Toyota Pallet Truck Service Manual Section 6.

Messages and Codes

Section 6. Messages and Codes

00700-CL398-13, Issued: 6 May 2013 6-1

 Service Manual Change History
Description Page # Date
Added Service Manual Change
1 History 2 7/15/13
2 Added Information Bulletins 3 7/15/13
3 Added SIB CC13-001 41-42 7/15/13
4 Added SIB CC13-005 43 7/31/13
5 Added SIB CE13-003 44-52 7/31/13
6 Added SIB CC13-007 53-54 7/31/13
6 Added SIB CC14-005 55-56 8/15/14
 Service Information Bulletin
1 SIB BF10-003R Tractor Cover Mounting update kit Section 7
2 SIB BF10-004 Fork Crack Repair For Demanding Applications Section 7
3 SIB BR13-001 Fixed Handle Adjustable Brake Potentiometer Section 7
4 SIB BR13-002 Handle Operating Range Section 7
5 SIB CC12-002 Pre-Programmed ETAC Card No Longer Available Section 7
6 SIB CC13-001 Software Update Information and Descriptions Section 6
7 SIB CC13-005 Power Steering Software Update (V1.9) Section 6
8 SIB CC14-005 8HBC & 8TB50 Floormatt Switch Operation Section 8
9 SIB CC14-006 Power Steering Unit Repair Instructions Section 6 & 7
10 SIB CE13-003 C81 Code Steer Potentiometer Section 6
11 SIB CC13-007 Vehicle Manager and Traction Amp Software Updates Section 6
12 SIB CE14-001 Twist Grip Shimming Section 7
13 SIB CE14-002 Power Steer Handle Bezel Update Section 7
14 SIB CE14-003 Solid State Steering Potenitomenter Instructions Section 7

Technical News Brief

1 TNB-2007-07 Setting Parameters in ETAC Card Units
2 TNB-2008-02 Change To All Metric Hardware
3 TNB-2008-03 Tandem Load Wheel Block Grease Fitting
4 TNB-2008-08 Excessive Throttle Play In Neutral
5 TNB-2008-09 Steer Bearing Shimming
6 TNB-2008-14 Use of Loctite on Pinion Nut
7 TNB-2008-18 Motor Controller Overtemp

Hotline Tech Tips

1 HTT-2007-11 Parameters
2 HTT-2008-04 Pinched Drive Motor Cables
3 HTT-2008-07 Using Loctite on Pinion Nut
4 HTT-2008-08 Truckcomm Software
5 HTT-2008-11 Drive Unit Tightening Sequence
6 HTT-2009-02 Rebuilding Cast style Lift cylinder
7 HTT-2009-03 Water In Grab Rail
8 HTT-2009-07 Gluing of Cushioned Floor Mat
9 HTT-2009-10 Travel Speed And Acceleration Parameters
10 HTT-2010-02 Fix For Loose Keyless Switch
11 HTT-2010-03 Curtis Handset Connection Procedure
12 HTT-2010-04 Static Return To Off; Reducing Steer Effort
13 HTT-2010-05 Parameter 24 Explained
14 HTT-2010-07 Greaseable Steer Bearing
15 HTT-2011-01 Motor Temperature Sensor Replacement
16 HTT-2011-07 Programming ETAC Card; Troubleshooting AMP LED Codes
17 HTT-2011-12 New ETAC Card Installation
Section 6. Messages and Codes Toyota Pallet Truck Service Manual

List of Messages and Codes

List of Messages and Code C74 (Model 8TB50 with

Power Steer) . . . . . . . . . . . . . . . 6-22
Codes Code C75 (Model 8TB50 with
Power Steer) . . . . . . . . . . . . . . . 6-22
Traction Amplifier LED Diagnostics . . . . . . . .6-5 Code C76 (Model 8TB50 with
Power Steer) . . . . . . . . . . . . . . . 6-23
Traction Amplifier Flash Codes . . . . . . . . . . .6-6 Code C77 (Model 8TB50 with
Caution and Error Codes . . . . . . . . . . . . . . .6-8 Power Steer) . . . . . . . . . . . . . . . 6-23
Code C78 (Model 8TB50 with
Caution Codes . . . . . . . . . . . . . . . . . . . . . . .6-9
Power Steer) . . . . . . . . . . . . . . . 6-23
Code ‘GATE’ . . . . . . . . . . . . . . . . . . 6-9 Code C79 (Model 8TB50 with
Code ‘SLO’ . . . . . . . . . . . . . . . . . . . 6-9 Power Steer) . . . . . . . . . . . . . . . 6-24
Code ‘Sro’ (C14) . . . . . . . . . . . . . . . 6-9 Code C80 (Model 8TB50 with
Code C19 . . . . . . . . . . . . . . . . . . . 6-10 Power Steer) . . . . . . . . . . . . . . . 6-24
Code HPd (C20) . . . . . . . . . . . . . . 6-10 Code C81 (Model 8TB50 with
Code C21 . . . . . . . . . . . . . . . . . . . 6-10 Power Steer) . . . . . . . . . . . . . . . 6-25
Code C22 . . . . . . . . . . . . . . . . . . . 6-11 Code C82 (Model 8TB50 with
Code C24 . . . . . . . . . . . . . . . . . . . 6-11 Power Steer) . . . . . . . . . . . . . . . 6-25
Code C25 . . . . . . . . . . . . . . . . . . . 6-11 Code C83 (Model 8TB50 with
Code C26 . . . . . . . . . . . . . . . . . . . 6-12 Power Steer) . . . . . . . . . . . . . . . 6-25
Code C27 . . . . . . . . . . . . . . . . . . . 6-12 Code C84 (Model 8TB50 with
Code C30 . . . . . . . . . . . . . . . . . . . 6-12 Power Steer) . . . . . . . . . . . . . . . 6-26
Code C31 . . . . . . . . . . . . . . . . . . . 6-13 Code C85 (Model 8TB50 with
Code C32 . . . . . . . . . . . . . . . . . . . 6-13 Power Steer) . . . . . . . . . . . . . . . 6-26
Code C33 . . . . . . . . . . . . . . . . . . . 6-13 Code C86 (Model 8TB50 with
Code C34 . . . . . . . . . . . . . . . . . . . 6-14 Power Steer) . . . . . . . . . . . . . . . 6-26
Code C35 . . . . . . . . . . . . . . . . . . . 6-14 Code C87 (Model 8TB50 with
Code C36 (Model 8TB50 with Power Steer) . . . . . . . . . . . . . . . 6-27
Power Steer) . . . . . . . . . . . . . . . 6-14 Code C88 (Model 8TB50 with
Code Lo (C41) . . . . . . . . . . . . . . . . 6-15 Power Steer) . . . . . . . . . . . . . . . 6-27
Code Hi (C42) . . . . . . . . . . . . . . . . 6-15 Code C89 (Model 8TB50 with
Code Hot1 (C44) . . . . . . . . . . . . . . 6-16 Power Steer) . . . . . . . . . . . . . . . 6-27
Code Hot2 (C45) . . . . . . . . . . . . . . 6-16 Code C90 (Model 8TB50 with
Code C50 . . . . . . . . . . . . . . . . . . . 6-17 Power Steer) . . . . . . . . . . . . . . . 6-28
Code C51 . . . . . . . . . . . . . . . . . . . 6-17 Code C94 (Model 8TB50 with
Code C52 . . . . . . . . . . . . . . . . . . . 6-17 Power Steer) . . . . . . . . . . . . . . . 6-28
Code C57 . . . . . . . . . . . . . . . . . . . 6-18
Code C60 . . . . . . . . . . . . . . . . . . . 6-18
Code C61 . . . . . . . . . . . . . . . . . . . 6-18 Click here for ETAC Software
Code C62 . . . . . . . . . . . . . . . . . . . 6-19 Update Information and Descriptions
Code C63 . . . . . . . . . . . . . . . . . . . 6-19
Code C64 . . . . . . . . . . . . . . . . . . . 6-19
Code C65 . . . . . . . . . . . . . . . . . . . 6-20
Code C66 . . . . . . . . . . . . . . . . . . . 6-20
Code C67 . . . . . . . . . . . . . . . . . . . 6-20
Code C68 . . . . . . . . . . . . . . . . . . . 6-21
Code C70 . . . . . . . . . . . . . . . . . . . 6-21
Code C71 . . . . . . . . . . . . . . . . . . . 6-21
Code C72 . . . . . . . . . . . . . . . . . . . 6-22

