Service Manual: Controller

Service Manual
Controller
FBC15N A4BC1-10200-up
FBC18LN A4BC1-30200-up
FBC25EN A4BC3-20200-up
99759-7C110
FOREWORD
This service manual is a guide to servicing of Mitsubishi forklift trucks. The instructions are
grouped by systems to serve the convenience of your ready reference.
Long productive life of your forklift trucks depends to a great extent on correct servicing —
servicing consistent with what you will learn from this service manual. Read the respective
sections of this manual carefully and familiarize yourself with all the components you will
work on, before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are of the trucks
with the serial numbers in effect at the time it was approved for printing. Mitsubishi forklift
truck reserves the right to change specifications or design without notice and without incurring
obligation.
Safety Related Signs
The following safety related signs are used in this service

manual to emphasize important and critical instructions:
Indicates a specific potential hazard

! WARNING that could result in serious bodily
injury or death.
Indicates a specific potential hazard

! CAUTION
that may result in bodily injury, or
damage to, or destruction of, the
machine.
Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.
Pub. No. 99759-7C110

! WARNING
SAFETY
! WARNING ! WARNING
The proper and safe lubrication and maintenance Do not operate this truck unless you have read
for this forklift truck, recommended by Mitsubishi and understand the instructions in the
OPERATION & MAINTENANCE MANUAL.
forklift truck, are outlined in the OPERATION &
Improper truck operation is dangerous and could
MAINTENANCE MANUAL for these trucks.
result in injury or death.
Improper performance of lubrication or maintenance
procedures is dangerous and could result in injury or 4. Lower the forks or other implements to the ground
death. Read and understand the OPERATION & before performing any work on the truck. If this
MAINTENANCE MANUAL before performing any cannot be done, make sure the forks or other
lubrication or maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
The serviceman or mechanic may be unfamiliar with 5. Use steps and grab handles (if applicable) when
many of the systems on this truck. This makes it mounting or dismounting a truck. Clean any mud
important to use caution when performing service or debris from steps, walkways or work platforms
work. A knowledge of the system and/or components before using. Always face truck when using steps,
is important before the removal or disassembly of any ladders and walkways. When it is not possible to
component. use the designed access system, provide ladders,
Because of the size of some of the truck components, scaffolds, or work platforms to perform safe repair
the serviceman or mechanic should check the weights operations.
noted in this Manual. Use proper lifting procedures 6. To avoid back injury, use a hoist when lifting
when removing any components. components which weigh 23 kg (50 lb.) or more.
Following is a list of basic precautions that should Make sure all chains, hooks, slings, etc., are in
always be observed. good condition and are of the correct capacity. Be
1. Read and understand all warning plates and decals sure hooks are positioned correctly. Lifting eyes
on the truck before operating, lubricating or are not to be side loaded during a lifting operation.
repairing the product. 7. To avoid burns, be alert for hot parts on trucks
2. Always wear protective glasses and protective which have just been stopped and hot fluids in
shoes when working around trucks. In particular, lines, tubes and compartments.
wear protective glasses when pounding on any part 8. Be careful when removing cover plates. Gradually
of the truck or its attachments with a hammer or back off the last two bolts or nuts located at
sledge. Use welders gloves, hood/goggles, apron opposite ends of the cover or device and pry cover
and other protective clothing appropriate to the loose to relieve any spring or other pressure, before
welding job being performed. Do not wear loose- removing the last two bolts or nuts completely.
fitting or torn clothing. Remove all rings from 9. Be careful when removing filler caps, breathers and
fingers when working on machinery. plugs on the truck. Hold a rag over the cap or plug
3. Do not work on any truck that is supported only by to prevent being sprayed or splashed by liquids
lift jacks or a hoist. Always use blocks or jack under pressure. The danger is even greater if the
stands to support the truck before performing any truck has just been stopped because fluids can be
disassembly. hot.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or 22. When handling the parts containing asbestos, be
wire to provide a weld metal strength equivalent at careful not to inhale the asbestos. Doing so is
least to that of parent metal. hazardous to your health.
15. Do not damage wiring during removal operations. If the shop dust may contain asbestos, follow the
Reinstall the wiring so it is not damaged nor will it precautions described below.
be damaged in operation by contacting sharp a. Do not use compressed air for cleaning.
corners, or by rubbing against some object or hot b. Do not brush or apply grinder on asbestos
surface. Place wiring away from oil pipe. containing materials.
16. Be sure all protective devices including guards and c. To clean asbestos containing materials, wipe
shields are properly installed and functioning with moistened cloth or use a vacuum cleaner
correctly before starting a repair. If a guard or with particle filter.
shield must be removed to perform the repair work,
d. If you have to handle the parts containing
use extra caution.
asbestos for a long time, be sure to do it in a
17. Always support the mast and carriage to keep well-ventilated area.
carriage or attachments raised when maintenance
e. If the asbestos in the air cannot be removed,
or repair work is performed, which requires the
wear a mask.
mast in the raised position.
f. Be sure to observe the working rules and
18. Loose or damaged fuel, lubricant and hydraulic
regulations.
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which g. When disposing of materials with asbestos, be
have been bent or damaged. Inspect lines, tubes sure to observe the environmental protection
and hoses carefully. Do not check for leaks with regulations of your area.
your hands. Pin hole (very small) leaks can result h. Avoid working in the atmosphere where
in a high velocity oil stream that will be invisible asbestos particles may be suspended.
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)
Disassembly diagram (example)
Procedures are described in the text.

Disassembling sequence
209603
Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)
Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.
209604
Service Data
0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.
Item SI unit Customary unit

1N 0.1020 kgf
Force
(1 lbf) (0.4536 kgf)
1 kPa 0.0102 kgf/cm2
Pressure
(1 psi) (0.0703 kgf/cm2)
1 N·m 0.1020 kgf·m
Torque
(1 lbf·ft) (0.1383 kgf·m)
GROUP INDEX
GROUP INDEX Items
Controller system, Controller features, Setup option, Diagnosis, Removal and

CONTROLLER
installation, Basic check
1
TROUBLESHOOTING
Faulty central vehicle monitor system, Faulty diagnosis indication,
FOR CONTROL 2
or Other abnormalities
CIRCUITS
Motor installation positions, Specifications, Structures, Tightening of high-power

MOTORS cable terminals, Procedures and suggestions for removal and installation, 3
Procedures and suggestions for disassembly and reassembly
CONTROLLER
Controller System .................................................................................... 1 – 1

System Configuration ............................................................................... 1 – 1 1
Controller Area Network (CAN) ................................................................. 1 – 3
Outline of Controller ................................................................................. 1 – 5
Controller Features ................................................................................. 1 – 8
Traction Control Features ......................................................................... 1 – 8
Lifting Control Features ............................................................................ 1 – 11
Steering Control Features ......................................................................... 1 – 11
Diagnosis/Run/Setup (DRS) Modes .......................................................... 1 – 12
Safety Function ........................................................................................ 1 – 16
Other Features .......................................................................................... 1 – 18
Setup Option ............................................................................................ 1 – 19
Outline ...................................................................................................... 1 – 19
Operation Procedure ................................................................................ 1 – 19
Details of Setup Options ........................................................................... 1 – 21
Diagnosis .................................................................................................. 1 – 38
Outline ...................................................................................................... 1 – 38
Operation Procedure ................................................................................ 1 – 38
Self-Diagnostics (Hydraulic control: Transistor Control Type) ................... 1 – 41
Self-Diagnostics (Hydraulic control: Contactor Control Type) ................... 1 – 42
Run Time Diagnostics ............................................................................... 1 – 43
Removal and Installation ....................................................................... 1 – 45
Inverter Discharging Procedure ................................................................ 1 – 45
Replacing Inverter ..................................................................................... 1 – 46
Insuring Proper Thermal Transfer............................................................... 1 – 46
Replacing DSP (Digital Signal Processor) Card ........................................ 1 – 52
Replacing Logic Unit ................................................................................ 1 – 54
Replacing Logic Card ............................................................................... 1 – 55
Replacing Power Supply Card .................................................................. 1 – 56
Basic Check ............................................................................................. 1 – 57
Testing Tools ............................................................................................. 1 – 57
Measurement of Card Voltage .................................................................. 1 – 58
Checking Contactor Coil .......................................................................... 1 – 61
Checking Contactor Tip ............................................................................ 1 – 61
Checking Inverter ..................................................................................... 1 – 62
Regeneration Check ................................................................................. 1 – 63
AC Motor System Basics ...................................................................... 1 – 64
AC Motor Troubleshooting .................................................................... 1 – 66
CONTROLLER
Controller System
System Configuration
The truck is controlled by the logic unit and the The logic unit and the inverter are linked together by
inverter. the Controller Area Network (CAN) to communicate
The system configuration is classified into two types with each other. The logic unit sends the motor control
according to the lifting control system: the Contactor command to the inverter and the inverter sends the
Control Type and the Transistor Control Type. sensing data to the logic unit.
The Contactor Control Type controls the DC pump The display unit indicates the truck conditions and
motor by the contactor. The Transistor Control Type setting data.
controls the AC induction pump motor by the inverter. The logic unit communicates with the display unit
The logic unit is the main part of the control system and through the serial communication protocol (RS232C).
controls the traveling, lifting and safety function The system configurations of the Contactor Control
systems. The logic unit is connected to the inverter, Type and the Transistor Control Type are as follows.
display unit and other control switches.
The inverter controls the AC induction traction (drive)
motor and the AC induction pump motor.
System Configuration for Contactor Control Type
Input switch signals RS232C

Key switch Display
Logic Unit
Direction lever
Accelerator Logic card
Service brake Warning buzzer
Traveling control
Parking brake Lifting control Contactor control signal
Seat switch Safety function
Seat belt switch Lift lock solenoid control signal
etc.
DRS switch Hydraulic lever
Other switches input
(Horn switch etc.)
CAN bus
Sensing data Motor control command
Traction Inverter
Lift cylinder
DSP card Micro Tilt cylinder
switches
Hydraulic
control valve
Sensors assembly Steering
U Lift lock Pump motor motor
solenoid
V IM valve
W
M M
Traction motor
Hydraulic
(Drive motor)
pump
Contactor Battery
Electric power
211390
1-1
CONTROLLER
System Configuration for Transistor Control Type
Input switch signals

Key switch RS232C Display
Direction lever Logic Unit
Accelerator
Service brake Logic card
Warning buzzer
Parking brake Traveling control
Seat switch Lifting control Contactor control signal
Seat belt switch Safety function
Lift lock solenoid control signal
DRS switch etc.
Other switches Hydraulic lever input
(Horn switch etc.)
CAN bus
Sensing data Motor control command Sensing data
Traction Inverter Pump Inverter

Lift cylinder
DSP card DSP card Tilt cylinder
Micro
switches
Steering
Hydraulic motor
Sensors Sensors control valve
U U assembly
Lift lock M
V IM V
IM solenoid
W W valve
Hydraulic
Traction motor Pump motor pump
(Drive motor)
Contactor Battery
Electric power
211391
1-2
CONTROLLER
Controller Area Network (CAN)

