CONTROLLER

Outline of Controller
The controller is the heart of the lift truck operation system.
The logic card contains judgement-making functions, and is equipped with a battery discharge indicator and a
malfunction diagnostic function.
The controller is used to operate the drive motor, pump motor and proportioning solenoids for finger-tip control
system.

3 4 5 6
209537

1 Logic card 5 Current sensor (PUMP U phase)

2 MOS-FET module 6 Current sensor (PUMP V phase)
3 Current sensor (DRIVE U phase) 7 DRS switch
4 Current sensor (DRIVE V phase)

Outline of Contactor Module

The contactor module has function of main-switch and

circuit-protector. 3

Two contactors are operated by the controller.

2

1 Line contactor
2 Line fuse (500 A)
3 Steering contactor 1

209538
3-1
CONTROLLER

Logic Card
1 3 2

209539A

1 Traction control CPU

2 Hydraulic control CPU
3 GSE connector

There are two CPUs on the logic card: the traction control
CPU and hydraulic control CPU.
The traction control CPU controls the drive motor,
monitors the traction system for malfunctions (malfunction
diagnostic function), and checks the state of the battery.
The hydraulic control CPU controls the pump motor and
the proportioning solenoid valve in the finger-tip control
(FC) system, and monitors the hydraulic system for
malfunctions.

3-2
 CONTROLLER

Logic Card and Connectors

209539

25 23 21 19 17 15 13 11 9 7 5 3 1 47 45 43 41 39 37 35 33 31 29 27
26 24 22 20 18 16 14 12 10 8 6 4 2 48 46 44 42 40 38 36 34 32 30 28
Harness side CN14 Harness side CN15

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48
Logic card side CN2

25 23 21 19 17 15 13 11 9 7 5 3 1 41 39 37 35 33 31 29 27
26 24 22 20 18 16 14 12 10 8 6 4 2 42 40 38 36 34 32 30 28
Harness side CN1 Harness side CN2

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54
Logic card side CN1

19 17 15 13 11 9 7 5 3 1 5 3 1
20 18 16 14 12 10 8 6 4 2 6 4 2
Harness side J3 MOS-FET module side CN1

1 3 5 7 9 11 13 15 17 19 1 3 5
2 4 6 8 10 12 14 16 18 20 2 4 6
Logic card side CN3 Logic card side CN5, 6, 7, 8, 9, 10

3-3
CONTROLLER

MOS-FET Modules

5 3 1
6 4 2
CN1

209540

MOS-FET
module

U V W U V W

For drive motor For pump motor

209541

There are six MOS-FET modules located behind the logic card.

The MOS-FET modules convert the battery DC current into

AC current for supplying to the drive and pump motors.
The MOS-FET modules create single-phase alternating
current. Since the controller controls the two three-phase
induction motors (drive motor and pump motor), it requires
six MOS-FET modules. See also the “AC motor system
basics” section on page 3-37.

3-4
 CONTROLLER

Operation Outline
(1) Power ON (2) Normal mode (RUN mode)
Turning on the key switch supplies power to the When the F-N-R lever is operated and the
logic card and display unit. The display unit shows accelerator pedal is pressed, the vehicle moves
3 kinds of hourmeters (i.e., drive motor, pump forward/backward. During deceleration, the drive
motor and vehicle hourmeters) in sequence, and motor conducts regenerative operation. Operating
then resumes the normal display mode (i.e., clock). a hydraulic lever activates the pump motor and
About 1 second (period for routine self-diagnostics) provides hydralic power.
after power is supplied to the logic card, the The controller monitors operating conditions.
controller turns the line contactor ON and the When an abnormality occurs, the display unit
steering contactor ON to provide power to the main indicates an error code and activates an appropriate
circuit. When the steering contactor turns ON, the fail-safe function. The error code is stored in the
steering motor starts rotation. logic card memory.
By turning on power with the DRS switch set to D,
it is possible to activate the self-diagnostic
function. Before that, remove all fuses.
By turning on power with the DRS switch set to S,
it is possible to set vehicle characteristic parameters
with setup options (See NOTE) and performance
data.
For details of the self-diagnostics and setup
options, refer to pages 3-15 and 3-12, respectively.

NOTE
The maximum vehicle speed, acceleration rate, lift
and tilt speeds, and other operational characteristics
of the truck depends on the setting of the truck
operation mode and setup option values stored in
the controller. The operation mode and setup
option values have been set to the default mode and
values before shipment from the factory but their
setting can be changed to make the truck operation
characteristics most suited to the working
conditions. The available truck operation modes,
the characteristic items that constitute each mode
and the default setup values for the items are shown
in the table on next page.

3-5
CONTROLLER

SUO#
Mode A b C d E 1
Feature/ Standard High Economy Long Short
Application Power Distance Shuttle
Vehicle speed Medium Fast Slow Fast Slow
Acceleration Medium Fast Slow Medium Fast
Power Medium High Low High Medium
Characteristic
Lift Medium Medium Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Regeneration Medium Medium Medium Medium Medium
Max vehicle speed 18 20 (18) *)
16 20 (18) *)
16 7
Acceleration rate 3 4 2 3 4 8
Traveling power 2 3 1 3 2 9
Default value Start lift speed 1 1 1 1 1 2
Top lift speed 9 9 8 9 9 3
Tilt speed 3 3 3 3 3 4
Automatic regeneration 7 7 7 7 7 23
*)
Max vehicle speed of 3.5 ton truck is 18 km/h.

When the truck operation mode (SUO #1) is set, the values above are entered in the applicable set option items.
When default settings are changed, the indication (A to E) flickered to indicate that the settings are modified.

3-6
 CONTROLLER

Drive System 3. Regeneration

(1) Lever regeneration
1. Neutral position
When the F-N-R lever is shifted into the position
In case the F-N-R lever is in the neutral position and all opposite to the vehicle’s traveling direction, the
of hydraulic levers are neutral for a preset period (chat regeneration function is activated. The amount of
timer SUO #24), the controller turns the line contactor regeneration is determined by lever regeneration
OFF and cuts off the current to the motors. characteristic, as shown in a diagram.
2. Powering
(1) Outline 100 10
Powering is a condition in which the motors are 9
...
powered by the battery and the controller supplies a
current determined by the powering characteristic. Amount of 5
...
The powering characteristic is a torque curve lever
2
regeneration
relative to vehicle speed based on the acceleration [%] 1
parameter, as shown in the diagram. The torque
demand value is obtained from the acceleration and
vehicle speed.
0
5 10 15
The power characteristic can be selected from three
types by SUO #9: ECONONY, STANDARD and The degree of acceleration pedal
HIGH POWER. 209548
The rate of output torque rise is selectable
(acceleration rate: SUO #8). Lever regeneration characteristic curve is selected
Torque
by SUO #22. The degree of acceleration serves as
[%] Thermal or BDI [0]*2 the parameter. The deeper the accelerator pedal is
100 HIGH POWER pressed, the higher the amount of regeneration
STANDARD becomes.
ECONOMY
The lever regeneration function is always operative
Brake limit*1 regardless of the regeneration mode.
(2) Auto regeneration

Speed When the accelerator pedal is not pressed or the

0 5 16 18 20 (km/h) brake pedal is pressed, the regeneration function is
Powering characteristic 209547 activated. The amount of regeneration is
*1
determined by the auto regeneration characteristic,
Brake limit: Torque value resulting from reduction in
as shown in a diagram. The auto regeneration
current when the service brakes or
characteristic curve is selected by SUO #23.
parking brake are applied.
*2
Thermal or BDI [0]: Curve of limited torque under a SUO #23
condition of overheating or 10
battery voltage low.
9
8
Regeneration
Torque ...
...
2
1

Truck Speed
209549

3-7
CONTROLLER

Hydraulic System Current to

solenoid [%]
There are two types of control systems for controlling the
hydraulic control valve: finger-tip control (FC) type and
100
mechanical control (MC) type. They are different in the
way of controlling the hydraulic cylinders.

