

For the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST
(Special Tool for Service).
The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functions and
the error information detected by the controller. It serves to check on the operating state of OPS functions and
shortens the repair time for a problem. Moreover, it is installed with save function to file data displayed on the screen
in the SST.

SST 09240-23323-71

Menu name Content of function Reference page

with the OPS controller on

DIAG MEMORY Indication of ten error codes and sub-codes in the past. 21-9
Communication function

the vehicle side

Monitoring input voltage values from the sensors and the output
IN/OUT MONITOR 21-10
signal, etc. to the solenoid, etc.
OPS

ACTIVE TEST Forced operation of solenoids and warning lamps. 21-11

CONTROLLER DATA Indication of OPS controller abbreviation number and version 21-12

SCREEN CONFIGURATION

Page
21-9
21-10
21-10
21-10
21-11
21-12
 21-7

BASIC OPERATION
Name of Sections and the Switch Functions
Position of
Name of section Mark Function Switch
indication
Main unit
• Move the cursor to the above item.
• Move to the preceding page.

Selector
A • Move the cursor to right or left. switch c

<Blank> <No function>

Connector • Select the item below.

• Move to the following page.
Selector
Screen title A Switch B
switch e
<Blank> <No function>

• Determine an item for selection.

Menu
C
B switch e
C Switch mark
indicator <Blank> • Move to MENU screen.

Caution on using:
• Keep the main unit, wire harness, connector, etc. away from the exhaust and other heated sections.
• Operate the switch with finger tip.
• Do not apply strong impact to the analyzer due to dropping or collision.
• Do not leave the analyzer under the direct rays of the sun for long time.

Connection and Operation of SST

1. Turn the ignition key switch OFF.
2. Open the diagnosis connector cover of the vehicle and
properly connect the connector on the SST side.
SST 09240-23323-71
SST Note:
Since the connector has no locking device, securely connect
Diagnosis it to prevent contact defect upon closing the engine hood with
connector the connector in connected state.

3. Turn the ignition key switch ON or start the engine.

4. Display of the initialization screen
After about 15 seconds of display, "LANGUAGE SET" or
"MAIN MENU" screen appears. The screen may be changed
during this period by pressing MENU switch e.
21-8

5. "LANGUAGE SET" screen

Since this screen appears only when the language is
undefined, determine a language to use for display.
(1) Select a display language by pressing selector switch c
or d.
• Japanese
• English
(2) Press MENU switch e to determine the language setting.
Note:
Once the display language is defined, "LANGUAGE SET"
screen will not be displayed from the next time onward. To
change the language, go to "TESTER SET" of "MAIN MENU".

6. "MAIN MENU" screen

(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
• SAS: Moves to SAS MENU screen.
• OPS: Moves to OPS ANALYZER MENU Screen.
• TESTER SET: Moves to TESTER SET screen.

Removal of SST
1. Check that the screen title is for one of the MENU screens.
2. Turn the ignition key switch OFF.
3. Disconnect the connector.
Note:
To disconnect, hold the body of the connector.
4. Close the diagnosis connector cover.
 21-9

ANALYZER
ANALYZER MENU Display contents and function Page
1. DIAG MEMORY Indication of error codes for 10 most recent errors 21-9
2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 21-10
3. ACTIVE TEST Forced operation signal output to the selected item 21-11
4. CONTROLLER DATA Indication of the OPS controller part number and version 21-12

Operation Procedure
1. Select and enter "2OPS" on the main menu screen to display
the OPS ANALYZER MENU screen.

2. ANALYZER MENU screen

(1) Move the cursor to the desired menu by operating
selector switch c or d, and enter by operating MENU
switch e.
(2) Select and enter "END" to return to the MAIN MENU
screen.

"1 DIAG MEMORY"

This screen displays ten error codes from the most recent one.
[Explanation on display contents]
(1) Order of error occurrence
(2) Error codes
[Clear memory]
Press selector switch c continuously for 2 seconds.
(1) (2)
[End]
Press MENU switch e to return to the ANALYZER MENU screen.
Note:
• Only "-" appears at the end of the item involving no error
occurrence.
• If reception has not been completed, only the number
appears without "-" indication.
21-10

"2 IN/OUT MONITOR"

[Explanation on display contents]
(1) (1) SEAT: Seat switch input signal
(2)
(2) DIR: Direction switch input signal (T/C vehicle only)
(3)
FWD: Forward direction switch input signal
(4) REV: Reverse direction switch input signal

(3) RLY: Output signal to forward/reverse interrupt relay and

backward tilt lock solenoid (T/C vehicle only)
FWD: Output signal to forward/reverse interrupt relay
(1)
(5) REV: Output signal to backward tilt lock solenoid
(6)
(7) (4) VOLTAGE: OPS controller power supply voltage
(8)
(5) LIFT LOWER: Lift lowering switch input signal
(4)
(6) UNLOAD SOL: Output signal to unload solenoid
(7) LWR SOL: Output signal to lowering lock solenoid

(8) TILS SOL: Output signal to tilt solenoid

(9) TILT: Tilt lever switch input signal
(1) FWD: Forward tilt switch input signal
(9)
BWD: Backward tilt switch input signal
*
(8) CONT: SAS tilt control command input signal
(10)
(4) (10) LSOPT: Reserved.
*: “CONT—” appears on the SAS-less spec. model. [End]
Press MENU switch e to return to the ANALYZER MENU screen.
 21-11

"3 ACTIVE TEST"

Note:
ON indication on the screen shows the controller output state.
(1)
(2) The operation, therefore, should be checked visually, by
(3) operating sound, etc.
(4)
(5) 1. Select the item by selector switch d, and set OFF/ON by
(6)
selector switch c.
(7)

[Explanation on display contents]

(1) RLY FWD*
Set to ON for forced output of forward/reverse interrupt
relay activating signal. (Forward/reverse traveling
disabled state)
(2) RLY REV*
Set to ON for forced output of backward tilt lock solenoid
activating signal. (Backward tilt disabled state)
(3) UNLOAD SOL
Set to ON for forced output of unload solenoid activating
signal. (Material handling disabled state)
(4) LWR SOL
Set to ON for forced output of lowering lock solenoid
activating signal. (Lowering enabled state)
(5) TILT SOL
Set to ON for forced output of tilt solenoid activating
signal. (Forward tilting enabled state with backward tilting
speed restriction)
(6) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(7) BUZZER
Set to ON for forced output of OPS buzzer sounding
signal. (Continuous OPS buzzer sounding)
* The drive power interrupting function is not provided on the
manual transmission vehicle.
2. After resetting all items to OFF, press MENU switch e to return
to the ANALYZER MENU screen.
21-12

"4 CONTROLLER DATA"

The OPS controller abbreviation No. and version No. can be
displayed on this screen.
[Explanation on display contents]
(1)
(1) DATA
Controller abbreviation No.
(2)

(2) VER
Version No.
[End]
Press MENU switch e to return to the ANALYZER MENU screen.
 21-13

TROUBLESHOOTING
z No display on the screen.

Related Portion

ECU-IG
1C-14
To IG SW

1C-6
A25-12
(IG, Power supply) 1
OPS controller

A22-1 A25-1 6
Analyzer

1E-14 A25-3 13
1C-22
Analyzer CN
(E2, Main GND)

Estimated Causes:
c Connector contact defect
d Analyzer harness (power supply) defect
e Plug-in analyzer defect

NG
Check A25 and analyzer connector for any disconnection. Screen check after correction.

OK NG

Inspection 1: NG
Harness defect on vehicle side
Measure the voltage between A25-12 and A25-3.
OK

Inspection 2: NG
Analyzer harness defect
Measure the voltage between analyzer CN-1 and analyzer CN-13.
OK

Plug-in analyzer defect

Inspection 1: 6 5 4 3 2 1
Measure the voltage between A25-12 and A25-3. 11 10 9 8 7
17 16 15 14 13 12

Ignition key switch ON (engine in stopped state)

A25 (REC)
Standard:
A25-12 (+) ~ A25-3 (-) 8 ~ 16 V

Inspection 2:
Measure the voltage between analyzer CN-1 and analyzer CN-13.
Ignition key switch ON (engine in stopped state) Analyzer CN (REC)

Standard:
Analyzer CN-1(+) ~ analyzer CN-13 (-) 8 ~ 16 V
21-14

z No data display on data (DIAG MEMORY, voltage value, etc) display screen

Related Portion
ECU-IG 1C-14
To IG SW

1C-6
A25-12
(IG, Power supply) 1
OPS controller

A22-1 A25-1 6
Analyzer

1E-14 A25-3 13
1C-22
Analyzer CN
(E2, Main GND)

Estimated Causes:
c Connector contact defective
d Analyzer harness (communication) defect
e Plug-in analyzer defect
f OPS controller defect

NG
Check A25 and analyzer connector for any disconnection. Data display check after correction.

OK NG

Inspection 1: NG
Harness defect on vehicle side
Check continuity between A25-1 and A22-1.
OK

Inspection 2: NG
Analyzer harness defect
Check continuity between analyzer CN-6 and A25-1.
OK

NG
Check data display by connecting the analyzer to another vehicle. Plug-in analyzer defect

OK

OPS controller defect

Inspection 1: 6 5 4 3 2 1
Check continuity between A25-1 and A22-1. 11 10 9 8 7
17 16 15 14 13 12

Ignition key switch OFF, disconnection between A25 and A22.

A25 (REC)
Standard:
A25-1 ~ A22-1 Continuity

Inspection 2:
Check continuity between analyzer CN-6 and A25-1.
Ignition key switch OFF, disconnection between analyzer CN and A25. A25 (TAB)
Analyzer CN (REC)
Standard:
Analyzer CN-6 ~ A25-1 Continuity
 21-15

OPS TROUBLESHOOTING
DIAGNOSIS
The diagnosis function informs the operator of a trouble occurrence and the trouble position by blinking the OPS
lamp on the combination meter when the OPS controller detects an abnormality. The trouble position is indicated by
the number of blinks of the OPS lamp.
Note:
• The OPS lamp is lit for 1 second upon ignition key switch ON for broken lamp check.
• The OPS lamp comes on when the operator leaves the seat.
• If multiple errors occur at a time, only the lowest error code appears. Upon correction of that error, the
next lowest error code appears.
Example:
Display example of error code 3

Break point indication Code indication

ON

OFF

2 sec. 0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.

0.5 sec. 0.5 sec. 0.5 sec.
Abnormality detection
(Code 3)
21-16

DIAGNOSIS ERROR CODE LIST

Error Phenomenon on vehicle
Lamp Vehicle spec. Error description Major cause
code T/C vehicle M/T vehicle
Dead lamp
ON — — — —
check
Blinking
Seat switch Sticking GND
(one short 1-1 SAS-less The OPS does not function.
abnormality fault
ON pulse)
Lift lowering
2-1 SAS-less switch
Blinking abnormality
Sticking GND No special change from normal state
(two short 2-2 fault (excessive leak during lowering)
ON cycles) Tilting switch
2-3 SAS-less*
abnormality
2-4
Forward/reverse
traveling is possible
Discontinuity
Forward/reverse when the OPS is
Blinking operated
SAS-less interrupt relay
(three short 3-1 —
T/C (RYF) GND fault ↑
ON cycles)
abnormality Forward/reverse
+B shorting traveling is always
disabled.
When the OPS is operated, fork lowering
and backward tilting are disabled but all
Discontinuity
other material handling operations are
possible.
Unload solenoid
GND fault ↑
4-1 (USOL)
abnormality When the OPS is operated all material
handling operations are disabled. When the
+B shorting OPS is not operated, only fork lowering is
possible and all other material handling
operations are disabled.
When the OPS is operated, all material
handling operations are disabled. When the
Blinking Discontinuity OPS is not operated, fork lowering is
(four short SAS-less disabled but all other material handling
Lowering lock
ON cycles) operations are possible.
4-2 solenoid (LSOL)
abnormality GND fault ↑
When the OPS is operated, fork lowering is
+B shorting possible but all other material handling
operations are disabled.
When the OPS is operated, all material
handling operations are disabled. When the
Tilt solenoid Discontinuity OPS is not operated, only forward tilting is
4-3 (TSOL) disabled but all other material handling
abnormality operations are possible.
GND fault ↑
+B shorting —
 21-17

Error Phenomenon on vehicle

Lamp Vehicle spec. Error description Major cause
code T/C vehicle M/T vehicle
When the OPS is operated, all material
handling operations are disabled. When the
Tilt backward Discontinuity OPS is not operated, backward tilting is
Blinking disabled but all other material handling
lock solenoid
(four short 4-4 SAS-less operations are possible.
(BSOL)
ON cycles)
abnormality GND fault ↑
It may tilt backward even when the OPS
+B shorting
system is in operation.
When the OPS is
Blinking operated, it cannot be
SAS-less Shift lever
(five short 5-1 +B shorting reset (locked state by —
T/C abnormality
ON cycles) the return to neutral
function).
7-1 The drive OPS does not function. Fork
ON 7-2 lowering is always disabled. The material
7-3 CPU handling OPS does not function.
abnormality
Blinking Controller
(seven short 7-4 SAS-less None in particular.
abnormality
ON cycles)
7-5 The drive OPS does not function. Fork
EEPROM
lowering is always disabled. The material
7-6 abnormality
handling OPS does not function.
The warning before OPS operation occurs,
ON Low voltage Low battery
SAS-less but the drive/material handling OPS does not
alarm voltage
— function.
Departure from
— OPS operation —
seat

*: SAS-less spec. model only because of detection by the SAS controller here on the SAS spec. models.
21-18

List of Reference Pages for Error Codes and Sub Error Codes
Without analyzer (SST) With analyzer (SST)
Error Error
Error description Page Error description Page
code code
1 Seat switch abnormality 21-19 1-1 Seat switch abnormality 21-19
2-1 Lowering switch abnormality 21-24
2-2 Tilt lever switch simultaneous ON abnormality 21-25
Lowering switch abnormality Forward tilt switch 2-minute shorting
2 21-22 2-3 21-25
Tilt switch abnormality (L/SAS spec.) abnormality
Backward tilt switch 2-minute shorting
2-4 21-25
abnormality
Forward/reverse interrupt relay (RYF) Forward/reverse interrupt relay (RYF)
3 21-27 3-1 21-27
abnormality abnormality
4-1 Unload solenoid (USOL) abnormality
4-2 Lowering lock solenoid (LSOL) abnormality
4 Solenoid (SOL) abnormality 21-29 21-29
4-3 Tilt solenoid (TSOL) abnormality
4-4 Backward tilt lock solenoid (BSOL) abnormality
5 T/C shift lever abnormality 21-31 5-1 T/C shift lever abnormality 21-32
7-1
7-2
CPU abnormality
7-3
7 OPS controller abnormality — —
7-4
7-5
EEPROM abnormality
7-6

List of Pages to be Referenced by Phenomenon

Pages to be referenced
Description Without With
analyzer analyzer
The OPS buzzer does not sound, or keeps sounding. 21-34 21-34
The OPS lamp does not come on. 21-38 21-38
The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled) 21-40 21-43
Cannot lower the fork. 21-45 21-48
The material handling OPS does not function. (Including when OPS for lowering is functional) 21-50 21-50
Material handling fails. (Including when fork lowering is not fail) 21-51 21-51
The mast backward tilting speed is slow. 21-52 21-52
Mast does not tilt forward. 21-53 21-53
The drive OPS does not function. (Excluding the M/T vehicle) 21-55 21-55
Traveling fails. (Including forward traveling only, reverse traveling only, and occasional
21-58 21-58
abnormalities) (Excluding the M/T vehicle)
Mast does not tilt backward. 21-61 21-63
 21-19

TROUBLESHOOTING BY ERROR CODE

z Error Code 1 · 1-1 (Seat switch abnormality)

Related Portion
OPS controller

A22-23 (DMI, Seat SW) AO1-1 XO4-1 X1-2

Seat switch
A22-17 (E03, Switch GND) 1B-24 1E-30 XO4-2 X1-1

Estimated Causes:
c Connector contact defect
d Seat switch defect
e Harness defect
f Controller defect

Error code 1

Check A22, 1B, 1E, XO4, AO1 and X1 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG

Inspection 1: NG
Seat switch defect
Check the seat switch individually for continuity.
OK

Inspection 2: NG
Harness defect
Check continuity between A22-23 and A22-17
OK

Controller defect

*: After correction, check the OPS lamp indication.

After connecting all connectors, turn the ignition key switch OFF once, then ON (for 2 seconds or more), and OFF
again.
After waiting without seating for about 15 minutes and turn the ignition key switch ON. The OPS must not display
error code 1 by blinking.
21-20

Inspection 1:
Check the individual seat switch for continuity.
Ignition key switch OFF, X1 disconnected.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity

Inspection 2:
Check for continuity between A22-23 and A22-17.
Ignition key switch OFF, A22 disconnected. (AO1, 1B, 1E, XO4 and X1 must be
kept connected.)
Standard:
Seated Unseated
A22-23 ~ A22-17 Continuity No continuity

Error code 1-1

Check A22, AO1, 1B, 1E, XO4 and X1 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG

Inspection 1: OK
Seat switch defect
With X1 disconnected, check the input signal to the controller.
NG

Inspection 2: NG
Harness defect
Check for continuity between A22-23 and A22-17.
OK

Controller defect

*: After correction, check the OPS lamp indication.

After connecting all connectors, turn the ignition key switch OFF once, then ON (for 2 seconds or more), and OFF
again.
After waiting without seating for about 15 minutes and turn the ignition key switch ON. The OPS must not display
error code 1 by blinking.
 21-21

Inspection 1:
With X04 disconnected, check the input signal to the controller.
X04 connector disconnected, ignition key switch OFF ⇒ ON
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR

Standard:
Seated Unseated
SEAT OFF OFF

Inspection 2:
Check for continuity between A22-23 and A22-17.
Ignition key switch OFF, A22 disconnected. (AO1, 1B, 1E, XO4 and X1 must be kept
connected.)
Standard:
Seated Unseated
A22-23 ~ A22-17 Continuity No continuity
21-22

z Error Code 2
z Error Code 2-1 (Lowering switch abnormality)
z Error Code 2-2 (Tilt lever switch simultaneous ON abnormality)
z Error Code 2-3 (Forward tilt switch 2-minute shorting abnormality)
z Error Code 2-4 (Backward tilt switch 2-minute shorting abnormality)

Related Portion

A22-25 (TFI, Forward tilt switch) A13-1

Forward tilt
A13-2
switch
A22-24 (TRI, Backward tilt switch) A13-3
OPS controller

Backward tilt
A13-4 switch
A22-26 (DOWN, Lowering switch) A14-1

1C-19
Lowering switch
1C-20
A22-17 (E03, SW-GND) 1B-24 1C-23 A14-2

Estimated Causes:
c Connector contact defect g Forward tilt switch defect
d Lowering switch defect h Backward tilt switch defect
e Harness defect i Tilt switch installation defect
f Controller defect j Lowering switch installation defect

Error code 2

Check the A22, A13, A14, 1B, and 1C connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG

Inspection 1: OK
Controller defect
Check the lift lowering switch wiring and tilt lever switch wiring for
continuity.
NG

Inspection 2: OK
Harness defect
Check the lift lowering switch and tilt lever switch individually
(as installed on the vehicle) for continuity.
NG

Inspection 3: NG
Switch defect
Check the lift lowering lever switch and tilt lever switch individually
(as removed from the vehicle) for continuity.
OK

Lever switch installation defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, operate the tilt lever forward and backward to check if the OPS lamp
blinks.
Or keep the tilt lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
Or keep the lift lever in the neutral position for 2 minutes and check if the OPS lamp blinks.
The OPS lamp must not indicate error code 2 by blinking.
 21-23

Inspection 1:
Check the lift lower lever switch wiring and tilt lever switch wiring for continuity.
Ignition key switch OFF, A22 disconnected.
Standard:
• Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A22-26 ~ A22-17 No continuity No continuity Continuity

• Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A22-25 ~ A22-17 No continuity Continuity No continuity
A22-24 ~ A22-17 No continuity No continuity Continuity

Inspection 2:
Check the lift lower lever switch and tilt lever switch individually (as installed on the 1
3
2
4
vehicle) for continuity.
Ignition key switch OFF, A14 and A13 disconnected.
Standard:
• Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A14-1 ~ A14-2 No continuity No continuity Continuity

• Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity

Inspection 3:
Check the lift lower lever switch and tilt lever switch individually (as removed from the 1
3
2
4
vehicle) for continuity.
Ignition key switch OFF, A14 and A13 disconnected.
Standard:
• Lift lower switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A14-1 ~ A14-2 Continuity No continuity

• Forward tilt switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A13-1 ~ A13-2 Continuity No continuity

• Backward tilt switch (switch on the lower side when installed on the vehicle)
Switch free Switch pressed
A13-3 ~ A13-4 Continuity No continuity
21-24

Error code 2-1

Check A22 and A14 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*

OK NG

Inspection 1: Inspection 4:
Disconnect A14, and check the switch output upon lowering operation. NG Check for continuity between A22 and
A14.
OK NG OK

Inspection 2: OK Harness Controller defect (Error

Check lift lower lever switch individually (as installed on the vehicle) for defect occurrence upon
continuity. continuing lowering
operation for 2 minutes
NG
or more, however, is
normal.)

Inspection 3: NG Lower switch defect

Check the lift lower lever switch individually (as removed from the
vehicle) for continuity.

OK

Lever switch installation defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, keep the lift lever in the neutral position for 2 minutes and check if the
OPS lamp blinks.
The OPS lamp must not indicate error code 2 with blinking.

Inspection 1:
Disconnect A14 and check the switch output upon lowering
operation.
Ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Lift lower switch
Lever at neutral position Lever at up position Lever at down position
LIFT LOWER OFF OFF OFF

Inspection 2:
Check the lift lower lever switch individually (as installed on the vehicle) for continuity.
Ignition key switch OFF, A14 disconnected.
Standard:
Lift lower switch
Lever at neutral position Lever at up position Lever at down position
A14-1 ~ A14-2 No continuity No continuity Continuity
 21-25

Inspection 3:
Check the lift lower lever switch individually (as removed from the vehicle) for continuity.
Ignition key switch OFF, A14 disconnected.
Standard:
Lift lower switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A14-1 ~ A14-2 Continuity No continuity

Inspection 4:
Check for continuity between A22 and A14.
Ignition key switch OFF, A22 and A14 disconnection.
Standard:
A22-26 ~ A22-17 No continuity

Error codes: 2-2, 2-3, and 2-4

Check A22 and A13 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG

Inspection 1: NG Inspection 4:
Disconnect A13, and check the switch output upon tilting operation. Check for continuity between A22 and
A13.
OK
NG OK

Inspection 2: OK Harness Controller defect

Check the tilt lever switch individually (as installed on the vehicle) for defect (Error occurrence upon
continuity. continuing lever
operation for 2 minutes
NG or more or upon
simultaneous ON during
installation adjustment,
however, is normal.)

Inspection 3: NG
Tilt switch defect
Check the tilt lever switch individually (as removed from the vehicle) for
continuity.

OK

Lever switch installation defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, keep the lift lever in the neutral position for 2 minutes and check if the
OPS lamp blinks.
The OPS lamp must not display error code 2 by blinking.
21-26

Inspection 5:
Check the switch output upon tilting operation after disconnecting
A13.
Ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
TILT FWD OFF OFF OFF
TILT BWD OFF OFF OFF

Inspection 6:
Check the tilt lever switch individually (as installed on the vehicle) for continuity. 1
3
2
4

Ignition key switch OFF, A13 disconnected.

Standard:
Tilt switch
Lever at forward tilt Lever at backward tilt
Lever at neutral position
position position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity

Inspection 7:
Check the tilt lever switch individually (as removed from the vehicle) for continuity. 1
3
2
4

Ignition key switch OFF, A13 disconnected.

