TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.

5 TON MODELS)

FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of trouble Trouble in vehicle Reset method
code Remarks
01 Travel power mod- ule is shorted Vehicle cannot travel or Turn key switch –
(Upper and lower FET's are short- handle cargo (MD connector OFF.
ed). is not closed).
(This trouble is also detected
when failure code 45 is
displayed.)

03 Main contactor (MD) is shorted or Vehicle cannot travel or Turn key switch –
open or its sensor circuit harness is handle cargo. OFF.
defective.

05 Travel power mod- ules are shorted Vehicle cannot travel or Turn key switch Failure code 05:
11 (Upper and lower modules are short- handle cargo. OFF. Detected when key
ed separately). switch is turned ON.
Failure code 11:
Detected after key switch
and MD are turned ON.

06 Travel power mod- ule is open. Vehicle cannot travel or Turn key switch Failure code 06: U-
08 U-, V-, or W-phase is disconnection. handle cargo. OFF. phase is open
09 (disconnected)
Failure code 08: V-
phase is open
(disconnected)
Failure code 09:
W-phase is open
(disconnected)

BE30 Series 70-73

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

Failure Contents of trouble Trouble in vehicle Reset method

code Remarks
07 Main contactor (MD) drive Tr is de- Vehicle cannot travel or Turn key switch –
fective (In CPU board: Tr4). handle cargo. OFF.
Main contactor coil is open.
Sensor circuit har- ness of main
contactor coil is defective.

16 F or R switch is de- fective. Vehicle cannot travel. Reset normal- ly. Turn F switch and R
switch ON simulta-
neously.

17 Travel accelerator output is defective. Vehicle can travel at Reset normal- ly. Normal source voltage of
40% of maximum speed. accelerator: 5 V (Be- tween
CN2-9 and 20) Output voltage
of accel- erator when
abnormality is detected: Max.
0.2 V, Min. 4.8 V (Between
CN2-8 and 20)

19 Output or wiring harness of travel Vehicle cannot travel. Turn key switch Normal sensor output
current sensor (CSDU, CSDW) is OFF. • During travel: 3.0 V
defective. – 11.0 V
• When FR switch is
in neutral and accel-
erator is OFF: Ap- prox. 7
V
CSDU: Between
CN5-4 and 14, 15
CSDW: Between
CN5-6 and 16, 17
Normal source volt- age
of sensor power supply:
15 V
Sensor output when
abnormality is detect- ed:
Max. 1.5 V, Min.
12.5 V
20 Travel main fuse (F1) is broken or its Vehicle cannot travel (MD Turn key switch Check voltage on sec-
sensor circuit har- ness is defective. contactor is closed). OFF. ondary side of fuse (F1).

21 Undervoltage is detected (Battery Vehicle cannot travel Turn key switch This trouble is detect- ed
voltage is lower). (MD/MPS connector is not OFF. when battery volt- age is
closed). When key switch is below 28.2 V for
turned ON again, vehicle 0.8 seconds.
can travel.

22 Output of travel controller tempera- ture Vehicle can travel normally Reset normal- ly. Voltage of tempera- ture
sensor (THD) is defective. (assuming temperature is sensor (THD) when
nor- mal). abnormality is detected:
Max. 0.2 V, Min. 4.95 V

23 Neutral is detect- ed.
* Neutral caused by mistake in op-
eration is not trouble.
Vehicle cannot travel.
Turn accel- erator When both of acceler- ator
and FR switch OFF. and FR switch are turned
ON, trouble is reset when
either of them is turned
OFF.

70-74 BE30 Series

TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of trouble Trouble in vehicle Reset method

code Remarks
24 Travel controller temperature is Vehicle can travel (Current is Con- troller is reset Normal resistance/
high. limited by temperature rise when temper- ature voltage of tempera- ture
Fan drive system is defective. and output is lowered). lowers below sensor
100°C. 25°C: 20kz/4.0 V
50°C: 7.2kz/3.0 V
80°C: 2.5kz/1.7 V
Tolerance of these
values is ± 10%.
1 ton models: 1 fan
CN7R-2, 8
2 ton models: 2 fans
CN7R-1, 7 added Above
100°C: Current is limited.
Above 103°C: Warn- ing
is displayed.

25 Travel motor tem- perature rises. Vehicle can travel (Current is Travel motor is reset Normal resistance/ voltage
limited by temperature rise when temper- ature of travel motor temperature
and output is lowered). lowers below sensor
160°C. 25°C: 10.7kz/3.5 V
50°C: 4.4kz/2.4 V
100°C: 1.0kz/0.9 V
150°C: 0.3kz/0.3 V
Tolerance of these
values is ± 10%. Above
160°C: Current is limited.
Above 163°C: Warn- ing
is displayed.