1. FC type Current increases

drastically as lever
The speed of operation of the hydraulic cylinders depends movement angle
on the valve-opening amount and pump motor output. The increases.
valve-opening amount and pump motor output are
controlled electrically in proportion to the amount of 0
100 Lever angle [%]
movement of the FC lever.
209550
(1) Valve opening control
Current characteristics of proportioning
The amount of current to the proportioning solenoid solenoid valve
valve varies with the amount of movement of the FC
lever. A specific amount of current for each lever angle Pump motor
is preset appropriately for each hydraulic cylinder. (See output [%] SUO #3
the graph on the right.) (top lift speed)

(2) Pump motor output control 100 HIGH POWER 10

STANDARD 9
The output of the pump motor varies with the amount
ECONOMY 8
of the FC lever movement. The amount of change in
SUO #2
motor output for a unit amount of lever movement can (start lift speed)
be adjusted by changing the relevant setup option
value. The second graph on the right shows the pump 1
output characteristic curves in relation with the lift
lever angle. These curves are for the high-power, 0
100 Lever angle [%]
standard and economy settings selected using SUO #3.
At the start of pump motor rotation, the output levels 209551
for the three settings are the same. As the lever angle Pump motor output characteristics
increases, the pump motor outputs for the settings (FC type, lift-up operation)
become different, with that of the high-power setting
being the highest. During a lift-down movement, SUO #4 (Tilt),
Pump motor
#5 (Att 1), #6 (Att 2),
however, the pump motor output remains constant. output [%]
#33 (Att 3)
The third graph on the right shows the pump motor output
characteristic curves in relation with tilt/attachment lever 100 10
angles. The pump motor output is high from very start of
the motor when the relevant SUO # value has been set high.

2
1

0
100 Lever angle [%]
209552

Pump motor output characteristics

(FC type, tilt and attachment 1, 2 and 3
operations)
3-8
 CONTROLLER

2. MC type Pump motor

(1) Valve opening control output [%]

The opening of the hydraulic control valve is HIGH POWER SUO #3

controlled mechanically by moving the MC lever. 100 STANDARD
ECONOMY 10
(2) Pump motor output control 9
During lift-up operation, the pump motor output is 8
SUO #2
controlled in two stages according to the amount of
movement of the MC lever. (See the first graph on the
right.)
During tilt operation or attachment operation, the pump 0
motor output is constant. (See the second graph on the 100 Lever angle [%]
right.) 209553
The output of the pump motor can be adjusted by Pump motor output characteristics
changing the setup option value. (MC type, lift-up operation)
NOTICE: The pump does not operate during
down operation of the mast.

Pump motor
output [%]

SUO #4, #5, #6, #33

100 10
9

0
100 Lever angle [%]

209554

Pump motor output characteristics

(MC type, tilt and attachment 1, 2 and
3 operations)

3-9
CONTROLLER

Fail-safe System (3) Traction module overheat (Error codes: E3)

The output power of the drive motor is controlled
1. Output power control at low battery voltage according to the output power control described in
the previous section.
(1) Battery discharge characteristic
(4) Hydraulic module overheat (Error codes: E7)
The BDI table shows the BDI indicator patterns on
the display and the corresponding voltage ranges. The output power of the pump motor is controlled
according to the output power control descried in
BDI TABLE the previous section.
(Normal) (Tubular) 3. Maximum vehicle speed control (SUO #7)
BDI# 80 V BDI# 80 V
The setup option setting limits the maximum vehicle
0 - 76.4 0 - 78.2
speed.
1 76.5 - 77.2 1 78.3 - 78.8
2 77.3 - 78.0 2 78.9 - 79.4 4. Output power control during braking
3 78.1 - 78.7 3 79.5 - 80.0 The maximum current is controlled 40 % of command
4 78.8 - 79.5 4 80.1 - 80.6 during the use of the service brake and parking brake.
5 79.6 - 80.3 5 80.7 - 81.1 See the speed-torque graph of powering characteristic
6 80.4 - 81.1 6 81.2 - 81.7 on page 3-5.
7 81.2 - 81.8 7 81.8 - 82.3
8 81.9 - 82.6 8 82.4 - 82.9 5. Chat timer (SUO #24)
9 82.7 - 83.4 9 83.0 - 83.5 When the following conditions remain for the time
10 83.5 - 10 83.6 - duration set by SUO #24, the line contactor turns OFF.
Accelerator: 0
(2) Output power control F-N-R lever: Neutral
When the BDI indicator shows 0, the following Lift, tilt and attach levers: OFF
output power control is activated. When any of the above are operated the line contactor
[Output power control] is closed.
Drive system – Power is controlled according to the 6. Seat switch timer (SUO #25)
powering characteristic. (See the speed-torque
When the operator leaves the seat for the time duration
graph of powering characteristic on page 3-5.)
set by SUO #25, the line contactor and steering
Hydraulic system – The output is reduced for lift contactor turns OFF. When the power switch is turned
and attach operations, and the output remains the ON without the operator sitting on the seat, the line
same for tilt operations and lift down operations. contactor keeps OFF and the “E” indication flickers on
Simultaneous operations – The drive system and the display unit.
hydraulic system cannot be operated With accelerator at 0, F-N-R lever in neutral and
simultaneously. hydraulic levers OFF, turning OFF the seat switch
2. Overheat resets the line contactor.

(1) Drive motor overheat (Error codes: E0)

The output power of the drive motor is controlled
according to the output power control described in
the previous section.
(2) Pump motor overheat (Error codes: E2)
The output power of the pump motor is controlled
according to the output power control descried in
the previous section.
3-10
 CONTROLLER

Malfunction Detection (Run Time

Diagnostics)

If a malfunction is detected, the LED flickers and an error

code is indicated on the display unit. The corresponding
fail-safe function is also activated at the same time. For
details, refer to the “Run Time Diagnostics” on page 3-22
and troubleshooting for control circuit.

Run position
Fault Data Record (History Folder)
Setup
R
position Diagnosis position
S D
1. Storage of fault data Pull up the
Stamped mark stopper, then
When any of the faults listed in the Run Time Diagnostics tilt the switch
table on page 3-22 occurs, the three items of data indicated to the desired
below will be stored in the memory of the logics card. The D R S position.

maximum number of faults that can be stored in the

memory is 32. When faults exceeding 32 occurs, overflow
data will be erased on the “first-in, first-out” basis. The
209436B
fault data items are as follows:
• Error code Operating DRS switch
Starting fault data review: Set the switch to D.
• Battery discharge indicator at the time of fault Reviewing the next older fault data:
• Vehicle hourmeter reading at the time of fault Cycle the switch D→R→D. Repeat this cycle for
further older fault's data.

2. Reviewing stored fault data

Battery discharge indicator
Error code
Follow the steps below to review the stored fault data. at the time of fault

(1) Set the DRS switch in the D (diagnosis) position.

(2) Turn OFF the seat switch.
(3) With the lift and tilt levers pulled back, turn the key
switch to the ON position.
(4) The data on the latest fault will appear on the display
unit. The data will contain the three items of
information listed in paragraph 1 above. (See the
illustration on the right.) If there are no data items
stored for the fault, “donE” will appear in the Vehicle hour-meter reading at the time of fault
hourmeter display area. After reaching the oldest fault data stored,
(5) To review the data of the next older fault, move the “donE” will appear in this area. 209556
DRS switch from the D position to the R position and
then back to the D position. Every time this cycle of NOTE
switch operation is performed, the display will go to
Fault data review is a one-way operation. You
the next older fault. When the cycle is performed after
can only proceed to the next older fault but
the oldest fault has been reached, “donE” will appear in
cannot go back to the newer fault. When
the hourmeter display area.
reviewing the data of a newer fault again, first
(6) To exit from the fault data review mode, turn OFF the terminate the review operation and then start
key switch and then set the DRS switch to R. another review operation.
3-11
CONTROLLER

3. Deleting stored fault data Step 1 (after review of all stored fault data)
Stored fault data can be deleted as follows after all of them R
S
have been reviewed through:
Wait
(1) With “donE” displayed in the hourmeter area in the more than
display unit, set the DRS switch in the S (set) position 1 second

and wait for more than one second.