Standard:
• Tilt forward switch (switch on the upper side when installed on the vehicle)
Switch free Switch pressed
A13-1 ~ A13-2 Continuity No continuity

• Tilt backward switch (switch on the lower side when installed on the vehicle)
Switch free Switch pressed
A13-3 ~ A13-4 Continuity No continuity

Inspection 8:
Check for continuity between A22 and A13.
Ignition key switch OFF, A22 and A13 disconnected.
Standard:
A22-25 ~ A22-17 No continuity
A22-24 ~ A22-17 No continuity
 21-27

z Error Code 3
z Error Code 3-1 (Forward/reverse interrupt relay (RYF) abnormality)

Related Portion

A22-10 (RYF, J/B

Forward/reverse interrupt relay) 1B-8 2
Forward
interrupt
OPS controller

1 relay
2
Reverse
interrupt
A22-17 (E03, SW-GND) 1B-24 1 relay
1A-9 1A-7

Estimated Causes:
c Connector contact defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect

Error Codes 3, 3-1

Check the A22, 1A and 1B connectors for disconnection or internal NG After correction, check the OPS lamp
wetting and the relays for insertion. indication.*
OK NG

Inspection 1: NG
Interrupt relay defect
Check the forward/reverse interrupt relay individually (on the coil side)
for the resistance value.
OK

Inspection 2: NG
Check the wiring between A22 and the interrupt relays for continuity. Harness defect

OK

Controller defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, place the shift lever in the forward or reverse position and leave the seat
to check if the OPS lamp blinks.
The OPS lamp must not display error code 3 by blinking.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See page 21-9 "1 DIAG MEMORY" for the error memory check method.
21-28

Inspection 1:
Check the forward/reverse interrupt relay (on coil side) individually.
Measure the resistance between terminals of each of the forward and reverse interrupt relays.
Ignition key switch OFF, relay disconnected from the J/B.
Standard:
Resistance
Forward interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)
Reverse interrupt relay, between terminals 1 and 2 Approx. 90 Ω (20°C)

Inspection 2:
Check for continuity of the wiring between A22 and interrupt relays.
Ignition key switch OFF, A22 disconnected, relay removed from the J/B.
Standard:
• Discontinuity check
A22-10 ~ Forward interrupt relay terminal 2 Continuity
A22-10 ~ Reverse interrupt relay terminal 2 Continuity
A22-17 ~ Forward interrupt relay terminal 1 Continuity
A22-17 ~ Reverse interrupt relay terminal 1 Continuity

• GND fault check

A22-10 ~ A22-17 No continuity

• +B shorting check
A22-10 ~ A22-32 No continuity

• IG line shorting check

A22-10 ~ A22-15,-16 No continuity
 21-29

z Error Code 4
z Error Code 4-1 (Unload solenoid (USOL) abnormality)
z Error Code 4-2 (Lowering lock solenoid (LSOL) abnormality)
z Error Code 4-3 (Tilt solenoid (TSOL) abnormality)
z Error Code 4-4 (Backward tilt lock solenoid (BSOL) abnormality)

Related Portion
A22-14 (VSOL, Unload SOL) A12-1
A12-2 Unload SOL

A22-13 (LSOL, Lowering lock SOL) A11-1

A11-2 Lowering lock SOL
OPS controller

A22-12 (TSOL, Tilt SOL) A10-1

A10-2 Tilt SOL
A22-28 (BSOL,
Backward tilt lock SOL) A56-1
Backward tilting lock
A22-30 (E01, SOL-GND) A56-2 SOL
A22-29 (E02, SOL-GND)
22 26 23 25 1A-21 2 3
1B 1C

(A4, Body GND)

Estimated Causes:
c Connector contact defect f Tilt solenoid defect
d Unload solenoid defect g Controller defect
e Lowering lock solenoid defect h Harness defect
i Tilt backward lock solenoid defect

Error Codes 4, 4-1, 4-2, 4-3, 4-4

Check the A22, 1A, 1B, 1C, A10, A11, A12 and A56 connectors for any NG After correction, check the OPS lamp
disconnection or internal wetting. indication.*
OK NG

Inspection 1: NG
Solenoid defect
Check the solenoids (USOL - BSOL) individually for the resistance
value.
OK

Inspection 2: NG
Harness defect
Check the wiring between A22 and each solenoid (USOL - BSOL) for
continuity.
OK

Controller defect

*: After correction, check the OPS lamp indication.

After starting the engine, operate lift up/down, forward/backward tilt in each of OPS activation and deactivation to
check if the OPS lamp blinks.
The OPS lamp must not display error code 4 by blinking.
Note:
When the analyzer is provided, check the related portion after checking the error memory for the current
error code. See page 21-9 "1 DIAG MEMORY" for the error memory check method.
21-30

Inspection 1:
Check the resistance of each solenoid (USOL to BSOL).
Ignition key switch OFF, A12, A11, A10 and A56 disconnected.
Standard:
Resistance
USOL A12-1 ~ A12-2 Approx. 9 Ω (20°C)
LSOL A11-1 ~ A11-2 Approx. 9 Ω (20°C)
TSOL A10-1 ~ A10-2 Approx. 9 Ω (20°C)
BSOL A56-1 ~ A56-2 Approx. 9 Ω (20°C)

Inspection 2:
Check for continuity of the wiring between A22 and each of solenoids USOL to BSOL.
Ignition key switch OFF, A22, A12, A11, A10 and A56 disconnected.
Standard:
• Discontinuity check
A22-14 ~ A12-1 Continuity
A22-29 ~ A12-2 Continuity
A22-30 ~ A12-2 Continuity
A12-2 ~ Frame Continuity

A22-13 ~ A11-1 Continuity

A22-29 ~ A11-2 Continuity
A22-30 ~ A11-2 Continuity
A11-2 ~ Frame Continuity

A22-12 ~ A10-1 Continuity A22-28 ~ A56-1 Continuity

A22-29 ~ A10-2 Continuity A22-29 ~ A56-2 Continuity
A22-30 ~ A10-2 Continuity A22-30 ~ A56-2 Continuity
A10-2 ~ Frame Continuity A56-2 ~ Frame Continuity

• GND fault check

A22-14 ~ A22-29,-30 No continuity
A22-13 ~ A22-29,-30 No continuity
A22-12 ~ A22-29,-30 No continuity A22-28 ~ A22-29,-30 No continuity

• +B shorting check
A22-14 ~ A22-32 No continuity
A22-13 ~ A22-32 No continuity
A22-12 ~ A22-32 No continuity A22-28 ~ A22-32 No continuity

• IG line shorting check

A22-14 ~ A22-15,-16 No continuity
A22-13 ~ A22-15,-16 No continuity
A22-12 ~ A22-15,-16 No continuity A22-28 ~ A22-15,-16 No continuity
 21-31

z Error Code 5 · 5-1 (T/C shift lever abnormality)

Related Portion

SFT CN41-6
I-2
To IG1
J/B

Forward Reverse Shift

OPS controller

interrupt relay interrupt relay lever

4 4
A22-3 (DRF, Forward drive SW) 1B-3 1B-36 A41-5
A22-4 (DRR, Reverse drive SW) 1B-19 1B-17 A41-1

Estimated causes:
c Connector contact defect f Controller defect
d Shift lever switch defect g Fuse defect
e Harness defect

Error Code 5

NG After correction, check the OPS lamp

Check if the fuse (SFT) is blown.
indication.*
OK NG

Check connectors A22, 1B and A41 for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*
OK NG

Inspection 1: NG
Shift lever defect
Check the shift lever individually for continuity.
OK

Inspection 2: NG
Harness defect
Check for the continuity of wiring between A22 and IG SW.
OK

Controller defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, operate the shift lever to forward or reverse position and check if the
OPS lamp blinks.
The OPS lamp must not display error code 5 by blinking.
21-32

Inspection 1:
Check the shift lever individually for continuity.
Ignition key switch OFF, A41 disconnected.
Standard:
Lever at neutral Lever at forward Lever at reverse
position traveling position traveling position
Between pins 5 and 6 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity

Inspection 2:
Check the wiring between A22 and A2 (IG SW) for continuity.
Ignition key switch OFF, A22 and A2 (IG SW) connectors disconnected.
(1B and A41 must be connected.)
Standard:
• Lever at neutral
A22-3 ~ A2-4 No continuity
A22-4 ~ A2-4 No continuity

• +B shorting check
A22-3 ~ A22-32 No continuity
A22-4 ~ A22-32 No continuity

• IG line shorting check

A22-3 ~ A22-15,-16 No continuity
A22-4 ~ A22-15,-16 No continuity

Error code 5-1

NG After correction, check the OPS lamp

Check if the fuse (SFT) is blown.
indication.*

OK NG

Check A22, 1B and A41 connectors for any disconnection or internal NG After correction, check the OPS lamp
wetting. indication.*

OK NG

Inspection 1: OK
Shift lever defect
Disconnect A41, and check the input signal to the controller.
NG

Inspection 2: NG
Harness defect
Check for wiring between A22 and IG SW for continuity.

OK

Controller defect

*: After correction, check the OPS lamp indication.

After the ignition key switch is turned ON, operate the shift lever to the forward or reverse position and check if the
OPS lamp blinks.
The OPS lamp must not indicate error code 5 by blinking.
 21-33

Inspection 1:
Disconnect A41, and check the input signal to the controller.
A41 disconnected, ignition key switch ON (engine in stopped state)
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR

Standard:
Lever at forward Lever at reverse
Lever at neutral position
traveling position traveling position
DIR FWD OFF OFF OFF
DIR REV OFF OFF OFF

Inspection 2:
Check the wiring between A22 and A2 (IG SW) for continuity.
Ignition key switch OFF, A22 and A2 (IG SW) connectors disconnected.
(1B and A41 must be connected.)
Standard:
• Lever at neutral
A22-3 ~ A2-4 No continuity
A22-4 ~ A2-4 No continuity

• +B shorting check
A22-3 ~ A22-32 No continuity
A22-4 ~ A22-32 No continuity

• IG line shorting check

A22-3 ~ A22-15,-16 No continuity
A22-4 ~ A22-15,-16 No continuity
21-34

TROUBLESHOOTING BY PHENOMENON
z The OPS buzzer does not sound.
z The OPS buzzer keeps sounding.

Related Portion
ECU-B
1C-12
To Batt

A22-32 (BATT) 1A-29

OPS controller

1B-5

A8-1
A22-9 (BZO, OPS buzzer) A8-2 OPS buzzer

Estimated Causes:
c Connector contact defect f Controller defect
d OPS buzzer defect g Fuse defect
e Harness defect

The OPS buzzer does not sound.

NG After correction, check if the OPS

Check for blown fuse (ECU-B).
buzzer sounds.*
OK NG

NG After correction, check if the OPS

Check the A22 and A8 for any disconnection or internal wetting.
buzzer sounds.*
OK NG

Inspection 1: NG Harness defect

Check for continuity between the A2 and A8, and between A22 and A8.

OK

Inspection 2: OK
Check for continuity between A8-2 and the frame. OPS buzzer defect

NG

Controller defect

*: After correction, check if the OPS buzzer sounds.

After connecting all connectors, turn the ignition key switch ON, and leave the seat to check if the buzzer sounds.
 21-35

Inspection 1:
Check for continuity between the 1C and A8, and between A22 and A8.
Ignition key switch OFF, A22, A8, 1C connector disconnected.
Standard:
A2-2 ~ A8-1 Continuity
A22-9 ~ A8-2 Continuity

Inspection 2:
Check for continuity between A8-2 and the frame.
• Without analyzer
Disconnect A8 and turn the ignition key switch ON (engine in stopped state).
Standard:
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity

* Normally, the buzzer sounds for 1 second upon lapse of 0.5 seconds after the operator leaves the seat.
• With analyzer
Disconnect A8 and turn the ignition key switch ON (engine in
stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check the continuity
between A8-2 and the frame.
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
21-36

The OPS buzzer keeps sounding.

NG After correction, check if the OPS

Check A22 and A8 for any disconnection or internal wetting.
buzzer sounds.*
OK NG

Inspection 1: NG
Harness defect
Check for continuity between A2 and A8, between A22 and A8, and
between A22 and the frame.
OK

Inspection 2: OK
OPS buzzer defect
Check for continuity between A8-2 and the frame.
NG

Controller defect

*: After correction, check if the OPS buzzer sounds.

After connecting all connectors, turn the ignition key switch ON and leave the seat to check if the buzzer sounds.

Inspection 1:
Check for continuity between the A2 and A8, and between A22 and A8.
Ignition key switch OFF, A22, A8, A2 connector disconnected.
Standard:
A2-2 ~ A8-1 Continuity
A2-9 ~ A8-2 Continuity
Between A2-9 and frame No continuity
 21-37

Inspection 2:
Check for continuity between A8-2 and the frame.
• Without analyzer
Disconnect A8 and turn the ignition key switch ON (engine in stopped state).
Standard:
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity

* Normally, the buzzer sounds for 1 second upon lapse of 0.5 sec after the operator leaves the seat.
• With analyzer
Disconnect A8 and turn the ignition key switch ON (engine in
stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS buzzer ON and OFF, and check for continuity
between A8-2 and the frame.
Buzzer ON Buzzer OFF
Between A8-2 and frame Continuity No continuity
21-38

z The OPS lamp does not come on.

Related Portion
GAUGE 1C-32
To IG SW

1C-27
OPS controller

QAI-12 Q1-1
A22-8 (RYLP, OPS lamp) QAI-7 Q1-4
Combination
1E-28 1C-8 QAI-4 Q1-8 meter
1C-25 QAI-13 Q1-9

Estimated Causes:
c Connector contact defect f Controller defect
d OPS lamp defect g Fuse defect
e Harness defect

NG After bulb replacement, check that the

Check if the OPS lamp is burnt out.
OPS lamp comes on.
OK NG

NG After correction, check that the OPS

Check for blown fuse (GAUGE).
lamp comes on.*
OK NG

NG After correction, check that the OPS

Check A22 and CN41 for any disconnection or internal wetting.
lamp comes on.*
OK NG

Inspection 1: NG
Harness defect
Check the A2, A22, Q1 and frame for continuity.
OK

Inspection 2: NG
OPS controller defect
Check the OPS controller.
OK

Meter defect

*: After correction, check that the OPS lamp comes on.

After connecting all connectors, turn the ignition key switch ON (engine in stopped state) and leave the seat to
check that the OPS lamp comes on.
 21-39

Inspection 1:
Check the A2, A22, Q1 and frame for continuity.
Turn the ignition key switch OFF, disconnect A2, A22 and Q1.
Standard:
Between A2-4 and Q1-1 Continuity
Between Q1-8 and the frame Continuity
Between A22-8 and Q1-4 Continuity

Inspection 2:
Check the OPS controller.
• Without analyzer
Turn the ignitionkey switch OFF, disconnect Q1 and then turn the ignition key
switch ON (engine in stopped state). Check for continuity between Q1-4 and the
frame with no one on the seat.
Standard:
Lamp ON Lamp OFF
Between Q1-4 and the frame No continuity Continuity

• With analyzer
Turn the ignition key switch OFF, disconnect Q1 and then turn the
ignition key switch ON (engine in stopped state). Check for
continuity between Q1-4 and the frame with no one on the seat.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS lamp ON and OFF, and check for continuity.
Lamp ON signal Lamp OFF signal
Between Q1-4 and the frame No continuity Continuity
21-40

z The OPS lamp keeps lighting. (Including when traveling and material handling are both disabled)

Related Portion

ECU-IG
1C-14
IG
ECU-B
1C-12
BATT
1E-14

A22-32 1B-5
A22-15 1B-6
A22-16 1B-7
A22-31 1B-20
OPS controller

A22-8 QA1-7 Q1-4 Combination

meter

A22-23 (DMI, Seat SW) AO1-1 XO4-1 X1-2

Seat switch
A22-17 (E03, Switch GND) 1B-24 1E-30 XO4-2 X1-1

Estimated Causes:
c Contactor contact defect g Fuse defect
d OPS lamp defect h Low battery voltage
e Harness defect i Seat switch discontinuity
f Controller defect
 21-41

Without Analyzer

NG After correction, check that the OPS

Check for blown fuse (ECU-B, ECU-IG).
lamp goes off.*
OK NG

Check A22, Q1, X1, XO4, AO1, 1B, 1E and 1C for any disconnection NG After correction, check that the OPS
or internal wetting. lamp goes off.*
OK NG

Inspection 1: NG
Harness defect
Check for continuity and measure the voltage between A2 and A22,
between A22 and the frame, between A22 and Q1, and between X1
and A22.

OK

Inspection 2: NG
Battery defect (low battery voltage)
Check the input voltage from the IG line to the controller.
OK

Inspection 3: NG
Seat switch defect
Check the seat switch.
OK

Inspection 4: NG
OPS controller defect
Check the OPS controller.
OK

Meter defect

*: After correction, check that the OPS lamp goes off.

After connecting all connectors, turn the ignition key switch ON while staying on the seat (engine in stopped state).
Check that the OPS lamp goes off after 1 second.
21-42

Inspection 1:
Check for continuity and measure the voltage between A2 and A22, between A22 and the frame, between Q1
and A22, and between X1 and A22.
Turn the ignition key switch OFF, disconnect A22, Q1, X1 and A2 connectors.
Standard:
A2-4 ~ A22-16 Continuity
A2-4 ~ A22-15 Continuity
A2-2 ~ A22-32 Continuity
A22-31 ~ frame Continuity
A22-23 ~ X1-2 Continuity
A22-17 ~ X1-1 Continuity
A22-8 ~ Q1-4 Continuity
A22-15 ~ A22-31 No continuity
A22-16 ~ A22-31 No continuity
A22-32 ~ A22-31 Approx. 12 V

Inspection 2:
Check the input voltage from the IG line to the controller.
Disconnect A22 and turn the ignition key switch ON. (Connectors other than A22 must
be connected).
Standard:
A22-15 ~ A22-31 11 V or more
A22-16 ~ A22-31 11 V or more

Inspection 3:
Check the individual seat switch for continuity.
Turn the ignition key switch OFF, and disconnect X1.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity

Inspection 4:
Check the OPS controller.
Turn the ignition key switch OFF, disconnect Q1 and then turn the ignition key switch ON
(engine in stopped state). Check for continuity between Q1-4 and the frame with no one on
the seat.
Standard:
Lamp ON Lamp OFF
Between Q1-4 and frame No continuity Continuity
 21-43

With Analyzer

NG After correction, check that the OPS

Check for blown fuse (ECU-B, ECU-IG).
lamp goes off.*
OK NG

Check A22, Q1, X1, XO4, AO1, 1B, 1C and 1E for any disconnection NG After correction, check that the OPS
or internal wetting. lamp goes off.*
OK NG

Inspection 1: NG
Harness defect
Check for continuity and measure the voltage between the A2 and
A22, between A22 and the frame, between A22 and Q1, and between
X1 and A22.
OK

Inspection 2: NG
Battery defect (low battery voltage)
Check the input voltage from the IG line to the controller.
OK
Inspection 3: NG
Seat switch defect
Check the seat switch.
OK

Inspection 4: OK
OPS controller defect
Check the OPS controller.
NG

Meter defect

*: After correction, check that the OPS lamp goes off.

After connecting all connectors, turn the ignition key switch ON while staying on the seat (engine in stopped state).
Check that the OPS lamp goes off after 1 second.
21-44

Inspection 1:
Check for continuity and measure the voltage between A2 and A22, between A22 and the frame, between Q1
and A22, and between X1 and A22.
Turn the ignition key switch OFF, disconnect A22, Q1, X1 and A2 connectors.
Standard:
A2-4 ~ A22-16 Continuity
A2-4 ~ A22-15 Continuity
A2-2 ~ A22-32 Continuity
A22-31 ~ frame Continuity
A22-23 ~ X1-2 Continuity
A22-17 ~ X1-1 Continuity
A22-8 ~ Q1-4 Continuity
A22-15 ~ A22-31 No continuity
A22-16 ~ A22-31 No continuity
A22-32 ~ A22-31 Approx. 12 V

Inspection 2:
Check the input voltage from the IG line to the controller.

After connecting all connectors, turn the ignition key switch ON

(engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR
Standard:
Ignition key ON
VOLTAGE 11 V or more

Inspection 3:
Check the seat switch individually.
Turn the ignition key switch OFF and disconnect X1.
Standard:
Seated Unseated
X1-1 ~ X1-2 Continuity No continuity

Inspection 4:
Check the OPS controller.
Turn the ignition key switch OFF, disconnect Q1, and then turn the
ignition key switch ON (engine in stopped state). Check for continuity
between Q1-4 and the frame with no one on the seat.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
Forcibly turn the OPS lamp on and off, and check for continuity.
Lamp ON signal Lamp OFF signal
Between Q1-4 and frame No continuity Continuity
 21-45

z Cannot lower the fork.

Related Portion

A22-26 (DOWN, Lowering switch) A14-1

Lowering switch
A22-17 (E03, SW-GND) 1B-24 1C-23 A14-2
OPS controller

A22-28 (BSOL, Backward tilt lock SOL) A11-1

Lowering lock
A22-30 (E01, SOL-GND) A11-2
SOL
A22-29 (E02, SOL-GND)
22 26 25
1B

Estimated Causes:
c Connector contact defect f Lowering lever switch installation defect
d Lowering switch defect g Controller defect
e Control valve lowering lock valve sticking defect h Harness defect
21-46

Without Analyzer

Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error? according to the error code.
No

No Perform troubleshooting for "The

Does the OPS lamp go off when seated?
OPS Lamp keeps lighting".
Yes
Check A22, 1B, 1C, A11 and A14 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG

Inspection 1: NG Inspection 2: NG
Harness defect
Check the lift lowering lever switch wiring for Check for continuity between A22
continuity. and A14.
OK OK

Inspection 3: NG Lowering switch

Check the lift lowering lever defect
switch (as removed from the
vehicle) for continuity.
OK

Lowering lever switch installation

defect

Put a hand on the lowering lock solenoid (at NG

Controller defect
the rear lower left-hand portion of the control
valve) and operate for lowering the fork while
seating to check the solenoid open/close
sound (with the engine in stopped state and
the fork in the fully lowered position).*
OK

Lowering lock valve sticking

Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:
Check the lift lowering lever switch wiring for continuity.
Turn the ignition key switch OFF and disconnect A22.
Standard:
Lever at neutral position Lever at up position Lever at lowering position
A22-26 ~ A22-17 No continuity No continuity Continuity
 21-47

Inspection 2:
Check for continuity between A22 and A14.
Turn the ignition key switch OFF, and disconnect A22 and A14.
Standard:
A22-26 ~ A14-1 Continuity
A22-17 ~ A14-2 Continuity

Inspection 3:
Check the lift lowering lever switch individually (as removed from the vehicle) for
continuity.
Turn the ignition key switch OFF, and disconnect A14.
Standard:
Free Pressed
A14-1 ~ A14-2 Continuity No continuity
21-48

With Analyzer

Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error? according to the error code.
No
Does the OPS lamp go off when seated? No Perform troubleshooting for "The
OPS Lamp keeps lighting."
Yes

Check A22, 1B, 1C, A11 and A14 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG

Inspection 1: NG Inspection 2: NG
Harness defect
Check the switch output when operated for Check for continuity between A22
fork lowering. and A14.
OK OK

Inspection 3: NG Lowering switch

Check the lowering lever switch defect
individually (as removed from the
vehicle) for continuity.
OK

Lowering lever switch installation

defect

Put a hand on the lowering lock solenoid (at NG

Controller defect
lower rear left-hand portion of the control
valve) and operate for fork lowering on the
seat to check the solenoid open/close sound
(with the engine stopped and the fork in the
fully lowered position).*
OK

Lowering lock valve sticking

Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:
Check the switch output when operated for lowering.
Turn the ignition key switch ON (engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU →
IN/OUT MONITOR

Standard:
Lever at neutral position Lever at up position Lever at lowering position
LIFT LOWER OFF OFF ON
 21-49

Inspection 2:
Check for continuity between A22 and A14.
Turn the ignition key switch OFF, and disconnect A22 and A14.
Standard:
A22-26 ~ A14-1 Continuity
A22-17 ~ A14-2 Continuity

Inspection 3:
Check the lift lowering lever switch individually (as removed from the vehicle) for
continuity.
Turn the ignition key switch to OFF, and disconnect A14.
Standard:
Free Pressed
A14-1 ~ A14-2 Continuity No continuity
21-50

z The material handling OPS does not function. (Including when OPS for lowering is functional)

Related Portion

A22-14 (VSOL, Unload SOL) A12-1

A12-2 Unload SOL
OPS controller

A22-13 (LSOL, Lowering lock SOL) A11-1

Lowering lock
A22-30 (E01, SOL-GND) A11-2 SOL
A22-29 (E02, SOL-GND)
22 26 25 2 3
1B 1C

(A4, Body GND)

Estimated Causes:
c Controller defect
d Control valve unload valve or lowering lock valve defect

Yes Perform troubleshooting according to

Is the OPS lamp blinking?*1
the error code.

No
NG
Check the operating sound of the control valve solenoid.*2 Controller defect

OK

Sticking unload valve on control valve or lowering lock valve

*1: Check if the OPS lamp is blinking.

Turn the ignition key switch OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle
as it is for 15 minutes or more, and turn the ignition key switch ON again to confirm that the OPS lamp does not
blink.
*2: Check the control valve solenoid operating sound.
• Turn the ignition key switch ON (engine in stopped state) and put a hand on the unload solenoid of the control
valve to check that the solenoid open/close sound is heard 2 seconds after leaving the seat or upon getting on
the seat.
• Put a hand on the lowering lock solenoid of the control valve while seating to check if the solenoid open/close
sound is heard upon fork lowering operation.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
 21-51

z Material handling fails. (Including when fork lowering is not fail)

Related Portion

A22-14 (VSOL, Unload SOL) A12-1

OPS controller

A12-2 Unload SOL

A22-30 (E01, SOL-GND)
A22-29 (E02, SOL-GND)
22 26 2 3
1B 1C

(A4, Body GND)

Estimated Causes:
c Sticking unload valve on control valve
d Controller defect

Yes Perform troubleshooting according to

Is the OPS lamp blinking to indicate an error?
the error code.
No

No Perform troubleshooting for "The OPS

Check if the OPS lamp turns OFF while sitting on the seat.
lamp keeps lighting".
Yes

NG
Check the unload solenoid operating sound.* Controller defect

OK

Sticking unload valve on control valve

*: Check the control valve solenoid operating sound.

Turn the ignition key switch ON (engine in stopped state) and put a hand on the unload solenoid of the control
valve to check if the solenoid open/close sound is heard 2 seconds after leaving the seat or upon getting on the
seat.
Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.
21-52

z The mast backward tilting speed is slow.