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

List of Messages and Codes

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code E101 . . . . . . . . . . . . . . . . . . 6-29
Code E106 . . . . . . . . . . . . . . . . . . 6-29
Code E107 . . . . . . . . . . . . . . . . . . 6-30
Code E108 . . . . . . . . . . . . . . . . . . 6-30
Code E140 . . . . . . . . . . . . . . . . . . 6-30
Code E141 . . . . . . . . . . . . . . . . . . 6-31
Code E150 . . . . . . . . . . . . . . . . . . 6-31
Code E157 . . . . . . . . . . . . . . . . . . 6-31
Code E159 . . . . . . . . . . . . . . . . . . 6-32
Code E160 . . . . . . . . . . . . . . . . . . 6-32
Code E201 . . . . . . . . . . . . . . . . . . 6-32
Code E202 . . . . . . . . . . . . . . . . . . 6-33
Code E203 . . . . . . . . . . . . . . . . . . 6-33
Code E220 . . . . . . . . . . . . . . . . . . 6-33
Code E221 . . . . . . . . . . . . . . . . . . 6-34
Code E222 . . . . . . . . . . . . . . . . . . 6-34
Code E223 . . . . . . . . . . . . . . . . . . 6-34
Code E224 . . . . . . . . . . . . . . . . . . 6-35
Code E225 . . . . . . . . . . . . . . . . . . 6-35
Code E228 . . . . . . . . . . . . . . . . . . 6-35
Code E230 . . . . . . . . . . . . . . . . . . 6-36
Code E232 . . . . . . . . . . . . . . . . . . 6-36
Code E233 . . . . . . . . . . . . . . . . . . 6-36
Code E235 . . . . . . . . . . . . . . . . . . 6-37
Code E252 . . . . . . . . . . . . . . . . . . 6-37
Code E253 . . . . . . . . . . . . . . . . . . 6-37

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

List of Messages and Codes

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Traction Amplifier LED Diagnostics

Figure 6-1. Traction Amplifier Status Indicator LED
Traction Amplifier LED
Section 6. Messages and Codes

P200-6901a.jpg

Diagnostics
Error conditions involving the traction amplifier
(TA) usually display as fault codes on the
Operator Display. See “Caution and Error
Codes” on page 6-8.

The TA also contains two Light Emitting Diodes

(LEDs). See Figure 6-1. The two LEDs have five
different display modes, indicating the type of
information they are providing. See Table 6-1
and Table 6-2. LEDs

Table 6-1. Traction Amplifier LED Display Modes

Display Status

Neither LED illuminated Controller is not powered ON or is severely damaged.

Orange LED flashing Controller is operating normally.

Orange and red LEDs ON solid Controller is in Flash program mode.

Red LED ON solid Watchdog failure. Cycle the truck OFF/ON to restart.

Orange and red LEDs flashing alternately Controller has found a fault. See “Traction Amplifier
Flash Codes” on page 6-6.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Traction Amplifier Flash Codes

Traction Amplifier Flash NOTE: When displaying a fault code, the red
LED flashes once for the first number,
Codes followed by the orange LED for the first
number of the code itself. The red LED
then flashes twice, followed by the
An internal microcontroller automatically orange LED flashing the second number
examines the function of the Traction Amplifier of the code.
(TA). When this microcontroller finds a fault,
the LEDs on the bottom of the TA flash the
appropriate code. See Table 6-2. Correct faults
by following the “Caution and Error Codes” on
page 6-8.

Table 6-2. TA Flash Codes

TA
Error
Flash Description Action
Code
Code
1,2 E201 Overcurrent Fault See “Code E201” on page 6-32.
1,3 E202 TA Current Sensor Error See “Code E202” on page 6-33.
1,4 E225 Pre-charge Fault See “Code E225” on page 6-35.
1,5 E223 TA Severe Under-Temperature Cutback See “Code E223” on page 6-34.
1,6 E224 TA Severe Over-Temperature Cutback See “Code E224” on page 6-35.
1,7 E221 Severe Battery Undervoltage See “Code E221” on page 6-34.
1,8 E222 Severe Battery Overvoltage See “Code E222” on page 6-34.
2,2 Hot2 TA in Warm Thermal Cutback See “Code Hot2 (C45)” on page 6-16.
2,3 Lo Battery Undervoltage Warning See “Code Lo (C41)” on page 6-15.
2,4 Hi Battery Overvoltage Warning See “Code Hi (C42)” on page 6-15.
2,5 E233 +5V Supply Failure See “Code E233” on page 6-36.
2,6 or C64 Digital Output Overcurrent See “Code C64” on page 6-19.
2,7
2,7 C63 Digital Output Open/Shorted - Coast See “Code C63” on page 6-19.
2,8 Hot1 Motor Temperature Hot Cutback See “Code Hot1 (C44)” on page 6-16.
2,9 C70 Motor Temperature Sensor Fault See “Code C70” on page 6-21.
3,1 E106 Main Contactor Driver Overcurrent Error See “Code E106” on page 6-29.
3,2 C66 Coil 2 Driver Open/Shorted - Brake See “Code C66” on page 6-20.
3,3 C60 Coil 3 Driver Open/Shorted - Lift See “Code C60” on page 6-18.
3,4 C62 Coil 4 Driver Open/Shorted - Horn See “Code C62” on page 6-19.
3,5 C61 PD Driver Open/Shorted - Lower See “Code C61” on page 6-18.
3,6 C71 Sensor Bearing Faulty See “Code C71” on page 6-21.
3,7 E203 Motor Open See “Code E203” on page 6-33.
3,8 E108 Contactor Weld Error See “Code E108” on page 6-30.
3,9 E107 Contactor OFF Error See “Code E107” on page 6-30.
4,6 E220 Default Parameters DNL See “Code E220” on page 6-33.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Traction Amplifier Flash Codes

TA
Error
Flash Description Action
Code
Code
4,9 E228 Parameter Change Fault See “Code E228” on page 6-35.
5,1 E150 Initial CAN Message Not Received See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
5,3 C60 Lift Contactor Coil (M2) Driver Shorted or See “Code C60” on page 6-18.
Open
6,1 E150 CAN Time-out Error See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,3 E150 Ead SDO CAN Message See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,5 E150 Ead Communication Spec See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,8 E232 VCL Runtime See “Code E232” on page 6-36.
6,9 E230 External Supply Out-of-Range See “Code E230” on page 6-36.
7,1 E150 CAN Time-out, No Truck Functions Active See Table 5-21 on page 5-24.
or
blank
7,2 E150 FDO CAN Message Time-out See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
7,3 C72 Traction Motor Stalled See “Code C72” on page 6-22.
9,2 C67 EM Brake Not Set See “Code C67” on page 6-20.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution and Error Codes

Caution and Error Codes

Figure 6-2. Operator Display
P0010517.tif

Explanation of Symbols:

A = Alpha-Numeric Field
B = Hour Meter Indicator
C = Parameter Control Indicator
D = Battery Indicator
E = Error Indicator

NOTE: If a Service Key is inserted into the

truck, the fault codes do not display on
the Operator Display. The fault is still
active, and displays when the Service
Key is removed. Caution Codes below 49
are not logged. See the following for how
to clear the code and the allowed activity
during error.

Codes that apply to certain configurations are

labeled to assist when servicing trucks. Electric
Power Steering is optional equipment on Model
8TB50 tow tractors.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Caution Codes
Code ‘GATE’

Code Title Battery Gate Switch Open

Operator Display 'GATE'

System Response Travel limited to 1 MPH (1.6 km/h)

Reason Battery gate missing and operator moved handle out-of-neutral. The TA detected
that Battery Gate Interlock switch S21 or S22 is open.

Tests to Run Troubleshoot wiring to and from switches. See “Pinout Matrix” on page 8-13.

How to Clear Make sure the battery gate is installed correctly. Adjust or replace switches.

Code ‘SLO’

Code Title Turtle Speed

Operator Display 'SLO'

System Response Travel Limited to Turtle Speed

Reason The 3-position key switch is in the Turtle Speed Position (normal operation), or
broken wire with 2-position key switch. The TA detects IGN2 (High Speed Enable) is
missing and limits speed.

Tests to Run Test key switch. Test harness to JP10-2.

How to Clear Replace switch or repair harness.

Code ‘Sro’ (C14)

Code Title SRO (Static Return to Off)

Operator Display 'Sro'

Error (E) and Parameter Control (C) Indicators Blinking. See Figure 6-2.

System Response Truck is disabled (Emergency Reverse is Active)

Reason Control handle out of the brake position when the truck is turned ON.
Spring-loaded handle or Power Steer handle is in the brake released range (out of
position) or the fixed handle has the hand brake released prior to the system being
powered ON.

Tests to Run Confirm switch function if brake applied and fault persists. See Table 5-23, “No
Travel. Static Return to OFF (SRO) Fault. Display may indicate ‘Sro’ and Error and
Parameter Control Indicators Blinking,” on page 5-25.

How to Clear Apply brake.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C19

Code Title Default Parameter Warning

Operator Display C19

System Response No effect on performance

Reason New default parameters have been loaded into RAM.