26 Travel controller temperature is Vehicle cannot travel. Con- troller is reset Normal resistance/
ab- normal. when temper- ature voltage of tempera- ture
Fan drive system is defective. lowers below sensor
115°C. 25°C: 20kz/4.0 V
50°C: 7.2kz/3.0 V
80°C: 2.5kz/1.7 V
Tolerance of these
values is ± 10%.
1 ton: 2 fans
CN7R-2, 8
2 ton: 3 fans CN7R-1, 7
added Above 115°C:
Travel is stopped.

27 Output of travel motor temperature Vehicle can travel normally Reset normal- ly. Voltage of tempera- ture
sensor is defec- tive. (assuming temperature is sensor when ab- normality
nor- mal). is detected: Max. 0.2 V,
Min. 4.95
V

28 Travel motor tem- perature is Vehicle cannot travel. Travel motor is reset Normal resistance/ voltage
abnor- mal. when temper- ature of travel motor temperature
lowers below sensor
175°C. 25°C: 10.7kz/3.5 V
50°C: 4.4kz/2.4 V
100°C: 1.0kz/0.9 V
150°C: 0.3kz/0.3 V
Above 175°C: Travel
is stopped.

BE30 Series 70-75

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

Failure Contents of trouble Trouble in Reset method

code vehicle Remarks
30 Cargo handling power module (TMPU) is Vehicle can handle Turn key switch OFF. –
shorted. cargo.
(MP contactor is
closed.)
(This trouble is also
detected when failure code
56 is displayed.)

31 Cargo handling power module (TMP) is Vehicle cannot han- dle Turn key switch OFF. –
open. Upper side of car- go handling cargo.
power module (TMP) (Be- tween P and (MP contactor is
OUT) is shorted. closed.)
Cargo handling motor is shorted or
open.

32 Chassis EMG switch is defective or its Vehicle cannot oper- ate Turn EMG switch and This trouble occurs only
circuit har- ness is disconnect- ed. work equipment. (MP key switch OFF. when CN1-24 is
contactor is not closed.) disconnected (and does
not occur while EMG
switch is pressed).

33 Cargo handling main fuse (F2) is Vehicle cannot han- dle Turn key switch OFF. Check voltage on sec-
broken its sensor circuit harness is cargo (MP contactor is ondary side of fuse (F2).
defective. closed).

35 Cargo handling lift VR is shorted or Vehicle operates with cargo Reset normal- ly. This code is applied to only
open. handling "ON" period ratio vehicle equipped with
at 100%. manual valve lift VR.
Output of lift VR when
abnormality is detect- ed:
Max. 0.2 V, Min.
4.8 V (Between CN2-
10 and 21)

36 Output of cargo handling controller Vehicle can handle cargo Reset normal- ly. Voltage of tempera- ture
temperature sen- sor (THP) is defec- normally (as- suming sensor when ab- normality
tive. temperature is normal). is detected: Max. 0.2 V,
Min. 4.95
V (Between CN7-6 and
12)

41 Output of travel speed sensor A is Vehicle cannot travel. Reset normal- ly. –
defective.

70-76 BE30 Series

TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of trouble Trouble in Reset method

code vehicle Remarks
42 Output of travel speed sensor B is Vehicle cannot travel. Reset normal- ly. –
defective.

45 Capacitor of travel capacitor port Vehicle can travel Turn key switch OFF. Note) If this trouble is left
(CBD) is charged abnormally. normally. When main as it is, travel contactor
contactor (MD) is turned (MD) is worn quickly by
ON, arc is generated. arcs.
(This trouble is also Repair it immediately.
detect- ed when failure
code
01 is displayed.)
50 PS main Tr or its drive circuit har- Steering wheel is Turn key switch OFF. –
ness are defective. EPS board is de- heavy.
fective. i If short circuit is made,
PS motor is open. this trouble is detected
before MPS contactor is
turned ON.

51 PS contactor (MPS) is shorted or its Vehicle operates nor- Turn key switch OFF. Timing of displaying
sensor circuit harness is defec- tive. mally. trouble
(Error is kept dis- When key is turned ON
played.) and when MPS drive is
turned OFF

52 PS main fuse (F3) Steering wheel is Turn key switch OFF. –

is open. heavy.
PS contactor (MPS) is open or its (PS contactor (MPS)
sensor circuit harness is defec- is not closed.)
tive.