Each controller is linked with the truck harness to form If the terminal resistors are not properly connected, the
a network as follows. communication failure may occur between the logic
The positions of terminal resistors (120 Ω) differ unit and the inverters.
between the Contactor Control Type and the Transistor For details, see the “Traction Inverter Fault (63)” and
Control Type. “Pump Inverter Fault (65)” in “Troubleshooting for
One of the terminal resistors is built into the traction Control Circuits.”
inverter and another terminal resistor is connected to
the inside of main harness (near the connector P3) in
the Contactor Control Type.
In the Transistor Control Type, the terminal resistors are
built into the traction inverter and the pump inverter.
Network for Contactor Control Type
Traction Logic
inverter unit
Built-in CAN H
CAN L *1
*1: Connected to inside of

main harness
211392
Network for Transistor Control Type
Traction Logic Pump

inverter unit inverter
Built-in CAN H Built-in
CAN L
211393
1-3
CONTROLLER
The data are expressed with electric potential difference

in high- and low-level signals as follows.
They are transferred to each controller through the
serial communication protocol.
Kind of VCAN-L
potential
bit Logic Vdiff Vdiff
dominant 0 VCAN-H
recessive 1 recessive dominant recessive

time
211176
Main specifications
Communication protocol CANbus 2.0B passive Non-Return to Zero method

Broadcast communication protocol
Communication line Dual 2-wire type serial communication
Communication speed 500 kbps
Data length 0 to 8 bytes
1-4
CONTROLLER
Outline of Controller
1. Logic unit
The logic unit consists of the logic card and the power The logic unit communicates with the display unit
supply card. through the RS232C. The truck speed and residual
The logic card has the CPU chips and controls all the battery power are monitored and shown on the display
jobs for the truck. unit. The seat belt and brake fluid level are also
monitored and shown on the LED of the display unit.
The logic unit calculates the traction motor control
command through the input of the direction lever or The logic unit sets the model information and optional
accelerator pedal and sends the command to the traction default data into internal memory. The information is
inverter. It also monitors malfunctions of the traveling secured even if the power supply for the logic unit is
control system. turned off. This information is set at the factory.
In the Transistor Control Type, the logic unit calculates The following table shows the model information. The
the AC induction pump motor control command system will not work properly if the actual controller
through the input of the hydraulic levers and sends the system is different from the model information.
command to the pump inverter. It also monitors
malfunctions of the lifting control system.
Model information
Item Description SUO No.

Truck type Model set #40
Battery voltage 36 V, 48 V #41
Battery type Battery type #42
Hydraulic control selection Contactor Control Type, #43
Transistor Control Type
Mast type Mast type #44
Battery voltage adjust Battery voltage adjustment #46
Foot direction Optional equipment #47
The current information is available to confirm and

modify.
Refer to “Setup Option” on page 1-19 for details and
setting procedures.
The model information and various features are set by
the Setup Option (SUO).
The power supply card changes the battery voltage and
supplies power to the logic card and the DSP card.
1-5
CONTROLLER
Logic unit
211394
Logic card
CN1
Logic card side CN1
Main harness side P3 Main harness side P4 Main harness side P5 211395
Power supply card
CN1
Power supply card side CN1 Main harness side P8

211396
The Service Tool connector exists on main harness P18.

1-6
CONTROLLER
2. Inverter
The inverter is a motor drive controller that consists of The DSP card has the DSP chips that enables high-
Digital Signal Processor (DSP) card, Insulated Metal speed calculation and controls the AC induction motors.
Substrate (IMS) module and their drive boards. The IMS module has plural MOS-FET modules and
It drives the AC induction motors according to the converts the battery DC current into AC current for
motor control command from the logic unit. It also supplying to the traction and pump motors. See also the
monitors malfunctions of motors and its own condition. “AC Motor System Basics” section on page 1-60.
When a malfunction occurs, it stops the motors and
informs the logic unit.
Traction and pump inverters
DSP card
211397
Traction and pump inverter

DSP card
CN2
Traction inverter card side CN2 Main harness side, Traction P1

Pump inverter card side CN2 Main harness side, Pump P2
211398
1-7
CONTROLLER
Controller Features
Traction Control Features

The line contactor closes in the following conditions 1. Powering
when the key switch is turned on. This enables the
inverter to control the traction motor. (1) Normal traveling
Truck speed is controlled by the accelerator pedal
Conditions for closing line contactor
depression. The speed is also controlled by the
All the following must be satisfied. accelerator pedal depression when descending a grade
• The seat switch is turned on. and it is controlled only in the output torque range of
the traction motor.
• The lifting operation is not performed (the hydraulic
lever input does not occur). The controller supplies power to the traction motor
according to the acceleration rate (set by SUO #8) and
• The traveling operation is not performed (the
the torque characteristic (set by SUO #9) when the
direction lever is placed to Neutral and the
accelerator pedal is pressed. The controller returns
accelerator pedal is not pressed).
power to the battery according to the deceleration rate
• Error related to the traveling and lifting operations and the torque characteristic that are set as fixed values
does not occur. when the truck is decelerated by releasing the
accelerator pedal (regeneration function).
Torque
[%]
100
HIGH POWER(3)
STANDARD(2)
ECONOMY(1)
Brake limit
APPROXIMATELY 400 AMPS CURRENT LIMIT
Thermal, BDI [0] or Service indicator
0 5 10 15 20 Speed
[km/h]
211399
*1 *2
Brake limit:Torque value resulting from reduction in Thermal, BDI Level [0] or Service indicator:
current when the service brake or parking Curve of limited torque under a condition
brake is applied. of overheating or battery voltage low or
maintenance time over.
1-8
CONTROLLER
(2) Boost
When truck traveling is blocked by a step, the boost If the service brake pedal is pressed or the parking
function prevents stalling of the truck. Usually the brake is applied, before the boost function is activated
motor maximum torque is set by SUO #9, but this or when the boost function is being activated, the
function allows the truck to bypass a step regardless of following occurs.
the value setting of the motor maximum torque. • When the service brake pedal is pressed or the
Fully depress the accelerator pedal for 2 seconds. The parking brake is applied, the boost function is not
boost function increases the motor maximum torque for activated.
5 seconds. If the pressure on the accelerator pedal is • If the service brake pedal is pressed or the parking
reduced or the direction lever is moved, the boost brake is applied when the boost function is being
function will be canceled immediately. activated, the boost function will be canceled
immediately.
Torque [%]
* Torque required to
climb over a step
* #9
100 HIGH POWER; Full acceleration
85 STANDARD; Full acceleration

70 ECONOMY; Full acceleration
0 Time [sec]
2 7
211324
NOTICE: When the motor overheats, the boost will not work.
If the stall time setting is small, the motor protection function will be applied during prolonged slow
speed traveling.
(3) Limitation of maximum travel speed

This function limits the maximum travel speed (set by
SUO #7) of the truck. Some software versions may
need to be updated for this speed limit.
The limitation that functions at all times and is used to
keep the speed within the limits.
1-9
CONTROLLER
2. Regeneration
There are three types of regeneration control: the
Amount of auto regeneration
accelerator regeneration, lever regeneration and controlled [%]
roll-back. 100 Accelerator regen
(1) Accelerator regeneration (Auto regen)

The accelerator regeneration starts when the accelerator
pedal is released with the direction lever shifted into the
forward or reverse position during traveling.
The amount of regeneration is determined by the
accelerator regeneration characteristic (set by SUO #23).
0
1 2 3 4 5 6 7 8 9 10
Value of #23
211400
(2) Lever regeneration

The lever regeneration starts when the direction lever is Amount of lever regeneration
shifted into the position opposite to the truck traveling [%]
100
direction with the accelerator pedal depressed during
traveling.
The amount of regeneration is determined by the lever
regeneration characteristic (set by SUO #22).
0
1 2 3 4 5 6 7 8 9 10
Value of #22
211401
(3) Controlled roll-back
This function prevents hazardous descending of the truck
on a grade.
The controlled roll-back is activated when the accelerator Truck descends slowly when accelerator
pedal is released on a grade.
pedal is released on a grade with the direction lever shifted
into the forward or reverse position.
The descending speed changes with the steepness of grade
and the weight of load.
NOTICE: This is not a function to stop the truck when the
accelerator pedal is released on a grade. This
function is activated only in the output torque
211402
range of the traction motor.
1-10
CONTROLLER
Lifting Control Features

There are two types of lifting control system configuration
as described on page 1-1: the Contactor Control Type and Pump motor
the Transistor Control Type. output [%]
The Contactor Control Type controls the DC pump motor SUO #4, #5
by the contactor. The Transistor Control Type controls the 100 10
AC induction pump motor by the inverter.
1. Contactor Control Type 2

1
The pump contactor closes and drives the DC pump motor
when the hydraulic levers are operated with all the
0
conditions for closing the line contactor (described in the SW Close Lever operation
traction control features) satisfied. 211403
The lift work speed is controlled by not the controller but Pump motor output characteristics
the hydraulic control valve when the hydraulic levers are (MC type, tilt and attachment 1, 2 operations)
operated.
2. Transistor Control Type Pump motor

output [%]
The controller drives the AC induction pump motor when
SUO #3
the hydraulic levers are operated with all the conditions for
100
closing the line contactor (described in the traction control 10
features) satisfied. 9
8
When the hydraulic levers are operated simultaneously,
SUO #2
priority is given in the following sequence: the tilt,
attachment and lift-up.
2
1
0
SW1 SW2 Lever operation
close close
211404
Pump motor output characteristics

(MC type, lift-up operation)
Steering Control Features

The steering contactor closes and drives the steering motor
when all the conditions for closing the line contactor
(described in the traction control features) are satisfied.
This enables the power steering operation.
After the steering contactor is closed, if the key switch is
not turned off or if error related to the steering operation
does not occur, the steering contactor will open when the
seat switch is opened.
1-11
CONTROLLER
Diagnosis/Run/Setup (DRS) Modes

In addition to the normal operation mode for controlling
the traveling and lifting operations, the controller has
two other modes: a mode related to the truck failure and
a mode for setting the truck parameter as shown in the
table below.
Mode Description
Self diagnosis Performs failure diagnosis of each equipment.
Diagnosis Displays and deletes fault data that were detected and
Run time diagnosis
stored in normal operation mode.
Run Normal operation mode
Default data set Sets default data of Group 1 & Group 2.
Group 1 data set Sets basic function.
Setup
Group 2 data set Sets detailed function.
Group 3 data set Sets model information.
1. Mode setting with DRS switch

To enter each mode, turn off the key switch and set the
DRS switch to the required position, then turn on the key R
switch. S D
NOTICE: If the DRS switch is set with the key switch

Pull
turned on, the mode will not be changed.
To enter the Diagnosis and Setup modes, it is required to

operate the seat switch, accelerator pedal, direction lever
211195
and hydraulic levers in addition to the DRS switch setting.
See “Setup Option” and “Diagnosis” for further details.
1-12
CONTROLLER
2. Mode setting on display unit (for setting SUO #1

of Setup Option Group 1)
The SUO #1 of the Setup Option data can be set (checked
and changed) by pressing the buttons on the display unit in
the RUN mode.
The setting procedures are as follows.
See “Setup Option” for details of SUO #1.
2.1 Turning on key switch in RUN mode

(1) Turn off the key switch, then set the DRS switch to the
RUN position.
(2) Turn on the key switch.
The mode becomes RUN mode (The traveling and lifting
operations can be performed). The display unit shows the
clock, truck speed and BDI (Battery Discharge
Indicator).
2.2 Setting SUO #1 (checking and changing data)

To check data, perform the following procedures.
(1) Turn off all the operations (Turn off the direction lever,
accelerator pedal and hydraulic lever operations).
(2) Press the right button on the display unit. Left button Right button
The mode changes to the data checking mode for SUO 211405
#1.
(Pressing the right button 4 seconds or more
changes the mode to the data changing mode.)
• The clock indication of the display unit changes to the
current data indication of SUO #1.
• The truck speed and BDI indications do not change.
E F
“APP-A” lights. When “A” is set

for SUO #1
211406
1-13
CONTROLLER
(3) When terminating the data checking mode for SUO #1,
perform the following procedure.
• Press the left button on the display unit.
The mode changes to RUN mode.
• Press the right button on the display unit.
• Press the right button 4 seconds or more.
The mode changes to the data changing mode for
SUO #1.
To change data, perform the following procedures.