Tests to Run None

How to Clear Self clears after timer expires (approximately 5 seconds).

Code HPd (C20)

Code Title HPD – Directional/Speed Control Warning (High Pedal Disable)

Operator Display 'HPd'

Error (E) and Parameter Control (C) Indicators Blinking. See Figure 6-2.

System Response Travel is disabled, all other systems active. Emergency reverse is active.

Reason Directional/Speed Control was not in neutral position at power ON, when brake is
released, or during auto steer centering. Failure of the Hall Effect sensor in speed
control circuit. Jog button controls activated when brake released.
Floor Mat Switch: Travel or lift requested with floor mat switch open when in the
travel restricted mode.

Tests to Run Confirm directional/speed control in neutral, and handle sensors and wiring are
correct. Examine function of jog switch and for shorts to related wiring harness.

How to Clear Return directional/speed controls to neutral position.

Code C21

Code Title Travel request from Directional/Speed Control and Jog Switch at same time

Operator Display C21

System Response Travel is disabled, all other functions are active. Emergency reverse is active.

Reason If the Jog Switch is actuated and the directional/speed control is rotated out of
neutral, the system ignores the two commands.

Tests to Run If commands are not active and code persists, examine sensors and wiring from
directional/speed controls and jog switch. See “Pinout Matrix” on page 8-13.

How to Clear Return directional/speed control to neutral and release Jog switch.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C22

Code Title Anti Tie-Down

Operator Display C22

System Response Travel is limited to Jog Pick speed, all other systems perform normally.

Reason Rabbit switch pressed ahead of the brake being released or throttle being applied.

Tests to Run Confirm Rabbit switch is not stuck or wiring is not shorted. See “Pinout Matrix” on
page 8-13.

How to Clear Release Rabbit switch.

Code C24

Code Title Lost High Speed Enable Input

Operator Display C24

System Response Travel is limited to Jog Pick speed. All other systems work normally.

Reason During truck operation the coast switch SW18 has stuck OPEN, a lead has come off
the switch, or a lead has been damaged between the switch and the controller.

Tests to Run Examine wiring to coast switch. Examine continuity of coast switch or open wires
to JP10-2 if there is no switch.

How to Clear Repair bad part.

Code C25

Code Title Jog Pick and Rabbit Requested at the Same Time

Operator Display C25

System Response Turns off Coast (Jog Pick) Solenoid driver output and limits travel to Jog Pick
speed.

Reason Both Coast Engage/Jog Switch and Rabbit switch are activated at the same time.

Tests to Run If fault does not clear on releasing switches and cycling brake, examine for stuck
switches or shorted wiring. See “Pinout Matrix” on page 8-13.

How to Clear Self clears after both of the switches are released and brake is cycled OFF/ON.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C26

Code Title Lift Switch Stuck

Operator Display C26

System Response Ignores stuck input. Turns off Lift Contactor. Lift contactor responds to input from
alternate switch if equipped.

Reason Lift request ON longer than time out value (10 seconds) and the lift cut-out switch
SW8 did not open. Either the lift cut-out switch is damaged (or out of adjustment)
or the lift system is prevented from lifting (jammed or too heavy a load) to a point of
activating the lift cut-out switch.

Tests to Run Examine for stuck switch or shorted wiring harness. See “Pinout Matrix” on
page 8-13.

How to Clear Release Lift switch.

Code C27

Code Title Lower Switch Stuck

Operator Display C27

System Response System ignores stuck input. Turns off Lower Solenoid. Stuck switch is disabled if
truck is equipped with an alternate switch and the alternate switch is still active.
Lower solenoid responds to input from alternate switch if equipped.

Reason Lower request on longer than time out value (10 seconds). Lower switch is jammed
or the operator is holding the switch for longer than is required to lower the forks.

Tests to Run Examine for stuck switch or shorted wiring harness. See “Pinout Matrix” on
page 8-13.

How to Clear Release Lower switch.

Code C30

Code Title Emergency Reverse has been Activated

Operator Display C30

System Response Normal travel controls are disabled. The truck responds only to activations of the
Emergency Reverse switch.

Reason The Emergency Reverse switch has been pressed and released.

Tests to Run Cycle the brake (deadman) switch by engaging the brake.

How to Clear Clears after the brake is applied.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C31

Code Title Lost Brake Pot VR1 Input (Brake Pot Out-of-Range)

Operator Display C31

TA Flash Code “3,4”

System Response No Travel

Reason Brake pot input at JP1-17 is open. See “Pinout Matrix” on page 8-13.

Tests to Run Troubleshoot wiring to and from the Brake pot.

How to Clear Adjust or replace pot or repair wiring. Cycle the truck OFF/ON.

Code C32

Code Title Emergency Reverse Before Brake Release

Operator Display C32

System Response Travel is disabled

Reason The emergency reverse switch is activated (depressed) prior to the brake being
released.

Tests to Run Examine for stuck emergency reverse switch.

How to Clear Clears after the Emergency Reverse switch is released.

Code C33

Code Title Horn Switch Stuck

Operator Display C33

System Response Ignores stuck input. Turns off Horn. Horn responds to input from alternate source
if equipped (this does not include the second horn switch on the control handle).

Reason Horn request ON longer than time out value (10 seconds). Stuck switch is disabled;
if equipped with an alternate switch, the alternate switch is still active.

Tests to Run Examine horn switch and related wiring. Examine grab rail switches if provided.
See “Pinout Matrix” on page 8-13.

How to Clear Release or repair Horn switch.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C34

Code Title Coast Engage Switch Stuck

Operator Display C34

System Response Ignore stuck input. Turn off Coast (Jog Pick) solenoid. Coast solenoid responds to
input from the Jog Switch.

Reason Jog Pick switch actuated longer than time out value (10 seconds). Stuck switch is
disabled.

Tests to Run Examine Jog Pick switch. Examine VM.

How to Clear Release Jog Pick switch.

Code C35

Code Title Brake Switch Error

Operator Display C35

System Response Normal travel controls are disabled. The truck responds only to activations of the
Emergency Reverse switch if the traction motor is rotating in tractor-first direction.

Reason The brake switch is out of adjustment or damaged. At the same time the traction
motor is detected rotating.

Tests to Run See “Pinout Matrix” on page 8-13 and see “Brake Potentiometer (VR1)” on page 7-76
for brake switch adjustment.

How to Clear Apply brake and have the switch adjusted or replaced.

Code C36 (Model 8TB50 with Power Steer)

Code Title Steering Not Learned at Startup

Operator Display C36

System Response No travel.

Reason Operator pushing on the steer tiller at key-on or handle not learned.

Tests to Run None

How to Clear Return steering handle to neutral and cycle the truck OFF/ON. If still not clear,
re-learn handle.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code Lo (C41)

Code Title Battery Undervoltage Warning

Operator Display 'Lo'

Error (E) and Battery Indicator (D) Blinking. See Figure 6-2. TA Flash Code “2,3”

System Response Travel performance may be limited due to low voltage.

Reason Battery voltage below approximately 17V. Battery discharged or excessive load on
battery.

Tests to Run Measure battery voltage at JP3-1. Refer to “Pinout Matrix” on page 8-13. Use
service key to read voltage. See “Service Input/Output Displays” on page 3-17.

How to Clear Battery needs to be charged. Examine battery and battery connections. The fault is
cleared when the battery voltage increases above 17V.

Code Hi (C42)

Code Title Battery Overvoltage Warning

Operator Display 'Hi'

Error (E) and Battery Indicator (D) Blinking. See Figure 6-2. TA Flash Code “2,4”

System Response Travel performance may be limited.

Reason Battery voltage over approximately 32V. This can be caused by wrong type of
battery installed in truck or overcharged battery.

Tests to Run Measure battery voltage at JP3-1. Refer to “Pinout Matrix” on page 8-13. Use
service key to read voltage. See “Service Input/Output Displays” on page 3-17.

How to Clear Make sure that correct size battery is installed in truck. The fault is cleared when
the battery voltage drops below 32V.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code Hot1 (C44)

Code Title Motor Temperature Hot Cutback

Operator Display Hot1

TA Flash Code “2,8”

System Response Travel performance may be limited.

Reason Traction motor temperature above 248°F (120°C). Resistance of temperature sensor
should be approximately 91 Ohms at room temperature.

Tests to Run Verify the Traction Amp is hot. If it is not, disconnect JP7 at the traction motor and
measure continuity. The resistance increases as the temperature increases. At
212°F (100°C), the resistance of the temperature sensor is approximately 100
ohms. At room temperature, the resistance is approximately 91 ohms. If it is,
determine the cause by checking for mechanical drag such as brakes dragging,
gear box issue, or load wheel binding. Check the current through U, V and W and
verify that they are even. See “Service Input/Output Displays” on page 3-17. Check
for mechanical binding or brake drag.