Step 2 Step 3 (exit from review mode)
(2) Place the DRS switch in the R (run) position.
R
(3) The hourmeter area displays flickering “donE”, S
showing that all the stored data have been deleted.
NOTICE: It is generally not recommended to erase fault
data. Fault data are useful as aids for proper
Flickers
management of the truck. 209557

Stored data erasing steps

Setup Option Setting

The tables on pages 3-17 to 3-19 show the setup options

classified in three groups. They include the number
assigned to each setup option (SUO #), its value set before
shipment from the factory (default value), and points to be
noted when changing the default value.
First SUO # of each group
To change a default value, use the following procedure: “01” for group 1
“11” for group 2
1. Entering and exiting from setup option mode “40” for group 3
To enter the mode:
The method to enter the mode (to cause the initial display
to appear) differs from group to group. Perform any of the
following operations as appropriate.
Group 1: Set the DRS switch to S, and turn on the key
switch. The display shows “(option #) 1”.
Group 2: Set the DRS switch to S, and turn on the key
switch while keeping the lift and tilt levers pulled
back in seat switch OFF. The display shows
“(option #) 11”. Current set value for SUO #11*
209558
Group 3: Set the DRS switch to S, and turn on the key
switch while keeping the attach 1 lever pulled First SUO # of Group 2 setup options
back in seat switch OFF. The display shows (example)
“(option #) 40”. *The current value is displayed. For the meaning
To exit from the mode: of each number or symbol displayed, refer to the
For the groups 1 and 2, turn the key switch OFF. For the “Range” column of the relevant Setup Options
group 3, advance the SUO # until “donE” appears. table and Notes below the table.
The steps described above are collectively shown in the
following table:

DRS switch
Mode Seat switch Other condition
position
Setup option group 1 (1 to 10) S – –
Setup option group 2 (11 to 33) S OFF Pull back lift lever and tilt lever
Setup option group 3 (40 to 47) S OFF Pull back attach 1 lever

3-12
 CONTROLLER

2. Selecting SUO # and changing set value

How to change set value
The set value changing procedure consists of selecting the When changing setting of SUO #20 (stall timer) from
desired SUO # using the DRS switch, changing the set default 5 seconds to 3 seconds:
value by moving the F-N-R lever, and registering the new
value. Step 1. Since the SUO #20 belongs to Group 2 setup
options, cause the first SUO # “11” of the group
to appear on the screen using the procedure 1 on
• Cycle the DRS switch S → R → S. The set value page 3-12.
displayed on the screen is registered. The SUO # on the
screen then advances to the next SUO #. Changing the
set value is now possible for the SUO #.
The earlier half of the DRS switch operation (S→R) is Step 2. Move the DRS switch as follows to cause the
for overwriting the previous value with the value on the current setting for the SUO #20.
screen (registering). When the value is registered, a set
R (1) Move the DRS switch S →R.
of three dotted lines appears on the screen as shown in S
The display changes as shown
the illustration on the right. The latter half operation below. The set value (0) for
(R→S) is for advancing the SUO #. the SUO #11 is overwritten
simultaneously.
• Every time the DRS switch is cycled S → R → S, the
SUO # increment. When advancing the SUO # without
changing the set value, simply repeat cycling of the
switch as many times as necessary. When the last SUO
# is reached, “donE” appears in the set value display
area. R (2) Move the DRS switch R →S.
S
The display shows the current
• Use the F-N-R lever to change the set value. The value
setting for the next SUO #14.
increases when the lever is cycled N → F → N; it
decreases when the lever is cycled N→R→N. In either
increasing or decreasing direction, the value returns to
the first or last value in the available value range.

(3) Cycle the DRS switch S→R→S twice to cause the

SUO #20 to appear on the screen.

Default value 5 for SUO #20

Step 3. Change the set value from 5 to 3 by moving the
F-N-R lever N→R twice.

Value increases.
F-N-R
lever F

N
R
Value decreases.
Step 4. Register the new value by cycling the DRS
switch S → R → S. The current value is
overwritten with the new value. The screen
shows the next SUO #21. 209559
3-13
CONTROLLER

3. Returning setting from option value to default

value
Use the following procedure to return an optionally set
value to the default value (factory set value) due to
occurrence of error code 61 or 65, or some other reasons.
(1) Turn OFF the seat switch.
(2) Set the DRS switch in the S position.
(3) Place the F-N-R lever in the R position, keep the
accelerator pedal depressed, and turn ON the key
switch.
(4) The set value area in the display shows “donE”.
(5) Set the DRS switch in the R position.
The default value is now set again.

3-14
 CONTROLLER

Self-diagnosis (3) When all the step items have been checked through,
turn OFF the key switch and place the DRS switch
By monitoring input and output signals of the in the R position. Do not fail to reinstall the 500 A
controller, the CPU of the controller checks operation line fuse.
of various switches, contactors and other components
on the truck under the control of the stored diagnosis
• Turn OFF the key switch to exit from the
program. The check items are shown in detail in the
diagnosis mode.
Self-Diagnostics table on page 3-20. It is
recommended to check the conditions of the truck’s • Repair all fault found immediately after
components using the diagnosis function of the diagnosis.
controller at the time of planned maintenance.
Perform diagnosis using the following procedure.
R
1. Preparatory operations S D

(1) Place the parking brake lever in the lock position.

(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Place the F-N-R lever in the N position.
209436C
(5) Set the DRS switch to the D (diagnosis) position.
(6) Remove the line fuse (500 A).
(7) Connect the battery plug. Diagnosis procedure requires moving the DRS switch
to the D or R position. Follow the instructions in the
2. Diagnosis procedure diagnosis procedure guide above as well as those in the
Perform the procedure using the Self-Diagnostics table applicable boxes in the “Do this” column.
in accordance with the following guide.
(1) Start diagnosis with the Step 0 item in the table. Diagnosis result indication
Turn ON the key switch according to the
instruction in the “Do this” box on the Step 0 line.
If the item passes the check without any problem,
the next step number “01” appears on the display.
If the item involves any problem and fails in the
check,“dd” is shown on the display. The display
also shows “dd” when diagnosis is started without
209561
removing the fuse. In this case, diagnosis is
prohibited from going even to the first step.
(2) When the Step 0 item has passed the check,
diagnosis may advance to the next Step 1 item (seat
switch). Cycle the seat switch OFF→ON→OFF
according to the instruction in the “Do this” box on
the Step 1 line. If the item passes the check, the
next step number “02” appears on the display. Do
likewise for the succeeding items, following the
instructions in the “Do this” column boxes. If the
item of a step fails in the check, diagnosis does not
advance automatically. In this case, diagnosis can
be forcibly advanced to the next step by cycling the
DRS switch D→R→D.
3-15
CONTROLLER

Other Functions

1. Service indicator (SUO #10)

When the vehicle hourmeter indication reches the set value,
the service indicator turns ON to notify the need for
maintenance. Output power control can be also activated at
the same time. The setting can be made in a range of 100
to 500 at 50 increments. The service indicator turns ON
when the hourmeter indication exceeds the value of the
current hourmeter reading plus the set value.
The indicator starts flickering 20 hours before the set time,
and remains lit when the hourmeter indication reaches the
set time. Setting “0.1” activates the demo mode. In this
mode, the output power control is conducted 6 minutes
after the setting is made.

2. Auxiliary input for function control (SUO #11, #14,

#17)
Auxiliary inputs to the logic card can be used to prohibit
lift.

3. Stall timer (SUO #20)

This option adjusts the time to shut down truck when the
drive motor current is too high.