(1) Perform steps (1) and (2) of the data checking
procedures to change the mode to the data checking
mode.
(2) Press the right button on the display unit 4 seconds or
more. The mode changes to the data changing mode for
SUO #1.
• Current data of SUO #1 flickers. This enables to
E F
change the SUO #1 data.
“APP-A” flickers. When “A” is set

for SUO #1
211407
(3) Press the left button on the display unit to change the
SUO #1 data.
E F
“APP-b” flickers.
211408
(4) When terminating the data changing mode for SUO #1,
perform the following procedure.
• Press the right button on the display unit.
1-14
CONTROLLER
NOTICE: • If the direction lever, accelerator pedal or

hydraulic lever is operated during SUO #1
setting, the SUO #1 setting will be canceled.
• When the display unit shows the error code
(except for “E” flickering and “L” flickering),
SUO #1 setting can not be performed.
If the error code is displayed during SUO #1
setting, the SUO #1 setting will be canceled.
1-15
CONTROLLER
Safety Function
1. PDS (Presence Detection System)
(1) Preventing operator's absence

This function prevents the truck from traveling or
lifting without the operator sitting on the seat.
For details, see the table below.
Prevention result
Item When turning on power, During normal operation,
operator is not on seat. operator is not on seat.
Stop Deceleration and stop
Traveling
Error code “E” flickers. Error code “E” flickers.
Stop Stop
Lifting
Error code “L” flickers. Error code “L” flickers.
Line contactor OPEN OPEN after truck stops.
Stop
Steering Operated
(Steering contactor OPEN)
(2) Preventing lever and accelerator pedal

operations
This function prevents the truck from traveling or
lifting when turning on the key switch with the levers
or accelerator pedal operated.
This also prevents the truck from traveling or lifting
even if the line contactor closes when the operator is on
the seat again after leaving the seat.
For details, see the table below.
Prevention result
Operated item When operator is on seat again
When turning on power
after leaving seat
Direction lever Traveling, lifting and steering stop. Traveling and lifting stop.
or accelerator pedal Error code “E” lights. Error code “E” lights.
Traveling, lifting and steering stop. Traveling and lifting stop.
Lift lever
Error code “H1” lights. Error code “H1” lights.
Traveling, lifting and steering stop. Traveling and lifting stop.
Tilt lever
Error code “H2” lights. Error code “H2” lights.
Attachment 1 lever Traveling, lifting and steering stop. Traveling and lifting stop.
or attachment 2 lever Error code “H3” lights. Error code “H3” lights.
1-16
CONTROLLER
(3) Preventing lift down

This function prevents the lift from lowering when the lift
lever is operated with the key switch turned off.
The lift does not lower as the lift lock valve is closed when
the key switch is turned off (when the control system is not
controlled by the controller).
(4) Warning buzzer

• Parking brake warning
The buzzer sounds when the key switch is turned off or
the operator leaves the operator's seat with the parking
brake not applied.
• Seat belt warning
The buzzer sounds when the seat belt is not fastened
with the operator on the operator's seat.
2. Stall timer
Traction Motor Stall Timer (Error code 16) error occurs to
prevent the traction motor from overheating when the truck
traveling is blocked for several seconds and the accelerator
pedal is fully depressed.
The time to shut down the truck can be set by SUO #20.
1-17
CONTROLLER
Other Features 3. Tire size
1. BDI (Battery Discharge Indicator) Tire diameter change resulting from tire wear can be
compensated for by SUO #27.
The BDI shows the remaining battery capacity of the
This setting is used to adjust the truck speed indication
current battery voltage with 11 levels from BDI 0 to
when it differs from the actual speed by tire wear.
BDI 10.
Set the BDI by SUO #40 and SUO #41 depending on
the installed battery type and voltage.
If the previous indication is BDI 4 or less and the
following indication is not BDI 7 or more when turning
on the key switch, the BDI will show the previous
indication.
When the battery voltage lowers, the following output
power control is activated by the BDI function to
protect the battery.
Control by BDI 1: Traveling is limited.
Control by BDI 0: Traveling and lifting are limited,
and simultaneous operations of
traveling and lifting are inhibited.
2. Service indicator
The maintenance time and the selection of output
power control can be set by SUO #10.
The service indicator starts flickering 20 hours before
the set maintenance time, and remains lit when the
truck hour meter indication reaches the set time.
If the output power control is selected at SUO #10, the
output power control will also be activated at the same
time to limit the traveling and lifting operations.
1-18
CONTROLLER
Setup Option turned off.

The model information and various features are set
Outline during factory shipment.
The logic unit is equipped with a type of memory The setup options are categorized from Group 1 to
module to hold recorded data even if the main power is Group 3 according to the feature levels.
Setup group
Group Description
Group 1 Basic function (#1 to #10)
Group 2 Detailed function (#20 to #27)
Group 3 Model information (#40 to #47)
The Group 1 and 2 are available to set the default value each setup mode.
in a one-step operation and can be customized in Summary list in each group is shown on page 1-34 to 1-
accordance with applications. Since the Group 3 is for 37.
model information, it is required to be set to the same
value as actual control system. It will not work properly
if the model information is different. Operation Procedure
When setting the setup option data for the first time Turning on the key switch allows you to enter one of
after the assembly is completed or the logic card is the modes in each setup group and is displayed as the
replaced, be sure to set Group 3 data first, then the figure. You can not transfer to another mode unless the
default data of Group 1 and 2, with the “service tool” in source power is turned off.
Entry to setup mode
DRS Direction Accel. Lift Tilt Attachment 1

Function Description Seat
switch lever pedal lever lever lever
Default data Sets default data of Not
S R ON OFF OFF OFF
set Group 1 & Group 2. sit
Checks and sets basic Not
Group 1 data S N OFF OFF OFF OFF
function (#1 to #10). sit
Checks and sets detailed Not Pull
Group 2 data S N OFF Pull OFF
function (#20 to #27). sit back
Checks and sets model Not Pull
Group 3 data S N OFF OFF OFF
information (#40 to #47). sit back
First SUO # of each group

“01” for group 1
Current set value for SUO #20

donE is flickering for Default data set 211409 *The current value is displayed. For the meaning of
each number or symbol displayed, refer to the
First SUO # of Group 2 setup options (example) “Range” column of the relevant Setup Options
table and Notes below the table.
1-19
CONTROLLER
Selecting SUO # and changing set value

How to change set value
The set value change procedure consists of selecting the When changing setting of SUO #7 (Top Travel Speed
desired SUO # using the DRS switch, changing the set Limit) from default 15 km/h to 13 km/h:
value by moving the direction lever, and registering the new
value. Step 1. Since the SUO #7 belongs to Group 1 setup
options, cause the first SUO # “01” of the group
to appear on the screen using the operation
• Cycle the DRS switch S → R → S. The set value procedure on page 1-19.
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 first half of the DRS switch operation (S→R) is for Step 2. Move the DRS switch as follows to change the
overwriting the previous value with the value on the current setting for the SUO #7.
screen (registering). When the value is registered, a set R
S (1) Move the DRS switch S → R.
of three dotted lines appears on the screen as shown in Pull The display changes as shown
the illustration on the right. The second half of the below. The set value (A) for
operation (R→S) is for advancing the SUO #. the SUO #1 is overwritten
simultaneously.
• Every time the DRS switch is cycled S→R→S, the SUO
# increments. When advancing the SUO # without
changing the set value, simply repeat by cycling 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
Pull The display shows the current
• Use the direction lever to change the set value. The
setting for the next SUO #2.
value increases when the lever is cycled N→F→N; it
decreases when the lever is cycled N→R→N. In either
case, by 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 4 times to cause the
SUO #7 to appear on the screen.
Default value 15 for SUO #7
Step 3. Change the set value from 15 to 13 by moving

the direction lever N→R twice.
Value increases.
Direction
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 #8. 211410
1-20
CONTROLLER
Details of Setup Options

1. Setup Options (Group-1)
#1 Application Pre-Sets (Truck Operation Mode)

Truck mode can be selected from A to E, each with
preset values for maximum vehicle speed, acceleration
rate, power, automatic regeneration power, start lift
speed, top lift speed and tilt speed.
These 7 settings are automatically set by changing the
value of this setting.
Preset values for each setting are as follows. The setting
range is A to E. (When #40 is set for “EE type” and #43
is set for “MC Contactor Control Type”: C only.)
For procedures for setting on the display unit, see page
1-13 in the “Controller Features.”
• 48V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Fast
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 9 10 8 9 10 3
Tilt Speed 7 7 7 7 7 4
Max Vehicle Speed 15 18 12 or 14*1 17 15 7
Default value
Acceleration Rate 3 5 2 3 5 8
Traveling Power 2 3 1 2 3 9
Automatic
7 7 7 7 7 23
Regeneration
*1
: When #41 is set for “48 volts” and #43 is set for
“MC Contactor Control Type”, mode C is 14 [km/h].
For setting other than above, mode C is 12 [km/h].
You can modify these 7 settings afterwards individually
provided you have software version 0043 and higher.
When settings are changed the indication (A to E) will
be flickered to indicate that the settings are modified.
1-21
CONTROLLER
• 36V type mode setting
SUO#
Mode A b C d E 1
Feature/ HIGH LONG SHORT
STANDARD ECONOMY
Application POWER DISTANCE SHUTTLE
Lift Medium Fast Slow Medium Medium
Tilt Medium Medium Medium Medium Medium
Vehicle speed Medium Fast Slow Fast Fast
Characteristic
Acceleration Medium Fast Medium Medium Fast
Power Standard Powerful Economy Powerful Standard
Regeneration Medium High Low Medium High
Start Lift Speed 1 1 1 1 1 2
Top Lift Speed 9 10 8 9 10 3
Tilt Speed 7 7 7 7 7 4
Max Vehicle Speed 15 18 or 17*1 12 or 11*2 17 15 7
Default value
Acceleration Rate 3 5 2 3 5 8
Traveling Power 2 3 1 2 3 9
Automatic
7 7 7 7 7 23
Regeneration
*1
: When #40 is set for “2.0 tons or more” and #41 is set
for “36 volts”, mode b is 17 [km/h].
For setting other than above, mode b is 18 [km/h].
*2
: When #40 is set for “less than 2.0 tons”, #41 is set
for “36 volts” and #43 is set for “MC Contactor
Control Type”, mode C is 11 [km/h].
For setting other than above, mode C is 12 [km/h].
#2 Start Lift Speed