How to Clear Permit motor to cool down. Replace temperature sensor.

Code Hot2 (C45)

Code Title Traction Power Amp Warm Thermal Cutback

Operator Display Hot2

TA Flash Code “2,2”

System Response Travel performance may be limited.

Reason TA internal heatsink temperature is above 185°F (85°C). Operation in extreme hot
environment, excessive load on vehicle, or incorrect TA mounting.

Tests to Run Verify the Traction Amp is hot. If it is, determine the cause by checking for
mechanical drag such as brakes dragging, gear box issue, or load wheel binding.
Check the current through U, V and W and verify that they are even. See “Service
Input/Output Displays” on page 3-17. Also see Table 5-22, “No Travel or Slow
Travel. TA Flash Code 2,2, (Thermal Cutback) Heatsink Temperature Exceeded
185°F (85°C). Operator Display May Indicate Hot2 (C45),” on page 5-24.

How to Clear Take action to bring heatsink temperature into normal operating range.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

NOTE: Caution Error Codes above 50 are

logged. See the following tables for how
to clear the code and the allowed activity
during the error. Some codes can be
cleared by cycling the truck OFF/ON.

Code C50

Code Title Lift Switch Active on Power Up

Operator Display C50

System Response Traction performance limited.

Outputs available: Main, Horn, and Lower

Reason Grab Rail/Load Backrest Lift switch (SW15) active on power up, or pin 12 on TA
shorted to B+. TA inputs to JP1-12 are ON.

Tests to Run Examine switch and related wiring.

How to Clear Clear input (held switch, stuck switch, or shorted lead). Cycle the truck OFF/ON.

Code C51

Code Title Lower Switch Active on Power Up

Operator Display C51

System Response Traction performance limited.

Reason Grab Rail/Load Backrest Lower switch active on power up or pin 11 on TA shorted
to B+. TA inputs to JP1-11 are ON.

Tests to Run Examine switch and related wiring.

How to Clear Clear input (held switch, stuck switch, or shorted lead). Cycle the truck OFF/ON.

Code C52

Code Title Grab Rail/Load Backrest Lift/Lower Switches Active at Same Time

Operator Display C52

System Response Traction performance limited.

Reason Grab Rail/Load Backrest Lift and Lower switches active on power up, or pin 11 and
12 shorted to B+. TA inputs to JP1-11 or JP1-12 are ON.

Tests to Run Examine Amplifier and related wiring.

How to Clear Clear inputs (held switches, stuck switches, or shorted leads). Cycle the truck
OFF/ON.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C57

Code Title Brake Interlock Proximity Switch Input Mismatch

Operator Display C57

System Response Hard Plug to 1 MPH (1.6 km/h)

Reason The TA detected that the input from the Brake Switch at JP1-9 and the Redundant
Brake Switch input at JP1-24 do not match.

Tests to Run Troubleshoot wiring to and from the Brake Switch. Troubleshoot wiring to and from
the Redundant Brake Switch. See “Pinout Matrix” on page 8-13.

How to Clear Investigate cause of open or short.

Code C60

Code Title Lift Contactor Coil (M2) Driver Shorted or Open

Operator Display C60

TA Flash Code “3,3” or “5,3”

System Response Lift function not available. Lower functions normally.

Reason Lift coil driver open or shorted.

Tests to Run Verify Parameter 38 is set correctly. See “Service Parameters” on page 3-10.
Examine lift contactor coil and wiring. Resistance of coil should be approximately
17 Ohms. See “Pinout Matrix” on page 8-13.

How to Clear Investigate cause of open or short and repair or replace as needed.

Code C61

Code Title Lower Solenoid Coil (Sol 1) Driver Shorted or Open

Operator Display C61

TA Flash Code “3,5”

System Response Lower function not available. Lift functions normally.

Reason Lower coil driver open or shorted.

Tests to Run Examine for short or open for lower coil, or related wiring. Resistance of coil should
be approximately 39 Ohms. See “Pinout Matrix” on page 8-13.

How to Clear Investigate cause of open or short and repair or replace as needed.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C62

Code Title Horn Coil Driver Shorted or Open

Operator Display C62

TA Flash Code “3,4”

System Response Horn function not available.

Reason Horn coil driver open or shorted.

Tests to Run Examine horn and related wiring. See “Pinout Matrix” on page 8-13.

How to Clear Investigate cause of open or short and repair or replace as needed.

Code C63

Code Title Coast Coil Driver Shorted or Open

Operator Display C63

TA Flash Code “2,7”

System Response Jog Pick function not available.

Reason Coast coil driver open or shorted. Resistance of coil should be approximately 37
Ohms.

Tests to Run Examine for open or shorted Coast Coil driver circuit and related harness. See
“Pinout Matrix” on page 8-13.

How to Clear Investigate cause of open or short and repair or replace as needed.

Code C64

Code Title Travel Alarm Inoperable

Operator Display C64

TA Flash Code “2,6 or 2,7”

System Response Travel limited to Coast speed.

Reason Digital output driver overcurrent

Tests to Run Examine for shorted travel alarm, or related wiring. See “Service Input/Output
Displays” on page 3-17. See also “Pinout Matrix” on page 8-13.

How to Clear Investigate cause of short and repair or replace as needed.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C65

Code Title Jog Switch Stuck

Operator Display C65

System Response Turn off Coast Solenoid. Ignore throttle commands from the two jog controls

Reason Jog switch active longer than timer (10 seconds). Either the Jog Trigger has been
held/pressed for longer than the time out or the switch is jammed in the operating
condition.

Tests to Run Examine function of jog switch and for shorts to related wiring harness. See
“Service Input/Output Displays” on page 3-17. See also “Pinout Matrix” on
page 8-13.

How to Clear Clear input (held switch, stuck switch, or shorted lead).

Code C66

Code Title Brake Coil Driver Open or Shorted

Operator Display C66

TA Flash Code “3,2”

System Response No Travel

Reason The TA detected an open or short in the Brake Coil Driver circuit.

Tests to Run Troubleshoot wiring to and from the brake and the brake coil for opens or shorts.
The brake coil should have approximately 14 ohms resistance. See “Pinout Matrix”
on page 8-13.

How to Clear Determine cause of short or open circuit and correct.

Code C67

Code Title EM Brake Not Set

Operator Display C67

TA Flash Code “9,2”

System Response No Travel

Reason Triggered if the brake switch is open (handle up) and the brake is applied and no
motion is detected and then motion is detected without releasing the brake. A weak
brake or excessive skidding and then gripping during a deadman braking event
could cause this.

Tests to Run Troubleshoot wiring to and from the brake and the brake coil for opens or shorts.
The brake coil should have approximately 14 ohms resistance. See “Pinout Matrix”
on page 8-13. Check brake gap. See “Checking the Gap” on page 7-60.

How to Clear Return throttle to neutral. Replace the brake or rotor as needed.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C68

Code Title Brake SelfTest Failed

Operator Display C68

System Response Traction performance limited to 1 MPH (1.6 km/h)

Reason Brake did not hold the truck stationary during SelfTest.

Tests to Run Check brake gap. See “Checking the Gap” on page 7-60.

How to Clear Replace the brake or rotor as needed. Cycle the truck OFF/ON.

Code C70

Code Title Motor Temperature Sensor Fault

Operator Display C70

TA Flash Code “2,9”

System Response Traction performance reduced.

Reason Failure of motor temperature sensor. Sensor or wiring to traction motor open or
shorted. Resistance of temperature sensor should be 591 Ohms at room
temperature.

Tests to Run Examine component and related wiring for shorts or open condition. See “Service
Input/Output Displays” on page 3-17. See also “Pinout Matrix” on page 8-13.

How to Clear Determine cause of short or open and correct.

Code C71

Code Title Failure Detected in Traction Motor Feedback Encoder

Operator Display C71

TA Flash Code “3,6”

System Response Traction performance limited.

Reason TA detects the loss of traction motor encoder input.

Tests to Run Use service key and test the traction motor encoder by scrolling to the RPM display
(D) in diagnostic displays and command the motor to rotate. The value displayed is
the motor RPM as reported from the TA. Examine wiring to traction motor encoder.
See “Service Input/Output Displays” on page 3-17. See also “Pinout Matrix” on
page 8-13.

How to Clear Troubleshoot and repair wiring to Traction Motor Encoder. If still not clear, replace
the encoder.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C72

Code Title Traction Motor Stalled

Operator Display C72

TA Flash Code “7,3”

System Response Traction performance limited until code cleared.

Reason TA detects that the traction motor has stalled.