Related Portion
OPS controller

A22-12 (TSOL, Tilt SOL) A10-1

A22-30 (E01, SOL-GND) A10-2 Tilt SOL
A22-29 (E02, SOL-GND)
22 26 23
1B

Estimated Causes:
c Controller defect
d Sticking tilt control valve

Yes Perform troubleshooting according to

Is the OPS lamp blinking?*1
the error code.

No
OK
Check the tilt solenoid operating sound.*2 Sticking tilt control valve

NG

OPS controller defect

*1: Check if the OPS lamp is blinking.

Turn the ignition key switch OFF → ON (2 seconds or more) → OFF with no one on the seat. Leave the vehicle
as it is for 15 minutes or more, and turn the ignition key switch ON again to confirm that the OPS lamp does not
blink.
Furthermore, operate the tilt lever to the forward position on the operator's seat, make sure that the OPS lamp
does not blink.
*2: Check the tilt solenoid operating sound.
Turn the ignition key switch ON (engine in stopped state) while staying on the seat and put a hand on the tilt
solenoid on the control valve to check if the solenoid open/close sound is heard when the tilt lever is operated to
the forward tilt position.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.
 21-53

z Mast does not tilt forward.

Related Portion

A22-25 (TFI, Forward tilt switch) A13-1

controller

Forward tilt
OPS

A22-17 (E03, SW-GND) 1B-24 1C-29 A13-2 lever switch

Estimated Causes:
c Connector contact defect f Forward tilt lever switch defect
d Harness defect g Forward tilt lever switch installation defect
e OPS controller defect h Sticking tilt control valve

Yes Perform troubleshooting according to

Check if the OPS lamp blinks to indicate an error.
the error code.
No

No Perform troubleshooting for Disabled

Stay on the seat and check if the fork can be lifted.
Material Handling error.
Yes

Check A22, 1B, 1C and A13 for any disconnection or internal wetting. NG After correction, check forward tilting
operation while sitting on the seat.*1
OK NG

Inspection 1: Inspection 2: OK
NG Harness defect
Check the forward tilt lever switch signal to Check the forward tilt lever switch
the OPS controller. individually (as installed on the vehicle) for
continuity.
OK
NG

Inspection 3: NG Forward tilt lever

Check the forward tilt lever switch switch defect
individually (as removed from the vehicle)
for continuity.

OK

Forward tilt lever switch installation defect

NG
Check the tilt solenoid operating sound.*2 OPS controller defect

OK

Sticking tilt control valve

21-54

*1: Stay on the seat and check the forward tilting operation.
After turning the ignition key switch ON, operate the tilt lever to check if the mast can be tilted forward.
*2: Check the tilt solenoid operating sound.
Stay on the seat and turn the ignition key switch ON (with the engine in stopped state), put a hand on the tilt
solenoid to hear the solenoid operating sound generated when the tilt lever is operated forward.
Caution:
*2: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:
Check the forward tilt lever switch signal to the OPS controller.
Ignition key switch OFF, A22 disconnected. (1B, 1C and A13 must be connected).
Standard:
Lever at backward tilt
Lever at neutral position Lever at forward tilt position
position
A22-25 ~ A22-17 No continuity Continuity No continuity

Inspection 2:
Check the forward tilt lever switch individually (as installed on the vehicle) for continuity. 1 2
3 4

Ignition key switch OFF, A13 disconnected.

Standard:
Lever at backward tilt
Lever at neutral position Lever at forward tilt position
position
A13-1 ~ A13-2 No continuity Continuity No continuity

Inspection 3:
Check the forward tilt lever switch individually (as removed from the vehicle) for continuity. 1 2
3 4

Ignition key switch OFF, A13 disconnected.

Standard:
Forward tilt switch (switch on the upper side as installed on the vehicle)
Free Pressed
A13-1 ~ A13-2 Continuity No continuity
 21-55

z The drive OPS does not function. (Excluding the M/T vehicle)

Related portion

SFT
I-2 A41-6
To IG1
A41-5
Shift lever
A41-1

J/B

A22-10 (RYF, Forward/ 1B

Reverse interrupt relay) 1B 36 37
8 2 4

1 3
24 7
A22-17 (E03, SW-GND) 9
Forward interrupt relay
OPS controller

1A 1A 1 4

2 3
A22-3 Reverse interrupt relay

(DRF, Forward drive SW) 1B

3
19 1A
A22-4 4 2
(DRR, Reverse drive SW)
1 2
A55

Shift SOL

Estimated Causes:
c Connector interrupt defect f Harness defect
d Forward interrupt relay defect g Controller defect
e Reverse interrupt relay defect
21-56

Yes Perform troubleshooting according to

Check if the OPS lamp blinks to indicate an error.*1
the error code.
No

Check A22, A41, 1A, 1B and A55 (A47) for any disconnection or NG After correction, check if the OPS
internal wetting, and any relay disconnection. functions normally.*2
OK NG

Inspection 1: NG
Harness defect
Check for continuity of the wiring between A41 and J/B, and the wiring
between A55 (A47) and J/B.
OK

Inspection 2: NG
Interrupt relay defect
Check the forward/reverse interrupt relay.
OK

Controller defect

*1: Check if the OPS lamp blinks to indicate an error.

Without getting on the seat, turn the ignition key switch OFF → ON (2 seconds or more) → OFF. Leave the vehicle
as it is for at least 15 minutes. Then turn the ignition key switch ON again and make sure that the OPS lamp does
not blink.
*2: After correction, check if the drive OPS functions normally.
Turn the ignition key switch ON, set the shift lever to either forward or reverse and leave the seat. Check if the
drive OPS is activated.

Inspection 1:
Check for continuity of the wiring between A41 and J/B, and the wiring between A55 (A47) and
J/B.
Turn the ignition key switch OFF, disconnect A41 and A55 (A47), and remove the relays from the
J/B.
Standard:
Between A41-5 and pin 4 of forward interrupt relay Continuity
Between A41-1 and pin 4 of reverse interrupt relay Continuity
Between A55 (A47)-1 and pin 3 of forward interrupt relay Continuity
Between A55-2 (A47-3) and pin 3 of reverse interrupt relay Continuity
A41-6 ~ A2-4 Continuity
 21-57

Inspection 2:
Check the forward/reverse interrupt relay individually.
(1) Turn the ignition key switch OFF and disconnect the relays from the J/B. Measure the
resistances between the specified pins of the forward/reverse interrupt relay.
Standard:
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

(2) Install the relay and disconnect A41 and A55 (A47). Leave the seat unseated, and turn the
ignition key switch ON (with the engine in stopped state).
• Without analyzer
Standard:
Unseated Seated
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity

• With analyzer
Forcibly turn the forward and reverse interrupt relays ON and OFF
and check for continuity in each state.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
• Forward and reverse interrupt relay (RLY FWD)
Relay ON Relay OFF
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
21-58

z Traveling fails. (Including forward traveling only, reverse traveling only, and occasional abnormalities)
(Excluding the M/T vehicle)

Related Portion

SFT
I-2 A41-6
To IG1
A41-5
Shift lever
A41-1

J/B

A22-10 (RYF, Forward/ 1B

Reverse interrupt relay) 1B 36 37
8 2 4

1 3
24 7
A22-17 (E03, SW-GND) 9
Forward interrupt relay
OPS controller

1A 1A 1 4

2 3
A22-3 Reverse interrupt relay

(DRF, Forward drive SW) 1B

3
19 1A
A22-4 4 2
(DRR, Reverse drive SW)
1 2
A55

Shift SOL

Estimated Causes:
c Connector contact defect g Controller defect
d Forward interrupt relay defect h Shift lever switch defect
e Reverse interrupt relay defect i Fuse defect
f Harness defect

Yes Perform troubleshooting according to

Check if the OPS lamp blinks to indicate an error.
the error code.
No

No Perform troubleshooting for "OPS lamp

Stay on the seat and check if the OPS lamp goes off.
keeps lighting".
Yes

NG After correction, check if the OPS

Check if the fuse (SFT) is blown.
functions normally.*
OK

Check A22, A41, 1A, 1B and A55 (A47) for any disconnection or NG After correction, check if the OPS
internal wetting. functions normally.*
OK NG

A
 21-59

Inspection 1: NG
Shift lever defect
Check the shift lever unit individually for continuity.
OK

Inspection 2: NG
Harness defect
Check the wirings between A41/A55 (A47) and the J/B, and between
A22 and A41 for continuity.
OK

Inspection 3: NG
Interrupt relay defect
Check the forward/reverse interrupt relay.
OK

Controller defect

* After correction, check if the OPS functions normally.

Check that the buzzer sounds at short intervals (pip-pip) when the shift lever is set to the forward position with the
operator taking seat after leaving the seat to operate the OPS while the ignition key switch is in the ON position.
Next, check that forward traveling is enabled if the shift lever is set to neutral once and then to forward again.

Inspection 1:
Check the T/C shift lever unit individually for continuity.
Ignition key switch OFF, A41 disconnected.
Standard:
Lever at neutral Lever at forward Lever at reverse
Between pins 6 and 5 on lever side No continuity Continuity No continuity
Between pins 6 and 1 on lever side No continuity No continuity Continuity

Inspection 2:
Check the wiring between A41/A55 (A47) and J/B and between A22 and A41 for continuity.
Turn the ignition key switch OFF, disconnect A41, A55 (A47) and A22, and disconnect relays from the J/B.

Standard:
Between A41-5 and pin 4 of forward interrupt relay Continuity
Between A41-1 and pin 4 of reverse interrupt relay Continuity
Between A55 (A47)-1 and pin 3 of forward interrupt relay Continuity
Between A55-2 (A47-3) and pin 3 of reverse interrupt relay Continuity
A41-6 ~ A2-4 Continuity
A22-3 ~ A41-5 Continuity
A22-4 ~ A55 (A47)-1 Continuity
21-60

Inspection 3:
Check the forward/reverse interrupt relay individually.
(1) Turn the ignition key switch OFF and remove the relays from the J/B. Measure the resistance between pins
of the forward and reverse interrupt relays.
Standard:
Resistance
Between forward interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)
Between reverse interrupt relay pins 1 and 2 Approx. 90 Ω (at 20°C)

(2) Install the relays and disconnect A41 and A55 (A47). Turn the ignition key switch ON (with the engine in
stopped state) after leaving the seat.
• Without analyzer
Standard:
Unseated Seated
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity

• With analyzer
Forcibly turn each of the forward and reverse interrupt relays ON
and OFF, and check for continuity in each state.
Analyzer: MAIN MENU → OPS → ANALYZER MENU → ACTIVE
TEST
Standard:
• Forward and reverse interrupt relay (RLY FWD)
Relay ON Relay OFF
A41-5 ~ A55 (A47)-1 No continuity Continuity
A41-1 ~ A55-2 (A47-3) No continuity Continuity
 21-61

z Mast does not tilt backward.

Related Portion

A22-24 (TRI, Backward tilt switch) A13-3

Backward tilt
A22-17 (E03, SW-GND) 1B-24 1C-20 A13-4 switch
OPS controller

A22-28 (BSOL, Backward tilt lock Solenoid) A56-1

Backward tilt
A22-30 (E3, SOL-GND) A56-2 lock SOL
A22-29 (E3, SOL-GND)
22 26 1A-21
1B

Estimated Causes:
c Connector contact defect f Backward tilt switch installation defect
d Backward tilt switch defect g Controller defect
e Control valve backward tilt lock valve sticking defect h Harness defect
21-62

Without Analyzer

Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error? according to the error code.
No
No Perform troubleshooting for "The
Does the OPS lamp go off when seated?
OPS Lamp keeps lighting".
Yes
Check A22, A13, 1B, 1C and A56 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG

Inspection 1: NG Inspection 2: NG
Harness defect
Check the backward tilt switch wiring for Check for continuity between A22
continuity. and A13.
OK OK

Inspection 3: NG Lowering switch

Check the backward tilt switch (as defect
removed from the vehicle) for
continuity.
OK

Backward tilt switch installation

defect

Put a hand on the tilt backward lock solenoid NG

Controller defect
(at the upper right-hand portion of the control
valve) and operate for tilting backward the
mast while seating to check the solenoid
open/close sound (with the engine in
stopped state, the fork in the fully lowered
position, and the mast in the fully backward
tilted position).*

OK

Tilt backward lock valve sticking

Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:
Check the backward tilt switch wiring for continuity.
Turn the ignition key switch OFF and disconnect A22.
Standard:
Lever at backward tilt Lever at forward tilt
Lever at neutral position
position position
A22-24 ~ A22-17 No continuity Continuity No continuity
 21-63

With Analyzer

Is the OPS lamp blinking to indicate an Yes Perform troubleshooting

error? according to the error code.
No
Does the OPS lamp go off when seated. No Perform troubleshooting for "The
OPS Lamp keeps lighting."
Yes

Check A22, A13, 1B, 1C and A56 for any NG After correction, get on the seat
disconnection or internal wetting. and check if the fork can be
lowered.
OK
NG

Inspection 1: NG Inspection 2: NG
Harness defect
Check the switch output when operated for Check for continuity between A22
tilting backward the mast. and A13.
OK OK

Inspection 3: NG Lowering switch

Check the backward tilt switch defect
individually (as removed from the
vehicle) for continuity.
OK

Backward tilt switch installation

defect

Put a hand on the tilt backward lock solenoid NG

Controller defect
(at the upper right-hand portion of the control
valve) and operate for tilting backward the
mast while seating to check the solenoid
open/close sound (with the engine in
stopped state, the fork in the fully lowered
position, and the mast in the fully backward
tilted position).*

OK

Tilt backward lock valve sticking

Caution:
*: Be careful so as not to get burnt because the solenoid may be hot.

Inspection 1:
Check the switch output when operated for lowering.
Turn the ignition key switch ON (engine in stopped state).
Analyzer: MAIN MENU → OPS → ANALYZER MENU → IN/OUT
MONITOR

Standard:
Lever at backward tilt Lever at forward tilt
Lever at neutral position
position position
TILT BWD OFF ON OFF
21-64

Inspection 2:
Check for continuity between A22 and A13.
Turn the ignition key switch OFF, and disconnect A22 and A13.
Standard:
A22-24 ~ A13-3 Continuity
A22-17 ~ A13-4 Continuity

Inspection 3:
Check the backward tilt switch individually (as removed from the vehicle) for continuity. 1
3
2
4

Turn the ignition key switch OFF, and disconnect A13.

Standard:
Free Pressed
A13-3 ~ A13-4 Continuity No continuity
 21-65

TROUBLESHOOTING (OPT EQUIPPED VEHICLE)

BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y-E ENGINE
It is extremely risky to begin troubleshooting for the 4Y engine on the basis of results only. It can lead to mistaken
corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, ask the customer about
detailed information on conditions around the time a problem occurred, based on the following.
Diagnostic Procedure
First, it is necessary to be informed of the "fault history and service history" for the vehicle, and then to gather definite
information about the fault occurence such as "when", "at what times", "in what places", "during what operations or
actions", "what happened afterwards", and “frequency of occurrence”.
Also, try to recreate the conditions for the fault occurence. (a. Recreation impossible b. Recreation possible: in what
condition?)
• General items
Customer name Date of delivery Date fault occurred / hour meter reading

Vehicle model Frame No. Engine No. (punched)

Fuel type
F Gasoline F LPG F Gasoline - LPG combination (Note LPG fuel company name: )

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

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)
a. Immediately after start-up (when cold - when warm) b. During deceleration c. After deceleration
4. Engine stalling d. Without sign e. After the engine has been running rough f. When steering
g. When handling materials h. Can be re-started immediately
a. Insufficient power output b. Hesitation
5. Defect operational
c. Surging (swaying forward and backward during acceleration) d. Knocking e. Backfiring f. After
status
firing
a. Excessive fuel consumption b. Excessive oil consumption c. Overheating d. Water or oil leaks
6. Other
e. Abnormal noise f. Other ( )
Environment at the time of the defect's occurrence
The time when the fault a. Since the vehicle was new b. Recently (from around the following date (month and year): )
began to occur c. After being serviced
Frequency of occurence a. Always b. Under certain conditions c. Sometimes
Sunny - cloudy - rain - snow - Approximately Approximately
Weather Temperature Humidity
thunderstorm °C %
Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: °C
a. No relation b. When idling c. When revving d. When accelerating
e. When traveling at constant speed f. When decelerating g. When climbing a slope
Operation conditions h. 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
21-66

DIAGNOSIS (SELF DIAGNOSIS FUNCTION)

General
When the computer detects a problem in the system, the fault is indicated by lighting a warning lamp on the
combination meter and displaying an error code, and fail-safe functions operate to ensure safety by stopping the
engine or controlling the engine to a low speed.

DIAGNOSIS DISPLAY METHOD

Error code display
1. Diagnosis display method
The diagnosis is displayed by means of an error code as
shown in the illustration to the left, and by the lights turning on.
When the ignition key switch is turned ON, the lamp lights
once to allow checking for the bulb, and then turns off again if
the status is normal.
With the ignition key switch ON, if an abnormality is detected
An orange colored lamp lights Lamp blinks when the vehicle is stopped, travelling or performing meterials
(Engine ECU only) handling operations, an error code is displayed and the lamps
turn on as a warning.
When this happens, stop the vehicle immediately and check
the error code.
2. Diagnosis memory display method
To display the diagnosis memory display, there are a method using the hour meter and tilt lever, a method using
the 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 page
18-30.
(2) A diagnosis No. and error code are displayed each time the knob switch is pressed and released. Each
error 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.

Knob switch

Diagnosis memory menu

Press the knob switch to return it.

Switches automatically
every 2 seconds
LIST OF DIAGNOSIS CODES
Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
01-1 01-1 Blinking 4Y-ECS Fuel feedback control error (gasoline) rich
21-75
01-2 01-2 Blinking 4Y-ECS Fuel feedback control error (gasoline) lean
The engine speed is unstable and it may stop.
01-3 01-3 Blinking 4Y-ECS Fuel feedback control error (LPG) rich
21-79
01-4 01-4 Blinking 4Y-ECS Fuel feedback control error (LPG) lean
01-5 01-5 Blinking 4Y-ECS O2 sensor open abnormality The engine speed is unstable and it may stop. 21-84
01-6 01-6 Blinking 4Y-ECS O2 sensor heater open abnormality Display only 21-86
02-1 02-1 Blinking 4Y-ECS Intake temperature sensor open abnormality The engine may have a problem at low
21-88
02-2 02-2 Blinking 4Y-ECS Intake temperature sensor short abnormality temperatures.
03-1 03-1 Blinking 4Y-ECS Intake pipe pressure sensor open abnormality
The engine may have a problem 21-90
03-2 03-2 Blinking 4Y-ECS Intake pipe pressure sensor short abnormality
04-1 04-1 Blinking 4Y-ECS Coolant temperature sensor open abnormality The engine may have a problem at low
21-92
04-2 04-2 Blinking 4Y-ECS Coolant temperature sensor short abnormality temperatures.
05-1 05-1 Blinking 4Y-ECS Throttle position sensor 1 open abnormality
05-2 05-2 Blinking 4Y-ECS Throttle position sensor 1 short abnormality
05-3 05-3 Blinking 4Y-ECS Throttle position sensor 2 open abnormality Limting speed of traveling and materials
21-94
05-4 05-4 Blinking 4Y-ECS Throttle position sensor 2 short abnormality handling due to limited engine power output
05-5 05-5 Blinking 4Y-ECS Throttle position sensor offset abnormality
05-6 05-6 Blinking 4Y-ECS Throttle position sensor out of range error
06-1 06-1 Blinking 4Y-ECS Throttle motor drive circuit open abnormality
21-96
06-2 06-2 Blinking 4Y-ECS Throttle motor drive circuit short abnormality
06-3 06-3 Blinking 4Y-ECS Throttle motor power supply circuit open abnormality Limting speed of traveling and materials
21-98
06-4 06-4 Blinking 4Y-ECS Throttle motor power supply circuit short abnormality handling due to limited engine power output
06-5 06-5 Blinking 4Y-ECS Throttle motor seizing abnormality 21-99
06-6 06-6 Blinking 4Y-ECS Electronic throttle system error 21-101
07-1 07-1 Blinking 4Y-ECS Air-fuel ratio motor open abnormality The engine speed is unstable and it may stop. 21-102
08-1 08-1 Blinking 4Y-ECS Low voltage (battery line open) error Display only 21-104
09-1 09-1 Blinking 4Y-ECS Ignition signal error The engine speed is unstable and it may stop. 21-105
0A-1 0A-1 Blinking 4Y-ECS Fuel specification determination signal error Display only
0A-2 0A-2 Blinking 4Y-ECS Fuel specification changeover switch error Display only 21-108
0A-3 0A-3 Blinking 4Y-ECS Fuel specification type unmatch Engine may stop
21-67
 Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-68

Limting speed of traveling and materials

0A-4 0A-4 Blinking 4Y-ECS Engine specification determination error 21-110
handling due to limited engine power output
13-1 13-1 Blinking ASC Motor relay contact point open abnormality Continuation of engine idling status
13-2 13-2 Blinking ASC Motor relay contact point short abnormality Display only 21-111
13-3 13-3 Blinking ASC Motor relay open circuit or load short abnormality Continuation of engine idling status
15-1 15-1 Blinking ASC NMR switch open abnormality The engine may idle during full acceleration.
21-113
15-2 15-2 Blinking ASC NMR switch short abnormality Continuation of engine idling status
Continuation of engine idling status after
15-3 15-3 Blinking ASC Idle / NMR switch simultaneously ON error 21-116
acceleration off.
16-1 16-1 Blinking ASC Idle switch open abnormality
Continuation of engine idling status 21-119
16-2 16-2 Blinking ASC Idle switch short abnormality
4Y-ECS Cam angle sensor open abnormality Engine stop 21-122
18-1 18-1 Blinking
ASC Engine speed sensor open abnormality Partial limitation of the drive control function. 21-126
4Y-ECS Cam angle sensor open abnormality (on start up) Engine will not start 21-122
18-2 18-2 Blinking
ASC Engine speed sensor GND short abnormality Partial limitation of the drive control function. 21-126
18-3 18-3 Blinking 4Y-ECS Crank angle sensor open abnormality Display only 21-124
Continuation of engine idling status
Maximum speed may be limited
1F-1 ~ 8 1F-1 ~ 8 Blinking ASC CPU error 21-128
Function of automatic idle speed increse during
lifting limited
41-1 41-1 Blinking SAS/OPS Matching connector open abnormality Display only 21-129
51-1 51-1 Blinking SAS/OPS Speed sensor open abnormality The vehicle speed indicator shows 0 km/h
Partial limitation of the rear wheel swing control
function. 21-130
51-2 51-2 Blinking SAS/OPS Speed sensor GND short abnormality Knob offest compensation stops
Partial limitation of the drive control function.
52-1 52-1 Blinking SAS/OPS Yaw rate sensor open abnormality
Partial limitation of the rear wheel swing control
52-2 52-2 Blinking SAS/OPS Yaw rate sensor VCC short abnormality 21-132
function
52-3 52-3 Blinking SAS/OPS Yaw rate sensor neutral voltage error
Partial limitation of the rear wheel swing control
54-1 54-1 Blinking SAS/OPS Swing lock solenoid open circuit or load short abnormality 21-134
function
61-1 61-1 Blinking SAS/OPS Load sensor open abnormality Partial limitation of the rear wheel swing control
function
Partial limitation of mast control function 21-136
61-2 61-2 Blinking SAS/OPS Load sensor VCC short abnormality Limitation of the drive control function
Load indicator cannot display
 Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
62-1 62-1 Blinking SAS/OPS Tilt angle sensor open abnormality
Partial limitation of mast control function 21-139
62-2 62-2 Blinking SAS/OPS Tilt angle sensor VCC short abnormality
63-1 63-1 Blinking SAS/OPS Tilt switches simultaneously ON
63-2 63-2 Blinking SAS/OPS Tilt switch forward tilt SW short Partial limitation of mast control function 21-142
63-3 63-3 Blinking SAS/OPS Tilt switch backward tilt SW short
64-1 64-1 Blinking SAS/OPS Lift lower lock solenoid open circuit or load short abnormality Lift lower may stop 21-145
Forward tilt may stop, backward tilt may go fully
65-1 65-1 Blinking SAS/OPS Tilt control solenoid open circuit or load short abnormality 21-147
back
66-1 66-1 Blinking SAS/OPS Outside matching value range for tilt angle error Partial limitation of mast control function 21-149
Partial limitation of the rear wheel swing control
function
67-1 67-1 Blinking SAS/OPS Lifting height switch open abnormality Partial limitation of mast control function 21-150
Limitation of the drive control function
Load indicator display is unsteady
Lowering may stop
68-1 68-1 Blinking SAS/OPS Lift switch raise and lower simultaneously ON error Function of automatic idle speed increse during
lifting limited
21-153
Function of automatic idle speed increse during
68-2 68-2 Blinking SAS/OPS Lift switch raise SW short abnormality
lifting limited
68-3 68-3 Blinking SAS/OPS Lift switch lower SW short abnormality Lowering may stop
Backward tilt lock solenoid open circuit or load short
69-1 69-1 Blinking SAS/OPS Backward tilt may stop 21-156
abnormality
71-1 71-1 Blinking SAS/OPS Tire angle sensor open abnormality
Knob offest compensation stops 21-158
71-2 71-2 Blinking SAS/OPS Tire angle sensor VCC short abnormality
72-1 72-1 Blinking SAS/OPS Steering-wheel angle sensor SS1 open abnormality
72-2 72-2 Blinking SAS/OPS Steering-wheel angle sensor SS2 open abnormality
Knob offest compensation stops 21-161
72-3 72-3 Blinking SAS/OPS Steering-wheel angle sensor SSC open abnormality
72-4 72-4 Blinking SAS/OPS Steering-wheel angle sensors SS1 and SS2 open abnormality
21-69
 Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-70