This setting affects pump speed when you start lifting
operation.
MC spec: speed when lift switch 1 is turned on
Lift speed of the rise direction will become faster if the
setting value is increased.
The setting range is 1 to 10 for all models.
1-22
CONTROLLER
#3 Top Lift Speed

Pump motor
This setting affects pump speed when you pull the lift lever. output [%]
If you set a smaller value than #2, then the #2 setting will SUO #3
be ignored. 100
10
MC spec: speed when lift switch 2 is turned on 9
8
Lifting speed will become faster if the value setting is
SUO #2
increased.
The setting range is 1 to 10 for all models.
2
1
0
SW1 SW2 Lever operation
close close
211404
Pump motor output characteristics

(MC type, lift-up operation)
#4 Tilt Speed
Tilt speed is locked and not adjustable. Tilt speed can be Pump motor
changed by replacing the flow screw in the hydraulic output [%]
control valve tilt section.
SUO #4, #5
100 10
2
1
0
SW Close Lever operation
1-23
CONTROLLER
#5 Auxiliary 1 Speed
This setting affects pump speed when you operate the
attachment 1 lever.
MC spec: speed when attachment 1 switch is turned on
Attachment 1 speed will become faster if the value
setting is increased. The range setting is 1 to 10 for all
models.
This setting is not used for all models.
Attachment 2 speed is the same as attachment 1 (#5).
#7 Top Travel Speed Limit

This setting affects maximum truck speed without load.
Truck speed with load will be less than this setting. This
setting affects top speed, and does not affect gradability
or acceleration. For this option to lock in speed,
software version 0043 and higher must be installed.
The range setting is 5 to 18 [km/h].
[When #40 is set for “2.0 tons or more (except for EE
type)”, #41 is set for “36 volts” and #43 is set for “MC
Transistor Control Type”: 5 to 17.]
[When #40 is set for “less than 2.0 tons (EE type)”, #41
is set for “36 volts” and #43 is set for “MC Contactor
Control Type”: 5 to 11.]
[When #40 is set for “2.0 tons or more (EE type)”, #41
is set for “36 volts” and #43 is set for “MC Contactor
Control Type”: 5 to 12.]
[When #41 is set for “48 volts (EE type)” and #43 is set
for “MC Contactor Control Type”: 5 to 14.]
#8 Acceleration Rate
This setting affects response time to calculate speed
order from accelerator pedal position.
Acceleration of trucks becomes faster if the value
setting is increased.
The range setting is 1 to 5.
(When #40 is set for “EE type” and #43 is set for “MC
Contactor Control Type”: 1 to 2.)
1-24
CONTROLLER
#9 Traveling Power
This setting affects speed order which is calculated The figure is a torque characteristic at the time of
from accelerator pedal position. Powering.
The values are selected from three types : ECONOMY,
STANDARD and HIGH POWER. (When #40 is set for
“EE type” and #43 is set for “MC Contactor Control
Type”: ECONOMY only.)
Torque
[%]
100
HIGH POWER(3)
STANDARD(2)
ECONOMY(1)
Brake limit
APPROXIMATELY 400 AMPS CURRENT LIMIT
Thermal, BDI [0] or Service indicator
0 5 10 15 20 Speed
[km/h] 211399
*1 *2
Brake limit : Torque value resulting from reduction in Thermal, BDI [0] or Service indicator :
current when the service brake or Curve of limited torque under a condition of
parking brake is applied. overheating or battery voltage low or
maintenance time over.
#10 Service Indicator
This setting sets the maintenance time. The time set You can reduce the truck power when the LED flickers
here is added to the truck’s hour meter and that value is by setting the service indicator selection. You can also
stored in memory as the “maintenance time.” set the demo-mode, which shows the Service Indicator
When the truck’s hour meter reaches maintenance time, function in a short period of time.
the service reminder LED turns on. The setting value is as follows.
It will flicker 20 hours before the time.
– 6 min (test) 100 150 In increments 950 1000
Maintenance time [hour]
of 50
Invalid 0
Set data on display Only warning 0.1 100 150 ····· 950 1000
Torque limit =0.1 =100 =150 ····· =950 =1000
The present hour meter time will be registered if the
DRS switch is operated after the display of #10.
Resetting Service Reminder Interrupt 6. Turn key to ON position.
To reset the Wrench Icon 7. Toggle DRS Switch from Setup to Run them back to
1. Set the park brake. Setup to advance to the next option.
2. Turn the key off. 8. Toggle the DRS Switch until you pass option 9* (or
10 depending on model), and stop.
3. Open door panel.
9. When the word “donE” is noticed on the Operator
4. Place DRS switch in Setup. display, in the Hour Meter & Clock area, the Service
5. Plug in battery (if unplugged). Indicator (wrench symbol) will turn off.
1-25
CONTROLLER
#11 Auxiliary Input for Lift and Drive Speed 1 When software version 0043 is installed this option
(Harness pin No. 47) is activated.
#12 Auxiliary Travel Speed Limit 1 When software version 0043 is installed this option
#13 Auxiliary Power Reduction 1 (Harness pin When software version 0043 is installed this option
No. 47) is activated.
#16 Auxiliary Power Reduction 2 When software version 0043 is installed this option
1-26
CONTROLLER
.
#19 Auxiliary Power Reduction 3 When software version 0043 is installed this option
#20 Stall Timer

This setting shuts down the truck when the traction
motor torque is very high (about 90% of maximum) and
the wheels are not turning. This function is used to
detect pulse sensor faults and to prevent the controller
from overheating.
The setting range is 2 to 10 [second] for all models.
#21 Regen Function

1-27
CONTROLLER
#22 Regen Adjustment for Lever Regen

This setting defines the “Lever regen” characteristic.
When the direction lever is shifted into the position
opposite to the truck’s traveling direction, the “Lever
regen” function is activated. The “Lever regen”
characteristic is shown in this diagram. The setting
range is 1 to 10 for all models.
Amount of lever regeneration

[%]
100
0
1 2 3 4 5 6 7 8 9 10
Value of #22
211401
Amount of deceleration when the accelerator pedal is

released is determined by #23.
1-28
CONTROLLER
#23 Regen Adjustment for Auto Regen

This setting defines amount of deceleration when
“Auto regen” is activated. The setting range is 1 to 10
for all models.
Amount of auto regeneration

[%]
100 Accelerator regen
0
1 2 3 4 5 6 7 8 9 10
Value of #23
211400
#26 Speed Alarm 1 (Harness pin No. ------)

#27 Tire Size Adjustment

This setting is used to adjust the truck speed indicator.
1 digit equals 1 mm (0.04 in.) of wear in the diameter.
Default setting is 20.
When the tire diameter becomes 8 mm (0.31 in.)
smaller than original, set 12 into this setting.
The setting range is 0 to 40 for all models. This allows
fitting a bigger diameter wheel.
1-29
CONTROLLER
#30 Auxiliary Input for Travel Speed (Harness pin No.

53)
#31 Auxiliary Maximum Travel Speed Setting

(Harness pin No. 53)
#32 Auxiliary Output Power Limit

(Harness pin No. 53)

#34 Speed Alarm 2

(Harness pin No. ------)
#35 Lowering Speed Adjust

1-30
CONTROLLER
#40 Truck Type

This setting defines the type of truck.
The setting value is as follows.
Display value Model

II II II II II No setting
15 FBC15N
15EE FBC15NEE
18 FBC18N, FBC18LN
18EE FBC18NEE, FBC18LNEE
20 FBC20N
20EE FBC20NEE
25 FBC25N, FBC25LN, FBC25EN
25EE FBC25NEE, FBC25LNEE, FBC25ENEE
30 FBC30N, FBC30LN
30EE FBC30NEE, FBC30LNEE
! CAUTION
If the truck type setting is incorrect, the truck may
show unexpected movement.
#41 Battery Voltage

This setting defines the voltage of battery carried in the truck.
The setting value is 36 or 48 [v].
No setting shows “II II II II II.”
1-31
CONTROLLER
#42 Battery Type

This setting defines the type of battery carried in the
truck.
The setting value is 0, 1 or 2.
0: Normal 1: Tubular 2: Reserve
This value selects Battery Discharge Indicator (BDI)
table. The table is as follows.
Normal BDI Tubular BDI
BDI# 36V 48V BDI# 36V 48V

0 – 34.4 – 45.9 0 – 35.2 – 46.9
1 34.5 – 34.8 46.0 – 46.4 1 35.3 – 35.5 47.0 – 47.3
2 34.9 – 35.2 46.5 – 46.9 2 35.6 – 35.8 47.4 – 47.7
3 35.3 – 35.6 47.0 – 47.4 3 35.9 – 36.1 47.8 – 48.1
4 35.7 – 36.0 47.5 – 47.9 4 36.2 – 36.4 48.2 – 48.5
5 36.1 – 36.4 48.0 – 48.4 5 36.5 – 36.7 48.6 – 48.9
6 36.5 – 36.7 48.5 – 48.9 6 36.8 – 37.0 49.0 – 49.2
7 36.8 – 37.0 49.0 – 49.8 7 37.1 – 37.2 49.3 – 49.5
8 37.1 – 37.3 49.4 – 49.7 8 37.3 – 37.4 49.6 – 49.8
9 37.4 – 37.6 49.8 – 50.1 9 37.5 – 37.6 49.9 – 50.1
10 37.7 – 50.2 – 10 37.7 – 50.2 –
Reserve BDI
BDI# 36V 48V

0 – –
1 – –
2 – –
3 – –
4 – –
5 – –
6 – –
7 – –
8 – –
9 – –
10 – –
1-32
CONTROLLER
#43 Hydraulic Control Selection #46 Battery Voltage Adjust

This setting defines the type of hydraulic control. This setting corrects the gap of the battery voltage
1: MC system (Transistor Control Type) which the controller recognizes, and actual battery
voltage. The display shows battery voltage which the
2: MC system (Contactor Control Type)
controller recognizes.
#44 Mast Type Measure actual battery voltage using a tester (or a
This setting defines the type of the mast. multi-meter) and operate the direction lever to adjust
the value.
2-FF: 2-stage full-free 3-FF: 3-stage full-free
Refer to the “Measurement of battery voltage” below.
2-SP: 2-stage panorama
NOTE: This setting may be adjusted lower than battery
#45 Valve Section voltage to achieve lift lockout at a higher voltage and
This setting is not used for all models. higher specific gravity.
Direction lever Accelerator pedal Value change [V]

N→F – +0.1
N→R – –0.1
F Release → depress +10
R Release → depress –10
Line
Pump contactor Steering
contactor contactor
- +
Battery
49.6V
V
- + Set 49.6 on display.
Tester or Multi-meter
Traction
inverter 211411
Measurement of battery voltage