Tests to Run Use service key and test the traction motor encoder by scrolling to the RPM display
(D) in diagnostic displays and command the motor to rotate. The value displayed is
the motor RPM as reported from the TA. See “Service Input/Output Displays” on
page 3-17. See also “Pinout Matrix” on page 8-13.

How to Clear Cycle the truck OFF/ON.

Code C74 (Model 8TB50 with Power Steer)

Code Title Steer Unit Internal Error - General

Operator Display C74

System Response No steering. Truck plugged to stop. No Travel. Brake applied at 0 mph.

Reason Fault internal to steer unit.

Tests to Run None

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. If still not clear, replace the PSU controller.

Code C75 (Model 8TB50 with Power Steer)

Code Title Steer Unit Bus Voltage too Low (less than 12V)

Operator Display C75

System Response No steering. Truck plugged to stop. No Travel.

Reason Bad wiring or contactor, blown fuse.

Tests to Run None

How to Clear Error automatically cleared if possible when truck goes idle. Cycle the truck
OFF/ON. If still not clear, replace the PSU controller.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C76 (Model 8TB50 with Power Steer)

Code Title Steer Unit Bus Voltage too High (greater than 39 volts)

Operator Display C76

System Response No steering. Truck plugged to stop. No Travel.

Reason Incorrect battery installed or possibly bad steer unit.

Tests to Run Check battery voltage to the PSU.

How to Clear Make sure the correct voltage battery is installed. Error automatically cleared if
possible when truck goes idle. If not, cycle the truck OFF/ON. Replace the PSU controller.

Code C77 (Model 8TB50 with Power Steer)

Code Title Steer Sensor 5V Power Supply Out-of-Range

Operator Display C77

System Response No steering. Truck plugged to stop. No Travel.

Reason Short in wiring.

Tests to Run Disconnect power steer sensor and check wiring for shorts.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

click here for more info

Code C78 (Model 8TB50 with Power Steer)
on code 78

Code Title Steer Unit Calculated Temperature at 100% of Maximum or Steering is Stalled

Operator Display C78

System Response No steering. Truck plugged to stop. No travel.

Reason Excessive loading and/or mechanical binding.

Tests to Run 1. Check for mechanical binding.

2. Check motor current draw.

How to Clear Allow steer amplifier to cool. Replace the PSU.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C79 (Model 8TB50 with Power Steer)

Code Title Steer Unit Measured Temperature Warning, 80% of Maximum

Operator Display C79

System Response Reduced steering torque. No Travel slowdown.

Reason Excessive loading and/or mechanical binding.

Tests to Run 1. Check for mechanical binding.

2. Check motor current draw.

How to Clear Allow steer amplifier to cool. Replace the PSU.

Code C80 (Model 8TB50 with Power Steer)

Code Title Steer Unit Calculated Temperature Warning, 80% of Maximum

Operator Display C80

System Response Reduced steering torque. No Travel slowdown.

Reason Excessive loading and/or mechanical binding.

Tests to Run 1. Check for mechanical binding.

2. Check motor current draw.

How to Clear Allow steer amplifier to cool. Replace the PSU.

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 Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes
Click here for more
information on C81
Code C81 (Model 8TB50 with Power Steer) Code

Code Title Steer Unit Sum of Analog Inputs Out-of-Range

Operator Display C81

System Response No steering. Truck plugged to stop. No Travel.

Click Reason Wiring problem to steering sensor or failed sensor. Open or shorted R2 (carbon
here for potentiometers only).
info on Tests to Run 1. Run Learn on the steering. See “Learn Steer” on page 7-13.
Steer Pot 2. Check wiring between pots and PSU. For trucks with a carbon potentiometer,
the resistance of R2 should be 620 ohms.
3. Verify pot voltages, V1 and V2, per “Pinout Matrix” on page 8-13.
NOTE: Toyota FlashWare can be used to monitor the voltages of V1 and V2.
4. Verify correct version of software is in the VM and PSU.
5. Check for shorts to frame.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

Code C82 (Model 8TB50 with Power Steer)

Code Title Steer Unit Analog Inputs Shorted Together

Operator Display C82

System Response No steering. Truck plugged to stop. No Travel.

Reason Wiring problem to steering sensor.

Tests to Run Check wiring to V1 and V2.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

Code C83 (Model 8TB50 with Power Steer)

Code Title Steer Unit Analog Input V2 Out-of-Range

Operator Display C83

System Response No steering. Truck plugged to stop. No Travel.

Reason Wiring problem to steering sensor or failed sensor.

Tests to Run 1. Check wiring to V2.

2. Replace Power Steer Sensor.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C84 (Model 8TB50 with Power Steer)

Code Title Steer Unit Analog Input V1 Out-of-Range

Operator Display C84

System Response No steering. Truck plugged to stop. No Travel.

Reason Wiring problem to steering sensor or failed sensor.

Tests to Run 1. Check wiring to V1.

2. Replace Power Steer Sensor.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

Code C85 (Model 8TB50 with Power Steer)

Code Title Both Steer Unit Analog Inputs (V1 and V2) Out-of-Range

Operator Display C85

System Response No steering. Truck plugged to stop. No Travel.

Reason Wiring problem to steering sensor or failed sensor.

Tests to Run 1. Check wiring to V1 and V2.

2. Replace Power Steer Sensor.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Run learn steer. If the code does not clear then replace the PSU controller.

Code C86 (Model 8TB50 with Power Steer)

Code Title Steer Unit - Communication Failure

Operator Display C86

System Response No steering. Truck plugged to stop. No Travel.

Reason No power to steering unit, broken CAN bus wires, or failed steer unit.

Tests to Run 1. Check for B+ at JP9-6 and B– at JP9-7 and JP9-15.

2. Verify CAN bus wiring. See “Troubleshooting the CAN Bus” on page 5-6.
3. Check cable between PSU and steer sensor for shorts.
4. Disconnect sensors. If code changes, replace power steer sensor.

How to Clear Cycle the truck OFF/ON. Replace the PSU controller.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Caution Codes

Code C87 (Model 8TB50 with Power Steer)

Code Title Home Switch Supply Out-of-Range

Operator Display C87

System Response No steering. Truck plugged to stop. No travel.

Reason Bad wiring or failed home switch.

Tests to Run Check wiring and voltage to switch.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Replace switch.

Click here for more info on

Code C88 (Model 8TB50 with Power Steer) C88 code

Code Title Reference Run Error

Operator Display C88

System Response No steering. Truck plugged to stop. No Travel.

Reason Bad wiring, failed home switch, or failed steer unit.

Tests to Run Check wiring and voltage to switch.

How to Clear Cycle the truck OFF/ON. Replace switch. Replace the PSU controller.

Code C89 (Model 8TB50 with Power Steer)

Code Title Steering Response is less than Request

Operator Display C89

System Response Travel limited to 1 MPH (1.6 km/h)

Reason Binding drive unit and/or steering gears, failed steering unit.

Tests to Run Check for binding in the steer gears and steering unit.

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. Replace the PSU controller.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Caution Codes

Code C90 (Model 8TB50 with Power Steer)

Code Title Steer Unit Internal Error - Shorted Phase

Operator Display C90

System Response No steering. Truck plugged to stop. No Travel.

Reason Fault Internal to Steer Unit.

Tests to Run None

How to Clear Error automatically cleared if possible when truck goes idle. If not, cycle the truck
OFF/ON. If still not clear, replace the PSU controller.

Click here for more info on

Code C94 (Model 8TB50 with Power Steer) code C94
Code Title Steer Unit Sum of Analog Inputs Warning Threshold Exceeded

Operator Display C94

System Response Travel Limited to approximately 1.73 MPH (2.8 km/h) and the horn will beep three
times in rapid succession.

Reason Wiring problem to steering sensor or steer sensor intermittent.

Tests to Run 1. Run Learn on the steering. See “Learn Steer” on page 7-13.
2. Check wiring between pots and PSU. For trucks with a carbon potentiometer,
the resistance of R2 should be 620 ohms.
3. Verify pot voltages, V1 and V2, following the “Pinout Matrix” on page 8-13.
NOTE: FlashWare can be used to monitor the voltages of V1 and V2.
4. Verify correct version of software is in the VM and PSU.
5. Check for shorts to frame.

How to Clear Error automatically cleared when the analog sum is back within threshold range
when the handle is lifted to the brake position. If not, cycle the truck OFF/ON.
Run learn steer. If the code does not clear then replace the PSU controller..

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Error Codes

Error Codes
NOTE: Error Codes are 100 and above. Error
codes are logged. No truck activity is
allowed during error. Some codes can be
cleared when the truck is cycled
OFF/ON (unless otherwise noted).

Code E101

Code Title Traction Amp Type Error

Operator Display E101

System Response No truck function active

Reason Incorrect Power Amplifier installed on truck.

Tests to Run Determine correct TA P/N. Verify TA and VM software versions.

How to Clear Replace with correct TA.