53 PS contactor (MPS) coil drive Tr or Steering wheel is Turn key switch OFF. –
its sensor circuit harness is defec- heavy.
tive.
(In CPU board: Tr5)

BE30 Series 70-77

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

Failure Contents of trouble Trouble in Reset method

code vehicle Remarks
54 Output of PS torque sensor is Steering wheel is Turn key switch Output voltage of torque
defective. heavy. OFF. sensor when abnormality
is detect- ed: Max. 0.2 V,
Min.
4.8 V (Between CN2-6 and
CN1-14)
55 Cargo handling controller tempera- ture Vehicle can handle cargo Con- troller is reset Normal resistance/
is high. ("ON" period ratio is limited when temper- ature voltage of tempera- ture
Fan drive system is defective. by tem- perature rise). lowers below sensor
100°C. 25°C: 20kz/4.0 V
50°C: 7.2kz/3.0 V
80°C: 2.5kz/1.7 V
Tolerance of these
values is ± 10%.

56 Capacitor of cargo handling capacitor Vehicle can handle cargo. Turn key switch Note) If this trouble is left
port (CBP) is charged abnormal- ly. When main contactor (MD) OFF. as it is, main
is turned ON, arc is contactor (MD) is
generated. (This trouble is worn quickly by arcs.
also detect- ed when failure Repair it
code immediately.
30 is displayed.)

60 • Key switch is turned ON while work • Only related opera- tions Turn key switch If E87 – E89 are also
( 2) equipment control lever is not in are impossi- ble. Error is OFF. displayed, check them first.
neutral. displayed immedi- ately For repair meth- od, see
(Note) This is not trouble. after key switch is turned each failure code section.
• Adjustment of work equipment Pot is ON.
abnormal.
• Work equipment
Pot is abnormal.
• Work equipment Pot circuit har- ness
is defective.

61 • Adjustment of work equipment Pot is • Only related opera- tions Turn key switch If E87 - E89 and E-60 are
( 2) abnormal. are impossi- ble. Error is OFF. also displayed, check them
• Work equipment displayed when le- ver is first. For repair method,
Pot is abnormal. operated. see each failure code sec-
• Work equipment Pot circuit har- ness tion.
is defective.

2. Displayed only proportional solenoid valve spec.

70- BE30 Series

7878
TROUBLESHOOTING
Failure Contents of trouble
code
61 • Output of lift pressure sensor is
(Con- abnormal.
tinued) • Lift pressure sensor circuit
( 2) harness is defec- tive.
(If automatic fork leveling device
is installed)
• Output of tilting angle sensor is
abnormal.
• Tilting angle sen- sor circuit har-
ness is defective.
62 • Proportional valve coil is dis-
( 2) connected.
• Wiring harness between propor-
tional valve and system controller operated. (Pump motor
has trouble of dis- connection,
leak- age, or defective contact.
• Relay, fuse, EMG switch, or
wiring harness is dis- connected.
• EMG relay in sys- tem controller
is open.
• Battery voltage lowers while lever (Pump motor rotates for
is operated. A 1
(Note) This is not trouble in
system controller.
• EMG switch is operated while
lever is operated, then only
propor- tional valve pow- er
supply circuit
is broken. A 2 (Note) This is not
trouble in system controller.
• Proportional valve drive circuit in
system con- troller is open.
2. Displayed only proportional solenoid valve spec.
BE30 Series
FAILURE CODES LIST (1.0 - 2.5 TON MODELS)
Trouble in Reset method
vehicle Remarks
• Vehicle can do all Turn key switch
operations. Re- sponse OFF.
is lowered, however, and
hunt- ing prevention func-
tion does not work when
lift lowers.
• Automatic lifting and
automatic fork level- ing (if
equipped) cannot be
applied. Error is displayed
immediately after key (Output voltage of
switch is turned ON. pressure sensor: Out of
0.34 – 4.8 V)
• Automatic fork lev- eling Set tilt lever in
cannot be ap- plied. neutral.
(• Fork can be moved
by manual operation.)
Error is displayed
immediately after key
switch is turned ON.
(Output voltage of tilt- ing
angle sensor: Out of 0.34 –
4.7 V) (Output of sensor
does not change dur- ing
fork leveling oper- ation.)
• Only related opera- tions Turn key switch If E87 – E89, E-60, and E-
are impossi- ble. Error is OFF. 61 are also dis- played,
displayed when le- ver is check them first. For repair
meth- od, see each failure
ro- tates for a moment.) code section.
A1 --- Example: Main
transistor of main con-
troller is shorted.
A2 --- Example: EMG
switch is operated mo-
mentarily or pushed
• Vehicle cannot op- erate Turn key switch halfway.
at all. OFF.
Error is displayed when
lever is oper- ated.
a mo- ment.)
• Only related opera- tions
are impossi- ble. Error is
displayed when le- ver is
operated. (Pump motor
ro- tates for a moment.)
70-79
FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