4. Tire size adjustment (SUO #27)

This function provides a correction value to compensate for
a diameter change resulting from tire wear. It is used to
adjust the vehicle speed data.

5. Auxiliary input for travel speed (SUO #30)

Auxiliary input to limit the maximum vehicle speed or
reduce output power.

6. Auxiliary maximum travel speed setting (SUO #31)

This option determines the maximum travel speed limit of
#30.

7. Auxiliary output power limit (SUO #32)

This option determines the output power limit in % of #30.

3-16
 CONTROLLER

Setup Options (Group 1)

SUO Default
Title of Option Description Range
# value
#1 Application pre-sets There are 5 truck modes and each has 7 A, b, C, d, E A
(truck operation option values: If any of these 7 option values are
mode) Top travel speed, Acceleration rate, changed, A to E will flicker.
Traveling power, Regen adjustment,
Start lift speed, Top lift speed,
Tilt speed.
#2 Start lift speed Lift speed when first lift switch closes. 1 to 10 1
Start lift speed cannot exceed top lift
speed.
(1: SLOW → 10: FAST)
#3 Top lift speed Lift speed when second lift switch 1 to 10 9
closes.
#4 Tilt speed Tilt speed is prior to lift speed in case 1 to 10 3
that the two levers are simultaneously
operated.
#5 Auxiliary 1 speed Speed setting for attachment 1. 1 to 10 3
#6 Auxiliary 2 speed Speed setting for attachment 2. 1 to 10 1
#7 Top travel speed Maximum travel speed 5 to 20 km/h 18
limit
#8 Acceleration rate Choice of acceleration rate. 1 to 5 3
(1: SLOW → 5: FAST)
#9 Traveling power Choice of powering characteristic 1, 2, 3 2
(1: ECONOMY, 2: STANDARD,
3: HIGH POWER)
#10 Service indicator This option sets the time which reminds 100 to 500 hours in 50-hr. increment. 0
the maintenance time. The time set Selecting “=” attached number makes
here is added to the truck’s hourmeter the power reduction function effective.
at that time and that value is stored in Selecting 0.1 makes the truck
memory as the “maintenance time”. demo-mode.
When the truck’s hourmeter reaches 0: Disable
the maintenance time, service reminder
LED turns on. It will flicker 20 hours
before the time. You can reduce the
truck power when the LED flickers
by setting selection. You can also set
the demo-mode, which shows the
Service Indicator function in a short
period of time.
Note:
(1) The service indicator shows the set value, not the current value. If the power switch is turned off without
entering data (without setting the switch to R), the current value is maintained.
(2) The output power control function of the service indicator is the same as the output power control that is
activated when the battery voltage level drops.
(3) When the truck mode is selected, all data is replaced by the set values of the selected mode. When the set values
are changed, the truck mode indicator (A to E) flickers to notify that the settings are modified.

3-17
CONTROLLER

Setup Options (Group 2)

SUO Default
Title of Option Description Range
# value
#11 Auxiliary input 1 When the auxiliary input signal is on, 0: Disabled 0
for lift the controller will inhibit lifting 1: Inhibit lifting (when close SW.)
according to the selection. 2: Inhibit lifting (when open SW.)
#14 Auxiliary input 2 Same as #11 Same as #11 0
for lift
#17 Auxiliary input 3 Same as #11 Same as #11 0
for lift
#20 Stall timer This option adjusts the time to shut 2 to 10 sec 5
down truck when the drive motor
current is too high.
#21 Regen function This option enables one of two Regen 1: Brake regen (accel must be off) 2
Modes. 2: Accelerator regen (also called “auto
regen”)
#22 Regen adjustment 10 steps for regen power on lever regen 1 to 10 7
for lever regen
#23 Regen adjustment 10 steps for regen power on brake/auto 1 to 10 7
for auto regen regen
#24 Chat timer The amount time required entering 0 to 40 sec 20
chat mode. 0: Disable
#25 Seat switch timer The amount of time required turning off 3 to 15 sec 5
line contactor, when the operator leaves
the seat.
#27 Tire size adjustment Adjusts the amount of tire wear. 0 to 40 20
It changes truck’s speed recognition.
#30 Auxiliary input for This input is used in conjunction with 0: Disabled 0
travel speed option #31, #32 to limit travel speed 1: Travel speed limit set by #31 on
and/or output power. close SW.
2: Power reduction set by #32 on
close SW.
3: Travel speed limit set by #31 on
open SW.
4: Power reduction set by #32 on
open SW.
#31 Auxiliary maximum This option determines the maximum 5 to 20 km/h 12
travel speed setting travel speed limit of #31.
#32 Auxiliary output This option determines the output 0 to 100 % 70
power limit power limit in % of #31.
#33 Auxiliary 3 speed Speed setting for attachment 3. 1 to 10 3

3-18
 CONTROLLER

Setup Options (Group 3)

SUO Default
Title of Option Description Range
# value
#40 Truck type This option is used to set the size and III: No setting –
type of the truck. P20: EP20
P25: EP25
P30: EP30
P35: EP35
#41 Battery voltage This option is used to set the voltage of 80: 80 V –
the battery.
#42 Battery type This option is used to set the type of the 0: Normal BDI –
battery. 1: Tubular BDI
Tubular BDI: For battery with different
discharge characteristic.
#43 Hydraulic control This option is used to set the type of the 0: FC –
selection hydraulic control. 1: MC
#44 Mast type This option is used to set the type of the 2FF: 2-stage full-free –
mast. 3FF: 3-stage full-free
2SP: 2-stage panorama
#45 Valve section This option is used to set the number of 1: 3 ways (lift, tilt, attach 1) –
valve section. 2: 4 ways (lift, tilt, attach 1, attach 2)
3: 5 ways (lift, tilt, attach 1, attach 2,
attach 3)
#46 Battery voltage In this option, the display shows battery
adjust voltage which controller recognized.
Using a tester (or a multi-meter), adjust
the value on the display to actual value.
Moving F-N-R lever from N to F, the
number increases (+0.1 V). From N – –
to R, the number decreases (-0.1 V).
Depress the acceleration pedal while
F-N-R lever is in F, the number
increases (+10 V). Depress the
acceleration pedal while F-N-R lever is
in R, the number decreases (-10 V).
#47 Foot directional This option is used to enable the 1: Disable (normal) –
option function for foot directional option. 2: Enable
Note:
(1) In Group 3, all options have no default value.
(2) All options must be set at first POWER-ON.
(3) If SUO data is out of proper range, “III” is displayed.

3-19
CONTROLLER

Self-diagnostics

Step Checking Do this Controller check this Result Display Motion

0 Power line Turn on key switch. Close the line contactor and Pass 01 Line contactor
voltage check the power line voltage. closes and
(fuse check) open
Fail dd
1 Seat switch Release and press and Input OFF → ON → OFF Pass 02
release seat switch.
Fail 01
2 Direction Cycle F-N-R lever. Input changes as Pass 03
switch N→R→N→F→N N→R→N→F→N
Fail 02
3 Parking brake Release and depress Input OFF → ON → OFF Pass 04
and release parking
brake. Fail 03

4 Service brake Depress and release Input OFF → ON → OFF Pass 05

service brake.
Fail 04
5 Accelerator Depress accelerator Pass Number 0 to 15 flickers as the
and release. accelerator is pressed.
Fail —
DIAG → RUN — 06
6 Battery voltage (Automatic) Check the battery voltage: Pass 07
RUN → DIAG (62 V to 110 V)
Fail 06
7 Lift switch Pull and release the Input OFF → ON → OFF Pass 08
lift lever.
Fail 07
8 Tilt switch Pull and release the Input OFF → ON → OFF Pass 09
tilt lever.
Fail 08
9 Auxiliary 1 Pull and release Input OFF → ON → OFF Pass 10
switch Aux. 1 lever.
Fail 9
10 Auxiliary 2 Pull and release Input OFF → ON → OFF Pass 11
switch Aux. 2 lever.
(DIAG → RUN → Fail 10
(*)
DIAG)
11 Auxiliary 3 Pull and release Input OFF → ON → OFF Pass 12
switch Aux. 3 lever.
(DIAG → RUN)
(*)
Fail 11
RUN → DIAG — 00
12 Hydraulic Pull any lever and Pass Flickering pump speed value.
speed check see display.
Fail Other than above
DIAG → RUN — 13
(*)
In case no Auxiliary 2 (3) switch, skip 10 (11).