Code E106

Code Title Main Contactor Driver Over-current Error

Operator Display E106

TA Flash Code “3,1”

System Response No truck function active

Reason Short in main contactor coil. Resistance of coil should be approximately 37 Ohms.

Tests to Run Examine main contactor for shorts to related wiring harness. See Table 5-13, “No
Travel, No Lift/Lower. TA Flash Code 3,1. Operator Display May Indicate Error
Code E106,” on page 5-22.

How to Clear Examine for shorted component or related wiring. Repair or replace as needed.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Error Codes

Code E107

Code Title Contactor Off Error

Operator Display E107

TA Flash Code “3,9”

System Response No truck function active

Reason Main contactor did not close. Open in main contactor coil.

Tests to Run Examine contactor circuit for opens in related wiring harness. See Table 5-16, “No
Travel, Main Contactor Does Not Close. TA Flash Code 3,9. Operator Display
Indicates Error Code E107,” on page 5-23. See “Service Input/Output Displays” on
page 3-17. Examine for open Main Contactor or related wiring.

How to Clear Repair/replace as needed.

Code E108

Code Title Contactor Weld Error

Operator Display E108

TA Flash Code “3,8”

System Response No truck function active

Reason Main Contactor welded (detected on start-up). Open in U phase of traction motor.

Tests to Run Inspect contact tips for welding. Check for B+ voltage at the B+ connection of the
traction amplifier. See “Service Input/Output Displays” on page 3-17.
NOTE: Check the U cable for correct connection and continuity. An open in only
the U circuit causes this code. An open in the V and W circuit causes codes
E201 and E203.
Examine for welded contact tips.

How to Clear Repair/replace as needed.

Code E140

Code Title Checksum Error

Operator Display E140

System Response No truck function active

Reason Software check sum not the same as the stored value.

Tests to Run None

How to Clear May clear on cycling key switch OFF/ON. Reload software in the VM. If not, replace
the VM.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Error Codes

Code E141

Code Title Software Problem

Operator Display E141

System Response No truck function active

Reason VM internal error, or missing or faulty software due to a failure or problem while
downloading. VM determined that software files were corrupt.

Tests to Run None

How to Clear Reload the software as allowed.

Click here for more

Code E150
info on E150 code

Code Title CAN Bus Communication Error

Operator Display E150

System Response No truck function active. Code may be displayed briefly then goes out.

Reason Grab rail (or load backrest) lift or lower switch active at power up. VM has not
detected any response from TA to CAN messages. Bad connection or terminal crimp
or a damaged wire between TA and VM. Check for low battery voltage. This can be
caused by accidental activation (operator pressing the switches) at or during
startup or pins 11 and 12 on the TA shorted to B+ (see codes C50, C51 and C52).
Examine VM, TA, and related wiring.

Tests to Run See “Troubleshooting the CAN Bus” on page 5-6.

How to Clear Repair/replace as needed.

Code E157

Code Title CAN Bus Off Error

Operator Display E157

System Response No truck function active

Reason TA did not reply to CAN messages.

Tests to Run See “Troubleshooting the CAN Bus” on page 5-6. Examine VM, TA, and related
wiring.

How to Clear Repair/replace as needed.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Error Codes

Code E159

Code Title CAN Bus Overrun Error

Operator Display E159

System Response No truck function active

Reason TA did not reply to CAN messages.

Tests to Run See “Troubleshooting the CAN Bus” on page 5-6. Examine VM, TA, and related
wiring.

How to Clear Repair/replace as needed.

Code E160

Code Title Belly Button/Hall Supply Error

Operator Display E160

System Response No truck function active

Reason Faulty hall effect sensor in handle (VM).

Tests to Run None

How to Clear The VM is the likely cause. Replace the VM.

Code E201

Code Title Overcurrent Fault

Operator Display E201

TA Flash Code “1,2”

System Response No truck function active

Reason TA faulty or motor short circuit. External short of U, V, or W traction motor

connections.

Tests to Run See Table 5-15, “No Travel, No Lift/Lower. TA Flash Code 1,2. Operator Display
Indicates Error Code E201,” on page 5-23. See “Service Input/Output Displays” on
page 3-17.

How to Clear Investigate cause of apparent short. Start with cables, then replace TA and/or
traction motor until problem is isolated.

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Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Error Codes

Code E202

Code Title TA Current Sensor Error

Operator Display E202

TA Flash Code “1,3”

System Response No truck function active

Reason Phase current sensor fault.

Tests to Run See Table 5-14, “No Travel, No Lift/Lower. TA Flash Code 1,3. Operator Display
Indicates Error Code E202,” on page 5-22. See “Service Input/Output Displays” on
page 3-17.

How to Clear Investigate cause of apparent short. Start with cables, then replace TA and/or
traction motor until problem is isolated.

Code E203

Code Title Motor Open

Operator Display E203

TA Flash Code “3,7”

System Response No truck function active

Reason Motor phase V or W detected open. Bad power amplifier.

NOTE: An open in the U phase causes a code E108.
Tests to Run Examine motor and related wiring for open circuit. See “Service Input/Output
Displays” on page 3-17.

How to Clear Repair cause of open circuit.

Code E220

Code Title Default Parameters DNL

Operator Display E220

TA Flash Code “4,6”

System Response No truck function active

Reason TA default parameters did not load.

Tests to Run None

How to Clear Reload software if allowed.

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Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Error Codes

Code E221

Code Title Severe Battery Undervoltage

Operator Display E221

TA Flash Code “1,7”, Battery icon blinking

System Response No truck function active

Reason Severe battery undervoltage, under 12V.

Tests to Run Measure battery voltage and specific gravity. See Table 5-21, “No Truck Functions
Active. TA Flash Code 1,7, (Low Battery Voltage). Operator Display May Indicate
E221,” on page 5-24. See “Service Input/Output Displays” on page 3-17.
NOTE: Check for other codes and, if others are present, troubleshoot following
those codes. (Failure of the M1 contactor circuit during operation causes
this code to be shown along with E106 and E107.)

How to Clear Replace battery with fully-charged batter. A bad TA or bad wiring could also be the
causey.

Code E222

Code Title Severe Battery Overvoltage

Operator Display E222

TA Flash Code “1,8”, Battery icon blinking

System Response No truck function active

Reason Severe battery overvoltage; over 42V during run time or above 32V at key ON.

Tests to Run Measure battery voltage. See Table 5-20, “No Truck Functions Active. TA Flash
Code 1,8, (Excessive Battery Voltage). Operator Display May Indicate E222,” on
page 5-24. See “Service Input/Output Displays” on page 3-17.

How to Clear Install battery of correct voltage. A bad TA or bad wiring could also be the cause.

Code E223

Code Title TA Severe Undertemperature Cutback

Operator Display E223

TA Flash Code “1,5”

System Response No truck function active

Reason TA heatsink temperature below minimum operating temperature (below

–40°C/–40°F).

Tests to Run Test the temperature sensor. See “Service Input/Output Displays” on page 3-17.

How to Clear Warm truck to normal operating temperature and cycle the truck OFF/ON.
Investigate to determine the cause of the undertemperature condition.

6-34 00700-CL398-13, Issued: 6 May 2013

Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Error Codes

Code E224

Code Title TA Severe Overtemperature Cutback

Operator Display E224

TA Flash Code “1,6”

System Response No truck function active

Reason TA heatsink temperature over maximum operating temperature (+95°C/203°F).

Tests to Run Test temp sensor. See “Service Input/Output Displays” on page 3-17.

How to Clear Allow truck to cool. Investigate to determine the cause of the overheating.

Code E225

Code Title Precharge Fault

Operator Display E225

TA Flash Code “1,4”

System Response No truck function active

Reason TA precharge circuit failed.

Tests to Run None

How to Clear Try cycling the truck OFF/ON. If that does not solve the problem, replace the TA.

Code E228

Code Title Parameter Change Fault

Operator Display E228

TA Flash Code “4,9”

System Response No truck function active

Reason TA parameters have changed. Critical TA parameter changed while operating.

Tests to Run None

How to Clear Cycle the truck OFF/ON.

00700-CL398-13, Issued: 6 May 2013 6-35

Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Error Codes

Code E230

Code Title External Supply Out-Of-Range

Operator Display E230

TA Flash Code “6,9”

System Response No truck function active

Reason External supply current out-of-range (+12V, +5V). Devices connected to these
outputs on the TA are drawing too much current (> 250 mA).

Tests to Run Check all wiring and components connected to the 12 volts from the TA for shorts.
If OK, check the wiring and encoder connected to JP1-26 for the traction motor for
shorts.

How to Clear Cycle the truck OFF/ON. If not cleared by cycling the truck OFF/ON, try to
determine what device caused the problem.