Failure Contents of trouble Trouble in vehicle Reset method

code Remarks
62 • Proportional valve coil is • Vehicle cannot op- erate Turn key switch If E87 – E89, E-60, and E-
(Con- shorted. at all. OFF. 61 are also dis- played,
tinued) Error is displayed when check them first. For repair
( 2) lever is oper- ated. (Pump meth- od, see each failure
motor rotates for a mo- code section.
ment.) A1 --- Example: Main
transistor of main con-
troller is shorted.
A2 --- Example: EMG
switch is operated mo-
mentarily or pushed
halfway.

(Check output corre-

• Proportional valve drive circuit in
system con- troller is shorted.
• Vehicle cannot op- erate sponding to input.)
at all.
Error is displayed when
lever is oper- ated. (Pump
motor rotates for a mo-
ment.)

64 [If automatic fork leveling device is • Automatic fork lev- eling Leave lever in (Fork is not in level po-
( 2) installed] device does not reach level neutral. sition.)
• Automatic fork leveling device does posi- tion or exceeds lev- el
not reach level position or exceeds position.
level po- sition. (• Fork can be tilted
(Note) This is not manually.)
trouble.

66 • Automatic lifting cannot be Turn key switch

[If automatic lifting device is installed]
( 2) • Automatic lifting control panel switch applied. (• Lift can be OFF.
is shorted before key switch is turned raised manually.)
ON. Error is displayed
immediately after key
switch is turned ON.

(when key switch is turned

ON, unloading, loading, or
number-of- layer setting (1 -
5 lay- ers) switch is turned
ON.)

67 • Automatic lifting cannot be Turn key switch

[If automatic lifting device is installed] (Source voltage: Be- low
( 2) • Automatic lifting encoder power applied. OFF. 4.77 V)
supply in system controller is de- • If this trouble occurs in
fective. automatic lifting mode,
• Battery voltage is low. vehicle stops.
(Note) This is not trouble in system (• Lift can be raised
controller. manually.)
(Example: Main tran- sistor of main con- Error is displayed
troller is shorted.) immediately after key
switch is turned ON.

2. Displayed only proportional solenoid valve spec.

70- BE30 Series

8080
TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of trouble Trouble in vehicle Reset method

code
67 [If automatic lifting device is
(Con- installed]
tinued) • Lifting encoder is defective.
( 2) • Lifting encoder circuit is
defec- tive.
Remarks
• Vehicle stops lifting Turn key switch (Note 1)
operation, then it cannot OFF. Encoder output pulses of 0
start auto- matic lifting V and 5 V. If it is
opera- tion any more. abnormal, its output only 0
(• Lift can be raised V or 5 V.
manually.) (Note 2)
Check encoder (2) only
when it is in- stalled.
(Note 3)
In specification shown in
standard connec- tion
diagram, lifting encoder
wire is pulled out when lift
is raised. In specification
where wire is pulled in
when lift is raised, A-
phases and B-phase are
on opposite sides. Ac-
cordingly, phases must be
confirmed.

[If automatic lifting device is • Vehicle stops lifting

installed] [When 2 encoders are operation, then it cannot
installed] start auto- matic lifting
• 1st and 2nd en- coders are opera- tion any more.
con- nected wrongly (when 2 (• Lift can be raised
encod- ers are installed). manually.)

[If automatic lifting device is • Vehicle stops lifting Turn key switch If E87 – E89, E60 and E61
installed] [When 2 encoders are operation, then it cannot OFF. are also dis- played, check
installed] start auto- matic lifting them first. For repair meth-
• Lifting 2) refer- ence switch is opera- tion any more. od, see each failure code
defective. (• Lift can be raised section. (Pulses are not
• Circuit harness of lifting (2) manually.) output from encoder during
refer- ence switch is defective. lifting operation.)

[If automatic lifting device is
installed]
• A-phase and B- phase of lifting
encoder are con- nected
opposite- ly.
• Vehicle stops lifting Turn key switch (Operating direction does
operation, then it cannot OFF. not conform to output
start auto- matic lifting direction of en- coder.)
opera- tion any more.
(• Lift can be raised
manually.)

[If automatic lifting device is • Vehicle cannot op- erate Turn key switch (Pulses are not output from
installed] automatic lift- ing work. OFF. encoder during lifting
• Lifting encoder input circuit in • Vehicle stops lifting operation.)
system control- ler is operation.
abnormal.