Knob position compensation solenoid open circuit or load short

73-1 73-1 Blinking SAS/OPS Knob offest compensation stops 21-169
abnormality
74-1 74-1 Blinking SAS/OPS Outside matching value range for tire angle error Knob offest compensation stops 21-171
Traveling and material handling possible even
after leaving the seat.
A5-1 A5-1 Blinking SAS/OPS Seat switch GND short abnormality 21-172
Parking brake reminder and release reminder
alarm partially disabled.
A7-1 A7-1 Blinking SAS/OPS Brake switch GND short abnormality Partial limitation of the drive control function 21-174
AD-1 AD-1 Blinking SAS/OPS CAN communication 4Y-ECS or ASC data reception error Partial limitation of the drive control function
AD-2 AD-2 Blinking 4Y-ECS CAN communication SAS/OPS data reception error Partial limitation of the drive control function
Limitation of the drive control function
Function of automatic idle speed increse during 21-176
AD-7 AD-7 Blinking SAS/OPS CAN communication display data reception error
lifting limited
Display warning function operation failure
AD-8 AD-8 – Display CAN communication SAS/OPS data reception error Display not stable
AF-1 ~ 3 AF-1 ~ 3 On SAS/OPS
CPU error Various control operations not stable 21-180
AF-4 ~ 8 AF-4 ~ 8 Blinking SAS/OPS
4Y-ECS
C4-1 C4-1 Blinking Accelerator sensor 1 open
ASC
4Y-ECS
C4-2 C4-2 Blinking Accelerator sensor 1 short
ASC
4Y-ECS
C4-3 C4-3 Blinking Accelerator sensor 2 open Limting speed of traveling and materials
ASC 21-184
handling due to limited engine power output
4Y-ECS
C4-4 C4-4 Blinking Accelerator sensor 2 short
ASC
4Y-ECS
C4-5 C4-5 Blinking Accelerator sensor offset abnormality
ASC
C4-6 C4-6 Blinking 4Y-ECS Accelerator sensor out of range error
Travel return to neutral operation disabled
C7-1 C7-1 Blinking SAS/OPS Shift lever forward and reverse travel switch open abnormality
Partial limitation of the drive control function.
21-187
Shift lever forward and reverse travel switches simultaneously Travelling may stop
C7-2 C7-2 Blinking SAS/OPS
ON error Partial limitation of the drive control function.
Forward and reverse travel T/C relay open circuit or load short Travelling and material handling enabled even
CA-1 CA-1 Blinking SAS/OPS 21-190
abnormality after leaving the seat.
 Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
Travelling and material handling enabled even
EC-1 EC-1 Blinking SAS/OPS Unload solenoid open circuit or load short abnormality 21-192
after leaving the seat.
F1-1 – Blinking
Meter SAS/OPS data reception error Display only 21-194
F1-2 – Blinking
F4-1 ~ 8 F4-1 ~ 8 Blinking Display CPU error Display not stable 21-195
H1-1 H1-1 Blinking SAS/OPS Lift lever potentiometer open abnormality
H1-2 H1-2 Blinking SAS/OPS Lift lever potentiometer VCC short abnormality Lift stop
H1-3 H1-3 Blinking SAS/OPS Lift lever potentiometer assembly error 21-196
H1-4 H1-4 Blinking SAS/OPS Lift lever potentiometer neutral abnormality Material handling disabled
H1-5 H1-5 Blinking SAS/OPS Lift lever potentiometer matching value abnormality Lift stop
H2-1 H2-1 Blinking SAS/OPS Tilt lever potentiometer open abnormality
H2-2 H2-2 Blinking SAS/OPS Tilt lever potentiometer VCC short abnormality Tilt stop
H2-3 H2-3 Blinking SAS/OPS Tilt lever potentiometer assembly error 21-199
H2-4 H2-4 Blinking SAS/OPS Tilt lever potentiometer neutral error abnormality Material handling disabled
H2-5 H2-5 Blinking SAS/OPS Tilt lever potentiometer matching error Tilt stop
H3-1 H3-1 Blinking SAS/OPS Attachment 1 lever potentiometer open abnormality
H3-2 H3-2 Blinking SAS/OPS Attachment 1 lever potentiometer VCC short abnormality Attachment 1 stop
H3-3 H3-3 Blinking SAS/OPS Attachment 1 lever potentiometer combination error 21-202
H3-4 H3-4 Blinking SAS/OPS Attachment 1 lever potentiometer neutral abnormality Material handling disabled
H3-5 H3-5 Blinking SAS/OPS Attachment 1 lever potentiometer matching value abnormality Attachment 1 stop
H4-1 H4-1 Blinking SAS/OPS Attachment 2 lever potentiometer open abnormality
H4-2 H4-2 Blinking SAS/OPS Attachment 2 lever potentiometer VCC short abnormality Lever 2 stop
H4-3 H4-3 Blinking SAS/OPS Attachment 2 lever potentiometer combination error 21-205
H4-4 H4-4 Blinking SAS/OPS Attachment 2 lever potentiometer neutral abnormality Material handling disabled
H4-5 H4-5 Blinking SAS/OPS Attachment 2 lever potentiometer matching value abnormality Lever 2 stop
H5-1 H5-1 Blinking SAS/OPS Lift PUSH solenoid open abnormality
Lift may stop 21-208
H5-2 H5-2 Blinking SAS/OPS Lift PULL solenoid open abnormality
H6-1 H6-1 Blinking SAS/OPS Tilt PUSH solenoid open abnormality
Tilt may stop 21-210
H6-2 H6-2 Blinking SAS/OPS Tilt PULL solenoid open abnormality
H7-1 H7-1 Blinking SAS/OPS Attachment 1 PUSH solenoid open abnormality
Attachment 1 may stop 21-212
H7-2 H7-2 Blinking SAS/OPS Attachment 1 PULL solenoid open abnormality
21-71
 Wrench Detection Described
Indication Spanner Error mode Phenomenon on vehicle
lamp ECU on page
21-72

H8-1 H8-1 Blinking SAS/OPS Attachment 2 PUSH solenoid open abnormality

Attachment 2 may stop 21-214
H8-2 H8-2 Blinking SAS/OPS Attachment 2 PULL solenoid open abnormality
HA-1 HA-1 Blinking SAS/OPS 3/4 way change relay GND short abnormality Attachment switching disabled 21-216
WARNING LIST
Caution:
If the wrench lamp illuminates and the following phenomena occur on the vehicle without an error being displayed, it is not a fault. Take the
appropriate corrective action.
Wrench Detection
Indication Memory Phenomenon on vehicle Content of warning Appropriate corrective action
lamp ECU
Water
temperatur Top speed and load lifting speed are limited.
OB-1 – 4Y-ECS Overheat Leave the vehicle at idle for a while
e gauge (Only when OPT equipped)
flashing
Swing lock control is always locked
Knob offset occurrence Use a battery of the specified
– – On SAS/OPS High battery voltage
Material handling disabled (mini lever) voltage
Material handling except lifting disabled
– – On SAS/OPS Swing lock control is always locked Low battery voltage Charge or replace the battery
– – On SAS/OPS Tilt operates to forward most tilt position Forward tilt restriction angle not matching
Tilt disabled with the knob switch in the ON
– – On SAS/OPS Auto leveling angle not matching
position
Tilt operates to forward most tilt position
SAS/OPS NL load not matching
– – On SAS/OPS Tilt disabled with the knob switch in the ON
(NL: No-load)
position
– – On SAS/OPS Knob offset occurrence Tire angle not matching Carry out matching for each item
– – On SAS/OPS Swing lock control disabled Swing leveling not matching
– – On SAS/OPS Lift stop Lift lever not matching
– – On SAS/OPS Tilt stop Tilt lever not matching
– – On SAS/OPS Attachment 1 stop Attachment 1 not matching
– – On SAS/OPS Attachment 2 stop Attachment 2 not matching
21-73
21-74

VIEWING RELATED PORTIONS

In the wiring diagrams for related portions, there are cases in which the parts are connected directly, and cases
where they are connected via a junction block or similar.
Refer below for how to identify wiring configuartions.
Example of a Related Portion

: Direct connection
: Connection via a junction
A21
ECU-B
8 (BATT)

1 (IG1) ECU-IG Q2

SAS/OPS 2 (IG2) 2 (IG)

controller A20
12 (CANH) 5 (CANH) Multifunction
13 (CANL) 6 (CANL) display

3 (E1)

A36
28 (CAN+)
29 (CAN-)
Engine
EFI 3 (BATT)
controller
IGN 9 (IGSW)

ERROR CONFIRMATION DRIVE MODE

c Turn the ignition key switch ON, start and completely warm up the engine.
d Fully depress the accelerator pedal for 3 to 5 minutes with the direction neutral.
e Release and leave the accelerator pedal (run the engine at idle) for 2 minutes.
f Repeat steps d and e 3 times.
g Turn the ignition key switch OFF (for 1 minute).
h Repeat steps c to g 3 times.
Engine speed 3 ~ 5 minutes 3 ~ 5 minutes 3 ~ 5 minutes

NMR

Warmed up
Idle

time
IG IG
OFF OFF

2 minutes 2 minutes 2 minutes

 21-75

TROUBLESHOOTING BY ERROR CODE

z Error codes 01-1, 01-2 (Fuel feedback control abnormality)
Related portion

A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor

Probable cause
c Intake system defect g Fuel system defect
d Exhaust system defect h Harness defect
e Sensor defect i Engine controller defect
f 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

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

Disconnect the battery negative terminal,

disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
21-74).
Error

Inspection 1: NG Intake system defect

Inspect the air intake Intake system connection defect

OK

A
21-76

Inspection 2: NG Exhaust system defect

Exhaust gas leakage inspection Exhaust system

OK

Inspection 3: NG Fuel system defect

Fuel leakage inspection Fuel system connection defect

OK

Pressure regulator defect

Inspection 4: NG
Fuel filter defect
Fuel pressure inspection
Fuel pump defect
OK

Inspection 5: NG
Spark plug individual inspection Spark plug defect

OK

Inspection 6: NG
Injector individual inspection Injector defect

OK

Inspection 7:
NG
Intake pipe pressure sensor voltage inspection Intake pipe pressure sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 8:
NG
Intake temperature sensor voltage inspection Intake temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 9:
NG
Coolant temperature sensor voltage inspection Coolant temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 10: NG
Harness continuity and short circuit inspection Harness defect

OK

B
 21-77

Inspection 11:
OK
O2 sensor voltage inspection Connector contact defect
ANL.:I/O ENGINE CTRL 8/10

NG

Inspection 12:
NG
O2 sensor voltage inspection Engine controller defect
ANL.:I/O ENGINE CTRL 8/10

OK

O2 sensor defect

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 PCV
hose 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 and
the 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 connections
between 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 the
fuel 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.
21-78

Inspection 7:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])

Inspection 8:
Inspect the intake temperature sensor voltage.
Ignition key switch ON, engine stopped
Intake temperature sensor voltage (I/O monitor: THA)
Standard:
2.4 ± 0.6 V (20 ± 10°C)
THA
0.55 ± 0.15 V (80 ± 10°C) (reference value)

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:
0.55 ± 0.15 V (80 ± 10°C)
THW
2.4 ± 0.6 V (20 ± 10°C) (reference value)

Inspection 10:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect battery negative terminal, disconnect A35 and C1.
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-20 ~ Frame No continuity
A35-21 ~ Frame No continuity

Inspection 11:
Inspect the O2 sensor output.
Connect A35 and C1, start the engine, warm up completely, set direction in neutral, fully open the accelerator
pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.4 V or less and 0.5 V or more alternately output

Inspection 12:
Inspect the O2 sensor output.
Disconnect C1, connect A35, start the engine, warm up completely, set direction in neutral, fully open the
accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.2 V or less
 21-79

z Error codes 01-3, 01-4 (Fuel feedback control abnormality) (LPG)

Related portion

A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor

Probable cause
c Intake system defect g Fuel system defect
d Exhaust system defect h Harness defect
e Sensor defect i Engine controller defect
f Ignition defect
Caution:
When another error code is occuring, repair the related parts first before carrying out the following.
Error codes 01-3 and 01-4

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

Disconnect the battery negative terminal,

disconnect TC terminal - E1 terminal, connect
the battery negative terminal, start the engine, No error
and check whether the error occurs after Connector contact defect
performing error confirmation drive mode (see
21-74).
Error

Inspection 1: NG Intake system defect

Inspect the air intake Intake system connection defect

OK

A
21-80

Inspection 2: NG Exhaust system defect

Exhaust gas leakage inspection Exhaust system connection defect

OK

Inspection 3: NG Fuel system defect

Fuel leakage inspection Fuel system connection defect

OK

Inspection 4: NG
Regulator primary pressure inspection Regulator defect

OK

Inspection 5: NG
Spark plug individual inspection Spark plug defect

OK

Inspection 6: NG
Injector individual inspection Injector defect

OK

Inspection 7: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect

OK

Inspection 8:
NG
Intake pipe pressure sensor voltage inspection Intake pipe pressure sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 9:
NG
Intake temperature sensor voltage inspection Intake temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 10:
NG
Water temperature sensor voltage inspection Water temperature sensor defect
ANL.: I/O ENGINE CTRL 3/10

OK

Inspection 11: NG
Harness continuity and short circuit inspection Harness defect

OK

B
 21-81

Inspection 12:
OK
O2 sensor voltage inspection Connector contact defect
ANL.:I/O ENGINE CTRL 8/10

NG

Inspection 13:
NG
O2 sensor voltage inspection Engine controller defect
ANL.:I/O ENGINE CTRL 8/10

OK

O2 sensor defect

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 PCV
hose 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 and
the cylinder head.
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 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 connections
between 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 the
fuel 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 LPG
adapter.
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.
21-82

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.

Inspection 8:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 3.6 ± 0.3 V (100 ± 10 kPa (1 ± 0.1 kgf/cm2) [14 ± 1.4 psi])

Inspection 9:
Inspect the intake temperature sensor voltage.
Ignition key switch ON, engine stopped
Intake temperature sensor voltage (I/O monitor: THA)
Standard:
2.4 ± 0.6 V (20 ± 10°C)
THA
0.55 ± 0.15 V (80 ± 10°C) (reference value)

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:
0.55 ± 0.15 V (80 ± 10°C)
THW
2.4 ± 0.6 V (20 ± 10°C) (reference value)

Inspection 11:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-20 ~ Frame No continuity
A35-21 ~ Frame No continuity
 21-83

Inspection 12:
Inspect the O2 sensor output.
Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.4 V or less and 0.5 V or more alternately output

Inspection 13:
Inspect the O2 sensor output.
Start the engine, warm up completely, put the direction in neutral, fully open the accelerator pedal
O2 sensor voltage (I/O monitor: OX)
Standard:
OX 0.2 V or less
21-84

z Error code 01-5 (O2 sensor open abnormality)

Related portion

A35 C1
20 (OX) 3 (OX)
Engine
controller 21 (E11) 4 (E11) O2 sensor

Probable cause
c O2 Sensor defect
d Harness defect
e Engine controller defect
Caution:
When another error code is present, repair the related parts first before carrying out the following.
Error code 01-5

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

Disconnect the battery negative terminal,

disconnect TC terminal - E1 terminal, connect
No error
the battery negative terminal, start the engine, Connector contact defect
and check whether the error occurs after
performing error confirmation drive mode (see
21-74).
Error

Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection

OK

O2 sensor defect
If the error occurs even
after replacing the O2
sensor

Engine controller defect

 21-85

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-20 ~ C1-3 Continuity
A35-21 ~ C1-4 Continuity
A35-21 ~ Frame No continuity
21-86

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

Related portion

A35
R/B EFI Main relay
C1 C1
Engine 6 (HTR) 1 (HTR) O2 2 (+) 3 (L) EFI
controller sensor main relay

Probable cause
c O2 Sensor defect
d Harness defect
e Engine controller defect
Error code 01-6

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
correcting disconnection of CN1 and internal
wetting, 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. No error
c Turn the ignition key switch ON. Connector contact defect
(Start and run the engine for more than 10
seconds.)
d Turn the ignition key switch OFF for more
than10 seconds.
e Turn the ignition key switch ON.
(Start and run the engine for more than 10
seconds.)
f Check for errors.

Error

Inspection 1: NG
O2 sensor individual inspection O2 sensor defect

OK

Inspection 2: NG
O2 sensor heater power voltage inspection Harness defect

OK

Inspection 3: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

 21-87

Inspection 1:
Carry out O2 sensor individual inspection.
2 1
Ignition key switch OFF, disconnect C1, connect A35 4 3
Standard: (Sensor side)
C1
C1-2 ~ C1-1 13 ~ 16 Ω (20°C)

Inspection 2:
Carry out O2 sensor heater power voltage inspection.
Ignition key switch OFF, diconnect C1, connect A35, start engine
Standard:
C1-2 ~ Frame 8 ~ 16 V

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C1
Standard:
A35-6 ~ C1-1 Continuity
A35-6 ~ Frame No continuity
21-88

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

Related portion

A35 C3
29 (THA) 2 (THA) Intake
Engine
controller 28 (E2) 1 (E2) temperature
sensor

Probable cause
c Intake temperature sensor defect
d Harness defect
e Engine controller defect
Caution:
When another error code is present, repair the related parts first before carrying out the following.
Error codes 02-1 and 02-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of C3 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Intake temperature sensor individual inspection Intake temperature sensor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

Inspection 1:
Carry out intake temperature sensor individual inspection.. 2 1
Ignition key switch OFF, disconnect C3, connect A35 C3
Standard: (Sensor side)
2.45 ± 0.24 kΩ (20°C)
C3-1 ~ C3-2
0.32 ± 0.03 kΩ (80°C)
 21-89

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and C3
Standard:
A35-29 ~ C3-2 Continuity
A35-28 ~ C3-1 Continuity
A35-29 ~ Frame No continuity
21-90

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

A35
G12
17 (VC) 3 (VC)
Engine Intake pipe
18 (PIM) 2 (PIM)
controller pressure
28 (E2) 1 (E2) sensor

Probable cause
c Intake pipe negative pressure sensor defect
d Harness defect
e Engine controller defect
Error codes 03-1 and 03-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G12 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2:
NG
Intake pipe pressure sensor voltage inspection Engine controller defect
ANL.: I/O ENGINE CTRL 3/10
OK

Intake pipe pressure sensor defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G12
Standard:
A35-18 ~ G12-2 Continuity
A35-28 ~ G12-1 Continuity
A35-18 ~ A35-17 No continuity
A35-17 ~ G12-3 Continuity
A35-18 ~ Frame No continuity
 21-91

Inspection 2:
Inspect the intake pipe pressure sensor voltage.
Ignition key switch OFF, disconnect G12, connect A35, ignition key switch ON, engine stopped
Intake pipe pressure sensor voltage (I/O monitor: PIM)
Standard:
PIM 4.80 V or more
21-92

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

Related portion

A35 G16
19 (THW) 2 (THW) Coolant
Engine
controller 28 (E2) 1 (E2) temperature
sensor

Probable cause
c Coolant temperature sensor defect
d Harness defect
e Engine controller defect
Error codes 04-1 and 04-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G16 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Water temperature sensor individual inspection Water temperature sensor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

Inspection 1:
Carry out coolant temperature sensor individual inspection.
Ignition key switch OFF, disconnect A35 and G16
Standard: (Sensor side)
2.45 ± 0.24 kΩ (20°C)
G16-1 ~ G16-2
0.32 ± 0.03 kΩ (80°C)
 21-93

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and G16
Standard:
A35-19 ~ G16-2 Continuity
A35-28 ~ G16-1 Continuity
A35-19 ~ Frame No continuity
21-94

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

G27 G6
20 (VC2) 5 (VC)

Engine 21 (VTA) 6 (VTA) Throttle

controller 29 (VTA2) 4 (VTA2) position sensor
28 (E21) 3 (E21)

Probable cause
c Throttle position sensor defect
d Harness defect
e Engine controller defect
Error codes 05-1, 05-2, 05-3, 05-4, 05-5, 05-6

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2:
Throttle position sensor voltage inspection NG
ANL.: I/O ENGINE CTRL 5/10 Engine controller defect

OK

Throttle position sensor defect

 21-95

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G6
Standard:
G27-21 ~ G6-6 Continuity
G27-28 ~ G6-3 Continuity
G27-21 ~ G27-20 No continuity
G27-20 ~ G6-5 Continuity
G27-21 ~ Frame No continuity
G27-29 ~ G6-4 Continuity
G27-29 ~ G27-20 No continuity
G27-29 ~ Frame No continuity
G27-21 ~ G27-29 No continuity

Inspection 2:
Inspect the throttle position sensor voltage.
Ignition key switch OFF, disconnect G6, connect G27, ignition key switch ON
Throttle position sensor voltage (I/O monitor: VTA1, VTA2)
Standard:
VTA1, VTA2 4.80 V or more
21-96

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

G27 G6
7 (+BM)
6 (M+) 2 (M+)
Throttle
Engine 5 (M-) 1 (M-) motor
controller 4 (ME01)

Probable cause
c Throttle motor defect
d Harness defect
e Engine controller defect
Error codes 06-1 and 06-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Throttle motor individual inspection Throttle motor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

 21-97

Inspection 1:
Carry out throttle motor individual inspection. 6 5 4 3 2 1
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection
Standard: (Motor side)
G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)

(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.