3-20
 CONTROLLER

Self-diagnostics (Continued)

Step Checking Do this Controller check this Result Display Motion

13 Line contactor → DIAG See line contactor close. Pass 13 Contactor
close
Fail 13 No operation
→ RUN See line contactor open. Pass 14 Contactor
opens
Fail 13 No operation
14 Steering → DIAG See steering contactor close. Pass 14 Contactor
contactor close
Fail 14 No operation
→ RUN See steering contactor open. Pass 98 Contactor
opens
Fail 14 No operation
98 Drive controller RUN → DIAG → See software version No. in — 99
software version RUN hourmeter
99 Pump controller RUN → DIAG → See software version No. in — done
software version RUN hourmeter

3-21
CONTROLLER

Run Time Diagnostics

Display

LED

Service Indicator
To return
Fault How to detect Result

Parking Brake
Code to normal

Battery Low
Brake Fluid

Over Temp.
Error
Drive Motor, Overheating Thermal contact (150ºC) * E0 Power reduction Cooling
Pump Motor, Overheating Thermal contact (150ºC) * E2 Power reduction Cooling
Traction Module, Overheating Thermistor (MOS 100ºC, C 90°C) * E3 Power reduction Cooling
Brake Fluid Low Level Level sensor (Contact) * Turn off key
Hydraulic Module Overheating Thermistor (MOS 95ºC, C 85°C) * E7 Power reduction Cooling
Drive Motor Fault Compare real current with command current * 10 Line contactor off (*) Turn off key
Drive Motor Driver U Fault Fault signal from the MOS-FET module U * 11 Line contactor off (*) Turn off key
Drive Motor Driver V Fault Fault signal from the MOS-FET module V * 12 Line contactor off (*) Turn off key
Drive Motor Driver W Fault Fault signal from the MOS-FET module W * 13 Line contactor off (*) Turn off key
Drive Motor Current Sensor Fault Out of normal range * 14 Line contactor off (*) Turn off key
Drive Motor Over-Current More than 640 A (80V) * 15 Line contactor hold Turn off key
Drive Stall Timer Measure the time (set by SUO #20) while stalling * 16 Line contactor hold Turn off key
Pump Motor Fault Compare real current with command current * 30 Line contactor off (*) Turn off key
Pump Motor Driver U Fault Fault signal from the MOS-FET module U * 31 Line contactor off (*) Turn off key
Pump Motor Driver V Fault Fault signal from the MOS-FET module V * 32 Line contactor off (*) Turn off key
Pump Motor Driver W Fault Fault signal from the MOS-FET module W * 33 Line contactor off (*) Turn off key
Pump Motor Current Sensor Fault Out of normal Range * 34 Line contactor off (*) Turn off key
Pump Motor Over-current Over 610 A * 35 Line contactor hold Turn off key
Line Contactor Fault Check voltage of power circuit * 40 Line contactor off (*) Turn off key
Accelerator Sensor Fault Out of normal range * 51 Line contactor hold Turn off key
FC Lever Fault Out of normal range * 54 Disable the lever op. Turn off key
FC Solenoid Fault Out of normal range * 55 Disable the solenoid Turn off key
FC Solenoid Current Leak Current is detected when current command is zero * 56 Disable the solenoid Turn off key
Pump Motor Speed Sensor Fault Input is absent or out of normal range * 57 Line contactor hold Turn off key
Drive Motor Speed Sensor Fault Out of normal range * 58 Line contactor hold Turn off key
F-N-R Lever or Accel. The lever/accel is not neutral at power-on E Line contactor off Neutral
Faulty Setting
Seat Switch Faulty Setting The switch is off at power-on (E) Line contactor off Switch on
Lift Lever Faulty Setting The lever is not neutral at power-on H1 Line contactor off Lever off/Neutral
Tilt Lever Faulty Setting The lever is not neutral at power-on H2 Line contactor off Lever off/Neutral
Attach 1 Lever Faulty Setting The lever is not neutral at power-on H3 Line contactor off Lever off/Neutral
Attach 2 Lever Faulty Setting The lever is not neutral at power-on H4 Line contactor off Lever off/Neutral
Attach 3 Lever Faulty Setting The lever is not neutral at power-on H5 Line contactor off Lever off/Neutral
Display Communication Fault When serial comunication is not goinf on * 60 Indicate if it possible Turn off key
EEPROM Fault Sum check of SUO data * 61 Line contactor off Turn off key
Logic Card Initialize Failure SUO Gr. #3 is not set * 65 Line contactor off Turn off key
Controller Fault Sum check of ROM & RAM * 66 Line contactor off Turn off key
Battery Voltage Too Low Voltage class is not correct * 68 Line contactor off Turn off key
Contactor Coil Fault Contactor coil current sensor * 72 Line contactor off Turn off key
Capacitor Charge Fault Abnormal charging/discharging of capacitor * 73 Line contactor off Turn off key
Battery Consumption Much Much consumption with small capacity battery (*) Power reductioin Charge battery
Battery Consumption Too Much Too much consumption with small capacity * (Lo) Line contactor off (*) Turn off key
battery
Note:
(1) E0 to E8 don’t appear on the display, but are stored in the history folder.
(2) E, (E), H1 to H5, Lo appear on the display, but no history folder. (E) means flickering.
(3) ‘Line contactor off (*)’ means that the contactor will open immediately when a fault is detected. ‘Line contactor off’ means that the
contactor will open when a current gets to 0.
3-22
 CONTROLLER

Display Unit

1. BDI (Battery Discharge Indicator)

The battery discharge level is indicated by the 10-
segment LCD. This indication is based on the BDI
characteristic. When the BDI shows only one segment,
the LED starts flickering to notify the low battery
power level. When the BDI indication disappears, the
206798
LED remains on and the output control is activated.
The BDI turns OFF when not necessary, such as during
4. Action indicators (LEDs)
setup option and self-diagnosis operation.
The indicators are activated when an error is detected
2. Hourmeters and time display during normal condition. They do not turn on during
(1) Normal operation setup option setting or self-diagnosis operation.
When the power switch is turned on, the (1) Service indicator (SUO #10)
hourmeters for the drive motor, pump motor and The indicator starts flickering 20 hours before
vehicle are indicated in sequence. The hourmeters maintenance is required and remains lit when the
for the motors show cumulative operating hours, set time is reached.
and the vehicle hourmeter indicates cumulative line
(2) Over temp
contactor ON hours.
The indicator turns ON when a motor or the
A clock display is shown under normal condition.
controller overheats.
(2) During setup option setting and self-diagnosis
(3) Battery low
operation
The indicator starts flickering when the BDI shows
The hourmeters are not displayed when the power
only segment, and remains lit when the BDI has no
switch is turned on.
segment indication.
Data are indicated on the display.
(4) Brake fluid
3. Vehicle speed and error code display The indicator flashes when the brake fluid level
The display indicates vehicle speed under normal becomes low.
condition, and shows an error code when a malfunction (5) Parking brake
is detected.
The indicator flashes when the parking brake is
The display shows the item number during setup option engaged.
setting and self-diagnosis operation.
(6) Error
The indicator flashes when a malfunction is
detected. Refer to the malfunction detection table.