#47 Foot Direction
This setting defines the foot direction option.
1: Standard direction lever
2: Foot Directional Control (FoDiCo)
1-33
CONTROLLER
Setup Options (Group 1)
Option Default
Title of Option Description Range
# Value
The value setting of the following 7 items
are registered beforehand.
Application Pre-Sets Top travel speed, Acceleration rate,
#1 A, b, C, d, E A (4)
(Truck Operation Mode) Traveling power, Regen adjustment, Start
(1), (4)
lift speed, Top lift speed, Tilt speed.
Refer to the explanation for details.
Beginning lift speed
Start lift speed cannot exceed top lift
#2 Start Lift Speed 1 to 10 1
speed.
(1: SLOW → 10: FAST)
Lift speed when operating the lever at
#3 Top Lift Speed 1 to 10 9 (4)
maximum
#4 Tilt Speed Speed setting for tilt 1 to 10 7
#5 Auxiliary 1 Speed Speed setting for attachment 1 1 to 10 3
#6 Auxiliary 2 Speed Not used – –
5 to 18 [km/h]
#7 Top Travel Speed Limit Maximum travel speed 15 (4)
or 5 to 17 [km/h] (3), (4)
Choice of acceleration rate
#8 Acceleration Rate 1 to 5 (4) 3 (4)
(1: SLOW → 5: FAST)
Choice of powering characteristic
#9 Traveling Power (1: ECONOMY, 2: STANDARD, 3: HIGH 1, 2, 3 (4) 2 (4)
POWER)
This function notifies service personnel 0, 0.1,
that maintenance time is approaching or 100, 150, ...950, 1000,
has passed. =0.1 (6 min.),
It means the lapsed time when setting up. =100, =150, ..=950, =1000
#10 Service Indicator Approached : !LED flicker (20 hour) (In increments of 50 [hour]) 0
Passed : !LED turn on
and power reduction (selected) ì= ”: power reduction
(2) 0: no action
NOTICE: (1) Before changing, when parameter data are different from the values of the selected mode, the truck
mode indicator (A to E) flickers.
When the truck mode is changed, all parameter data is replaced by the set values of the selected
mode.
(2) The data from the truck hour meter at set time is saved apart from the selected value. If the key switch
is turned off without setting the DRS switch to R, the data at set time is maintained.
When the DRS switch is set to R, the data at set time is replaced by the current truck hour meter data.
(3) When #40 is set for “2.0 tons or more” and #41 is set for “36 volts”, the setting range is 5 to 17
[km/h].
For setting other than above, the setting range is 5 to 18 [km/h].
1-34
CONTROLLER
(4) When #40 is set for “EE type” and #43 is set for “MC Contactor Control Type”, the setting range
and default value of each Setup Option data are as follows.
Option Default
Range
# Value
#1 C only C
#3 1 to 10 8
(#40 “less than 2.0 tons” and #41 “36 volts”) 5 to 11 11
#7 (#40 “2.0 tons or more” and #41 “36 volts”) 5 to 12 12
(#41 “48 volts”) 5 to 14 14
#8 1 to 2 2
#9 1 only 1
Option Title of Option Description Range Default Harness

# Value Pin No.
When the auxiliary input 1 signal is on, 0: Disable
travel speed or lift speed is limited to 1: Disable lift (switch closed)
set value. 2: Speed limit (switch closed)
Auxiliary Input for The amount of maximum speed is 3: Power reduction — 47
#11 Lift and Drive defined at #12. (switch closed)
Speed 1 The amount of power reduction is 4: Disable lift (switch open)
defined at #13. 5: Speed limit (switch open)
6: Power reduction
(switch opened)
#12 Auxiliary Travel Travel speed Limit for #11 5 to 17 [km/h] — 47

Speed limit 1
#13 Auxiliary Power Traction Power reduction ratio for #11 0 to 100 [%] — 47
Reduction 1

Auxiliary Input for The amount of maximum speed is 3: Power reduction
#14 Lift and Drive defined at #15 (switch closed) — 39
Speed 2 The amount of power reduction is 4: Disable lift (switch opened)
defined at #16 5: Speed limit (switch opened)
6: Power reduction
(switch opened)
#15 Auxiliary Travel Travel speed limit for #14 5 to 17 [km/h] — 39

Speed limit 2
Reduction 2
1-35
CONTROLLER
Option Title of Option Description Range Default Harness

# Value Pin No.
#17 Lift and Drive defined at #18. (switch closed)
Speed 3 The amount of power reduction is 4: Disable lift (switch opened)
defined at #19. 5: Speed limit (switch opened)
6: Power reduction
(switch opened)
#18 Auxiliary Travel Travel speed Limit for #17 5 to 17 [km/h] — 30

Speed limit 3
Reduction 3
This option allows to shut down truck

#20 Stall Timer when the traction motor torque is too 2 to 10 [sec] 5 —
high and wheels are not turning.
#21 Regen Function Not used — — —
#22 Regen Adjustment 10 steps for regen power on lever regen 1 to 10 7 —

for Level Regen
#23 Regen Adjustment 10 steps for regen power on 1 to 10 5 —

for Auto Regen brake/accelerator regen
#26 Speed Alarm 1 Not used — — —
#27 Tire Size Adjusts the amount of tire wear. It 0 to 40 — —

Adjustment changes truck’s speed recognition. (diameter -20 to +20mm)

#30 Travel Speed defined at #31 (switch closed)
The amount of power reduction is 4: Disable lift (switch opened)
defined at #32 5: Speed limit (switch opened)
6: Power reduction
#31 Auxiliary Maximum Travel speed limit for #30 5 to 17 [km/h] — 53

Travel Speed Setting
#32 Auxiliary Output Traction Power reduction ratio for #30 0 to 100 [%] — 53
Power Limit
#33 Auxiliary 3 Speed Not Used — — —
#34 Speed Alarm 2 Not Used — — —
#35 Lower Speed Adjust Not Used — — —
1-36
CONTROLLER
Option Default
Title of Option Description Range
# Value
This option is used to set the size and type
15 (E3000) to 30EE
#40 Truck Type of the truck. –
(E6000EE) 10 patterns
This option is used to set the voltage of
#41 Battery Voltage 36, 48 [V] –
the battery.
This option is used to set the type of the
0: Normal BDI
battery.
#42 Battery Type 1: Tubular BDI –
The electric discharge characteristic of a
2: Reserve BDI
battery changes with battery type.
1: MC specification
Hydraulic Control This option is used to set the type of the (Transistor Control Type)
#43 –
Selection hydraulic control. 2: MC specification
(Contactor Control Type)
2FF: 2-stage full-free
This option is used to set the type of the
#44 Mast Type 3FF: 3-stage full-free –
mast.
2SP: 2-stage panorama
#45 Valve Section Not used – –
This setting corrects the gap of the battery
voltage which the controller recognizes,
and actual battery voltage.
Measure actual battery voltage and
operate the direction lever in order to
#46 Battery Voltage Adjust 5.0 to 120.0 [V] –
adjust the value which is shown on the
display to actual battery voltage.
N→F: +0.1 F, Accel off→on: +10
N→R:–0.1 R, Accel off→on: –10
Refer to the explanation for operation. (4)
1: Standard direction lever
This option is used to enable the function
#47 Foot Direction 2: Foot Directional Control –
for foot direction option.
(FoDiCo)
NOTICE: (1) The data of group 3 has no default value, but it needs to set data by the actual truck type. If the
value and the truck model aren’t in agreement, the truck does not operate normally.
(2) When you set up for the first time, set up group 3 first, and then set default data of group 1 and 2.
(3) If SUO data is not set, “| |” is displayed.
(4) This value was adjusted at the time of LOGIC CARD inspection. Adjust the value, when the value
shown on the display is different from actual battery voltage.
(5) Use this option to achieve the lift lockout at the designed battery voltage.
(6) Setting volts lower than battery volts will activate lift lock out at a higher voltage.
(7) Setting higher than battery voltage will discharge the battery to a deeper level.
1-37
CONTROLLER
Diagnosis
Outline
The controller monitors status of various input/output
equipment to allow diagnosis of truck’s malfunction.
There are two types of diagnosis: Run Time Diagnosis,
diagnosis during normal operation, and Self Diagnosis,
performing equipment check during maintenance.
Diagnosis
Diagnosis Description
Self diagnosis Checks function of each equipment.
Run time diagnosis Diagnosis during normal operation
The logic unit is equipped with a type of memory

module to hold recorded data even if the main power is
turned off. The errors occurring during truck use are
compared with the Run Time Diagnosis and recorded so
as to be able to show.
Operation Procedure
To perform the Self Diagnosis or review the fault data
stored by the Run Time Diagnosis, perform the
following procedure.
Turning on the key switch allows you to enter each
diagnosis mode. You can not transfer to another mode
unless the source power is turned off.
Entry to diagnosis mode
Function DRS switch Seat Lift lever Tilt lever
Self diagnosis D – – –
Run time diagnosis D Not sit ON ON
1-38
CONTROLLER
Self Diagnosis
Perform the Self Diagnosis using the following
procedure.
1. Preparatory operations
Perform the following procedures.
(1) Place the parking brake lever in the locked position.
(2) Turn OFF the key switch.
(3) Disconnect the battery plug.
(4) Discharge all inverters. See page 1-45.
(5) Place the direction lever in the N position.
(6) Place all the hydraulic levers in their OFF
positions.
(7) Set the DRS switch to the D (diagnosis) position.
R
(8) Remove the traction fuse, pump fuse and steering
S D
fuse.
(9) Connect the battery plug. Pull
2. Diagnosis procedure
Perform the procedure using the Self-Diagnostics table
in accordance with the following guide.
211195
(1) Start diagnosis with the Step 0 item in the table.
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
Diagnosis result indication
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 removing the fuse
or when all the hydraulic levers are not placed in
their OFF positions. In this case, diagnosis is
prohibited from going even to the first step. 209561
(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.
1-39
CONTROLLER
(3) When all the step items have been checked through,
turn OFF the key switch and place the DRS switch in R
the R position. Do not forget to reinstall the traction S D
fuse, pump fuse and steering fuse.
Pull
• Turn OFF the key switch to exit from the diagnosis
mode.
• Repair all faults found immediately after diagnosis.
Diagnosis procedure requires moving the DRS switch to
211196
the D or R position. Follow the instructions in the
diagnosis procedure guide above as well as those in the
applicable boxes in the “Do this” column.
Fault Data Record of Run Time Diagnosis

When the fault is detected by the Run Time Diagnosis, the
Battery discharge indicator
fault data will be stored in the memory of the logic card. at the time of fault
The fault data includes the error code, the battery discharge
indicator at the time of fault and the vehicle hourmeter
reading at the time of fault. The stored data is maintained
even if the key switch is turned off.
E F
The maximum number of faults that can be stored in the
memory is 32. When faults exceeding 32 occur, the oldest
data will be erased to accommodate new data.
The data on the latest fault will appear on the display unit.
After all the fault data are reviewed or when there are no Vehicle hourmeter reading Error code
data items stored for the fault, “donE” will appear. at the time of fault
211412
Perform the following procedures to review the stored fault
data.
• To review the data of the next older fault
Move the DRS switch from the D position to the R
position and then back to the D position.
• To review the data of the latest fault again E F
With “donE” appeared on the display after all the fault
data are reviewed, move the DRS switch from the D
position to the R position and then back to the D
position.
• To delete all the stored fault data After all the fault data are reviewed or when
there are no data items stored for the fault,
With “donE” appeared on the display after all the fault "donE" will appear.
data are reviewed, move the DRS switch from the D When all the stored data have been deleted,
position to the R position and then to the S position. "donE" flickers.
When all the stored data have been deleted, “donE” 211413
flickers. Never turn off the key switch until “donE”
flickers.
NOTICE: If the key switch is turned off before data
deletion is completed, erroneous data will be
displayed when reviewing the fault data. In this
case, be sure to delete all the stored fault data
by using the proper procedure again.
1-40
CONTROLLER
Self-Diagnostics (Hydraulic control: Transistor Control Type)