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G6
Standard:
G27-6 ~ G6-2 Continuity
G27-5 ~ G6-1 Continuity
G27-6 ~ Frame No continuity
G27-5 ~ Frame No continuity
G27-6 ~ G27-5 No continuity
G27-6 ~ G27-7 No continuity
G27-5 ~ G27-7 No continuity
21-98

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

G27

Engine E-THRO
7 (+BM)
controller

Probable cause
c Harness defect
d Engine controller defect
Error codes 06-3 and 06-4

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G27 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Throttle motor power voltage inspection Harness defect

OK

Engine controller defect

Inspection 1:
Inspect the throttle motor power voltage.
Ignition key switch OFF, disconnect G27
Standard:
G27-7 ~ Frame 8 ~ 16 V
 21-99

z Error code 06-5 (Throttle motor seized abnormality)

Related portion
E-THRO

G27
G6
7 (+BM)
6 (M+) 2 (M+)
Throttle
Engine 5 (M-) 1 (M-) motor
controller 4 (ME01)

Probable cause
c Throttle motor defect
d Harness defect
e Engine controller defect
Error code 06-5

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of G6 and internal Connector contact defect
wetting, 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

Inspection 1: NG
Throttle motor individual inspection Throttle motor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

Inspection 1:
Carry out throttle motor individual inspection. 6 5 4 3 2 1
Ignition key switch OFF, disconnect G6, connect G27
G6
(1) Throttle motor resistance inspection
Standard: (Motor side)
G6-2 ~ G6-1 0.3 ~ 100 Ω (20°C)

(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
21-100

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G6 and G27
Standard:
G27-6 ~ G27-5 No continuity
G27-6 ~ G27-7 No continuity
G27-5 ~ G27-7 No continuity
 21-101

z Error code 06-6 (Electronic throttle abnormality)

Related portion

Engine
controller

Probable cause
c Engine controller defect
Error code 06-6

Disconnect the negative terminal of the battery for

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

Engine controller defect

21-102

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

Related portion

R/B Main relay

G28 G13 G13
21 (FCM1) 3 (FCM1) 2 (B1) 3 (L) EFI
31 (FCM2) 6 (FCM2) Air-fuel 5 (B2) main relay
Engine
controller 20 (FCM3) 1 (FCM3) ratio
motor
30 (FCM4) 4 (FCM4)

Probable cause
c Air-fuel ratio motor defect
d Harness defect
e Engine controller defect
Error code 07-1

Disconnect the battery negative terminal (for more

than 10 seconds), after inspecting and correcting
No error
disconnection of G13 and internal wetting, Connector contact defect
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

Inspection 1: NG
Air-fuel ratio motor individual inspection Air-fuel ratio motor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

 21-103

Inspection 1:
Carry out an individual inspection of the air-fuel ratio motor. 3 2 1
(1) Air-fuel ratio motor resistance inspection 6 5 4
Ignition key switch OFF, disconnect G13, connect G28
G13
Standard: (Air-fuel ratio motor side)
G13-2 ~ G13-1
G13-2 ~ G13-3 20 ± 5 Ω (-10 ~ 50°C)
G13-5 ~ G13-4 25 ± 5 Ω (50 ~ 100°C)
G13-5 ~ G13-6

(2) Valve operation check

Connect 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 side
G13-4→G13-1→G13-6→G13-3: Moves to the open side

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G28, G13 and R/B main relay
Standard:
G28-21 ~ G13-3 Continuity
G28-31 ~ G13-6 Continuity
G28-20 ~ G13-1 Continuity
G28-30 ~ G13-4 Continuity
G13-2 ~ R/B main relay terminal 3 Continuity
G13-5 ~ R/B main relay terminal 3 Continuity
G28-21 ~ Frame No continuity
G28-31 ~ Frame No continuity
G28-20 ~ Frame No continuity
G28-30 ~ Frame No continuity
21-104

z Error code 08-1 (Low voltage abnormality)

Related portion

A36

EFI
Engine 3 (BATT)
controller

Probable cause
c Harness defect
d Engine controller defect
Error code 08-1

Disconnect the battery negative terminal (for more

than 10 seconds), after inspecting and correcting
No error
disconnection of A36 and internal wetting, Connector contact defect
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

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A36
Standard:
A36-3 ~ EFI Continuity
A36-3 ~ Frame No continuity
 21-105

zError code 09-1 (Ignition signal abnormality)

Related portion

IGN

G27 G25 G25

33 (IGT) 2 (IGT) 3 (IG2)
Engine
32 (IGF) 1 (IGF) Igniter 5 (IG1)
controller

G21
2 (IG-)
Ignition coil 1 (IG+)

Probable cause
c Ignition coil
d Igniter defect
e Harness defect
f Engine controller defect
21-106

Error code 09-1

Disconnect the battery negative

terminal (for more than 10
seconds), after inspecting and
correcting disconnection of G21 Engine will not start
and G25 and internal leakage,
reconnect all connectors and the
battery negative terminal, turn the
ignition key switch ON to start the
engine.
Engine
starts

Operate the accelerator pedal and No error

check whether there is an error. Connector contact defect

Error

Inspection 2:
Inspection 1: NG NG
Harness continuity and short circuit Harness defect
Ignition abnormality signal (IGF) inspection
inspection
OK
OK

Engine controller defect

Igniter defect

Inspection 3: NG
Ignition coil individual inspection Ignition coil defect

OK

Inspection 4:
NG
Harness continuity and short circuit Harness defect
inspection

OK

Inspection 5: NG
Igniter IGT signal inspection Engine controller defect

OK

Igniter defect

Inspection 1:
Carry out an ignition signal (IGF) inspection. 5 4 3 2 1
Ignition key switch OFF, disconnect G25, connect G27, ignition key switch ON, engine G25
stopped
Standard:
G25-1 ~ Frame 4.0 ~ 5.5 V
 21-107

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G25
Standard:
G27-32 ~ G25-1 Continuity
G27-32 ~ Frame No continuity

Inspection 3:
Carry out distributor individual inspection. 2 1
Ignition key switch OFF, disconnect G21 and G25, connect G27
G21
Standard:
Primary side (G21-1 ~ G21-2) 1.2 ~ 1.5 Ω
Secondary side (IIA inner terminal) 7.7 ~ 10.4 Ω

Inspection 4:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27, G21 and G25
Standard:
G27-33 ~ G25-2 Continuity
G27-32 ~ G25-1 Continuity
G27-33 ~ G27-32 No continuity
G27-33 ~ Frame No continuity
G27-32 ~ Frame No continuity
G25-5 ~ G21-2 Continuity
G25-3 ~ G21-1 Continuity
G25-5 ~ G25-3 No continuity
G25-5 ~ frame No continuity
G25-3 ~ frame No continuity

Inspection 5:
Carry out an igniter (IGT) signal inspection. 5 4 3 2 1
Ignition key switch OFF, disconnect G21 and G25, connect G27, ignition key switch G25
ON, (cranking)
Standard:
G25-2 ~ Frame Not 0 V
21-108

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

Related portion

G28 T6 T6 R/B EFI Main relay

14 (GAS) 6 (GAS) Fuel
4 (IG) 3 (L) EFI
13 (LPG) 3 (LPG) changeover
main relay
switch
G27
15 (SEL1)
Engine
controller 14 (SEL2)
13 (SEL3) Connection status of SEL1 to 4
differs depending on vehicle specification (refer to inspection 3).
12 (SEL4)
10 (ESEL)

Probable cause
c Fuel changeover switch defect
d Harness defect
e Engine controller defect
Error codes 0A-1, 0A-2, 0A-3

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
correcting disconnection of T6 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error

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

OK

Inspection 2: NG
Fuel changeover switch defect
Fuel changeover switch individual inspection

OK

Inspection 3: NG
Harness defect
Harness continuity and short circuit inspection

OK

Engine controller defect

 21-109

Inspection 1:
Carry out switch input signal inspection.
Ignition key switch ON
Switch input signal (I/O monitor: G/LP, SEL1-4)
Standard:
Vehicle specification Fuel changeover switch G/LP SEL
Gasoline specification – 10 1100
LPG exclusive – 01 0101
Gasoline selection 10
LPG/Gasoline convertible LPG selection 01 0110
Neutral 00
Gasoline selection 10
Gasoline/CNG convertible LPG selection 01 0011
Neutral 00

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 outside 6 43
the standard value)
T6
Ignition key switch OFF, disconnect T6, connect G28 and G27
Standard: (Switch side)
Fuel changeover switch
Gasoline LPG/CNG Neutral
T6-4 ~ T6-6 Continuity No continuity No continuity
T6-4 ~ T6-3 No continuity Continuity No continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness. (Begin with the place that was outside the standard
value in inspection 1)
Ignition key switch OFF, disconnect G28, G27 and T6
Harness
Vehicle specification
SEL1 SEL2 SEL3 SEL4
Short circuit to Short circuit to
Gasoline specification – –
ESEL ESEL
Short circuit to Short circuit to Short circuit to
LPG exclusive –
ESEL ESEL ESEL
Short circuit to Short circuit to
LPG/Gasoline convertible – –
ESEL ESEL
Short circuit to Short circuit to
Gasoline/CNG convertible – –
ESEL ESEL
21-110

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

Related portion

Engine
controller

Probable cause
c Engine controller defect
Error code 0A-4

Disconnect the battery negative terminal (for 10

seconds or more), reconnect the battery No error
Normal
negative terminal, then turn the ignition key
switch ON (start the engine) and check whether
or not there is an error.

Error

Engine controller defect

 21-111

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

Related portion

IGN
To IGN SW

G39 R/B ASC relay

5 (SRLY) 1
13 (E01) 2
ASC controller ASC relay
3
2 (MEN+) 5

G37
Step motor

Probable cause
c Connector contact defect
d ASC relay defect
e Harness defect
f ASC controller defect
Error codes 13-1, 13-2, 13-3

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of G39
No error Connector contact defect
and the ASC relay and internal wetting, reconnect
ASC relay not plugged in properly
all connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.

Error

Inspection 1: NG
ASC relay individual inspection ASC relay defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

ASC controller defect

21-112

Inspection 1:
Carry out ASC relay individual inspection.
Ignition key switch OFF, remove ASC relay
Standard: (Relay side)
ASC relay
1 ~ 2 terminals Continuity
At all times
3 ~ 5 terminals No continuity
When battery voltage is applied
3 ~ 5 terminals Continuity
between terminals 1 ~ 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G39, remove ASC relay
Standard:
G39-2 ~ ASC relay terminal 3 Continuity
ASC relay terminal 5 ~ IGN Continuity
G39-2 ~ BATT No continuity
G39-5 ~ ASC relay terminal 1 Continuity
G39-5 ~ G39-13 No continuity
G39-5 ~ Frame No continuity
G39-5 ~ BATT No continuity
ASC relay terminal 2 ~ Frame Continuity
 21-113

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

Related portion

IGN
To IGN SW

G36
G39
2
12 (NMR) 1 NMR switch

ASC controller
R/B Starting motor relay

2 (STA) 1 Starting motor relay

Probable cause
c Connector contact defect
d NMR switch defect
e Harness defect
f ASC controller defect
g Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
21-114

Error codes 15-1, 15-2

Disconnect the battery negative terminal, then

inspect and repair disconnection of G36, G39 and
starting motor relay and any internal leakage.

Reconnect the connectors and the battery negative

terminal, then repeat the operations c to f below
several times and check whether an error occurs.
c Turn the ignition key switch ON (engine stopped)
d Operate the accelerator pedal ON/OFF (several No error
times) Connector contact defect
e Start the engine with the accelerator fully
depressed
f Release the accelerator pedal and turn the
ignition key switch OFF
Error

Inspection 1: NG
NMR switch individual inspection NMR switch defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 3:
Inspection of the status of the NMR switch in the NG
ASC controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection

items such as link catching or switch position
adjustment.

Inspection 1:
Carry out an NMR switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-1 ~ G36-2 No continuity Continuity
 21-115

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36, G39 and starting motor relay
Standard:
G39-12 ~ G36-1 Continuity
IGN ~ G36-2 Continuity
G39-2 ~ Starting motor relay terminal 1 Continuity
G39-12 ~ IGN No continuity

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 ON
NMR switch (I/O monitor: NMR)
Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
21-116

z Error code 15-3 (NMR switch abnormality)

Related portion

IGN
To IGN SW

G39 G36
2
12 (NMR) 1 NMR switch

ASC controller
G36
4
15 (ZERO) 3 Idle switch

Probable cause
c Connector contact defect
d NMR switch defect
e Idle switch defect
f Harness defect
g ASC controller defect
h Mechanical system defect (link catching, switch position adjustment, step motor defect etc.)
 21-117

Error code 15-3

Disconnect the battery negative terminal, then

inspect and repair disconnection of G39 and G36
and any internal leakage.

Reconnect the connectors and the battery negative

terminal, then repeat the operations c to e below
several times and check whether an error occurs.
c Turn the ignition key switch ON (engine stopped) No error
Connector contact defect
d Operate the accelerator pedal ON/OFF (several
times)
e Turn the ignition key switch OFF
Error

Inspection 1: NG NMR switch defect

NMR and idle switch individual inspection Idle switch defect
OK

Inspection 2: NG
Carry out harness continuity and short circuit Harness defect
inspection

OK

Inspection 3:
Inspection of the status of the NMR and idle NG
switches in the controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection

items such as link catching or switch position
adjustment.

Inspection 1:
Carry out an NMR and idle switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-1 ~ G36-2 No continuity Continuity
G36-3 ~ G36-4 No continuity Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36 and G39
Standard:
G39-12 ~ IG No continuity
G39-15 ~ IG No continuity
21-118

Inspection 3:
Carry out inspection of the status of the NMR and idle switches in the 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 ON
NMR and idle switches (I/O monitor: NMR, IDLE)
Standard:
Analyzer display Switch OFF Switch ON
NMR 0 1
IDLE 0 1
 21-119

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

Related portion

IGN
To IGN SW

G36
G39
4
15 (ZERO) 3 Idle switch

G38 G37
ASC controller 11 (NINA) 2
12 (NINB) 1
3 (INA) 5 Step motor

4 (INB) 4

Probable cause
c Connector contact defect
d Idle switch defect
e Harness defect
f ASC controller defect
g 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.
21-120

Error codes 16-1, 16-2

Disconnect the battery negative terminal, then

inspect and repair disconnection of G39, G36 and
G37 and any internal wetting.

Reconnect the connectors and the battery negative

terminal, then repeat the operations c to e below
several times and check whether an error occurs.
No error
c Turn the ignition key switch ON (engine stopped) Connector contact defect
d Operate the accelerator pedal ON/OFF (several
times)
e Turn the ignition key switch OFF
Error

Inspection 1: NG
Idle switch individual inspection Idle switch defect

OK

Inspection 2: NG
Carry out harness continuity and short circuit Harness defect
inspection
OK

Inspection 3:
Inspection of the status of the idle switch in the NG
controller ASC controller defect
ANL.: I/O ENGINE CTRL 1/3

OK

Refer to and carry out mechanical system inspection

items such as link catching or switch position
adjustment.

Inspection 1:
Carry out idle switch individual inspection.
Ignition key switch OFF, disconnect G36, connect G39
Standard: (Switch side) G36
Switch OFF Switch ON
G36-3 ~ G36-4 No continuity Continuity
 21-121

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G36, G37, G38 and G39
Standard:
G39-15 ~ G36-3 Continuity
IGN ~ G36-4 Continuity
G39-15 ~ IGN No continuity
G38-11 ~ G37-2 Continuity
G38-12 ~ G37-1 Continuity
G38-3 ~ G37-5 Continuity
G38-4 ~ G37-4 Continuity
G38-11 ~G38-12 No continuity
G38-11 ~ G38-3 No continuity
G38-11 ~ G38-4 No continuity
G38-12 ~ G38-3 No continuity
G38-12 ~ G38-4 No continuity
G38-3 ~ G38-4 No continuity
G38-11 ~ IGN No continuity
G38-12 ~ IGN No continuity
G38-3 ~ IGN No continuity
G38-4 ~ IGN No continuity

Inspection 3:
Carry out inspection of the status of the idle switch in the controller.
Ignition key switch OFF, remove idle switch so that it can be turned ON and OFF manually, connect G36 and
G39, ignition key switch ON
Idle switch (I/O monitor: IDLE)
Standard:
Analyzer display Switch OFF Switch ON
IDLE 0 1
21-122

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

IGN

G25
3 (IG2)
Igniter 5 (IG1)

G27 G19 G21

31 (NE+) 1 (NE+) 2 (IG-)
Engine controller 30 (NE-) 2 (NE-) Distributor 1 (IG+)

Probable cause
c Distributor (cam angle sensor) defect
d Starter defect
e Defect in the part connecting the starter and engine
f Harness defect
g Engine controller defect
Caution:
If the engine does not crank, troubleshoot "Does not crank (see 21-217)" first.
Error codes 18-1, 18-2

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
correcting disconnection of G19 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error

Inspection 1: NG
Distributor individual inspection Distributor (cam angle sensor) defect

OK

Inspection 2: NG Starter defect

Timing rotor operation inspection Defect in the part connecting the starter and engine
OK

Inspection 3: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect

 21-123

Inspection 1:
Carry out distributor individual inspection. 2 1
Ignition key switch OFF, disconnect G19 and G21, connect G27
G19
(1) Pickup coil (2 in series) resistance measurement
Standard: (Distributor side)
G19-1 ~ G19-2 460 ± 50 Ω

(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

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G19, G21 and G27
Standard:
G27-31 ~ G19-1 Continuity
G27-30 ~ G19-2 Continuity
G27-31 ~ G27-30 No continuity
21-124

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

Related portion

G27 G18
11 (G2) 1 (G2)
Crank angle
Engine controller 22 (G-) 2 (G-) sensor

Probable cause
c Crank angle sensor defect
d Harness defect
e Engine controller defect
Error code 18-3

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
correcting disconnection of G18 and internal No error
wetting, reconnect all connectors and the battery Connector contact defect
negative terminal, turn the ignition key switch
ON (start the engine) and check whether or not
there is an error.
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Crank angle sensor individual inspection Crank angle sensor defect

OK

Inspection 3:
Crank angle sensor installation inspection

Install the crank angle sensor, connect G27, G18

and battery negative terminal, start the engine. No error Normal
Check whether an error occurs. (Entry of foreign matter etc.)

Error

Engine controller defect

 21-125

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G27 and G18
Standard:
G27-11 ~ G18-1 Continuity
G27-22 ~ G18-2 Continuity
G27-11 ~ G27-22 No continuity

Inspection 2:
Carry out crank angle sensor individual inspection.
Ignition key switch OFF, disconnect G27 and G18 2 1
Standard: (Sensor side)
G18-1 ~ G18-2 1100 ± 150 Ω G18

Inspection 3:
Carry out crank angle sensor installation inspection.
Ignition key switch OFF, disconnect G27 and G18
Standard:
Remove the crank angle sensor, ensure that there is no foreign matter etc. adhereing to the sensor part.
If there is remove it.
21-126

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

Related portion

G39 G31
9 (NE+) 2
Engine speed
ASC controller 22 (NE-) 1 sensor (NE sensor)

Probable cause
c Connector contact defect
d Engine speed sensor defect
e Harness defect
f ASC controller defect
Caution:
In the event that the engine stops while traveling, when the ignition key switch is turned from OFF to ON, an
18-2 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key switch OFF and restart the engine.
Error codes 18-1, 18-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of G31
and G39 and internal wetting, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Engine speed sensor individual inspection Engine speed sensor defect

OK

ASC controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G31 and G39
Standard:
G39-9 ~ G31-2 Continuity
G39-22 ~ G31-1 Continuity
G39-9 ~ G39-22 No continuity
 21-127

Inspection 2:
Carry out engine speed sensor individual inspection.
2 1
Ignition key switch OFF, disconnect G31 and G39 3
Standard: (Sensor side)
G31
G31-1 ~ G31-2 Approx. 1 kΩ
21-128

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

ASC controller

Probable cause
c ASC controller defect
 21-129

z Error code 41-1 (Matching connector abnormality)

Related portion

A20 A45
24 (MAT) 1
SAS/OPS Matching
controller 1 (E3) 2 connector

Probable cause
c Connector contact defect
d Matching connector harness defect
e SAS/OPS controller defect
Error code 41-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and A45 internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.
Error

Inspection 1: NG
Matching connector defect
Matching connector individual inspection

OK

Inspection 2: NG
Harness defect
Harness continuity check

OK

SAS/OPS controller defect

Inspection 1:
Inspect for continuity of the matching connector. 1 2 3
Ignition key switch OFF, disconnect A45 and A46 4 5 6
Standard: (Matching connector side) A45
A45-1 ~ A46-1 Continuity

Inspection 2:
Inspect for continuity of the harness.
Ignition key switch OFF, disconnect A20, A45 and A46
Standard:
A20-24 ~ A45-1 Continuity
A20-1 ~ A46-1 Continuity
21-130

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

Related portion

A20 A19
22 (SPD+) 1
SAS/OPS Speed
controller 23 (SPD-) 2 sensor

Probable cause
c Connector contact defect
d Harness defect
e Speed sensor defect
f SAS/OPS controller defect
Error code 51-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A19
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: No error
Speed sensor inspection Speed sensor defect

Error

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS controller defect

Inspection 1:
Carry out speed sensor individual inspection.
Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,
engine stopped
51-1, 51-2 displayed → to inspection 2
No error displayed → Speed sensor error
 21-131

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A19 and A20
Standard:
A20-22 ~ A19-1 Continuity
A20-23 ~ A19-2 Continuity
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity

Error code 51-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A19
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: No error
Speed sensor inspection Sensor defect

Error

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS controller defect

Inspection 1:
Carry out speed sensor individual inspection.
Ignition key switch OFF, disconnect A19, use SST 09236-13900-71 to short circuit A19, ignition key switch ON,
engine stopped
51-2 displayed → to next inspection
No error code → Speed sensor defect

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A19 and A20
Standard:
A20-22 ~ A19-1 Continuity
A20-23 ~ A19-2 Continuity
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity
21-132

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

Related portion

A21
O1
24 (YRS+) 1
SAS/OPS 25 (YRS) 2 Yaw-rate
controller sensor
26 (YRS-) 3

Probable cause
c Connector contact defect
d Yaw rate sensor harness defect
e Yaw rate sensor defect
f SAS/OPS controller defect
Error code 52-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of O1
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 52-2 is displayed

Yaw rate sensor defect
Yaw rate sensor inspection

52-1 is displayed

Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

Inspection 1:
Carry out a yaw and rate sensor individual inspection.
Ignition key switch OFF, disconnect O1, use SST 09232-13130-71 to short circuit O1-1 and O1-2, ignition key
switch ON, engine stopped
52-1 displayed → to inspection 2
52-2 displayed → Yaw rate sensor defect
 21-133

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect O1 and A21
Standard:
A21-25 ~ O1-3 Continuity
A21-26 ~ O1-2 Continuity
A21-25 ~ Frame No continuity
A21-26 ~ Frame No continuity

Error codes 52-2, 52-3

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of O1
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Turn the ignition key switch OFF, disconnect the

battery negative terminal, disconnect O1,
connect the battery negative terminal, turn the 52-1
Yaw-rate sensor defect
ignition key switch ON (engine stopped), check
whether the error changes.

52-2 or 52-3

Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect O1 and A21
Standard:
A21-25 ~ O1-3 Continuity
A21-26 ~ O1-2 Continuity
A21-25 ~ Frame No continuity
A21-26 ~ Frame No continuity
21-134

z Error code 54-1 (Swing lock solenoid abnormality)

Related portion

A20 Z1
3 (SWN+) 1
Swing lock
2 (SWN-) 1 solenoid
SAS/OPS
controller 8 (E01)
9 (E02)

Probable cause
c Connector contact defect
d Harness defect
e Swing lock solenoid defect
f SAS/OPS controller defect
Error code 54-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and Z1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.

Error

Inspection 1: NG
Swing lock solenoid individual inspection Swing lock solenoid defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

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.
2 1
Ignition key switch OFF, disconnect Z1
Standard: (Solenoid side) Z1
Z1-1 ~ Z1-2 Approx. 6 Ω (20°C)
 21-135

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Z1 and A20
Standard:
A20-3 ~ Z1-1 Continuity
A20-2 ~ Z1-2 Continuity
A20-3 ~ Frame No continuity
A20-2 ~ Frame No continuity
21-136

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

Related portion

A21
A18
19 (5PRS) 1
SAS/OPS 27 (PRES) 2 Load sensor
controller 5 (E2) 3

Probable cause
c Connector contact defect
d Load sensor defect
e Harness defect
f SAS/OPS controller defect
Error code 61-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A18
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 61-2 is displayed

Load sensor individual inspection Load sensor defect

61-1 is displayed

Inspection 2: No continuity
Main harness defect
Harness continuity and short circuit inspection

Continuity

Inspection 3: No continuity
SAS/OPS controller defect
Harness continuity and short circuit inspection

Continuity

Main harness 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), ignition
key switch ON, engine stopped
61-1 displayed → to inspection 2
61-2 not displayed → load sensor defect
SST
 21-137

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)
Standard:
A21-19 ~ A21-27 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-27 ~ A21-5 No continuity

Error code 61-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A18
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Disconnect A18, ignition key switch ON (engine 61-1

stopped), inspect the diplayed error code.

61-2

Inspection 1: No continuity SAS/OPS

Harness continuity and short circuit inspection controller defect

Continuity

No continuity Inspection 2:
Main harness defect
Load sensor individual inspection

Continuity

· Sub harness defect

· Load sensor defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-19 ~ A21-27 No continuity
21-138

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
 21-139

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

Related portion

A21
A42
28 (5MA) 1
SAS/OPS 32 (MA) 2 Tilt angle
controller sensor
5 (E2) 3

Probable cause
c Connector contact defect
d Tilt angle sensor harness defect
e Tilt angle sensor defect
f SAS/OPS controller defect
Error code 62-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

62-2 is
Inspection 1: displayed
Tilt angle sensor individual inspection Tilt angle sensor defect

62-1 is displayed

Inspection 2: No continuity
Harness continuity and short circuit inspection Main harness defect

Continuity

Inspection 3: No continuity
Harness continuity and short circuit inspection SAS/OPS controller defect

Continuity

Main harness 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 (main
harness side), ignition key switch ON (engine stopped)
62-1 displayed → to inspection 2
62-2 not displayed → tilt angle sensor defect
21-140

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 (with the SST used in inspection 1 still connected)
Standard:
A21-28 ~ A21-32 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-32 ~ A21-5 No continuity

Error code 62-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A21
and A42 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 62-1 is displayed

Tilt angle sensor individual inspection
62-2 is displayed

Inspection 2: No continuity SAS/OPS

Harness continuity and short circuit inspection controller defect

Continuity

No continuity Inspection 3:
Main harness defect
Tilt angle sensor individual inspection

Continuity

Tilt angle sensor defect

Inspection 1:
Carry out tilt angle sensor individual inspection.
Ignition key switch OFF, disconnect A42, ignition key switch ON, engine stopped
62-1 displayed → to inspection 3
62-2 displayed → to inspection 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-28 ~ A21-32 No continuity
 21-141

Inspection 3:
Carry out tilt angle sensor individual inspection.
Ignition key switch OFF, disconnect A21 and A42, use SST 09232-13130-71 to short circuit A21-2 and A42-3
(main harness side)
Standard:
A42-32 ~ A21-5 Continuity
21-142

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

Related portion

A20 A13
20 (MF) 1
Forward tilt
1 (E3) 2 switch
SAS/OPS
controller
21 (MR) 3
Backward tilt
4 switch

Probable cause
c Connector contact defect f Harness defect
d Forward tilt switch defect g Tilt switch installation defect
e Backward tilt switch defect h SAS/OPS controller defect
 21-143

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

Disconnect the battery negative

terminal, after inspecting and
correcting disconnection of A13
and A20 and internal moisture No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON and check
whether or not there is an error.*
Error

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

Inspection 2:
Inspection 4:
Individual continuity inspection of OK NG
Harness continuity and short circuit
the tilt lever switch(es) that was
inspection
abnormal in inspection 1 (while still
installed on the vehicle). OK
NG
SAS/OPS controller defect

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

OK

Inspection 4:
OK
Harness continuity and short circuit Tilt switch installation defect
inspection

NG

Harness defect

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

Inspection 1:
Check the condition of the switch.
Ignition key switch ON, engine stopped
Tilt switch (I/O monitor: MF·MR)
Standard:
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
MF (Forward tilt switch) 0 1 0
MR (Backward tilt switch) 0 0 1
21-144

Inspection 2:
Individual continuity inspection of the tilt lever switch (still installed on the vehicle).
Ignition key switch OFF, disconnect A13
Standard: (Switch side)
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
A13-1 ~ A13-2 No continuity Continuity No continuity
A13-3 ~ A13-4 No continuity No continuity Continuity

Inspection 3:
Carry out individual continuity inspection of the tilt lever switch (removed from the vehicle).
Ignition key switch OFF, disconnect A13
Standard: (Sensor side) 1 2
Switch OFF Switch ON 3 4
A13-1 ~ A13-2 No continuity Continuity A13
A13-3 ~ A13-4 No continuity No continuity

Inspection 4:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A13 and A20
Standard:
A20-20 ~ A20-1 No continuity
A20-21 ~ A20-1 No continuity
A20-20 ~ A20-21 No continuity
A20-20 ~ Frame No continuity
A20-21 ~ Frame No continuity
 21-145

z Error code 64-1 (Lift lock solenoid abnormality)

Related portion

A20 A11
7 (LSOL) 1
Lift lock
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)

Probable cause
c Connector contact defect
d Harness defect
e Lift lock solenoid defect
f SAS/OPS controller defect
Error code 64-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A11
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*

Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Lift lock solenoid individual inspection Solenoid defect

OK

SAS/OPS controller defect

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

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A11 and A20
Standard:
A20-7 ~ A11-1 Continuity
A11-2 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-7 ~ Frame No continuity
21-146

Inspection 2:
Carry out lift lock solenoid individual inspection. 1 2
Ignition key switch OFF, disconnect A11
A11
Standard: (Solenoid side)
A11-1 ~ A11-2 9.9 ± 0.5 Ω (20°C)
 21-147

z Error code 65-1 (Tilt control solenoid abnormality)

Related portion

A20 A10
4 (TSOL) 1
Tilt control
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)

Probable cause
c Connector contact defect
d Harness defect
e Tilt control solenoid defect
f SAS/OPS controller defect
Error code 65-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A10
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*

Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Tilt control solenoid individual inspection Solenoid defect

OK

SAS/OPS controller defect

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

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A10 and A20
Standard:
A20-4 ~ A10-1 Continuity
A10-2 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-4 ~ Frame No continuity
21-148

Inspection 2:
Carry out tilt control solenoid individual inspection.
1 2
Ignition key switch OFF, disconnect A10
A10
Standard: (Solenoid side)
A10-1 ~ A10-2 9.9 ± 0.5 Ω (20°C)
 21-149

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

Related portion

SAS/OPS
controller

Probable cause
c Tilt horizontal angle matching value is outside the specified range for matching.
d Tilt forward tilt angle matching value is outside the specified range for matching.
e Load sensor matching value is outside the specified range for matching.
Error code 66-1

Carry out tilt horizontal angle matching, tilt

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

Error

Controller defect
21-150

z Error code 67-1 (Lifting height switch abnormality)

Related portion

Single tire, V mast, mast lifting height: ~ H2500

A20 b1
1 (E3) 1
31 (MH1) 2 Lifting height
SAS/OPS 32 (MH21) 3 switch
controller
33 (MH22)
N.C.