Code E232

Code Title VCL Runtime

Operator Display E232

TA Flash Code “6,8”

System Response No truck function active

Reason Internal TA software error.

Tests to Run None

How to Clear Cycle the truck OFF/ON. Reinstall software if allowed.

Code E233

Code Title +5V Supply Failure

Operator Display E233

TA Flash Code“2,5”

System Response No truck function active

Reason Controller +5V supply failed.

Tests to Run Check all wiring and components connected to the 12 volts from the TA for shorts.
If OK, check the wiring and encoder connected to JP1-26 for the traction motor for
shorts. See Code E230. See “Pinout Matrix” on page 8-13.

How to Clear Cycle the truck OFF/ON.

6-36 00700-CL398-13, Issued: 6 May 2013

Toyota Pallet Truck Service Manual Section 6. Messages and Codes

Error Codes
Click here for
Code E235 more info on
E235
Code Title NVM Reset Error

Operator Display E235

System Response No truck function active

Reason TA NVM (Non-Volatile Memory) error. TA Non-volatile memory corrupted, unable to

reset.

Tests to Run None

How to Clear Try cycling the truck OFF/ON. If that does not solve the problem, replace the TA.

Code E252

Code Title Not Speed Program

Operator Display E252

System Response No truck function active

Reason Detected Inputs/Outputs do not match the selected configuration.

Tests to Run None

How to Clear Truck may not be configured to match Sub Model type (Parameter 37). See
“Programming Service Parameters” on page 3-9.

Code E253

Code Title Invalid Sub Model

Operator Display E253

System Response No truck function active

Reason Detected Inputs/Outputs do not match the selected configuration.

Tests to Run None

How to Clear Truck may not be configured to match Sub Model type (Parameter 37). See
“Programming Service Parameters” on page 3-9.

00700-CL398-13, Issued: 6 May 2013 6-37

Section 6. Messages and Codes Toyota Pallet Truck Service Manual

Error Codes

This page intentionally left blank.

6-38 00700-CL398-13, Issued: 6 May 2013

 Control Circuit
CC13-001
January 15, 2013
ETAC Software Update Information
and Descriptions
8HBW30, 8HBC(E)30-40 and 8TB50
SERVICE INFORMATION BULLETIN

Subject: ETAC Software Update Information and Descriptions Page 1 of 2

MODEL APPLICATION:
8HBW30, 8HBE30-40, 8HBC30-40 and 8TB50

GENERAL INFORMATION:
Two new software versions are currently available and are downloadable from the TMHU
Portal via TIS (Toyota Information System).

REPAIR INFORMATION:
This bulletin explains the software version information including a description of changes and
additions to each software versions.

1. Error code C88 can be logged with older versions of PSU software. Loading a new version
of code with Flashware should correct this issue. If loading the new version does not correct
the C88 error code, the PSU must be replaced.
2. A Code C78 now causes the VM to command the truck to plug to a stop on tow
tractors with Electric Steer.
3. Previous versions of software would not record or display two error codes that are
detected by the power amp, E150 and E235. The traction system would shut
down in these cases, but no error would be reported. This version now records
and displays the errors.
4. Travel speed will now be consistent when in a slight turn with or without a load.
5. Auto steer center is now enacted any time the main contactor is disabled then
re-enabled on an electric steer truck. If the throttle is engaged while an auto steer
center is in progress, an HPd will be displayed. Traction is disabled until the
throttle is returned to neutral.
6. The maximum steering angle on an Electric Steer tow tractor can be adjusted
from 20 degrees through 80 degrees based on direction of travel (default is 80
degrees in both directions). Use parameter #22 for forks-first maximum steer
angle and parameter #23 for tractor-first maximum steer angle.
7. Instances of nuisance error codes C74, C86, and C88 have been reduced on trucks
equipped with a PSU.
Subject: ETAC Software Update Information and Descriptions Page 2 of 2

The following software is being used in current production effective serial numbers:
8HBW30-40402, 8HBE30-42456, 8HBE40-40109, 8HBC30-40089, 8HBC40-40014 and
8TB50-40629

1. Added a minimum delay of 400 milliseconds between back to back lifts to

prevent contactor chatter.
2. Added more options to Travel Alarm (Parameter 16) so that travel and battery cutout
alarm can occur at the same time on 8TB50 trucks. The battery cutout alarm sounds slightly
different and takes priority over the travel alarm.
0=No Alarm
1=Tractor-First Travel
2=Forks-First Travel,
3=All Travel
4=Low Battery
5=Low Battery and Tractor-First Travel,
6=Low Battery and Forks-First Travel
7=Low Battery and All Travel
3. Changed the following on electric steer trucks:
a. Reduced logging of C88 error codes by increasing the steering speed during auto steer
center.
b. Made steer centering more accurate. The time allowed for completion was also increased.
c. Re-Enabled backlash parameter setting for electric steer tow tractors sent to the PSU from
the VM when the key is turned ON to eliminate the clunking sound some tow tractors made
when steering.
4. Parameter 11 will now show up on all 8HBC30-40 and 8TB50 trucks. On trucks
without electric steer, the parameter must be set to 0 or the travel function will
be disabled.
5. Added a drop down for Toyota 8HBC3040/8TB50 Trucks in FlashWare.
Changed Truck code to automatically set/clear the Tow bit based on the
configured model. Setting the Truck as Model 8HBC30/40 will clear the Tow bit.
Setting the Truck as Model 8TB50 will set the Tow bit.
6. Added detection of LOS (Limited Operating Strategy) mode being reported by the
Power Amp. This does not change truck functionality because the Amp is already
limiting the truck speed, but now an error code will be displayed (Code 72) when
the Truck is in LOS mode.
 Control Circuit
CC13-005
May 31, 2013
8TB50 Power Steering Software
Update (v1.9)
8TB50 with Power Steering
SERVICE INFORMATION BULLETIN

Subject: 8TB50 Power Steering Software Update (v1.9) Page 1 of 1

MODEL APPLICATION:
8TB50 with Power Steering

GENERAL INFORMATION:
This bulletin is being distributed to notify dealers and field personnel of the following changes
included in the ETAC software version 1.9 for the 8TB50 with power steering.

The update includes:

• Addition of new Code C94.
• Changes to Code C81

SERVICE INFORMATION:
Flashware software file name is: 915A0019.s19.

Install software 915A0019.s19 and PSU (Power Steer Unit) software 915A9160.s19 for the
Code C94 to be enabled. If either of the new software versions are combined with an older
software version, the C94 code will not be displayed.

Code C94 information:

Code C94 has been added to identify lower steer unit sum of analog inputs out-of-range
conditions. See page 6-28 of the 8 series pallet truck service manual 00700-CL398-13 issued
May 6, 2013 for troubleshooting information.

C94 is similar to C81 except C94 attempts to detect the out-of-range condition sooner using a
smaller range and where C81 will disable steering and plug the truck to a stop; C94 leaves the
steering enabled and slows the truck to 1.7 mph.

System Response in the event of a C94:

- The horn will beep three times in rapid succession.
- Steering remains enabled but travel is de-rated to 1.7 mph.
- If the out-of-range condition returns to normal before the handle is lifted to the brake
position, the code is cleared when the handle is lifted and normal operation is resumed.

Change made to Code C81:

- If the out-of-range condition returns to normal while the truck is plugging to a stop,
steering will be re-enabled.
 Chassis Electrical
CE13-003
May 31, 2013
C81 Code – Steer Potentiometer
8TB50 with Power Steering
SERVICE INFORMATION BULLETIN

Subject: C81 Code – Steer Potentiometer Page 1 of 9

MODEL APPLICATION:
8TB50 with Power Steering

GENERAL INFORMATION:
Some customers have reported code C81 at low hour meter readings.

This code may be caused by the carbon steer potentiometer. A solid state potentiometer
(P/N 00590-51016-71) is now available as a replacement. Follow the instructions on the
following pages when replacing a carbon steer potentiometer with a solid state potentiometer.

Use FlashWare and install VM software version 1.9 or higher (915A0019.s19) and PSU
software version 160 or higher (915A9160.s19).

Note: Please be sure to re-learn the steering using Flashware after installation.

SERVICE INFORMATION:

Steering Potentiometer Replacement instructions for Solid State Potentiometer

1. Remove the Control Handle (P/N 00590-50709-71):

a. Remove the (4) screws around the bezel.
Subject: C81 Code – Steer Potentiometer Page 2 of 9

b. Lift the entire assembly out of the handle bracket.

c. The cable is retained in the bracket and can be removed by releasing the retainer at
bottom of bracket.

2. Remove the (2) screws in the face of the cover. Remove the (2) screws on the side of the
cover, then remove the cover.

Note: The screws in the plastic on the face are coarse thread, the screws in the side are fine
thread.