2. Displayed only proportional solenoid valve spec.

BE30 Series 70-81

FAILURE CODES LIST (1.0 - 2.5 TON MODELS) TROUBLESHOOTING

Failure Contents of trouble Trouble in vehicle Reset method

code Remarks
68 [If automatic lifting device is • Vehicle cannot op- erate Set lever in [Fork leveling opera- tion is
( 2) installed] or [If automatic fork leveling automatic lift- ing work. neutral. abnormal]
device is installed] • Vehicle cannot op- erate fork • Operation is in re- verse
• Automatic lifting operation and leveling work. direction. [Automatic lifting
fork leveling op- eration are de- (• Fork can be lev- eled oper- ation is abnormal]
fective. manually.) • Reference switch is not
detected or num- ber of
layers is not set.
• Number of layers is
changed during op- eration
[If automatic lifting device is • Vehicle cannot op- erate Set lever in or automatic operation is
installed] or [If automatic fork leveling automatic lift- ing work. neutral. started in manual operation
device is installed] (•Fork can be leveled manually.) mode.
• Automatic lifting reference switch • Operation is in re- verse
is defective. direction or it is performed
• Wiring harness of automatic lifting at short distance.
reference switch is defective.

[If automatic fork leveling device is • Fork cannot be tilt- ed Set lever in
installed] manually. neutral.
• Tilt display switch is shorted.
• Tilt display switch harness is short-
ed.

69 [If automatic lifting device is • Fork stops before set stop Set lever in After fork stops before set
( 2) installed] position in automatic lifting neutral. stop position, if it is moved to
• Automatic lifting device does not mode. set stop po- sition manually,
reach set stop position. buzz- er sounds.
(Note) This is not
trouble.

70 [If automatic lifting device is • Fork stops after set stop Set lever in After fork stops ex- ceeding
( 2) installed] position in au- tomatic lifting neutral. set stop posi- tion, if it is
• Automatic lifting device exceeds mode. moved to set stop position
set stop position. man- ually, buzzer sounds.
(Note) This is not
trouble.

87 • Sensor power supply in system
( 2) controller is ab- normal.
• Battery voltage is low.
(Note) This is not trouble in system
controller. (Example: Main transistor
of main controller is short- ed.)
• Vehicle cannot op- erate at Turn key
all. switch OFF.
Error is displayed immediately
after key switch is turned ON.

(Source voltage: Below

4.5 V)

2. Displayed only proportional solenoid valve spec.

70-82 BE30 Series

TROUBLESHOOTING FAILURE CODES LIST (1.0 - 2.5 TON MODELS)

Failure Contents of trouble Trouble in vehicle Reset method

code Remarks
89 • Work equipment switch • Pump motor rotates at low Turn key
( 2) signal is shorted to GND or it speed. switch OFF.
is leaking. • Vehicle cannot op- erate at
• Work equipment switch all.
circuit of main controller is Error is displayed immediately
abnormal. after key switch is turned ON.

(When key switch is turned

ON, hydraulic chopper starts
without receiving operation
in- put.)

• Proportional valve EMG relay • Error is displayed immediately Turn key (When key switch is turned
in system con- troller is after key switch is turned ON. switch OFF. ON, EMG relay in board is
shorted. closed.)

95 Multi-controller is defective. • Error is displayed immediately Turn batter –

after key switch is turned ON. con- nector
(Vehicle operates normally.) OFF.

97 Communication between main Error is displayed when Per- Occasional occur- rence of
con- troller and multi- controller abnormality is detected. form au- tomatic this trouble is caused by
is abnor- mal. • Main controller can- not be reset- ting nor- defective contact. In this
adjusted. mally. case, connect and discon-
• It cannot display fail- ure codes. nect connector.
(Vehicle operates normally.)

98 Communication between Error is displayed when Per- Occasional occur- rence of

( 2) system controller and multi- abnormality is detected. form au- tomatic this trouble is caused by
controller is abnormal. System controller cannot display reset- ting nor- defective contact. In this
failure codes. (Vehicle oper- mally. case, connect and discon-
ates normally.) nect connector.

99 Communication between meter Error is displayed when Per- Occasional occur- rence of
panel and multi- controller is abnormality is detected. form au- tomatic this trouble is caused by
abnor- mal. • Main controller can- not be reset- ting nor- defective contact. In this
adjusted. mally. case, connect and discon-
• Main controller, sys- tem nect connector.
controller, and multi-controller
can- not display failure codes.
(Vehicle op- erates normally.)

2. Displayed only proportional solenoid valve spec.

BE30 Series 70-83