Step Checking Do this Controller check this Result Display Contactor operation
Power line Close line contactor and Pass 01 Line contactor and
0 voltage Turn on key switch. steering contactor, and steering contactor
*
(Fuse check) check power line voltage. Fail dd close and open.
Release & press & release Input Pass 02
1 Seat switch
seat SW. OFF → ON → OFF Fail 01
Direction Cycle direction lever. Input changes as Pass 03
2
switch N→R→N→F→N N→R→N→F→N Fail 02
Release & depress & Input Pass 04
3 Parking brake
release parking brake. OFF → ON → OFF Fail 03
Depress and release Input Pass 05
4 Service brake
service brake. OFF → ON → OFF Fail 04
Number 0 to 15 flickers as
Depress accelerator and Pass
accelerator is pressed.
5 Accelerator release.
Fail -
DIAG → RUN - 07
Check battery voltage: Pass 08
7 Battery voltage Automatic
(34V-51V) Fail 07
Input Pass 09
8 Lift switch Pull and release lift lever. OFF → ON (lift up) → OFF
Fail 08
→ ON (lift down) → OFF
Input Pass 10
9 Tilt switch Pull and release tilt lever.
OFF → ON → OFF Fail 09
Auxiliary 1 Pull and release Aux. 1 Input Pass 11
10
switch lever. OFF → ON → OFF Fail 10
11
Pull any lever and see Pass Flickering pump speed value
Hydraulic
13 display. Fail Other than above
speed check
RUN → DIAG → RUN - 14
Pass 14 Contactor closes.
RUN → DIAG See line contactor close. Contactor does not
Fail 14
close.
14 Line contactor
Pass 16 Contactor opens.
DIAG → RUN See line contactor open. Contactor does not
Fail 16
open.
See steering contactor
RUN → DIAG Contactor does not
close. Fail 16
Steering close.
16
contactor Pass 98 Contactor opens.
DIAG → RUN Contactor does not
open. Fail 98
open.
Controller
See software version No.
98 software RUN → DIAG → RUN - donE
in hourmeter.
version
* (dd indicates the fuse needs to be removed.
1-41
CONTROLLER
Self-Diagnostics (Hydraulic control: Contactor Control Type)
Step Checking Do this Controller check this Result Display Contactor operation
Close line contactor, Line contactor,
Power line Pass 01
pump contactor and pump contactor and
0 voltage Turn on key switch.
steering contactor, and * dd steering contactor
(Fuse check) Fail
check power line voltage. close and open.
Release & press & release Input Pass 02
1 Seat switch
seat SW. OFF → ON → OFF Fail 01
Direction Cycle direction lever. Input changes as Pass 03
2
switch N→R→N→F→N N→R→N→F→N Fail 02
Release & depress & Input Pass 04
3 Parking brake
release parking brake. OFF → ON → OFF Fail 03
Depress and release Input Pass 05
4 Service brake
service brake. OFF → ON → OFF Fail 04
Depress accelerator and Pass Number 0 to 15 flickers as
accelerator is pressed.
5 Accelerator release.
Fail -
DIAG → RUN - 07
Check battery voltage: Pass 08
7 Battery voltage Automatic
(34V-51V) Fail 07
Input Pass 09
8 Lift switch Pull and release lift lever. OFF → ON (lift up) → OFF
Fail 08
→ ON (lift down) → OFF
Input Pass 10
9 Tilt switch Pull and release tilt lever.
OFF → ON → OFF Fail 09
10
11
Pull any lever and see Pass Flickering pump speed value
Hydraulic
13 display. Fail Other than above
speed check
RUN → DIAG → RUN - 14
RUN → DIAG See line contactor close. Contactor does not
Fail 14
close.
14 Line contactor
Pass 15 Contactor opens.
DIAG → RUN See line contactor open. Contactor does not
Fail 15
open.
See pump contactor
close. Fail 15
Pump close.
15
See pump contactor
open. Fail 16
open.
close. Fail 16
Steering close.
16
open. Fail 98
open.
Controller
See software version No.
98 software RUN → DIAG → RUN - donE
in hourmeter.
version
* (dd indicates the fuse needs to be removed.
1-42
CONTROLLER
Run Time Diagnostics

Display
Steering operation
LED
Service Indicator
To return Memory
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Traction Motor, Overheating Thermistor (150°C, -25°C) * E0 Power reduction Cool *
Power reduction
Thermistor (150°C, -25°C) (Transistor Control
Pump Motor, Overheating (Transistor Control type) Type)
* E2 Operates 1 s only (Lift, Cool *
Thermal SW ON (Contactor Control Type) Attachment) (Contactor
Control Type)
Traction Inverter, Overheating Thermistor
Cool
(IMS 100°C, -25°C. Capacitor 110°C, -25°C) * E5 Power reduction *
Thermistor (Transistor Control Type) Power reduction
(IMS 100°C, -25°C. Capacitor 110°C, -25°C) (Transistor Control Type)
Pump Inverter, Overheating * E7 Operates 1 s only (Lift, Cool *
Thermistor (Contactor Control Type) Attachment) (Contactor
(IMS 105°C, -25°C. Capacitor 115°C, -25°C) Control Type)
Pump Motor BWI Operates 1 s only
(Contactor Control Type) Pump motor BWI SW ON * br (Lift, Attachment) Turn off key *
Traction Motor Current Sensor Fault Out of normal range 14 Line contactor Off(*) Turn off key
* Steering contactor Hold *
More than 985 Arms (1.6 ms), 990 Arms Line contactor Off
Traction Motor Over-current (1 ms), 1018 Arms (a moment) * 15 Steering contactor Hold
Turn off key *
16 Line contactor Off
Traction Motor Stall Timer Measures time (set by SUO#20) while stalling. * Steering contactor Hold
Turn off key *
Pump Motor Current Sensor Fault Out of normal range 34 Line contactor Off(*)
(Transistor Control Type) * Steering contactor Hold
Turn off key *
Pump Motor Over-current More than 985 Arms (1.6 ms), 990 Arms Line contactor Off
(Transistor Control Type) (1 ms), 1018 Arms (a moment) * 35 Steering contactor Hold
Turn off key *
Line contactor Off(*)
Line Contactor Fault Checks voltage of power circuit. * 40 Steering contactor Hold Turn off key *
Steering Contactor Fault Checks voltage of power circuit. * 41 Steering contactor Off(*) Turn off key *
Pump Contactor Fault Line contactor Off(*)
(Contactor Control Type) Checks voltage of power circuit. * 42 Steering contactor Hold Turn off key *
Line contactor Off
Traction Motor Open Traction motor open 45 Turn off key *
* Steering contactor Hold
Pump Motor Open Line contactor Off
Pump motor open 47 Turn off key *
(Transistor Control Type) * Steering contactor Hold
Accel SW ON: Below 0.3V
Accelerator Sensor Fault Accel SW OFF: More than 1.41V 51 Line contactor Off Turn off key
* Steering contactor Hold *
Below 0.2V, More than 4.8V
Line contactor Off Turn off key
Traction Motor Pulse Input Fault Out of normal range (5800 rpm) * 52 Steering contactor Hold *
Out of normal range (4000 rpm, 2 s)
Pump Motor Pulse Input Fault With no rotation input during a current output 57 Line contactor Off Turn off key
(Transistor Control Type) * Steering contactor Hold *
(More than 240 Arms, 0 rpm, 1 s)
Lever/accel is not neutral at power-on and Line contactor Off Seat switch ON
Direction Lever or Accelerator, seat SW on. Steering contactor Off Direction lever
Faulty Setting Seat SW is turned on after lever/accel is E Slow down and Line is in neutral
operated. contactor Off accel off
Line contactor Off Seat switch ON
Seat Switch, Faulty Setting For Seat SW is off at power-on. Steering contactor Off Direction lever
Traction (E) is in neutral
Seat SW is off. Slow down and Line
contactor Off accel off
Lever is not neutral at power-on and seat SW Line contactor Off
on. Steering contactor Off Seat switch ON
Lift Lever, Faulty Setting H1 Lever is in
Seat SW is turned on after lever is operated. Disables lever neutral
operation
on. Steering contactor Off Seat switch ON
Tilt Lever, Faulty Setting H2 Lever is in
Disables lever neutral
Seat SW is turned on after lever is operated. operation
Attachment 1 Lever, Faulty Setting on. Steering contactor Off Seat switch ON
H3 Lever is in
Disables lever neutral
Seat SW is turned on after lever is operated. operation
1-43
CONTROLLER
Display
Steering operation
LED
Service Indicator
To return Memory
Parking Brake
Battery Low
Fault How to detect Result
Over Temp.
Code
to normal
Brake Oil
Seat Belt
Error
Seat SW is off at power-on. Line contactor Off
Seat switch, Faulty Setting For Steering contactor Off Seat switch ON
(L) Disables lever
Lever is in
Hydraulic Seat SW is off. neutral
operation
When serial communication is not going on ERROR LED (!)
flickers
Display Communication Fault * 60 Turn off key *
Display hour meter error ERROR LED (!) lights
Logic Card Initialize Failure SUO Gr.#3 and default setting are not set. Line contactor Off Turn off key
Inverter setting error * 61 Steering contactor Off *
Sum check of ROM
Logics Fault 62 Line contactor Off
Memory check of RAM * Steering contactor Off
Turn off key *
Sum check of SUO data (EEPROM)
Sum check of ROM
Memory check of RAM Line contactor Off
Traction Inverter Fault Initial mode SW setting fault * 63 Steering contactor Off Turn off key *
When CAN communication is not going on
Sum check of ROM
Pump Inverter Fault Memory check of RAM 65 Line contactor Off
Initial mode SW setting fault * Steering contactor Off
Turn off key *
When CAN communication is not going on
Contactor coil current sensor
Line contactor Line contactor Off
Contactor Coil Fault
Pump contactor * 72 Steering contactor Off
Turn off key *
Steering contactor
Disables lever
Hydraulic Lock Solenoid Fault Checks current of lift lock valve power circuit. * 74 operation Turn off key *
Electromagnetic Brake Solenoid Line contactor Off
Checks current of electromagnetic brake valve 75 Steering contactor Turn off key *
Fault power circuit. * Hold
Line contactor Off
Battery Voltage Too Low Voltage class is not correct. * 78 Steering contactor Off Turn off key *
Line contactor Off
Battery Voltage Too High Voltage class is not correct. * 79 Steering contactor Off Turn off key *
Much consumption with small capacity Power reduction
Battery Consumption Much battery * (economy table) Charge battery
Too much consumption with small capacity
Battery Consumption Too Much
battery * (Lo) Steering contactor
Off(*)
Turn off key
Brake Oil, Low Level Level sensor (Contact) * Turn off key
NOTICE: (1) E0, E2, E5 and E7 don’t appear on the display, but are stored in the memory.
(2) E, (E), (L), H1-H3, and Lo appear on the display, but are not stored in the memory. (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 current goes to 0.
(4) Contactor “hold” means “no change.” When the error occurs while the contactor is turned on, it
stays on.
1-44
CONTROLLER
Removal and Installation
Inverter Discharging Procedure