3-23
CONTROLLER

Removal and Installation

Removal and Installation of Controller

Assembly
Tightening torques
WARNING
Size N·m kgf·m lbf·ft
Disconnect the battery plug and discharge the
capacitor before approaching the controller. M3 0.98 0.1 0.7
Check the voltage between CNT and NEG
M4 1.47 0.15 1.1
terminal of the controller to confirm discharge.
M5 2.94 0.3 2.1

NOTE M6 4.41 0.45 3.1

See the table on the right for the tightening torques of M8 and 1/4-20 11.77 1.2 8.7
the controller terminal nuts, contactor terminal nuts stud terminal nuts
and controller component mounting screws. Remarks: The tolerance for these torques is ± 10
%.

1. Removal of rear cover

(1) Turn the key switch off.
(2) Disconnect the battery plug.
(3) Remove the rear cover of the counterweight.

2. Removal of controller assembly

(1) Disconnect connectors CN1, CN2, CN14 and CN15.

NOTE
Rear cover
Hold the connectors to unplug. Do not pull the 208272
harnesses to disconnect the connector.

CAUTION
Be sure to regularly check the tightened torque
of the high-tension battery cable terminals. If
the cables are loosely connected, excessive
contact resistance results, and it can cause
over heating and lead to a fire in the worst case.
When checking or adjusting the cable routing,
avoid pulling the cables. If cables move even
slightly at the terminals loose connections will
result. While working with the cables, be sure
to tighten the terminal connections.

(2) Remove the power cables (for battery and motors).

8 × M8 stud terminals on controller
3 × 1/4-20 terminals on contactor plate
209527A

3-24
 CONTROLLER

• Contactor terminal
Be sure to
A disc spring is used for securing the contactor mount in the
terminal. Install the disc spring with the convex Bus bar indicated
side toward the nut as shown on the right. Flat washer (large) direction.

• Controller stud terminal Disc spring

(small)
The stud terminal sections have resin parts. 1/4-20
Observe
When tightening the nut, hold the resin parts installation
with a wrench (17 mm size). (Indicated by the direction.
arrow in the illustration on the right.)
206246
• When installing the stud terminal on the
aluminum plate, apply Loctite to threads of the
terminal and tighten the terminal to a torque
within the range shown below.

11.77 ± 1.96 N·m

Tightening torque for
(1.2 ± 0.2 kgf·m) M8
stud terminal (M8)
[8.7 ± 1.4 lbf·ft]
Nut

(3) Remove the controller assembly.

Remove the controller mounting bolts (M10: 6
locations for controller. 4 locations for contactor
plate), and remove the controller.

Aluminum
39 ± 7.8 N·m plate
Tightening torque for
(4 ± 0.8 kgf·m)
mounting bolt (M10)
[29 ± 6 lbf·ft] 209562

3. Installation of controller assembly

To install, follow the reverse of removal procedure, and do
the following.

NOTE
There is silicone grease between counterweight and Unit: mm (in.)
480 (18.9)
controller. It is important to cooling the controller. 10 (0.4) 10 (0.4)
10 (0.4)

Spread the silicone grease flatly then mount controller

on it.
275 (10.8)
10 (0.4)

Hatched area
must be coated
thin with silicone
grease. 209563

3-25
CONTROLLER

Removal and Installation of Logic Card

1. Removal of controller cover

Remove the cover mounting screws (M6: 8 locations),
and remove the controller cover.

2. Removal of logic card

(1) Disconnect CN3, CN5, CN6, CN7, CH8, CH9,
CH10
(2) Remove the logic card bracket mounting screws
(M4: 4 locations marked A in the illustration
below), and remove the logic card with bracket.
(3) Remove the logic card bracket mounting screws
(M3: 7 locations marked B in the illustration
below), and the heat-sink mounting screws (M4: 2
locations marked C in the illustration below), and
remove the logic card.

CN5 CN6 CN7 CN8 CN9 CN10

A

B
B B
A
C B
A
A

B CN3
B
B

The screws marked A are for mounting the logic card bracket. The screws marked B and C are for mounting
the logic card.
209564

3. Installation of logic card

Follow the removal procedure in reverse.

3-26
 CONTROLLER

Removal and Installation of MOS-FET Module

D
E D Bus bar (POS)

F MOS-FET
module

Never remove
any of the screws
with a white insulator
under the head.

D
Bus bar (NEG) D 209565

(1) Removal of controller cover (7) Installation of MOS-FET modules

Remove the cover mounting screws (M6: 8 Follow the removal sequence in reverse. Also do
locations), and remove the controller cover. the following:
(2) Disconnect CN3, CN5, CN6, CN7, CH8, CH9 and
CH10, and cut the cable tie on both sides of the NOTE
CN1. (See the logics card removal procedure on There is silicone grease between MOS-FET
page 3-26.) module and base plate. It is important to cooling
(3) Removal of logic card the controller. Spread the silicone grease
uniformly then mount MOS-FET module on it.
Remove the bracket mounting screws (M6: 4
locations marked D in the illustration above), and Use only “Shin-Etsu Silicone G747” grease.
remove the logic card with brackets.
(4) Remove bus bars (POS, NEG) mounting screws
(M5: 12 locations marked E in the illustration
above, M8 stud: 2 locations marked F in the
illustration above), and remove bus bars.
(5) Disconnect J5 or J6 or J7 or J8 of the current sensor
input connector if necessary.
(6) Remove MOS-FET module mounting screws (M4:
3 locations marked G in the illustration above), and
remove the MOS-FET module. There are three
mounting screws for each MOS-FET module. They
are identified by arrows on the molding of the Apply a thin coat of grease here.
module. Never remove any of the screws that have 209566
a white insulator under the head.

3-27
CONTROLLER

Basic Check

Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm the description of the problem with an
operational check.
• Visually inspect cables, connectors, contactor tips, etc.
• Perform basic battery cables to frame resistance test. (at
least 20 k ohm)
• Check battery condition.
Always check each option and write down the reading.

Testing Tools
(a) Circuit tester
(b) Clamp meter (b)
(c) IC clip
(a)
NOTE
(c)
The illustrations show digital circuit testers. In these
testers, the positive (+) terminal is applied with positive
charge, and the negative (–) terminal with negative
charge. It should be noted that the terminals must be
connected inversely when using an analog meter tester.
208282

WARNING
Disconnect the battery plug and discharge the
capacitor before approaching the controller.
Check the voltage between CNT and NEG
terminal of the controller to confirm discharge.

3-28
 CONTROLLER

Measurement of Logic Card Voltage

WARNING
To prevent accidental movement of the vehicle,
place wood blocks under the vehicle to lift the
front wheels off the ground. Stay clear of the
front wheels.

1. Place wood blocks under the vehicle to lift the front

wheels off the ground.
2. Turn the key switch off.
3. Disconnect the battery plug.
4. Remove the rear cover from counterweight.
5. Using an IC clip, connect the positive (+) terminal of
the circuit tester to the intended one of the logics-card-
side pins that are associated with the harness-side
connectors CN1, CN2, CN14 and CN15. The logics-
card-side pins are covered with insulation coating, so
remove the coating from the pin to which the IC clip is
going to be connected.
6. Set the circuit tester to the 100-VDC range.
7. Reconnect the battery plug.
8. Turn the key switch on. Connect the negative terminal
of the circuit tester to the NEG terminal (terminal
portion of the NEG bus bar, for example) of the
controller. Measure the standby voltage.
9. Then operate a control (a switch for example) to
measure the activation voltage.

NOTE
Exercise care not to let pins be shorted when
measuring the voltage.

For the normal voltage value, refer to the logic card

voltage chart on the next page.