Probable cause
c Connector contact defect
d Harness defect
e Lifting height switch defect
f SAS/OPS controller defect
g IG fuse defect
 21-151

Error code 67-1

Disconnect the battery negative

terminal, after inspecting and
correcting disconnection of A20
and b1 and internal moisture, Error
reconnect all connectors and the None
Connector contact defect
battery negative terminal, turn the
ignition key switch ON (engine
stopped) and check whether or not *: Raise the lift lever from the fully lowered
there is an error.* position until an error is detected.
Error

Except Inspection 2:
Inspection 1: MH000 Harness continuity and short circuit MH:000 Lifting height switch
Lifting height switch input value inspection
inspection defect
ANL.: I/O M.HANDLING 2/6
ANL.: I/O M.HANDLING 2/6
Except MH:000
MH:000

Inspection 3:
OK SAS/OPS
Harness continuity and short circuit
controller defect
inspection

NG

Main harness defect

Inspection 4: NG
Lifting height switch individual Lifting height switch defect
inspection
OK

Inspection 5:
OK SAS/OPS
Harness continuity and short circuit
controller defect
inspection

NG

Main harness defect

21-152

Inspection 1:
Check the condition of the switch.
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 detection
MH: Except 000 → to inspection 2

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1, ignition key switch ON, stop the
engine, check the display
MH: 000 displayed → sub harness defect or lifting height switch defect
MH: Except 000 → to inspection 3

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 and b1
Standard:
A20-1 ~ A20-31 No continuity
A20-1 ~ A20-32 No continuity
A20-1 ~ A20-33 No continuity
A20-31 ~ A20-32 No continuity
A20-32 ~ A20-33 No continuity
A20-33 ~ A20-31 No continuity

Inspection 4:
Carry out lifting height switch individual inspection. 1 3 2
Maintain the error status, ignition key switch OFF, disconnect b1 b1
Standard: (Switch side)
b1-1 ~ b1-2 No continuity

Inspection 5:
Inspect for continuity and short circuiting of the harness.
Put the lift in fully lowered state, ignition key switch OFF, disconnect A20 adn b1, use SST 09236-13900-71 to
short circuit the terminals
Standard:
Inspection terminal Short circuit terminals Continuity
A20-1 ~ A20-31 b1-1 ~ b1-2 Continuity
A20-1 ~ A20-32 b1-1 ~ b1-3 Continuity
 21-153

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

Related portion

A20 A14
22 (MU) 3
Raising lift
1 (E3) 4 switch
SAS/OPS
controller
23 (MD) 1
Lowering lift
2 switch

Probable cause
c Connector contact defect f Harness defect
d Raising lift switch defect g Lift switch installation defect
e Lowering lift switch defect h SAS/OPS controller defect
21-154

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

Disconnect the battery negative

terminal, after inspecting and
correcting disconnection of A14
and A20 and internal moisture, Error
reconnect all connectors and the None
battery negative terminal, turn the Connector contact defect
ignition key switch ON (engine
stopped) and check whether or not
there is an error.*
Error

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

Inspection 2:
Inspection 4:
Individual continuity inspection of OK NG
Harness continuity and short circuit
the lift lever switch(es) that was
inspection
abnormal in inspection 1 (while still
installed on the vehicle). OK
NG
SAS/OPS controller defect

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

OK

Inspection 4:
OK
Harness continuity and short circuit Lift switch installation defect
inspection

NG

Harness defect
*: Make sure there is no error displayed after turning the ignition key switch ON, and moving the lift lever upward and
downward. Also, make sure that no error is displayed when the lift lever is left standing in neutral position for 2
minutes.
 21-155

Inspection 1:
Check the condition of the switch.
Ignition key switch ON (engine stopped)
Lift switch (I/O monitor: MU·MD)
Standard:
Lever in neutral Lever in forward tilt Lever in backward
position position tilt position
MU (Raising switch) 0 1 0
MD (Lowering switch) 0 0 1

Inspection 2:
Carry out individual continuity inspection of the lift lever switch (still installed on the vehicle).
Ignition key switch OFF, disconnect A14
Standard: (Switch side)
Lever in neutral Lever in raised Lever in lowered
position position position
A14-3 ~ A14-4 No continuity No continuity Continuity
A14-1 ~ A14-2 No continuity Continuity No continuity

Inspection 3:
Carry out individual continuity inspection of the lift lever switch (removed from the vehicle).
Ignition key switch OFF, disconnect A14
Standard: (Switch side) 2 1
Switch ON Switch OFF 4 3
A14-3 ~ A14-4 Continuity No continuity
A14
A14-1 ~ A14-2 Continuity No continuity

Inspection 4:
Harness continuity and short circuit inspection
Ignition key switch OFF, disconnect A14 and A20
Standard:
A20-22 ~ Frame No continuity
A20-23 ~ Frame No continuity
A20-22 ~ A20-1 No continuity
A20-23 ~ A20-1 No continuity
A20-22 ~ A20-33 No continuity
21-156

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

Related portion

A20 A56
10 (BTSL) 1
Backward tilt
SAS/OPS 9 (E02) 2 lock solenoid
controller 8 (E01)

Probable cause
c Connector contact defect
d Harness defect
e Backward tilt lock solenoid defect
f SAS/OPS controller defect
Error code 69-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and A56 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.*

Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Backward tilt lock solenoid individual inspection Solenoid defect

OK

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.
Ignition key switch OFF, disconnect A20 and A56
Standard:
A56-2 ~ Frame Continuity
A20-8 ~ A20-9 Continuity
A20-10 ~ Frame Continuity
 21-157

Inspection 2:
Carry out tilt backward tilt lock solenoid individual inspection. 1 2
Ignition key switch OFF, disconnect A56
A56
Standard: (Solenoid side)
A56-1 ~ A56-2 9.9 ± 0.5 Ω (20°C)
21-158

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

Related portion

A21
Z3
30 (5T) 3
SAS/OPS 34 (T) 2 Tire angle
controller 5 (E2) sensor
1

Probable cause
c Connector contact defect
d Tire angle sensor harness defect
e Tire angle sensor defect
f Tire angle sensor joint, rear axle link system defect
g SAS/OPS controller defect
Error code 71-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 71-2 is displayed

Tire angle sensor individual inspection Tire angle sensor defect

71-1 is displayed

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 3: OK
Harness continuity and short circuit inspection SAS/OPS controller defect

NG

Harness 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 key
switch ON, engine stopped
71-1 displayed → to inspection 2
71-2 displayed → Tire angle sensor defect
 21-159

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
(With the SST used in inspection 1 still connected)
Standard:
A21-30 ~ A21-34 Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
In the same state as for inspection 2
Standard:
A21-34 ~ A21-5 No continuity

Error code 71-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of Z3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (engine stopped)
and check whether or not there is an error.

Error

Inspection 1: 71-1 is displayed

Tire angle sensor individual inspection

71-2 is displayed

Inspection 2: OK SAS/OPS
Harness continuity and short circuit inspection controller defect

NG

No continuity Inspection 3:
Main harness defect
Tire angle sensor individual inspection

Continuity

Tire angle sensor defect

Inspection 1:
Carry out tire angle sensor individual inspection.
Ignition key switch OFF, disconnect Z3, ignition key switch ON, engine stopped
71-1 displayed → to inspection 3
71-2 displayed → to inspection 2
21-160

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-30 ~ A21-34 No continuity

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 (main
harness side)
Standard:
A21-34~ A21-5 Continuity
 21-161

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

A21
1 (IG1) A3
2 (IG2) 1

SAS/OPS 14 (SS1) 3
Steering angle
controller 15 (SS2) 4 sensor
16 (SSC) 5
2
5 (E2)

Probable cause
c Connector contact defect f SAS/OPS controller defect
d Steering angle sensor harness defect
e Steering angle sensor defect
21-162

Error code 72-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error

Check the STS value with an analyzer while

1**
operating the steering.
ANL.: I/O STEERING 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.

Check the STS value with an analyzer while

1**
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

0**

Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

Disconnect the battery negative terminal and A3,

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

Check the STS value with an analyzer while

0**
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

1**

Inspection 2: NG
Main harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

 21-163

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-14 ~ A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-14 ~ A21-5 No continuity
21-164

Error code 72-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate (rotate) the
steering and check whether or not there is an
error.
Error

Check the STS value with an analyzer while

*1*
operating the steering.
ANL.: I/O STEERING 1/1

*0*
(* is 0 or 1)

Disconnect the battery negative terminal and A3,

short circuit A3-2 to A3-4 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.

Check the STS value with an analyzer while

*1*
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

*0*

Inspection 1: NG
Harness continuity and short circuit inspection Main harness defect

OK

SAS/OPS controller defect

Disconnect the battery negative terminal and A3,

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

Check the STS value with an analyzer while

*0*
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

*1*

Inspection 2: NG
Main harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

 21-165

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 No continuity
21-166

Error code 72-3

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A3 and
A21 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, turn Connector contact defect
the ignition key switch ON, operate the steering
(one or more rotations) and check whether or not
there is an error.
Error

Check the STS value with an analyzer while

**1
operating the steering.
ANL.: I/O STEERING 1/1

**0
(* is 0 or 1)

Disconnect the battery negative terminal and A3,

short circuit A3-2 to A3-5 (main harness side)
using SST 09232-13130-71, reconnect the
battery negative terminal, and turn the ignition
key switch ON.

Check the STS value with an analyzer while

**1
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

**0

Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

Disconnect the battery negative terminal and A3,

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

Check the STS value with an analyzer while

**0
operating the steering. Steering angle sensor defect
ANL.: I/O STEERING 1/1

**1

Inspection 1: NG
Main harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

 21-167

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-16 ~ A21-5 Continuity

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21
Standard:
A21-15 ~ A21-5 No continuity

Error code 72-4

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A3
and A21 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate (rotate)
the steering and check whether or not there is an
error.
Error
Battery voltage
Inspection 1: (approx. 12 V) Disconnect the battery negative terminal and A3,
Steering angle sensor supply voltage inspection reconnect the battery negative terminal, and turn
the ignition key switch ON.
Approx. 0 V

To troubleshooting for 72-1 and 72-2

Inspection 2: NG
Harness continuity and short circuit inspection Main harness defect

OK

SAS/OPS controller defect

Inspection 1:
Carry out steering angle sensor supply voltage inspection.
Standard:
A3-1 ~ A3-2 Battery voltage (approx. 12 V)
21-168

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A3 and A21
Standard:
A21-1 ~ A3-1 Continuity
A21-2 ~ A3-1 Continuity
A21-5 ~ Frame Continuity
A3-2 ~ Frame Continuity
 21-169

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

Related portion

A20 A5
6 (STRG) 1
Knob position
SAS/OPS 9 (E02) 2 compensation
controller
8 (E01)

Probable cause
c Connector contact defect
d Harness defect
e Knob position compensation solenoid defect
f SAS/OPS controller defect
Error code 73-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A5
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error

Inspection 1: NG
Harness defect
Harness continuity and short circuit inspection

OK

Inspection 2: NG
Knob position compensation solenoid defect
Knob position compensation solenoid individual
inspection

OK

SAS/OPS controller defect

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

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A5 and A20
Standard:
A20-6 ~ A5-1 Continuity
A5-2 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-6 ~ Frame No continuity
21-170

Inspection 2:
Carry out knob position compensation solenoid individual inspection. 2 1
Ignition key switch OFF, disconnect A5
Standard: (Solenoid side) A5

A5-1 ~ A5-2 Approx.10 Ω (20°C)

 21-171

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

Related portion

SAS/OPS controller

Probable cause
c Tire alignment value is outside the specified range for matching.
Error code 74-1

Perform tire alignment.

(Refer to section 18)

Error

Controller defect
21-172

z Error code A5-1 (Seat switch abnormality)

Related portion

A20 X1
35 (DMS) 1
SAS/OPS
1 (E3) 2 Seat switch
controller

Probable cause
c Connector contact defect
d Seat switch defect
e Harness defect
f SAS/OPS controller defect
Error code A5-1

Disconnect the battery negative terminal, then

No error
inspect and repair disconnection of A20 and X1 Connector contact defect
and any internal moisture.*

Error

Inspection 1:
NG
Check the condition of the switch Seat switch defect
ANL.: I/O M.HANDLING 1/6

OK

Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection

OK

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 seat
empty for 15 minutes.

Inspection 1:
Check the condition of the switch.
Disconnect X1, ignition key switch ON, engine stopped
Seat switch (I/O monitor: SEAT)
Standard:
Analyzer display When seat is empty When seat is occupied
SEAT 0 1
 21-173

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and X1
Standard:
A20-35 ~ A20-1 No continuity
A20-35 ~ Frame No continuity
21-174

z Error code A7-1 (Brake switch abnormality)

Related portion

BATT

A20 A6
1
Brake
SAS/OPS 17 (BSW) 2 switch
controller

Probable cause
c Connector contact defect
d Brake switch defect
e Harness defect
f SAS/OPS controller defect
Error code A7-1

Disconnect the battery negative

terminal, then inspect and repair No error
disconnection of A20 and A6 and Connector contact defect
any internal moisture.*

Error

Inspection 1: Inspection 2:
NG NG
Check the condition of the switch Harness continuity and short circuit Harness defect
ANL.: I/O TRAVELING 1/3 inspection

OK OK

SAS/OPS controller defect

Inspection 3:
Individual continuity inspection of NG
the brake switch (removed from Brake switch installation defect
the vehicle)

OK

Brake switch 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 seat
empty for 15 minutes.

Inspection 1:
Check the condition of the switch.
Disconnect A6, ignition key switch ON, engine stopped
Brake switch (I/O monitor: BRKSW)
Standard:
Analyzer display Pedal not depressed Pedal depressed
BRKSW 0 1
 21-175

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A6 and A20
Standard:
A20-17 ~ BATT No continuity

Inspection 3:
Carry out individual continuity inspection of the brake switch (removed from the vehicle).
Ignition key switch OFF, disconnect A6
Standard: (Switch side) 1 2
Switch OFF Switch ON
A6
A6-1 ~ A6-2 No continuity Continuity
21-176

z Error codes AD-1, AD-2, AD-7, AD-8 (4Y-E spec.) (CAN communication abnormality)
Related portion
A21
ECU-B
8 (BATT)
1 (IG1) ECU-IG Q2
2 (IG2) 2 (IG)
SAS/OPS
controller A20
12 (CANH) 5 (CANH) Multi-function
13 (CANL) 6 (CANL) display
3 (E1)

A36
28 (CAN+)
29 (CAN-)

EFI 3 (BATT) Engine

controller
IGN
9 (IGSW)

Probable cause
c Connector contact defect g Engine controller defect
d Engine controller harness defect h Option display defect
e Optional display harness defect i SAS/OPS controller defect
f Fuse defect
Caution:
When the controller or optional display is replaced into another vehicle with different specifications, AD-1
and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".
Error codes AD-1, AD-2, AD-7, AD-8

Disconnect the negative terminal of the battery NG

and inspect the fuses. Fuse defect

OK

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, A36 and
Connector contact defect
Q2 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.*
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect (AD-1)

Optional display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
 21-177

*: 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 not
occurred.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
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
A21-2 ~ ECU-IG Continuity
Q2-2 ~ ECU-IG Continuity
21-178

z Error codes AD-1, AD-2, AD-7, AD-8 (ASC spec.) (CAN communication abnormality)
Related portion
A21
8 (BATT) ECU-B

1 (IG1) ECU-IG Q2
SAS/OPS 2 (IG2) 2 (IG)
controller A20
12 (CANH) 5 (CANH) Multi-function
13 (CANL) 6 (CANL) display
3 (E1)

G38
28 (CANH)
29 (CANL)
ECU-B2 3 (BATT) Engine
controller
IGN
9 (IGSW)

Probable cause
c Connector contact defect g Engine controller defect
d Engine controller harness defect h Option display defect
e Optional display harness defect i SAS/OPS controller defect
f Fuse defect
Caution:
When the controller or optional display is replaced into another vehicle with different specifications, AD-1
and AD-7 may occur. In such cases, perform "Engine and display ECU information clear".
Error codes AD-1, AD-2, AD-7, AD-8

Disconnect the negative terminal of the battery NG

and inspect the fuses. Fuse defect

OK

Disconnect the battery negative terminal (for

more than 10 seconds), after inspecting and
No error
correcting disconnection of A20, A21, G38 and
Connector contact defect
Q2 and internal moisture, reconnect all
connectors and the battery negative terminal,
turn the ignition key switch ON and check
whether or not there is an error.*
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Engine controller defect (AD-1)

Optional display defect (AD-7)
SAS/OPS controller defect (AD-8)
SAS/OPS controller or
engine controller defect (AD-2)
 21-179

*: 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 not
occurred.

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect Q2 (unnecessary if AD-7 and AD-8 have not occurred), A20, A21 and G38
(unnecessary if AD-1 and AD-2 have not occured)
Standard:
A20-12 ~ Q2-5 Continuity
A20-13 ~ Q2-6 Continuity
A20-12 ~ G38-28 Continuity
A20-13 ~ G38-29 Continuity
A20-12 ~ Frame No continuity
A20-13 ~ Frame No continuity
21-180

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

SAS/OPS controller

Probable cause
c SAS/OPS controller defect
Caution:
When AF is displayed, the SAS/OPS controller is defective and must be replaced.
 21-181

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

A35 a1
25 (VCPA) 5
26 (VPA) 4
27 (EPA) 6
ASC controller Accelerator
33 (VCP2) 1 sensor
34 (VPA2) 3
35 (EPA2) 2

Probable cause
c Connector contact defect
d Accelerator sensor defect
e Harness defect
f 4Y-E controller defect
Error codes C4-1, C4-2, C4-3, C4-4, C4-5

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A35
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error.*
Error

Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

ASC controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated.
21-182

Error code C4-5

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A35
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*
Error

Inspection 1: NG
Accelerator sensor defect
Accelerator sensor individual inspection

OK

Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection

OK

Inspection 3:
NG
Accelerator sensor voltage inspection Accelerator sensor defect
ANL.: I/O ENGINE CTRL 4/10

OK

ASC controller defect

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

Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect a1, conenct A35
(1) Accelerator sensor resistance measurement
6 5 4 3 2 1
Standard: (Sensor side)
a1
a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ
a1-1 ~ a1-2 (released)

(2) Accelerator sensor output circuit resistance measurement

Standard: (Sensor side)
a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the
a1-3 ~ a1-2 rotation of the potentiometer when the potentiometer section is rotated.
 21-183

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A35 and a1
Standard:
A35-26 ~ a1-4 Continuity
A35-25 ~ a1-5 Continuity
A35-26 ~ Frame No continuity
A35-27 ~ a1-6 Continuity
A35-25 ~ A35-26 No continuity
A35-26 ~ A35-33 No continuity
A35-34 ~ a1-3 Continuity
A35-33 ~ a1-1 Continuity
A35-34 ~ Frame No continuity
A35-34 ~ A35-25 No continuity
A35-34 ~ A35-33 No continuity
A35-26 ~ A35-34 No continuity

Inspection 3:
Inspect the accelerator sensor voltage.
Ignition key switch OFF, disconnect a1, connect A35, ignition key switch ON
Accelerator sensor (I/O monitor: VPA1, VPA2)
Standard:
VPA1 0.20 V or less
VPA2 0.20 V or less
21-184

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

G39 a1
19 (VCPA) 5
6 (VPA) 4
7 (EPA) 6
ASC controller Accelerator
18 (VCP2) 1 sensor
5 (VPA2) 3
17 (EPA2) 2

Probable cause
c Connector contact defect
d Accelerator sensor defect
e Harness defect
f ASC controller defect
Error codes C4-1, C4-2, C4-3, C4-4, C4-5

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of G39
and a1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine),
and check whether or not there is an error.*
Error

Inspection 1: NG
Accelerator sensor individual inspection Accelerator sensor defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 3: NG
Accelerator sensor voltage inspection Accelerator sensor defect
ANL: I/O ENGINE CTRL 1/3

OK

ASC controller defect

*: Make sure that no error code is displayed when the accelerator pedal is operated.
 21-185

Inspection 1:
Carry out accelerator sensor individual inspection.
Ignition key switch OFF, disconnect a1, conenct G39
(1) Accelerator sensor resistance measurement
6 5 4 3 2 1
Standard: (Sensor side)
a1
a1-5 ~ a1-6 Approx. 1.8 ~ 3.5 kΩ
a1-1 ~ a1-2 (released)

(2) Accelerator sensor output circuit resistance measurement

Standard: (Sensor side)
a1-4 ~ a1-6 Make sure that the resistance value increases proportionally to the
a1-3 ~ a1-2 rotation of the potentiometer when the potentiometer section is rotated.
21-186

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect G39 and a1
Standard:
G39-6 ~ a1-4 Continuity
G39-19 ~ a1-5 Continuity
G39-6 ~ Frame No continuity
G39-7 ~ a1-6 Continuity
G39-19 ~ G39-6 No continuity
G39-6 ~ G39-18 No continuity
G39-5 ~ a1-3 Continuity
G39-18 ~ a1-1 Continuity
G39-5 ~ Frame No continuity
G39-5 ~ G39-19 No continuity
G39-5 ~ G39-18 No continuity
G39-6 ~ G39-5 No continuity

Inspection 3:
Inspect the accelerator sensor voltage.
Ignition key switch OFF, disconnect a1, connect G39, ignition key switch ON
Accelerator sensor (I/O monitor: VPA1, VPA2)
Standard:
VPA1 0.20 V or less
VPA2 0.20 V or less
 21-187

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

Related portion

SFT

A41
6

A20
18 (DRF) 5 Shift switch

SAS/OPS
controller 19 (DRR) 1

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
c Connector contact defect f Harness defect
d Forward travel shift switch defect g Shift switch installation defect
e Reverse travel shift switch defect h SAS/OPS controller defect
Caution:
In the event that the engine stops while travelling, when the ignition key switch is turned from OFF to ON, an
C7-1 error may be detected, however this is not a fault.
Stop the vehicle, turn the ignition key switch OFF and restart the engine.
21-188

Error code C7-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*

Error

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

OK

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

OK

Inspection 3: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS controller defect

*: Check if an error occurs after turning the ignition key switch ON, moving the shift lever and traveling from stopped
state to more than 10 km/h within 3 seconds.
Error code C7-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and A41 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*

Error

Inspection 4:
OK
Check the condition of the switch Shift switch defect
ANL.: I/O TRAVELING 2/3

NG

Inspection 3: OK
Harness continuity and short circuit inspection Harness defect

NG

SAS/OPS controller defect

*: Make sure there is no error after turning the ignition key switch ON, and move the shift lever to forward and reverse
travel.
 21-189