Discharge electric charges stored in the inverters by using
the following procedure.
1. Turn off the key switch.
2. Disconnect the battery plug.
3. Remove the rear cover.
Rear cover
211414
4. Place a 150 Ω/25 W resistor between P and N

terminals in the traction inverter to discharge electric
charges stored in the inverter.
5. After touching the resistor to the P and N terminals for
approx. five seconds, measure the voltage between the
terminals with a multimeter and confirm a reading of 5
V or less.
6. Perform the same procedure for the pump inverter in
order to discharge electric charges from all inverters.
Check whether the resistance between + and - of the battery

plug on the truck side is 1 kΩ or more when connecting the
battery plug for the first time after maintenance. 211415
(Discharge electric charges completely before measuring.
Longer measurement time reduces resistance value.)
Discharge Tool 16A68-02600.
1-45
CONTROLLER
Replacing Inverter
Removal
1. Raise the front wheels.
2. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Ensure to discharge electric charges from all
inverters.
3. Disconnect all five power cables from F, N, U, V and

W terminals.
4. Disconnect the connector.
! CAUTION
When disconnecting the connector, hold the
connector housing and plug, and unlock the
connector.
Holding the case may cause damage to the inside
card, while holding the cable may cause wire
breakage.
211416
5. Remove M10 bolts (four places) fixing the inverter,

then remove the inverter.
Insuring Proper Thermal Transfer
Mounting Instructions for DC/AC Inverters
In the design of this family of DC/AC Inverters,

performance assumptions were made based on heat transfer
between the inverter and the ambient environment. The
vehicle mounting surface acts as a heat sink, which increases
the effective surface area for heat dissipation. If this
assumed heat transfer is not achieved during inverter
installation and operation, the inverters will fall short of their
anticipated performance. It should be noted that the
condition of the mounting surface, and the quality of the
resulting interface between the control and the vehicle, can
significantly hinder heat transfer from the inverter. This is
why each inverter has a heat sink between the inverter and
the frame of the truck. Traction and Hydraulic Inverter
1-46
CONTROLLER
The presence of contaminant's or air voids created by

surface inconsistencies in either the vehicle or the heat sink
will degrade the inverter’s capacity for heat transfer. The
inverter’s performance is de-rated proportionally as its own
thermal sensors reduce its operation to protect it from
damage due to excessive heating.
Contained within the software of the controls are several
diagnostic status codes related to controller thermal
performance. Failure to follow these mounting
recommendations increases the likelihood of encountering
these status codes.
Careful surface preparation, including adequate application
of thermal compound, as detailed in the following
paragraphs, must be completed during the installation of the
controls. There are many techniques for applying thermal
compound. One approach is outlined below that has shown
to apply a consistent thickness of material.
Necessary Tools
Recommended use of the following components, or

equivalent substitutions, during the control installation
process:
a) Thermal compound, (5P9837), maintained per the
manufacturer’s recommendations and free of
contaminant's
b) 3/32" notched trowel, such as an adhesive spreader,
P/N SE000049
c) Calibrated torque wrench (0 – 15 ft-lbs)
The Inverters
During the manufacture of the control, the surface flatness is

maintained at 0.005" per linear inch (not to exceed 0.025"
per 10.0 inches). The surface finish of the control has a Ra
(average roughness) of 64 (micro inches), or better. This
finish is consistent with cold rolled or extruded aluminum.
Care should always be taken in the handling and storage of
controllers. The base of the control should be free from
nicks, bumps, protrusions or any other foreign object that
would prevent the control from sitting flush with the vehicle
mounting surface. Examine the base of the control to verify
that it is in good condition and free from damage or
contamination.
1-47
CONTROLLER
Vehicle Mounting Surface
The quality of the vehicle mounting surface is critical for the

optimum heat transfer between the inverter and the ambient
environment. Conduction through the base of the inverter is
the inverter’s only means of heat rejection. While the
inverters are highly efficient, a few percent of the electrical
energy will be converted into heat. As previously mentioned,
if this energy is not dissipated through the base of the
inverter, a thermal protector will reduce the performance of
the inverter until the temperature stabilizes. For optimal heat
transfer from control to vehicle, the flatness of the vehicle
mounting surface should be equivalent to the flatness of the
control surface (0.005" per linear inch). Use a straight edge
or dial indicator to verify the mounting surface. The biggest
hindrance to heat transfer is the presence of rust, scale, weld
splatter or paint on the vehicle mounting surface. If any of
these items are noted, prepare the surface per the following
guidelines:
a) Clean the mounting surface with a rotary wire brush
until the metal surface is exposed.
b) Using 80-100 grit emery paper, sand the surface until
the metal shines.
c) Flush the surface clean with an appropriate liquid
de-greaser or parts cleaner.
! CAUTION
Apply thin and even thermal paste since it works to
release generated heat from the inverter to the
truck body.
1-48
CONTROLLER
Application of Thermal Compound
Due to the minute differences in the inverter mounting

surface and the vehicle mounting surface, small pockets of
air will be created. These air pockets will add to the overall
thermal resistance of the interface. To avoid these air
pockets and improve thermal conductivity, thermal
compound must be applied between the control base plate
and the vehicle mounting surface. The function of this
compound is to conform to surface discrepancies, filling
gaps and optimizing the metal-to-metal contact of the
inverter and the vehicle.
a) Prepare the two mounting surfaces (inverter and vehicle)
as indicated above.
b) Using a triangular notched trowel of 3/32" (.09" +/- .01),
apply the grease to the vehicle mounting surface.
c) Use straight, non-crossing strokes of the trowel to apply
the compound.
d) Make multiple vertical passes until a uniform
consistency is achieved.
1-49
CONTROLLER
Mounting the Inverter
After inverter mounting surface is prepared with heat sink

grease
a) Prepare mounting surface of truck using the same
procedure as the inverter heat sink.
b) Place the inverter with desired orientation on mounting
surface of truck with mounting holes aligned.
c) Move the inverter slightly in all directions to eliminate
voids and enhance the distribution of the thermal
compound.
d) Insert all of the mounting hardware 10 mm, 1.25 thread
pitch, with washers (4 bolts necessary for the mounting
of the respective inverter).
e) Tighten these bolts to half of the nominal torque value
34.8 N-m (3.5 kgf-m) 34.8 ft-lb.
f) Lastly, tighten the bolts to the nominal torque value
69.6 N-m (7.1 kgf-m) 51.4 ft-lb.
g) Torque wrench, extension and socket required to
complete installation.
1-50
CONTROLLER
• Connect the power cables to F, N, U, V and W

terminals. Proper stack method is: Cable, flat washer,
Belleville washer and nut.
! CAUTION
Use the correct power cables and terminate
marked cable ends to the correct terminals marked
on the motor.
Cables terminated at the wrong terminals on the
motor may cause the motor to rotate in the
opposite direction when activated.
Tightening torque for power cables
16.0 N·m for UVW

141.6 ± 2 lb. in.
10.0 ± 1 N·m for Pos and Neg Fuse
88.5 ± 2 lb. in.
• Connect the main harness connector to the inverter.
! CAUTION
Forcibly pressing the connector may cause damage
to the DSP card. Hold the connector housing and
press the connector, it may not be easy to lock.
NOTICE: It is recommended to check or replace the

inverters every 10,000 hours of service
operation.
NOTICE: It is recommended to torque the U, V, W, P, N

and F terminals after 30 days service and at
1000 hour intervals.
1-51
CONTROLLER
Replacing DSP (Digital Signal Processor)

Card
Removal
1. Perform step 1 to 5 in Inverter Discharging Procedure.
! CAUTION
Make sure to discharge inverters before working on
the electrical system.
2. Disconnect the connector.
! CAUTION
When disconnecting the connector, hold the
connector.
breakage.
3. Push and lift up at the four corners of the card cover to

remove the cover.
211417
4. Unlock the connector that is connected to the flat cable.

Hold the both ends of the white part of the connector
and pull it straight up.
5. Pull the flat cable to disconnect it.
If it cannot be disconnected smoothly, raise the lock
again to unlock.
6. Pinch the plastic spacers at the four corners of the DSP
card with pliers to unlock and remove the card.
! CAUTION
211201
Be careful not to damage mounted parts with the
pliers since the card has a number of fragile parts.
1-52
CONTROLLER
Installation
1. Align the four mounting holes of the new DSP card
with the plastic spacer positions and press it into place.
! CAUTION
Press at the card edges.
Make sure that the spacer lock works completely
and the card cannot be removed.
2. Confirm that the flat cable connector is unlocked by

raising the connector lock.
3. Insert the flat cable into the connector. Press down the
connector lock.
! CAUTION
Do not forcibly bend the flat cable. Insert its
conductive surface in the direction shown in the
illustration.
Also, confirm that the cable is not tilted.
4. Install the cover while pushing the flat cable toward the
card side slightly.
211202
! CAUTION
Do not push the flat cable by the inside of the
inverter cover. Do not forcibly bend the flat cable.
Make sure that the cable will not be pinched
underneath the cover. Confirm that the cover is
completely locked.
5. Connect the main harness connector to the inverter.
! CAUTION
Forcibly pressing the connector may cause damage
to the DSP card. Hold the connector housing and 211418
press the connector, it may not be easy to lock.
1-53
CONTROLLER
Replacing Logic Unit

Removal
1. Turn off the key switch.
2. Disconnect the battery plug.
Rear cover 211414
4. Disconnect the connector (P3, 4, 5 complex) from the

logic card and the connector (P8) from the power
supply card.
! CAUTION Logic unit

When disconnecting the connector, hold the 211419
connector.
breakage.
Take care when working on logic card removal. The
DRS switch is located on the left side and can
become damaged by rough handling.
5. Remove M10 bolts (two places) and remove the logic

unit.
Installation
Follow the removal sequence in reverse.
211420
1-54
CONTROLLER
Replacing Logic Card

Cover
NOTICE: When replacing the logic card, it is
recommended to replace the logic unit as an
assembly.
When the cover is removed from the logic unit
case, its tapped holes may be damaged.
Replace the cover if the tapped holes of the
cover are damaged.
Removal
1. Perform step 1 to 5 in Replacing Logic Unit.
2. Remove M3 flat head screws (four places) from the
bottom of the logic unit to remove the cover.
3. Remove M3 screws (seven places) fixing the logic card
to the logic unit case to remove the logic card.
4. Remove the grommet from the logic card.
Logic unit
case
211421
Logic card
Heat sink
Installation
! CAUTION
When installing the logic card onto the logic unit
case, carefully tighten the logic card and heat sink
fixing screws to the specified torque to avoid
excessive stresses. Repair the heat sink first. 211422
Tightening torque
0.98 ± 0.20 N·m

M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
0.30 ± 0.10 N·m
M3 flat head screw (0.03 ± 0.01 kgf·m)
[0.22 ± 0.074 lbf·ft]
211423
1-55
CONTROLLER
Replacing Power Supply Card

Cover
NOTICE: When replacing the power supply card, it is
recommended to replace the logic unit as an
assembly.
When the cover is removed from the logic unit
case, its tapped holes may be damaged.
Replace the cover if the tapped holes of the
cover are damaged.
Removal
1. Perform step 1 to 5 in Replacing Logic Unit.
2. Remove M3 flat head screws (four places) from the
bottom of the logic unit to remove the cover.
3. Remove M3 screws (seven places) fixing the power
supply card to the logic unit case to remove the power
supply card.
4. Remove the grommet from the power supply card.
Logic unit
case
211421
Power supply
Heat sink card
Installation
! CAUTION
When installing the power supply card onto the
logic unit case, carefully tighten the power supply
card and heat sink fixing screws to the specified
torque to avoid excessive stresses. Apply a small
amount of heat sink compound before installing.
211424
Tightening torque
0.98 ± 0.20 N·m

M3 screw (0.10 ± 0.02 kgf·m)
[0.72 ± 0.15 lbf·ft]
0.30 ± 0.10 N·m
M3 flat head screw (0.03 ± 0.01 kgf·m)
[0.22 ± 0.074 lbf·ft]
211425
1-56
CONTROLLER
Basic Check
Always follow basic troubleshooting steps.