3-29
CONTROLLER

Logic card measured voltage chart

Stand-by Activate
No. Name Note
voltage voltage
CN1-1, 2, 3, 4 V POW (FROM KEY) Vbatt* Vbatt* 0 V: Key OFF, Vbatt*: Key ON
CN1-5 REVERSE SW 14.5 to 15.5 V 0 V
CN1-6 TRACTION MOTOR 14.5 to 15.5 V 0 V
THERMAL SW
CN1-7 ACCEL IDLE SW 14.5 to 15.5 V 0V
CN1-8 PARK BRAKE SW 14.5 to 15.5 V 0V
CN1-9 SEAT SW 14.5 to 15.5 V 0V
CN1-10 BRAKE FLUID SW 14.5 to 15.5 V 0V
CN1-11 SPEED LIMIT SW 14.5 to 15.5 V 0V
CN1-12 FORWARD SW 14.5 to 15.5 V 0V
CN1-13 SERVICE BRAKE SW 14.5 to 15.5 V 0V
CN1-14, 15, GND 0V 0V
16, 17
CN1-18 5 V (ACCEL) 5V 5V
CN1-19 ACCEL ANGLE 1V 1 to 4 V
CN1-20 GND (ACCEL) 0V 0V
CN1-21 DISPLAY GND 0V 0V
CN1-22 DISPLAY TXD 0 to 12 V 0 to 12 V
CN1-23 DISPLAY RXD 0 to 12 V 0 to 12 V
CN1-24 BRAKE IDLE SW 14.5 to 15.5 V 0V
CN1-25, 26 OPEN
CN2-27, 28 OPEN
CN2-29 MAIN FUSE VOLTAGE Vbatt* Vbatt* 0 V to Vbatt*: Key OFF
Vbatt*: Line contactor ON
CN2-30 POS VOLTAGE Vbatt* Vbatt*
CN2-31 +VE Vbatt* Vbatt* 0 V: Key OFF, Vbatt*: Line contactor ON
CN2-32 STEERING CONTACTOR Vbatt* 0V
CN2-33 LINE CONTACTOR Vbatt* 0V
CN2-34 CHARGE RESISTOR + Vbatt* Vbatt* 0 V to Vbatt*: Key OFF
Vbatt*: Line contactor ON
CN2-35 CHARGE RESISTOR – 0V 0V
CN2-36 SET SW 14.5 to 15.5 V 0V
CN2-37 DIAG SW 14.5 to 15.5 V 0V
CN2-38 GND 0V 0V
CN2-39 15 V (SPEED SENSOR) 14.5 to 15.5 V 14.5 to 15.5 V
CN2-40 DRIVE MOTOR 0 to 5 V 0 to 5 V
REV A +
CN2-41 DRIVE MOTOR 0 to 5 V 0 to 5 V
REV B +
CN2-42 GND 0V 0V
Vbatt* = battery voltage

3-30
 CONTROLLER

Logic card measured voltage chart

Stand-by Activate
No. Name Note
voltage voltage
CN14-1 15 V 14.5 to 15.5 V 14.5 to 15.5 V
CN14-2 PUMP MOTOR REV A + 0 V 0 to 5 V
CN14-3 PUMP MOTOR REV B + 0 V 0 to 5 V
CN14-4 GND 0V 0V
CN14-5 AUTO LIGHT RELAY Vbatt* 0 to 5 V
CN14-6 AUTO LIGHT 15 V 14.5 to 15.5 V 14.5 to 15.5 V
CN14-7 AUTO LIGHT SENSOR 0 to 5 V 13 to 15.5 V
CN14-8 LIFT LIMIT SW1 14.5 to 15.5 V 0V
CN14-9 LIFT LIMIT SW2 14.5 to 15.5 V 0V
CN14-10 LIFT LIMIT SW3 14.5 to 15.5 V 0V
CN14-11 PUMP MOTOR 14.5 to 15.5 V 0V
THERMAL SW
CN14-12 STEERING SW 14.5 to 15.5 V 0V
CN14-13 LIFT SW1 14.5 to 15.5 V 0V
CN14-14 LIFT SW2 14.5 to 15.5 V 0V
CN14-15 TILT SW 14.5 to 15.5 V 0V
CN14-16 ATTACH 1 SW 14.5 to 15.5 V 0V
CN14-17 ATTACH 2 SW 14.5 to 15.5 V 0V
CN14-18 ATTACH 3 SW 14.5 to 15.5 V 0V
CN14-19, 20 GND 0V 0V
CN14-21 5 V (JOYSTICK) 5V 5V
CN14-22 LIFT JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-23 TILT JOYSTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-24 ATTACH 1 JOYTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-25 ATTACH 2 JOYTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN14-26 ATTACH 3 JOYTICK 2.3 to 2.7 V 0.1 to 4.9 V
CN15-27 12 V (EMERGENCY) 9 to 15 V 9 to 15 V
CN15-28, 29 OPEN
CN15-30 GND 0V 0V
CN15-31 OPEN
CN15-32 VALVE POW (11 to 13 V) (11 to 13 V) Open: Emergency ON
CN15-33 LIFT VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-34 LIFT VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-35 LIFT VALVE COM 11 to 13 V 11 to 13 V
CN15-36 TILT VALVE COM 11 to 13 V 11 to 13 V
CN15-37 TILT VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-38 TILT VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-39 ATTACH 1 VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-40 ATTACH 1 VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-41 ATTACH 1 VALVE COM 11 to 13 V 11 to 13 V
CN15-42 ATTACH 2 VALVE COM 11 to 13 V 11 to 13 V
CN15-43 ATTACH 2 VALVE A 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-44 ATTACH 2 VALVE B 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-45 (ATTACH 3 VALVE A) 11 to 13 V 0 to 13 V Open: Emergency ON
CN15-46 (ATTACH 3 VALVE B) 11 to 13 V 0 to 15 V Open: Emergency ON
CN15-47 (ATTACH 3 VALVE COM) 9 to 15 V 11 to 13 V
CN15-48 OPEN
Vbatt* = battery voltage

3-31
CONTROLLER

Check Contactor Coil

WARNING
Disconnect the battery plug and discharge the Coil resistance 118 to 145 ohm
capacitor before approaching the controller.
Check the voltage between CNT and NEG
terminal of the controller to confirm discharge.

1. Disconnect the lead wire of coil.

2. Set the circuit tester to 200 ohm range.
3. Measure coil resistance.
(It must be 118 to 145 ohm)
• If the measured value deviates from the above range,
replace the contactor assembly.
4. With the lead wire of contactor coil connected, set the
circuit tester to 200-VDC range.
5. Connect the negative (–) terminal of the circuit tester to
the negative-side coil terminal (small fasten terminal)
and the positive (+) terminal of the circuit tester to the
positive-side coil terminal (large fasten terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
Gap 3.15 ± 0.12 mm
7. The circuit tester should indicate a value between 23.4 (Contactor tip) (0.124 ± 0.004 in.)
and 52 V after the contactor the contactor operates.
When the contactor is found normal in the coil
resistance test and if the measured voltage is not within
this range, replace the logic card.

Check Contactor Tip

1. Visually inspect the contactor tips for melting,
adhesion, heat seizure and pitting corrosion.
2. To check for interference, press the tips and release it.
3. Visually inspect the contactor assemblies. Make sure
there are no foreign materials in the assemblies to
interfere with contactor movement.
208284
4. Measure the gap at each contactor tips using a
thickness gauge.
(It must be 3.15 ± 0.12 mm.)
• If you find any troubles, replace tip or correct
contactor.

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 CONTROLLER

Check Current Sensor of Controller

1. Turn the key switch off.
WARNING
2. Disconnect battery plug.
To prevent the vehicle from moving suddenly,
3. Disconnect current sensor connector.
lift the front wheels off the ground by placing
Location Connector name wood blocks under the vehicle. Do not
approach the front wheels during testing.
Drive U phase J7
Drive V phase J8 7. Turn the key switch off and disconnect the battery
Pump U phase J5 plug. Connect current sensor connector.