Inspection 1:
Check the condition of the switch.
Ignition key switch ON
Direction switch (I/O monitor: DRF - DRR)
Standard:
Lever in neutral Lever in forward Lever in reverse
position travel position travel position
DRF (for forward travel) 0 1 0
DRR (for reverse travel) 0 0 1

Inspection 2:
9 8 7 6 5 4 3 2 1
Individual continuity inspection of the direction lever switch(es) (still installed on the
vehicle). 1817161514131211 10

Ignition key switch OFF, disconnect A41 A41

Standard: (Switch side)
Lever in neutral Lever in forward Lever in reverse
position travel position travel position
A41-6 ~ A41-5 No continuity Continuity No continuity
A41-6 ~ A41-1 No continuity No continuity Continuity

Inspection 3:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A41
Standard:
A20-18 ~ A41-5 Continuity
A20-18 ~ Frame No continuity
A20-19 ~ A41-1 Continuity
A20-19 ~ Frame No continuity
A20-18 ~ A41-6 No continuity
A20-19 ~ A41-6 No continuity
A20-18 ~ A20-19 No continuity

Inspection 4:
Check the condition of the switch.
Disconnect A41, ignition key switch ON (engine stopped), direction switch (I/O monitor: DRF·DRR)
Standard:
Analyzer display
DRF (for forward travel) 0
DRR (for reverse travel) 0
21-190

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

Related portion

A20
17 (RYF) 1
Forward travel
43 (E01) 2
relay
44 (E02)
SAS/OPS
controller
1
Reverse travel
2 relay

Probable cause
c Connector contact defect f Reverse travel relay harness defect
d Forward travel relay harness defect g Reverse travel relay defect
e Forward travel relay defect h SAS/OPS controller defect
Error code CA-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and internal moisture, reconnect all connectors No error
and the battery negative terminal, turn the Connector contact defect
ignition key switch ON and check whether or not
there is an error.
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

Inspection 2: NG
Relay individual inspection Relay defect

OK

SAS/OPS controller defect

Inspection 1:
Carry out relay individual inspection.
Ignition key switch OFF, disconnect forward/reverse relay, connect A20
Standard: (Relay side)
R/B forward relay terminal 1 ~
Forward/reverse relay
R/B forward relay terminal 2
91 ± 15 Ω (20°C)
R/B reverse relay terminal 1 ~
R/B reverse relay terminal 2
 21-191

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and forward/reverse relay
Standard:
A20-17 ~ R/B forward relay terminal 1 Continuity
R/B reverse relay terminal 2 ~ Frame Continuity
A20-44 ~ Frame Continuity
A20-43 ~ Frame Continuity
A20-17 ~ Frame No continuity
21-192

z Error code EC-1 (Unload solenoid abnormality)

Related portion

A20 A12
5 (USOL) 1
Unload
SAS/OPS 9 (E02) 2 solenoid
controller 8 (E01)

Probable cause
c Connector contact defect
d Harness defect
e Unload solenoid defect
f SAS/OPS controller defect
Error code EC-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A12
and A20 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON (start the engine)
and check whether or not there is an error.*

Error

Inspection 1: NG
Unload solenoid defect
Unload solenoid individual inspection

OK

Inspection 2: NG
Harness defect
Harness continuity and short circuit inspection

OK

SAS/OPS controller defect

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

Inspection 1:
Carry out unload solenoid individual inspection.
1 2
Ignition key switch OFF, disconnect A12
A12
Standard: (Solenoid side)
A12-1 ~ A12-2 9.9 ± 0.5 Ω (20°C)
 21-193

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and A12
Standard:
A20-5 ~ A12-1 Continuity
A12-2 ~ Frame Continuity
A20-8 ~ Frame Continuity
A20-9 ~ Frame Continuity
A20-5 ~ Frame No continuity
21-194

z Error codes F1-1, F1-2 (Controller to combination meter communication abnormality)

Related portion

A20 Q1
SAS/OPS 14 (SIL) 3 (SIL)
Combination
controller 9 (WITHOUT SAS)
N.C. meter

Probable cause
c Connector contact defect
d Hour meter harness defect
e Hour meter defect
f SAS/OPS controller defect
Error codes F-1, F-2

Disconnect the battery negative terminal, after

inspecting and correcting disconnection of A20
and Q1 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON and check
whether or not there is an error.
F1-1 F1-2

Combination meter defect

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS controller or
combination meter defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A20 and Q1
Standard:
Q1-9 ~ Frame No continuity
Q1-3 ~ Frame No continuity
A20-14 ~ Q1-3 Continuity
 21-195

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

Multi-function display

Probable cause
c Multi-function display board defect
21-196

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

A23
7 (IG1)
8 (IG2) Y6
29 (LIF+) 4
27 (LIF1) 3
SAS/OPS/ Lift lever
28 (LIF2) 2 potentiometer
mini lever
controller 26 (E2) 1
9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)

Probable cause
c Connector contact defect
d Lift lever potentiometer harness defect
e Lift lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
 21-197

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

Disconnect the battery negative

terminal, after inspecting and
correcting disconnection of A21,
A23 and Y6 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.

Error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the lift lever H2-4 Inspection 1: OK
potentiometer with the tilt lever Lift lever potentiometer inspection Installation defect
potentiometer, and check if there is
any change in the error. NG

H1-*
H2-1·H2-2·H2-3
Lift lever potentiometer abnormality

Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection

OK

NG
Fuse inspection Replace fuse
OK

SAS/OPS/mini lever
controller defect
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 20), ignition key switch ON, match lift lever
potentiometer
21-198

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y6
Standard:
A23-29 ~ Y6-4 Continuity
A23-27 ~ Y6-3 Continuity
A23-28 ~ Y6-2 Continuity
A23-26 ~ Y6-1 Continuity

Error code H1-5

OK
Match lift lever potentiometer Matching value misalignment
NG

SAS/OPS/mini lever
controller defect
 21-199

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

A23
7 (IG1)
8 (IG2) Y5
30 (TIL+) 4
11 (TIL1) 3
SAS/OPS/ Tilt lever
12 (TIL2) 2 potentiometer
mini lever
controller 26 (E2) 1
9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)

Probable cause
c Connector contact defect
d Tilt lever potentiometer harness defect
e Tilt lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-200

Error codes H2-1, H2-2, H2-3, H2-4

Disconnect the battery negative

terminal, after inspecting and
correcting disconnect of A21, A23
and Y5 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.

Error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the lift lever H1-4 Inspection 1: OK
potentiometer with the tilt lever Installation defect
Tilt lever potentiometer inspection
potentiometer, and check if there is
any change in the error. NG

H2-*
H1-1·H1-2·H1-3
Tilt lever potentiometer abnormality

Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection

OK

NG
Fuse inspection Replace fuse
OK

SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.

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 20), ignition key switch ON, match tilt lever
potentiometer
 21-201

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y5
Standard:
A23-30 ~ Y5-4 Continuity
A23-11 ~ Y5-3 Continuity
A23-12 ~ Y5-2 Continuity
A23-26 ~ Y5-1 Continuity

Error code H2-5

OK
Match tilt lever potentiometer Matching value misalignment
NG

SAS/OPS/mini lever
controller defect
21-202

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

A23
7 (IG1)
8 (IG2) Y2
31 (AT1+) 4
13 (AT11) 3
Attachment 1 lever
14 (AT12) 2
potentiometer
SAS/OPS/ 26 (E2) 1
mini lever 9 (E43)
controller 10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)

Probable cause
c Connector contact defect
d Attachment 1 lever potentiometer harness defect
e Attachment 1 lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
 21-203

Error codes H3-1, H3-2, H3-3, H3-4

Disconnect the battery negative

terminal, after inspecting and
correcting disconnect of A21, A23 Error
and Y2 and internal moisture, None
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.

Error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the attachment 1 Inspection 1:
H2-4 NG
lever potentiometer with the tilt Attachment 1 lever potentiometer Installation defect
lever potentiometer, and check if inspection
there is any change in the error. OK
H3-*

H2-1·H2-2·H2-3 Attachment 1
lever potentiometer abnormality

Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection

OK

NG
Fuse inspection Replace fuse
OK

SAS/OPS/mini lever
controller defect
Note:
If the lever has been removed, be sure to perform matching after the lever is reinstalled.

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 original
positions
Check attachment 1 lever potentiometer installation (refer to section 20), ignition key switch ON, match
attachment 1 lever potentiometer
21-204

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y2
Standard:
A23-31 ~ Y2-4 Continuity
A23-13 ~ Y2-3 Continuity
A23-14 ~ Y2-2 Continuity
A23-26 ~ Y2-1 Continuity

Error code H3-5

OK
Match attachment 1 lever potentiometer Matching value misalignment
NG

SAS/OPS/mini lever
controller defect
 21-205

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

A23
7 (IG1)
8 (IG2) Y3
32 (AT2+) 4
15 (AT21) 3
16 (AT22) 2 Attachment 2 lever
SAS/OPS/ potentiometer
mini lever 26 (E2) 1
controller 9 (E43)
10 (E44)
A21
10 (E42)
9 (E41)
3 (E11)
4 (E12)

Probable cause
c Connector contact defect
d Attachment 2 lever potentiometer harness defect
e Attachment 2 lever potentiometer defect
f SAS/OPS controller defect
g Fuse defect
21-206

Error codes H4-1, H4-2, H4-3, H4-4

Disconnect the battery negative

terminal, after inspecting and
correcting disconnect of A21, A23
and Y3 and internal moisture, No error
reconnect all connectors and the Connector contact defect
battery negative terminal, turn the
ignition key switch ON, and check
whether or not there is an error.
Error

Turn the ignition key switch OFF,

disconnect the battery negative
terminal, replace the attachment 1 Inspection 1:
H3-4 NG
lever potentiometer with the Attachment 2 lever potentiometer Installation defect
attachment 2 lever potentiometer, inspection
and check if there is any change in
OK
the error.
H4-*

H3-1·H3-2·H3-3 Attachment 2
lever potentiometer abnormality

Inspection 2:
NG
Harness continuity and short circuit Harness defect
inspection

OK

NG
Fuse inspection Replace fuse
OK

SAS/OPS/mini lever
controller defect

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

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 original
positions
Check attachment 2 lever potentiometer installation (refer to section 20), ignition key switch ON, match
attachment 2 lever potentiometer
 21-207

Inspection 2:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21, A23 and Y3
Standard:
A23-32 ~ Y3-4 Continuity
A23-15 ~ Y3-3 Continuity
A23-16 ~ Y3-2 Continuity
A23-26 ~ Y3-1 Continuity

Error code H4-5

OK
Attachment 2 lever potentiometer matching Matching value misalignment
NG

SAS/OPS/mini lever
controller defect
21-208

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

Related portion

A23 A51
17 (LSO+) 5
Lift PUSH
18 (LPSH) 1 solenoid
SAS/OPS/
mini lever
controller A52
5
Lift PULL
19 (LPLL) 1 solenoid

Probable cause
c Connector contact defect f Lift PULL solenoid harness defect
d Lift PUSH solenoid harness defect g Lift PULL solenoid defect
e Lift PUSH solenoid defect h SAS/OPS/mini lever controller defect
Error codes H5-1, H5-2

H5-1 is now described. For H5-2, substitute A52 for A51 and PULL for PUSH in the following.
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate the lift
lever and check whether or not there is an error.
Error

Inspection 1: NG
Lift solenoid individual inspection Lift PUSH solenoid defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS mini lever controller defect

Inspection 1:
Carry out lift solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect battery negative terminal, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-5 ~ A51-1 7.2 ± 0.36 Ω (20°C)
 21-209

Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect battery negative terminal, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-17 ~ A51-5 Continuity
A23-18 ~ A51-1 Continuity
A23-17 ~ A23-18 No continuity
A23-17 ~ A23-19 No continuity
21-210

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

Related portion

A23 A51
1 (TSO+) 6
Tilt PUSH
2 (TPSH) 2 solenoid
SAS/OPS/
mini lever
A52
controller
6
Tilt PULL
3 (TPLL) 2 solenoid

Probable cause
c Connector contact defect f Tilt PULL solenoid harness defect
d Tilt PUSH solenoid harness defect g Tilt PULL solenoid defect
e Tilt PUSH solenoid defect h SAS/OPS/mini lever controller defect
Error codes H6-1 and H6-2

H6-1 is now described. For H6-2, substitute A52 for A51 and PULL for PUSH in the following
Disconnect the battery negative terminal, after
inspecting and correcting disconnect A23 and
A51 and internal moisture, reconnect all No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate the tilt
lever and check whether or not there is an error.
Error

Inspection 1: NG
Tilt solenoid individual inspection Tilt PUSH solenoid defect

OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS mini lever controller defect

Inspection 1:
Carry out tilt solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-6 ~ A51-2 7.2 ± 0.36 Ω (20°C)
 21-211

Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-1 ~ A51-6 Continuity
A23-2 ~ A51-2 Continuity
A23-1 ~ A23-2 No continuity
A23-1 ~ A23-3 No continuity
21-212

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

Related portion

A23 A51
20 (3SO+) 7
Attachment 1
21 (3PSH) 3 PUSH solenoid
SAS/OPS/
mini lever
A52
controller
7
Attachment 1
22 (3PLL) 3 PULL solenoid

Probable cause
c Connector contact defect
d Attachment 1 PUSH solenoid harness defect
e Attachment 1 PUSH solenoid defect
f Attachment 1 PULL solenoid harness defect
g Attachment 1 PULL solenoid defect
h SAS/OPS/ mini lever controller defect
Error codes H7-1, H7-2

H7-1 is now described. For H7-2, substitute A52 for A51 and PULL for PUSH in the following
Disconnect the battery negative terminal, after
inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate
attachment lever 1 and check whether or not
there is an error.
Error

Inspection 1: NG Attachment 1 PUSH

Attachment 1 solenoid individual inspection solenoid defect
OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS mini lever controller defect

 21-213

Inspection 1:
Carry out attachment 1 solenoid individual inspection.
1 2 3 4
Ignition key switch OFF, disconnect A51 5 6 7 8
Standard: (Solenoid side) A51
A51-7 ~ A51-3 7.2 ± 0.36 Ω (20°C)

Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-4 ~ A51-8 Continuity
A23-5 ~ A51-4 Continuity
A23-4 ~ A23-5 No continuity
A23-4 ~ A23-6 No continuity
21-214

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

Related portion

A23 A51
4 (4SO+) 8
Attachment 2
5 (4PSH) 4 PUSH solenoid
SAS/OPS/
mini lever
A52
controller
8
Attachment 2
6 (4PLL) 4 PULL solenoid

Probable cause
c Connector contact defect
d Attachment 2 PUSH solenoid harness defect
e Attachment 2 PUSH solenoid defect
f Attachment 2 PULL solenoid harness defect
g Attachment 2 PULL solenoid defect
h SAS/OPS/ mini lever controller defect
Error codes H8-1, H8-2

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

Disconnect the battery negative terminal, after

inspecting and correcting disconnect of A23 and
A51 and internal moisture, reconnect all
No error
connectors and the battery negative terminal, Connector contact defect
turn the ignition key switch ON, operate
attachment lever 2 and check whether or not
there is an error.
Error

Inspection 1: NG Attachment 2 PUSH

Attachment 2 solenoid individual inspection solenoid defect
OK

Inspection 2: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS mini lever controller defect

 21-215

Inspection 1:
Carry out attachment 2 solenoid individual inspection.
Ignition key switch OFF, disconnect battery negative terminal and A51
Standard: (Solenoid side) 1 2 3 4
A51-8 ~ A51-4 7.2 ± 0.36 Ω (20°C) 5 6 7 8
A51
Inspection 2:
Inspect for continuity and short circuiting of the harness.
1 2 3 4
Ignition key switch OFF, disconnect A23 and A51 5 6 7 8
Standard: A52
A23-4 ~ A51-8 Continuity
A23-5 ~ A51-4 Continuity
A23-4 ~ A23-5 No continuity
A23-4 ~ A23-6 No continuity
21-216

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

Related portion

IG

A21
1
3/4-way change
12 (ATSO) 2 relay 1
SAS/OPS/
Mini lever
controller 3
3/4-way change
4 relay 2

Probable cause
c Connector contact defect
d 3/4-way change relay 1 harness defect
e 3/4-way change relay 1 defect
f 3/4-way change relay 2 harness defect
g 3/4-way change relay 2 defect
h SAS/OPS controller defect
Error code HA-1

Disconnect the battery negative terminal, after

inspecting and correcting disconnect of A21 and
internal moisture, reconnect A21 and the battery
No error
negative terminal (leave relay disconnected), 3/4-way change relay defect
turn the changeover switch to the 3-way side,
turn the ignition key switch ON, and check
whether or not there is an error.
Error

Inspection 1: NG
Harness continuity and short circuit inspection Harness defect

OK

SAS/OPS/mini lever controller defect

Inspection 1:
Inspect for continuity and short circuiting of the harness.
Ignition key switch OFF, disconnect A21 and change relay
Standard:
A21-12 ~ Relay terminal 2 Continuity
A21-12 ~ Relay terminal 4 Continuity
A21-12 ~ Frame No continuity
 21-217

TROUBLESHOOTING WHEN THERE IS NO ERROR CODE

4Y-E Engine List by Symptom
Symptom Portion to be inspected Page for reference
1. Starter relay and starter 21-218
Does not crank
2. Neutral start switch –
1. ECU power supply system 21-220

Cannot start 2. Igniter system 21-105

(no starting combustion) 3. Fuel pump circuit 21-222
4. Fuel injector Refer to engine repair manual
1. Fuel pump circuit 21-222
Cannot start
2. Igniter system 21-105
(no complete combustion)
3. Fuel injector Refer to engine repair manual
1. Electronic throttle Refer to engine repair manual
2. Fuel pump circuit 21-222
3. Igniter system 21-105
Does not start well
4. Spark plugs Refer to engine repair manual
5. Fuel injector Refer to engine repair manual
6. Compression Refer to engine repair manual
Fast idling rough 1. Electronic throttle Refer to engine repair manual
1. Electronic throttle Refer to engine repair manual
Idle speed high 2. ECU power supply system 21-220
3. Neutral start switch –
1. Electronic throttle Refer to engine repair manual
2. Fuel injector Refer to engine repair manual
Idle speed low 3. Igniter system 21-105
4. Compression Refer to engine repair manual
5. Fuel pump circuit 21-222
1. Electronic throttle Refer to engine repair manual
Idle unstable 2. ECU power supply system 21-220
3. Fuel pump circuit 21-222
1. Fuel injector Refer to engine repair manual
Hunting 2. Fuel pump circuit 21-222
3. Igniter system 21-105
1. Igniter system 21-105
Hesitation, poor acceleration 2. Spark plugs Refer to engine repair manual
3. Fuel injector Refer to engine repair manual
1. Fuel pump circuit 21-222
After fire 2. Spark plugs Refer to engine repair manual
3. Fuel injector Refer to engine repair manual
Engine stalling 1. Fuel pump circuit 21-222
(immediately after start up)
Engine stalling 1. Fuel injector Refer to engine repair manual
(immediately after deceleration) 2. Engine control computer –
21-218

z Starter relay and starter

Related portion

STA
5 3
Starter
1 2

to meter-related circuit Starter relay

Ignition switch Neutral switch

G27-24 (STA)

Engine controller

Probable cause
c Neutral switch defect
d Starter relay defect
e Starter defect
f Wire harness, connector defect
Inspection 1:
OK Neutral switch defect
Starter signal inspection
ANL.: I/O ENGINE CTRL 1/10 Starter relay defect

NG

Inspection 2: OK
Wire harness and connector inspection Starter defect

NG

Wire harness, connector defect

Inspection 1:
Carry out starter signal inspection.
Ignition key switch ON
Starter signal (I/O motor: STA)
Standard:
Starter stopped Starter in operation
STA 0 1
 21-219

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 0V
Relay terminal 3 ~ frame 0V
Relay terminal 5 ~ frame 9 ~ 14 V
21-220

z ECU power supply system

Related portion

A36 G28
IGN
3 (BATT)
BATT 3 (E1)

EFI Engine
5 3 1 (+B) controller 2 (E01)
2 (+B1)
1 2 19 (MREL) 1 (E02)

EFI main relay

Probable cause
c Blown fuse
d EFI main relay defect
e Wire harness, connector defect
Inspection 1: NG
EFI and IGN fuse inspection Replace fuse

OK

Inspection 2: NG
EFI main relay operation and continuity EFI main relay defect
inspection
OK

Inspection 3: NG
Harness continuity inspection Wire harness, connector defect

OK

Engine controller defect

Inspection 1:
Carry out a fuse continuity inspection.
Remove the EFI fuse and IGN fuse.
Standard: Continuity exists.
 21-221

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:
Relay terminals 1 ~ 2 Continuity EFI relay
Relay terminals 3 ~ 5 No continuity

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2.
Standard: Continuity exists.

Inspection 3:
Inspect for continuity of the wire harness.
Ignition key switch OFF
Standard:
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
E02 ~ frame Continuity
E1 ~ frame Continuity
21-222

z Fuel pump control system

Related portion

Fuel changeover switch

6 (GAS) T6
4 (IG) 3 5
3 (LPG)
Engine 1 2
controller
5 3 EFI relay
FC 1 2 4 O2
Fuel pump
Circuit
opening 5
relay

Probable cause
c Blown fuse
d EFI main relay defect
e Wire harness, connector defect
f Fuel pump defect
Inspection 1: NG
Fuse inspection Replace fuse

OK

Inspection 2: NG
EFI main relay operation and continuity inspection EFI main relay defect

OK

Inspection 3: NG
Harness continuity inspection Wire harness, connector defect

OK

Fuel pump defect

Inspection 1:
Carry out a fuse continuity inspection.
Remove the EFI fuse and IGN fuse.
Standard: Continuity exists.
 21-223

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:
Relay terminals 1 ~ 2 Continuity EFI relay
Relay terminals 3 ~ 5 No continuity

(3) Inspect for continuity between relay terminals 3 and 5 when the battery voltage is applied
accross terminals 1 to 2.
Standard: Continuity exists

Inspection 3:
Inspect for continuity of the wire harness.
Ignition key switch OFF
Standard:
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
Defect Causes When There is No SAS/OPS Error Display
Caution:
21-224

If an error code or wrench lamp is flashing, repair it first.

Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Brake switch unit:
Open fault
(Stuck in depressed state, or
internal damage) ON/OFF check with analyzer Harness check or replace switch
Brake switch line:
For T/C vehicles with drive control: Disconnection fault
Engine is always slow to rev up. (Harness, connector, fuse)
(Even with the direction lever left in F
Accelerator sensor unit:
or R position and the brake applied,
Internal damage Accelerator pedal position check:
the engine is still slow to rev up) If not close to 0%, installation check or
Accelerator sensor installation: Check the opening degree of the
replace sensor.
Link, installation part destroyed, accelerator pedal when not operated.
damaged
SAS/OPS controller:
– Replace
Controller defect
Drive control Lift raise switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Lift raise switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
For vehicles with drive control: (Harness, connector)
Even if the lift is raised, the idle Switch ground line:
speed does not rise. Disconnection fault
(Harness, connector)
Display setting:
Check settings with option set and
Lift idle up disabled, Idle up speed Change
tuning
tuning value low
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check:
(Power supply, signal, ground): If there is no change, perform a
Mount a load, ground the forks and
Disconnection fault harness check or replace the sensor.
check the change in voltage.
(Harness, connector)
For T/C vehicles with drive control: Short or link fault
Speed limit applies at high lifting (Harness, connector)
height despite not being loaded
Check the setting content of the
Display setting:
maximum speed limiter, check the
Maximum speed limiter, Change
setting content of the speed limit
Speed limit setting enabled
setting.
SAS/OPS controller:
– Replace
Controller defect
Load sensor unit:
Drive control
Sensor defect
Load sensor line
Load sensor voltage check:
(Power supply, signal, ground): If there is no change, perform a
Mount a load, ground the forks and
Disconnection fault harness check or replace the sensor.
check the change in voltage.
(Harness, connector)
Short or link fault
For T/C vehicles with drive control:
(Harness, connector)
Despite being loaded
at high lifting height the speed limit Lifting height switch unit:
does not operate. Disconnection fault (internal damage, ON/OFF check with analyzer Harness check or replace sensor
stuck)
Display setting:
Traveling limit setting disabled Check setting values with option set Change
Load sensing speed limit disabled
SAS/OPS controller:
– Replace
Controller defect
21-225
 Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lifting height switch unit:
21-226

Disconnection fault ON/OFF check with analyzer Harness check or replace switch
(Internal damage, stuck)
For T/C vehicles with drive control: Check the setting content of the
Display setting:
Speed limit applies when loaded maximum speed limiter, check the
Maximum speed limiter, speed limiter Change
despite being at a low lifting height setting content of the speed limit
setting enabled
setting.
Drive control SAS/OPS/mini lever controller:
– Replace
Controller defect
Check the setting content of the
Display setting:
maximum speed limiter, check the
For T/C vehicles with drive control: Maximum speed limiter, speed limiter Change
setting content of the speed limit
Speed limit applies at all times setting enabled
setting.
regardless of lifting height or load
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Lead-in side):
Buzzer sounds constantly Ground short or link fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
OPS leaving seat warning does not (Harness, connector)
sound.
Display setting:
OPS leaving seat notification buzzer Check setting values with option set Change
setting disabled
SAS/OPS controller, OPS controller:
– Replace
Controller defect
 Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
T/C vehicles: Direction lever unit:
Traveling OPS return to neutral alarm Lever defect
Refer to "Traveling OPS does not Refer to "Traveling OPS does not
does not sound. Direction lever signal:
operate, cannot travel". operate, cannot travel".
Disconnection fault
(Harness, connector)
Display setting:
Check setting values with option set. Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
Buzzer related
Buzzer unit:
Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
For cowl lever vehicles: Lowering lever switch: Refer to “Cowl lever vehicles: cannot
Material handling OPS return to Lever defect lower lift”.
Refer to “Cowl lever vehicles: cannot
neutral alarm does not sound. Lowering lever signal: *: The material handling OPS return to
lower lift”.
Disconnection fault neutral is only a function for the
(Harness, connector) lowering lever on cowl lever vehicles.
Display setting:
Check setting values with option set. Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
21-227
 Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Buzzer unit:
21-228

Buzzer defect
Buzzer harness line
– Harness check or replace buzzer
(Power supply side, lead-in side):
Disconnection fault
(Harness, connector)
Material handling lever potentiometer
unit: If there is no change, perform a
For mini lever vehicles: Lever defect Material handling lever potentiometer harness check or replace the
Material handling OPS return to Material handling lever line voltage check: potentiometer
neutral alarm does not sound. (Power supply, signal, ground): Move the lever into forward and If none of the material handling levers
Disconnection fault reverse tilt positions and check the move, refer to “Cowl lever vehicles,
(Harness, connector) voltage change. mini lever vehicles: cannot perform
Short or link fault any material handling”.
(Harness, connector)
Display setting:
Check setting values with option set Change
USA specification enabled
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer related Buzzer defect
Buzzer harness line – Harness check or replace buzzer
(Power supply side, lead-in side):
Fault (Harness, connector)
Parking brake switch unit:
Open fault
(stuck in released state, internal
damage) If there is no change, perform an
Vehicles with multi display, multi Parking brake detection mechanism: ON/OFF check with analyzer. installation check, harness check, or
display DX: Always released replace the switch.
Parking brake reminder alarm does Parking brake line:
not sound. Disconnection fault
(Harness, connector)
Display setting:
Parking brake reminder alarm setting
Check setting values with option set Change
disabled.
USA specification enabled
SAS/OPS controller setting:
– Follow matching procedure to match.
Not matched
SAS/OPS controller:
– Replace
Controller defect
 Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Parking brake switch unit:
Ground short fault
(Stuck in released state, internal
Vehicles with multi display, multi damage) If there is no change, perform an
display DX: Parking brake detection mechanism: ON/OFF check with analyzer installation check, harness check, or
Parking brake reminder alarm Always released replace the switch.
continues to sound even after the Parking brake line:
parking brake has been depressed Ground short fault
(or pulled). (Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Buzzer unit:
Buzzer defect
Buzzer harness line – Harness check or replace buzzer
Buzzer related (Power supply side, lead-in side):
Vehicles with multi display, multi Fault (Harness, connector)
display DX:
Vehicle speed sensor unit:
Parking brake return reminder alarm Check sensor voltage and vehicle
Cannot detect low speed
does not sound. speed with the analyzer
(Internal damage) If there is no change, perform an
* First perform a “Parking brake * With the parking brake not returned,
Vehicle speed sensor line installation check or replace the
reminder alarm does not sound” even when the accelerator pedal is
(SPD+ side, SPD- side): sensor.
check. depressed, the alarm only sounds at
Link fault
speeds above 2 km/h.
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Vehicles with multi display, multi Meter unit (with OK monitor):
– Replace
display DX: Meter defect
Parking brake return reminder alarm SAS/OPS controller:
sounds on traveling. – Replace
Controller defect
21-229
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load indicator switch unit:
21-230

Open fault (Internal damage)

Load indicator switch detection
mechanism (Mini lever, joystick):
Vehicles with multi display DX: If there is no change, perform an
Detection part gap adjustment defect
When the load indicator switch is ON/OFF check with analyzer installation check, harness check, or
Load indicator switch line
pressed, the load is not displayed. replace the switch (lever).
(Power supply, signal, ground):
Open fault
(Power supply, harness,
connector)
Load indicator switch unit:
Short fault (Internal damage)
Vehicles with multi display DX: Load indicator switch detection
Display If there is no change, perform an
When the vehicle is stopped, the mechanism (Mini lever, joystick):
function ON/OFF check with analyzer installation check, harness check, or
display continually shows load Detection part gap adjustment defect
replace the switch (lever).
indicator. Load indicator switch line (Signal):
Short fault
(Harness, connector)
Follow the procedure for matching,
Carry out rematching and check
and rematch (cylinder bore, number of
operation
cylinders, 0 point correction)
Load sensor voltage check:
Display setting: In cases where precision is required,
Vehicles with multi display DX: Mount a load, ground the forks and
Cylinder bore, number of cylinders, 0 adjust on the load indicator matching
The correct load is not displayed. check the change in voltage
point correction, calibration LOAD CALIBRATION screen.
* At high lifting height, correct load
If there is no change during the voltage
cannot be calculated and the display
check, perform a harness check or
flashes.
replace the sensor.
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Torque converter oil temperature
sensor unit:
Open fault (Internal damage)
Torque converter oil temperature
T/C vehicles with multi display, multi
sensor line (Signal, ground): Start the engine and after leaving the
display DX: Harness check or replace sensor, or
Disconnection fault vehicle running for a while, check the
Torque converter oil temperature replace SAS/OPS controller
(Harness, connector) indicator.
indicator stays at level 1.
+B short fault
(Harness, connector)
SAS/OPS controller:
Controller defect
Torque converter oil temperature
Display sensor unit:
function T/C vehicles with multi display, multi Short fault (Internal damage)
display DX: Torque converter oil temperature Stop the engine and after leaving the
Harness check or replace sensor, or
Torque converter oil temperature sensor line (Signal): vehicle stopped for a while, check the
replace SAS/OPS controller
indicator continually displays Ground short fault indicatior.
overheat warning indication. (Harness, connector)
SAS/OPS controller:
Controller defect
There is no display on MT vehicles. If the TEMPGAUGE is set to NO on
T/C vehicles with multi display, multi Display setting: Check that the TEMPGAUGE on the the option set screen, change it to
display DX: Torque converter oil temperature option set screen is set to YES, and YES, and if MTC on the analyzer I/O
Torque converter oil temperature emergency setting enabled that the MTC on the analyzer I/O OTHERS screen is set to 1, perform a
indicator does not display. SAS/OPS controller: OTHERS screen is set to 0. harness check or replace the SAS/
Controller defect (MTC line short) OPS controller.
21-231
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire unit:
21-232

Burst, tire pressure adjustment – Adjust or replace

defect
Lock cylinder unit:
Leak, cannot lock
(Internal damage) Check the locked status with an active
Replace
Lock cylinder locked status: test.
Installation part damaged or
destroyed
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Peform lift relief and check the installation check or replace the
Disconnection fault
change in voltage. sensor.
(Harness, connector)
Short or leak fault
Feels unstable when traveling. (Harness, connector)
Swing lock (Traveling lock has become difficult or Lifting height switch unit:
no longer possible) Disconnection fault ON/OFF check with analyzer Harness check or replace switch
(Internal damage, stuck)
Yaw rate sensor unit:
Reduced sensitivity, voltage stuck Yaw rate sensor voltage check:
(Internal damage) Check that the voltage is
Installation check or replace sensor
Yaw rate sensor line (Signal): approximately 2.5 V when the vehicle
Leak is stopped.
(Harness, connector)
Vehicle speed sensor unit:
Cannot detect low speeds
(Internal damage) If there is no change, perform an
Check sensor voltage and vehicle
Vehicle speed sensor line installation check or replace the
speed with the analyzer
(SPD+ side, SPD- side): sensor.
Leak fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lock cylinder unit: Check the locked status with an active
Replace
Lock stuck (internal damage) test.
Swing lock solenoid line (SWN+,
SWN-):
Disconnection fault
Check the locked status with an active
(Harness, connector) Harness check or replace solenoid
test.
Solenoid ground line (E01, E02):
Disconnection fault
(Harness, connector)
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Swing lock continually activates while Peform lift relief and check that the installation check or replace the
Disconnection fault
traveling and material handling voltage rises. sensor.
Swing lock (Harness, connector)
operations, or swing lock activates Short or leak fault
frequently. (Harness, connector)
Lifting height switch unit (2200H):
Disconnection fault (internal damage,
stuck)
ON/OFF check with analyzer Harness check or replace switch
Lifting height switch unit (4000H):
Disconnection fault (internal damage,
stuck)
Yaw rate sensor voltage check:
Yaw rate sensor unit:
Check that the voltage is
Reduced sensitivity, voltage stuck Installation check or replace sensor
approximately 2.5 V when the vehicle
(Internal damage)
is stopped.
SAS/OPS controller:
– Replace
Controller defect
21-233
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
21-234

Sensor defect If there is no change, perform an

Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Automatic fork leveling switch unit:
Open fault (internal damage)
Forward tilt automatic fork leveling Automatic fork leveling switch
does not stop. detection mechanism (mini lever,
Tilt control (Continues to tilt to the forward most joystick):
tilt position without stopping at the ON/OFF check with analyzer. Harness check or replace switch
Detection part gap adjustment defect
level position) Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
C/V tilt control valve: Turn the tilt solenoid OFF and operate If forward tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Display setting (mini lever, joy stick):
3/4 way change over specification is Check the option set content. Change
set to 2/3 way change over setting
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Peform lift relief and check that the installation check or replace the
Disconnection fault
voltage rises. sensor.
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value:
Follow matching procedure to
Forward tilt automatic fork leveling Does not match actual status –
rematch.
does not stop. (rematch)
Tilt control
(Stops at a position slightly off the level Tilt angle sensor unit:
Tilt angle sensor voltage check:
position) Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
SAS/OPS controller:
– Replace
Controller defect
21-235
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Load sensor unit:
21-236

Sensor defect
Load sensor line
Load sensor voltage check: If there is no change, perform an
(Power supply, signal, ground):
Check that the voltage rises on lift installation check or replace the
Disconnection fault
relief. sensor.
(Harness, connector)
Short or leak fault
(Harness, connector)
Load sensor no-load matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Forward tilt automatic fork leveling
does not stop. Tilt angle sensor unit:
Tilt angle sensor voltage check:
Tilt control (Stops at the position where the Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
automatic fork leveling switch is Tilt angle sensor installation: installation check or replace the
positions and check the voltage
pressed) Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Lifting height switch unit (2200H):
Disconnection fault (internal damage, ON/OFF check with analyzer. Harness check or replace switch
stuck)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Automatic fork leveling switch unit:
Open fault (internal damage)
Automatic fork leveling switch
detection mechanism (mini lever,
joystick):
ON/OFF check with analyzer Harness check or replace switch
Detection part gap adjustment defect
Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
Mast backward tilting speed is not
limited. Turn the tilt solenoid ON/OFF and If there is no change in the backward
Tilt control C/V tilt control valve:
Or, backward tilting speed is always operate to backward tilt using an active tilting speed when ON/OFF operated,
Stuck (internal damage)
slow. test. replace the C/V tilt control valve.
Lifting height switch unit (2200H):
Disconnection fault (internal damage, ON/OFF check with analyzer Harness check or replace switch
stuck)
Display setting
(mini lever, joystick):
Check the option set content. Change
3/4-way change over specification is
set to 2/3-way change over setting
SAS/OPS controller:
– Replace
Controller defect
21-237
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
21-238

Sensor defect If there is no change, perform an

Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Link, installation part destroyed, sensor.
change.
damaged
Horizontal matching value for tilt angle
sensor: Follow matching procedure to
–
Does not match actual status rematch.
(rematch)
Automatic fork leveling switch unit:
Mini lever, joystick vehicles:
Open fault (internal damage)
Backward tilt automatic fork leveling
Automatic fork leveling switch
does not stop. (Continues to tilt to
detection mechanism (mini lever,
backward most tilt position without
Mini lever joystick):
stopping at the level position) ON/OFF check with analyzer Harness check or replace switch
function Detection part gap adjustment defect
Automatic fork leveling switch line
(Power supply, signal, ground):
Disconnection fault
(Harness, connector)
Display setting (mini lever, joy stick):
3/4-way change over specification Check the option set content Change
set to 2/3-way change over setting
SAS/OPS controller:
– Replace
Controller defect
Mini lever, joystick vehicles: Refer to forward tilt automatic fork
Backward tilt automatic fork leveling leveling does not stop (stops at the
– –
does not stop. (Stops at a position position where the automatic leveling
slightly off the level position) switch is pressed).
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tilt angle sensor unit:
Tilt angle sensor voltage check:
Sensor defect If there is no change, perform an
Tilt to forward and backward tilt
Tilt angle sensor installation: installation check or replace the
positions and check the voltage
Mini lever, joystick vehicles: Link, installation part destroyed, sensor.
change.
Backward tilt automatic fork leveling damaged
does not stop. (Stops at the position Horizontal matching value for tilt angle
where the automatic fork leveling sensor: Follow matching procedure to
–
switch is pressed) Does not match actual status rematch.
(rematch)
SAS/OPS controller:
– Replace
Controller defect
Lever change over switch unit:
Open fault (internal damage)
Mini lever Lever change over switch detection
function mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(Power supply, signal, ground):
Mini lever 3/4-way (2/3-way) change Disconnection fault
over specification: (Harness, connector)
3-way (2-way) operation even when
Lever change over relay 1 or 2 unit:
the lever change over switch is
Stuck, welding fault (internal
pressed. (Does not change over)
damage)
Check the changeover status with an
Lever change over relay 1 or 2 primary Harness check or replace relay
active test.
side line:
Disconnection fault
(wire, connector)
AS/OPS/mini lever controller:
– Replace
Controller defect
21-239
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lever change over switch unit:
21-240

Ground short fault (Internal damage)

Lever change over switch detection
mechanism (mini lever):
Detection part gap adjustment defect ON/OFF check with analyzer Harness check or replace switch
Lever change over switch line
(signal):
Ground short fault
Mini lever 3/4-way (2/3-way) change (Harness, connector)
over specification: Lever change over relay 1 or 2 unit:
4-way (3-way) continues to operate Stuck, welding fault (internal
even though the lever change over damage)
switch has been operated. (Stays Check the changeover status with an
Lever change over relay 1 or 2 primary Harness check or replace relay
changed over) active test.
side lower line:
Mini lever Ground short fault
function (wire, connector)
Display setting:
Number of attachment levers is not Check the option set content. Change
set to 5 way
SAS/OPS controller:
– Replace
Controller defect
Mini lever 2/3-way change over
specification: Display setting:
During ATT1 operation and high Number of attachment levers is not Check the option set content. Change
lifting height, and when loaded, ATT1 set to 2/3-way
stops and pull-side operation is slow.
3-way (4-way) specifcation: Display setting:
Although ATT1 (ATT2) is operated, it Number of attachment levers is not Check the option set content. Change
does not work. set to 3-way (4-way)
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire angle sensor unit:
Sensor defect Tire angle sensor voltage check: If there is no change, perform an
Tire angle sensor installation: Operate the steering and check the installation check or replace the
Looseness of the attachment part, change in voltage. sensor.
damage, bearing housing damage
Tire angle sensor matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Steering angle sensor unit:
Knob moves out of alignment into a Sensor defect
Knob ON/OFF check with analyzer Harness check or replace sensor
certain position. Steering angle sensor installation:
compensaiton
(More than 10° off the straight ahead Cam or steering wheel defect
control
position) Using an active test, turn the knob
compensation SOL ON and OFF and
operate the steering at the tire end.
Knob compensation valve unit: SOL ON: check that the steering
Replace
Leak, stuck, (internal damage) wheel can be turned freely.
SOL OFF: Check that the steering
wheel cannot be turned freely
(steering is heavy).
SAS/OPS controller:
– Replace
Controller defect
21-241
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Tire angle sensor unit:
21-242

Sensor defect Tire angle sensor voltage check: If there is no change, perform an
Tire angle sensor installation: Operate the steering and check the installation check or replace the
Looseness of the attachment part, change in voltage. sensor.
damage, bearing housing damage
Tire angle sensor matching value:
Follow matching procedure to
Does not match actual status –
rematch.
(rematch)
Steering angle sensor unit:
Sensor defect Check sensor voltage with the
Harness check or replace sensor
Steering angle sensor installation: analyzer.
Cam or steering wheel defect
Using an active test, turn the knob
compensation SOL ON and OFF and
operate the steering at the tire end.
Knob compensation valve unit: SOL ON: Check that the steering
Replace
Knob Knob position is out of alignment. Leak, stuck, (internal damage) wheel can be turned freely.
compensation (Knob position is not constant when SOL OFF: Check that the steering
control traveling straight ahead) wheel cannot be turned freely
(steering is heavy).
PS cylinder system link defect:
– Replace
Eccentric pin, kingpin defect
Vehicle speed sensor unit:
Cannot detect low speed (internal
damage)
Vehicle speed sensor installation:
High speed not detected correctly If there is no change, perform an
Check sensor voltage and vehicle
(sensor tip has metallic particle installation check or replace the
speed with the analyzer.
adhered) sensor.
Vehicle speed sensor line
(SPD+ side, SPD- side):
Leak fault
(Harness, connector)
SAS/OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Fuse:
ECU+B fuse blown – Check for blown fuse
ECU-IG fuse blown
Meter communication line:
Ground short
(Harness, connector)
Disconnection fault
(Harness, connector) – Harness check
SAS/OPS IG line, +B line, ground
system:
Disconnection fault
Wrench lamp is lit continually.
(Harness, connector)
Battery unit:
Check battery voltage with the Keep the engine at high speed for a
Low voltage, intake heater, large
analyzer. while.
current auxiliary equipment operation
SAS/OPS controller setting: Follow matching procedure to
–
Not matched rematch.
Meter Meter unit:
– Replace
Meter defect
SAS/OPS controller:
– Replace
Controller defect
Meter power supply line:
The wrench lamp does not light even Disconnection fault – Harness check
when the ignition key switch is turned (Harness, connector)
ON. Meter unit:
– Replace
Meter defect
Line to the meter
(OPS lamp output):
– Harness check
Ground short fault
ROW standard (except for compact (Harness, connector)
vehicles):
Meter unit:
OPS lamp does not light. – Replace
Meter defect
OPS controller:
– Replace
Controller defect
21-243
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Line to the meter
21-244

(OPS lamp output):

– Harness check
Disconnection fault
(Harness, connector)
Meter unit:
– Replace
Meter defect
Seat switch unit:
ROW standard (except for compact Open fault (internal damage)
vehicles): Seat switch line
ON/OFF check with plug-in analyzer Harness check or replace switch
OPS lamp is lit continually. (Signal, ground):
Disconnection fault
(Harness, connector)
Meter
Battery unit:
Check battery voltage with plug-in Keep the engine at high speed for a
Low voltage, intake heater, large
analyzer. while.
current auxiliary equipment operation
OPS controller:
– Replace
Controller defect
Hour meter start connector:
Not connected
Hour meter start signal line: – Harness check or replace connector
Hour meter is not displayed. Disconnection fault
(Harness, connector)
Meter unit:
– Replace
Meter defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Lift lower switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Lift lower switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
Cannot lower the lift.
Using an active test, turn the lift lower
C/V lift lower lock valve If the lift cannot lower by lower
lock solenoid ON and perform lower
Stuck (internal damage) operation, replace the C/V.
operation.
Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
OPS (Harness, connector)
Forward tilt switch unit:
Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Forward tilt switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
For cowl lever vehicles: Disconnection fault
Cannot perform forward tilt. (Harness, connector)
C/V tilt control valve Turn the tilt solenoid ON and operate If forward tilt cannot be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
21-245
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Backward tilt switch unit:
21-246

Open fault
(Switch mounted incorrectly,
internal damage, stuck)
Backward tilt switch line:
ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
Switch ground line:
Disconnection fault
For cowl lever vehicles: (Harness, connector)
Cannot perform backward tilt.
Turn the backward tilt lock solenoid If backward tilt cannot be performed,
C/V backward tilt lock valve
ON and operate to backward tilt using replace the C/V backward tilt lock
Stuck (internal damage)
an active test. valve.
OPS Seat switch unit:
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
Turn the unload valve solenoid OFF
and perform raising operation using
Cannot perform material handling C/V unload valve: an active test. If raising cannot be performed, replace
except for lift lower. Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid ON
and perform raising operation using
an active test.
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
C/V tilt control valve: Turn the tilt solenoid OFF and operate If forward tilt can be performed,
Stuck (internal damage) to forward tilt using an active test. replace the C/V tilt control valve.
Turn the backward tilt lock solenoid
C/V backward tilt lock valve: If backward tilt can be performed,
OFF and operate to backward tilt using
Stuck (internal damage) replace the C/V tilt control valve.
an active test.
Using an active test, turn the lift lower
C/V lift lower lock valve: If lowering can be performed, replace
lock solenoid OFF and perform lower
Stuck (internal damage) the C/V lift lower lock valve.
operation.
For cowl lever vehicles:
Turn the unload valve solenoid ON
and perform lift raising operation
Material handling OPS does not C/V unload valve: using an active test. If raising can be performed, replace
OPS
operate. Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid OFF
and perform lift raising operation
using an active test.
Seat switch unit:
Short fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
21-247
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Seat switch unit:
21-248

Open fault (internal damage)

Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
For cowl lever vehicles:
Cowl lever, mini lever vehicles:
Turn the unload valve solenoid OFF
No material handling can be
and perform lift raising operation
performed.
C/V unload valve: using an active test. If raising cannot be performed, replace
Stuck (internal damage) For mini lever vehicles: the C/V unload valve.
Turn the unload valve solenoid ON
and perform lift raising operation
using an active test.
SAS/OPS controller, OPS controller:
– Replace
OPS Controller defect
Forward travel interrupt relay unit: If forward travel can be performed,
Stuck (internal damage, welded) replace the forward travel interrupt
Turn the forward and reverse travel
Reverse travel interrupt relay unit: relay.
interrupt relays ON and operate
Stuck (internal damage, welded) If reverse travel can be performed,
forward and reverse travel using an
Relay secondary side line: replace the reverse travel interrupt
active test.
Short fault relay.
(Harness, connector) Or perform a harness check.
T/C vehicles:
Short switch unit:
Traveling OPS does not operate.
Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
Control type Phenomenon on vehicle Malfunction area · mode Checking method Corrective action
Fuse:
– Check for blown fuse
Shift fuse blown
Forward travel interrupt relay unit:
Open fault
If forward travel cannot be performed,
(internal damage, welded)
Turn the forward and reverse travel replace the forward travel interrupt
Reverse travel interrupt relay unit:
interrupt relays OFF and operate relay. If reverse travel cannot be
Open fault
forward and reverse travel using an performed, replace the reverse travel
(internal damage, welded)
active test. interrupt relay. Or perform a harness
Relay secondary side line:
check.
Open fault
(Harness, connector)
T/C vehicles: Seat switch unit:
OPS
Cannot travel. Open fault (internal damage)
Seat switch line
ON/OFF check with analyzer Harness check or replace switch
(Signal, ground):
Disconnection fault
(Harness, connector)
Direction lever unit:
Open system fault (internal damage)
Direction lever signal line: ON/OFF check with analyzer Harness check or replace switch
Disconnection fault
(Harness, connector)
SAS/OPS controller, OPS controller:
– Replace
Controller defect
21-249
Defect Causes When There is No ASC Error Display
Caution:
21-250

If an error code or wrench lamp is flashing, repair it first.

Phenomenon on vehicle Malfunction area · mode Checking method Corrective action

NMR switch unit:
Switch defect
NMR switch line:
Harness check or
Disconnection fault
Occaisonally full speed is not reached ON/OFF check with analyzer replace switch, or adjust switch, adjust and
(Harness, connector)
even with the accelerator pedal fully repair mechanical parts.
NMR switch adjustment:
depressed. (NMR speed not acheived) Adjustment defect, seal bolt position
defect or some other mechanical defect
ASC controller:
– Replace
Controller defect
Idle switch adjustment:
– Switch adjustment
Adjustment defect or mechanical defect
Accelerator sensor:
Accelerator sensor adjustment, or, if a fault
Sensor catching, mistake in procedure
occurs after sensor replacement, turn the
during sensor replacement (when the
Idle speed is higher than specified speed ignition key ON with the accelerator sensor
sensor is beng replaced, if a C4 series Check accelerator sensor voltage with the
even when the accelerator pedal is not connectors removed, in order to create an
error is not created by turning the ignition analyzer.
depressed. error once.
key ON while the sensor connector is
Then turn the ignition key OFF, connect
disconnected, the fully closed position
connectors and turn the ignition key ON
learning value is not reset)
ASC controller:
– Replace
Controller defect
Drop in battery voltage:
Check battery voltage with the analyzer. Battery replacement
Battery life, intake heater, afterheat
Engine rev up is poor or slow.
ASC controller:
– Replace
Controller defect
IGN, +B line:
Disconnection fault
(Harness, connector, fuse)
Check battery voltage with the analyzer. Harness check or replace fuse
GND line complete loss:
Does not rev up from idling Disconnection fault
(Harness, connector)
ASC controller:
– Replace
Controller defect