3. Remove the (2) screws in the cover.

Subject: C81 Code – Steer Potentiometer Page 3 of 9

4. Remove the cover over the cable, cut the wire tie, and remove.

5. Remove the (4) screws indicated to separate the control handle. Unplug the (2) connectors
on the harness, one from the side of the housing, one at the base of the handle. Cut the wire
ties at the holders. Note where the cables were tied and length of the service loop left
available. Remove the entire cable assembly and potentiometer. These will be replaced with
the new Solid State Steering potentiometer/cable.

6. Connect the new potentiometer and cable assembly (P/N 00590-51016-71) to the housing
and the proximity sensor cable. Use a wire tie to secure the cables to the yellow wire tie pad.
Subject: C81 Code – Steer Potentiometer Page 4 of 9

7. Rotate the wire tie so the end rests on either side of the cables but not on top for clearance
reasons.

8. Reassemble in the upper handle with (4) screws. It is important to torque these screws to 12
in. lbs. (1.35 Nm).

CAUTION: Over torqueing can cause throttle to bind. Test operation of the throttle to verify
return to center when activated.
Subject: C81 Code – Steer Potentiometer Page 5 of 9

9. Assemble the upper handle assembly back into the mounting bracket. Push the cable
retainer at the end of the new cable into the retainer hole in the bracket before lowering the
handle. Route the cable between the front edge of the bracket and post on the lower bearing.

10. Insert the potentiometer into the cavity at the base of the handle.

11. The shaft of the potentiometer must engage the “D” shaped opening in the bottom bearing.
Refer to the picture below to see the indexing feature on the lower bearing for the
potentiometer.
Subject: C81 Code – Steer Potentiometer Page 6 of 9

12. Replace the two screws that mount the potentiometer with M3 x 16 mm screws (P/N
00590-51061-71). Apply thread-locking compound (P/N 00590-04864-71) to the screws. Install
the cover over the loomed cable with the larger loom opening oriented out away from the
handle and the smaller towards the handle. Make sure no wires are caught under the flanges
of the cover when assembled.

13. Wire tie cables together as shown. Make sure to maintain a service loop for the handle to
rotate up and down.
Subject: C81 Code – Steer Potentiometer Page 7 of 9

14. Replace the two lower covers.

15. Install the (4) screws around the perimeter of the top bezel.

NOTE: Do Not use thread-locking compound on the bezel screws or near the plastic.

16. Replace the Resistor Module shown below with a jumper (P/N 00590-52188-71).
Subject: C81 Code – Steer Potentiometer Page 8 of 9

17. Inspect splices SPL11, SPL12, and SPL13 to verify complete crimps were performed.

Note: SPL11 can sometimes be buried in the center of the harness.

Make sure there is a crimp on both the wire area and the insulation area of the splice.

If a crimp is weak or missing, manually crimp and document what needed to be done.
Subject: C81 Code – Steer Potentiometer Page 9 of 9

Replace any removed cable ties.

18. Install new Vehicle Manager software (version 1.9 or higher) into the truck using Flashware
5.5 or above.

19. Install new Power Steer Unit software (version 160 or higher) into the truck using
Flashware 5.5 or above.

20. Relearn steering using Flashware 5.5 or above and test the function of the truck before
returning the truck to service.
 Control Circuit
CC13-007
October 15, 2013
Vehicle Manager and Traction Amp
Software Updates
8HBW30, 8HBE30-40, 8HBC30-40,
SERVICE INFORMATION BULLETIN 8TB50 and 8TB50 with Power Steering

Subject: Vehicle Manager and Traction Amp Software Updates Page 1 of 2

MODEL APPLICATION:
8HBW30, 8HBE30-40, 8HBC30-40, 8TB50 and 8TB50 with Power Steering

GENERAL INFORMATION:
This bulletin is being distributed to notify dealers and field personnel of a new software release
for the Vehicle Manager (VM) and Traction Power Amplifier (TPA) on the above models.

IMPORTANT:
• To install these software updates you must use Flashware 5.7 or later.
• On the 8HBC30-40 and 8TB50 with Power Steering if the PSU (Power Steer Unit)
software is older than 915A9160.s19, please update accordingly as these software
updates are designed to work together.
(example of old PSU software: 915A9140 or 9150)

Flashware 5.7 and the s19 software files are available for download on TIS. Please remember
to uninstall the current version of Flashware on your computer before installing the new
version.

SERVICE INFORMATION:
Subject: Vehicle Manager and Traction Amp Software Updates Page 2 of 2

Summary of Changes included in these software updates:

1) Reduced the occurrence of C81 error codes by increasing some timeouts for the solid state
steer potentiometers by a factor of 10 (Changed from 2 ms to 20 ms).

2) Reduced the occurrence of C83 and C84 error codes on trucks with the solid state steer
potentiometers when the truck is powered on and the handle is not centered.

3) Reduced the occurrence of C74 error codes when the truck is powered on.

4) Disabled the Lift contactor driver check on Model 8TB50 trucks.

5) Changes were made to improve the reliability of the lift contactor which include a new
Traction Amplifier Flash Code, 5,3. It will be shown on the operator display as a Code C60 -
Lift Contactor Coil (M2) Driver Shorted or Open. Troubleshooting in the repair manual for
the Code C60 remains the same (See page 6-18 of manual 00700-CL398-13).

This change requires:

a) Flashware 5.7 or higher to update the TPA.
b) The new VM sofware for the truck being updated (as shown in the table on page 1), and
c) the updated Traction Amp sofware version 12.82.

6) Added error code E109 to indicate the failure of a device on the truck to respond to a CAN
message sent by the VM. The original code for this was C86. Use the C86 – Steer Unit
Communication Failure information in the repair manual to troubleshoot a code E109. (See
page 6-26 of manual 00700-CL398-13)

NOTE:

Trucks produced after the following model-serial numbers will have these software updates.

• 8HBW30-40480
• 8HBE30-43112
• 8HBE40-40126
• 8HBC30-40108
• 8HBC40-40014
• 8TB50-40949
 Control Circuit
CC14-006
August 15, 2014
Power Steer Unit Controller Repair
Instructions
SERVICE INFORMATION BULLETIN 8HBE30-40, 8HBC30-40, 8TB50

Subject: Power Steer Unit Controller Repair Instructions Page 1 of 2

MODEL APPLICATION:
Power Steer Models: 8HBE30, 8HBE40, 8HBC30, 8HBC40 and 8TB50

GENERAL INFORMATION:
This bulletin is being released to announce that the power steer unit (PSU) controller is now
available separately from the motor, gearbox and pinion gear and to provide instructions for
how to replace the controller section of the power steer unit assembly.
 Power Steer Unit Controller individual part (P/N 00590-50525-71)
 Motor, gearbox, and pinion gear without Controller (P/N 00590-50526-71)

SERVICE INFORMATION:
In the Service Manual (00700-CL398-13) the following changes have been made:

 Change the wording in Codes C74, C75, C76, C86, C88, C89, and C90 in the How to
Clear section from “Replace the PSU” to “Replace the PSU Controller.”

 Change the wording in Codes C77, C81, C82, C83, C84, C85, and C94 in the How to
Clear section from “Replace the PSU” to “Run Learn Steer. If the code does not clear,
then replace the PSU Controller.”

 Added instructions for replacing the power steer unit controller on page 7-13

Please use the following procedures when removing and installing the controller.

Removing and Installing the PSU Controller

1. Remove the PSU from the truck.

2. Place the PSU on a Static Mat. Put on the wrist strap and connect the ground cord to the
mat.

3. Remove the two screws connecting the controller to the motor.

4. Grab the casing with the bare hand to avoid potential electrical differences between your
body and the unit. NOTE: Do not wear gloves.
Subject: Power Steer Unit Controller Repair Instructions Page 2 of 2

5. Carefully lift the controller slightly and turn it 90 degrees. See figure 1. Connect the ground
cord to the housing of the controller before performing the next step.

Figure 1

6. Remove the connector by pressing the locking device to the left. See figure 2. Remove the
three flat pin connectors (to the left in the picture). Do NOT pull on the motor cables/wires
directly. Grip the connector itself and pull.

Figure 2
7. Remove the new controller from its packaging. Connect the ground cord to the housing of
the controller.

8. Reconnect the wires as shown in figure 2. From left to right, the three wire colors are Red,
Black, and Yellow. Connect the small wires. Make sure the locking tab engages.

9. Place the controller onto the motor. Make sure no cables are pinched between the housing
and motor. Apply a drop of thread-locking compound (P/N 00590-01931-71) on the screws.
Torque the screws to 7 in. lb. (80 Nm).

10. Install the PSU assembly in the truck. Run “Learn” and test for correct operation. Steering
can be learned using FlashWare or the Service Key. See pages 7-13 and 7-14 of the repair
manual for instructions.