Pump V phase J6 8. Place wood blocks under the vehicle to lift the front
wheels off the ground. Engage the parking brake.
4. Set the circuit tester to the 20-VDC range. Connect 9. Set the circuit tester to the 20-VDC range. Connect
the positive (+) terminal of the circuit tester to a the positive (+) terminal of the circuit tester to a
point on the No. 4 pin circuit (for example, the point on the No. 2 pin circuit of the current sensor.
logics-card-side pin of the CN3 connector
associated with the No. 4 pin). Connect the Standard
Location Pin No. condition
negative (–) terminal of the circuit tester to the
NEG terminal. Drive U phase J7-2BrY 2 to 3 V
Standard Drive V phase J8-2BrY 2 to 3 V
Location Pin No. condition
Pump U phase J5-2BrY 2 to 3 V
Drive U phase J7-4GR 14 to 16 V
Pump V phase J6-2BrY 2 to 3 V
Drive V phase J8-4GR 14 to 16 V
Pump U phase J5-4GR 14 to 16 V 10. Connect the battery plug and turn the key switch
ON.
Pump V phase J6-4GR 14 to 16 V
• If values measured in the above step deviate
5. Connect the battery plug and turn the key switch from the specified ranges, replace the current
ON. sensor.

• If values measured in the above step deviate 11. Shift the F-N-R lever to forward. Gradually
from the specified ranges, replace the logic card. depress the accelerator pedal (with front wheels
stationary) and read the voltage change.
6. Then connect the positive (+) terminal of the circuit
tester to a point on the No. 2 pin circuit. Standard
Location Pin No. condition
Standard
Location Pin No. condition 0.5 to 4.5 V
Drive U phase J7-2BrY (unstable)
Drive U phase J7-2BrY 4 to 6 V
Drive V phase J8-2BrY 0.5 to 4.5 V
Drive V phase J8-2BrY 4 to 6 V (unstable)

Pump U phase J5-2BrY 4 to 6 V • If values measured in this step deviate from the
specified condition, replace the current sensor.
Pump V phase J6-2BrY 4 to 6 V

• If values measured in this step deviate from the

specified ranges, replace the logic card.

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CONTROLLER

12. Shift the lift lever to forward (lowering) and read

the voltage change.
Standard
Location Pin No. condition

Pump U phase J5-2BrY 0.5 to 4.5 V

(unstable)

Pump V phase J6-2BrY 0.5 to 4.5 V

(unstable)

• If values measured in this step deviate from the

specified condition, replace the current sensor.

3-34
 CONTROLLER

Check MOS-FET Module

WARNING
Disconnect the battery plug and discharge the
capacitor before approaching the controller.
Check the voltage between CNT and NEG
terminal of the controller to confirm discharge.
Standard tester
+ of tester – of tester indication
1. Turn the key switch off. TU truck OL
2. Disconnect battery plug. TV truck OL
3. Remove all high-tension cable (except NEG) from TW truck OL
traction controller.
PU truck OL
4. Remove logic card with bracket and bus bars (POS,
NEG). PV truck OL
5. Set the circuit tester to the 20 k ohm range. Measure PW truck OL
the resistance between each of the terminals shown in
the table on the right and the truck body. If the tester
reading does not conform to the indication in the table,
replace the MOS-FET module.
• If you find any troubles, replace the MOS-FET
P terminal N terminal
module.
Unit Test
1. Turn the key switch off.
2. Disconnect battery plug.
3. Remove the MOS-FET module from the controller. F terminal
4. Set the circuit tester 20 k ohm range. Measure
Heat sink
resistance between each terminal.
5 3 1
• If you find any troubles, replace the MOS-FET 6 4 2
module. CN1

Standard tester 209555

+ of tester – of tester indication
CN1-1 (+15 V) N terminal 10.0 to 10.4 k ohm
CN1-1 (+15 V) CN1-3 1.48 to 1.54 k ohm
CN1-1 (+15 V) CN1-4 1.48 to 1.54 k ohm
CN1-2 N terminal OL
P terminal Heat sink OL
N terminal Heat sink OL
F terminal Heat sink OL

3-35
CONTROLLER

5. Short-circuit P terminal and N terminal. Set circuit Unit: mm (in.) 10 (0.39)

tester 20 k ohm range. Measure resistance between
each terminal.

Standard tester
+ of tester – of tester indication
N terminal F terminal 1 M ohm or higher
P terminal F terminal 1 M ohm or higher

6. Set the circuit tester 20 k ohm range. Measure

resistance for each FET.
0.75 (0.03)
NOTE 2.54 (0.1) 2.54 (0.1)
The terminals of each MOS-FET module are covered

(0.18)
with insulation coating. Remove the coating from the

4.5
1 2 3
terminals shown in the illustration below before
performing measurement. Apply insulation coating to
the terminals after measurement. 2

1 Gate
Standard tester 2 Drain
Locaion + of tester – of tester indication 1 3 Source

QL01 to Gate Source 10.0 to 10.4 k ohm

QL20 terminal terminal Exactly same for all
3 209560
QH01 to Gate Source 10.0 to 10.4 k ohm
QH20 terminal terminal Exactly same for all

D NEG
G S

Terminal

Terminal

S G
D POS 209567

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 CONTROLLER

AC Motor System Basics

1. Feature of AC motor
The PAC model lift trucks covered by this manual use The frequency and voltage can be controlled in a
AC motors (three-phase induction motors) as the drive variety of methods including the “vector control
motor and pump motor. AC motors have the following method” employed in the PAC model lift trucks. This
advantages over DC motors: method provides highly responsive control according to
(1) AC motors are simple in construcion. As they have ever changing truck-operating conditions through high-
no such friction parts as brushes and commutators, speed calculation on huge amount of data. The vector
daily maintenance load is significantly reduced. control calculation is performed by one of the CPUs on
the logics card. (Fig. 2)
(2) AC motors are compatible with high-speed
operation.
(3) An AC motor of a certain size produces higher
U
power than a DC motor of the same size.

2. Speed control of induction motors Controller V

IM
Speed control of DC motors depends on regulation of
W
the field and armature current amounts, while that of
AC motors basically depends on adjustment of the
frequency of alternating current power supply. Very
simply speaking, the speed of an AC motor is V V
U V W
determined by the frequency of the power supply AC
current and the load on the motor. In addition, the
t t
voltage and current to the motor must be controlled
properly such that the motor operates in its optimum
Low-speed operation High-speed operation
characteristic range. (Fig. 1) (low frequency)
209542

Fig. 1

Logics card Gate

driving MOS-FET modules
pulse

Accelerator Calculation for Vector control

F required output calculation IM
N
R

Current
Brake Truck speed Speed

209543

Fig. 2

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CONTROLLER

3. Inverter Switch
The truck battery delivers DC current, so the current must
be converted into AC current to drive an AC motor. The VB VL Load
device that converts direct current into alternating current is
generally called “inverter”. The processes involved in
T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = × VB
T1 + T2
(1) Changing DC voltage cyclically ON OFF ON
Average voltage VL
If the switch in a circuit like a one shown in Fig. 3 is
turned on for time T1 and then turned off for time T2
and this on-off operation is repeated many times, the Small duty ratio Large duty ratio
average of the voltage applied to the load is determined ON ON ON

by the ratio between T1 and T2. Varying the ratio,

therefore, results in varying voltage. The ratio between
OFF OFF
T1 and T2 is called “duty ratio”. By changing the duty 209544
ratio cyclically, it is possible to obtain cyclically
Fig. 3
changing DC voltage shown in Fig. 3.
(2) Converting DC power into AC power
Driving a three-phase AC motor using battery delivered
power requires creating three phase outputs (U, V, W)
of an identical waveform that differ in phase by 120°
using a circuit with six switches S1 to S6 that are S1 S3 S5
arranged as shown in Fig. 4. The outputs thus created U
V
forms a three-phase alternating current. Fig. 5 shows W
on-off condition of each switch (arm) and output S2 S4 S6
voltage variation.
Functioning as switches in the inverter of the AC motor
trucks are MOS-FET transistors. The MOS-FET
209545
transistors can switch at very high speeds, thus creating
smooth waveforms of alternating current. Fig. 4

S1 ON

Switching for U phase

S3 ON
S2 ON
Switching for V phase

S5 ON S4 ON

Switching for W phase

S6 ON
209546
Voltage between output wires
Fig. 5

3-38