• Talk to the operator.
• Confirm his 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
(d) Correct software P.C. program. (a)
(c)
NOTE
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 208282
connected inversely when using an analog meter tester.
! WARNING
Disconnect the battery plug before inspecting or
adjusting the controller.
1-57
CONTROLLER
Measurement of Card Voltage
! WARNING
To prevent accidental movement of the truck, place
wood blocks under the truck to lift the front wheels
off the ground. Do not place wood blocks close to
the front wheels.
1. Tilt the mast fully backward. Place blocks under the

mast, and tilt the mast forward.
2. Turn the key switch off.
3. Disconnect the battery plug. Remove the cover.
4. Reconnect the battery plug.
5. Turn the key switch on. Connect the negative terminal
of the circuit tester to the V GND terminal of the card.
6. Set the circuit tester to the 100-VDC range.
7. Connect the positive terminal of the circuit tester to
each pin of connectors.
NOTE
Be careful not to short-circuit pins. For normal voltage
value, refer to the card voltage chart on the following
pages.
1-58
CONTROLLER
Logic card voltage chart
Card side connector No.: CN1 Main harness side connector No.: P3, P4 and P5
No. Name Stand-by voltage Active voltage Note
1 GND-L 0V 0V 0V
2 +15V-L 13.0V to 16.0V 13.0V to 16.0V 14.6V
3 GND-L 0V 0V
4 +5V-L 5V 5V 4.99V
5 CANH 0 to 5V 0 to 5V Between CANH and CANL 2.57V
6 CANL 0 to 5V 0 to 5V Prohibition of [V] measurement with GND terminal 2.35V
7 BOOT 4.75V 0V 5.3V
8 FWE 4.75V 0V 5.3V
9 GND 0V 0V
10 -
11 -
12 -
13 -
14 DISPLAY1-TxD 0 to 12V 0 to 12V 8.3 to 7.5V
15 -
16 DISPLAY1-RxD 0 to 12V 0 to 12V 3.1 to 2.8V
17 GSE-TxD - -
18 GSE-RxD - -
19 POS VOLTAGE Vbatt Vbatt 38V
20 ACCEL ANGLE 0V 0 to 4.7V Battery connector attached : Vbatt 4.53aP .89 down
21 -
22 -
23 GND 0V 0V
24 +5V 5V 5V 4.9V
25 GND 0V 0V
26 +5V 5V 5V 4.9V
27 -
28 -
29 -
30 -
31 DC PUMP MOTOR TH SW 11.5V 0V NA
32 SEAT BELT SW 11.8V 0V
33 SEAT SW 11.8V 0V
34 PARK BRAKE SW 11.8V 0V
35 SERVICE BRAKE SW 0 11.8V
36 REVERSE SW 37.1V 0V Connected to Back-up Alarm
37 FORWARD SW 11.8V 0V
38 BRAKE FLUID SW 11.8V 0V
39 -
40 DC PUMP MOTOR BWI1 11.5V 0V N/A
41 DC PUMP MOTOR BWI2 11.5V 0V N/A
42 ACCEL IDLE SW 11.8V 0V
43 GND 0V 0V
44 BUZZER 37.7V 0 to Vbatt
45 DIAG SW 11.8V 0V
46 SET SW 11.8V 0V
47 -
48 LIFT DOWN SW 11.8V 0V
49 ATTACH1 SW 11.8V 0V
50 TILT SW 11.8V 0V
51 LIFT2 SW 11.8V 0V
52 LIFT1 SW 11.8V 0V
53 -
54 PUMP CONTACTOR D1 0V 37.6V N/A
55 STEER CONTACTOR D1 0V 37.6V
56 -
57 LIFT LOCK + 0V 37.6V
58 LIFT LOCK - 0V 0V
59 LINE CONTACTOR CON 37.8V 9.7V
60 HYDRAULIC CONTACTOR 0V 0 to Vbatt N/A
61 CON 37.8V 0V
62 STEER CONTACTOR CON 0V 0 to Vbatt N/A
63 BRUSHLESS DC CONTROL CON Vbatt 37.8V 37.2V
64 CON VE 37.8V .5V
Vbatt: Battery voltage
1-59
CONTROLLER
Power supply card voltage chart

Card side connector No.: CN1 Main harness side connector No.: P8
No. Name Voltage Note
1 +12V 12V Fan
2 GND 0V Fan
3 +15V-L 13.0V to 16.0V DSP
4 +5V 8V DSP
5 +15V-G 12V DSP
6 GND 0V DSP
7 +VE-L Vbatt
8 +VE-L Vbatt
9 +15V-L 13.0V to 16.0V Logic
10 +5V 5V Logic
11 GND 0V Logic
12 GND 0V Logic
13 V POW Vbatt Input
14 V POW Vbatt Input
15 V GND 0V Input
16 V GND 0V Input
DSP card voltage chart

Card side connector No.: CN2 Main harness side connector No.: P1 (traction) and P2 (pump)
No. Name Stand-by voltage Active voltage Note
1 MOTOR THERMAL + 0 to 5V 0 to 5V
2 MOTOR THERMAL - 0 to 5V 0 to 5V
3 CANH 0 to 5V 0 to 5V Between CANH and CANL
Prohibition of [V] measurement with
4 CANL 0 to 5V 0 to 5V GND terminal
5 ROTARY SENSOR +15V 12V 12V
6 ROTARY SENSOR A+ 0 to 5V 0 to 5V
7 ROTARY SENSOR B+ 0 to 5V 0 to 5V
8 MODE1 11.5V 0V
9 MODE2 11.5V 0V
10 BOOT 11.5V 0V
11 GND 0V 0V
12 TxD(GSE) - -
13 RxD(GSE) - -
14 CANR+ - -
15 CANR- - -
16 +15V-G 12V 12V
17 +15V-L 13.0V to 16.0V 13.0V to 16.0V
18 +5V 8V 8V
19 GND 0V 0V
20 GND 0V 0V
1-60
CONTROLLER
Checking Contactor Coil
! CAUTION
Disconnect the battery plug and discharge the
inverter before working on electrical system.
1. Disconnect the lead wire of coil.

2. Set the circuit tester to 200 ohm range.
3. Measure coil resistance.
The resistance must be 44 ohm at -30°C (-22°F) to 65
ohm at 80°C (176°F).
• 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 terminal) and the
positive (+) terminal of the circuit tester to the positive-
side coil terminal (large terminal).
6. Connect the battery, and operate the control device that
activates the contactor.
7. The circuit tester should indicate about 24V after the
contactor operates. If the contactor is found normal
during the coil resistance test and if the measured
voltage is not 24V, replace the logic card.
Checking 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
them.
3. Visually inspect the contactor assemblies. Make sure
there are no foreign materials in the assemblies to
interfere with contactor movement.
4. Measure the gap at each contactor tips using a
208284
thickness gauge.
[It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)]
• If you find any troubles, replace or repair contactor.
5. Check for free movement of contactor.
1-61
CONTROLLER
Checking Inverter
! CAUTION
Disconnect the battery plug and discharge the
inverter before working on electrical system.
Be sure discharging is complete before starting
ohm measurement.
1. Disconnect all five power cables from F, N, U, V and

W terminals.
2. Check the resistance between terminals shown in the
following table.
Positive probe Negative probe Resistance (ohm)

U
N V - +
W
8k to 11k Tester
U 211426
V P
W
NOTICE: Short-circuit/disconnection of the inverter

MOSFET can be confirmed by this check.
Other fault cannot be determined.
NOTE
On diode scale you will read about .460 volts on all
test.
1-62
CONTROLLER
Regeneration Check
The AC motor uses a common circuit for current flow in
both loading and regeneration. This allows the following
procedure to confirm regeneration.
1. Place the clamp ammeter onto the cable connected to
the inverter’s F terminal (use DC current range). This is
positive direction as current flows from the battery to
the inverter.
2. Run the truck forward. With the direction lever shifted
in F position, release the accelerator pedal. Then
perform a full-reverse operation.
3. The clamp ammeter should show a negative value. This
value becomes the regeneration current.
Energy is generated when a motor is rotated with external

force. The regeneration power is produced when this energy
is larger than the one that is consumed by the controller and Clamp ammeter
motor. This means that the regeneration current is not setting direction 211427
measured if the speed or load changes gradually.
1-63
CONTROLLER
AC Motor System Basics
1. Feature of AC motor
The AC motor model trucks covered by this manual use The frequency and voltage can be controlled by a
AC motors (three-phase induction motors) as the variety of methods including the “vector control
traction motor and pump motor. AC motors have the method” employed in the AC motor model trucks. This
following advantages over DC motors: method provides highly responsive control according to
(1) AC motors are simple in construction. As they ever changing truck-operating conditions through high-
have no such friction parts as brushes and speed calculation on huge amount of data. The vector
commutators, daily maintenance load is control calculation is performed by the inverter. (Fig. 2)
significantly reduced.
(2) AC motors are compatible with high-speed U
operation.
(3) An AC motor of a certain size produces higher Inverter V IM
power than a DC motor of the same size.
W
2. Speed control of induction motors
Speed control of DC motors depends on regulation of
the field and armature current amounts, while that of V V
AC motors basically depends on adjustment of the U V W
frequency of the alternating current power supply. The
speed of an AC motor is determined by the frequency of t t
the power supply AC current and the load on the motor.
In addition, the voltage and current to the motor must Low-speed operation High-speed operation
(low frequency)
be controlled properly so that the motor operates in its 209542
optimum characteristic range. (Fig. 1)
Fig. 1
Logic unit Inverter
Gate
driving MOS-FET modules
pulse
Speed
Calculation for order
Accelerator Vector control
required output
F
calculation IM
N
R
Truck
speed
Current
Brake Speed
211214
Fig. 2
1-64
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 an “inverter.” The processes involved in
T1 T2 T1 T2 T1
creating AC current from DC current are described below. VL = × VB
T1 + T2
ON OFF ON
(1) Changing DC voltage cyclically
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
ON ON ON
average of the voltage applied to the load is determined
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
V lt b t t t i
Fig. 5
1-65
CONTROLLER
AC Motor Troubleshooting 3. Problem:

Motor makes squealing sound like a bearing noise.
Motor Noises Check:
1. Problem: Check sensor bearings to see if signals are ok. Check
Clunking on direction changes. motor connections and stator windings. In order to
check and isolate bearing sounds using a stethoscope. If
Check: the sound is a general area sound then use a piece of
To see if stator is loose in frame of motor. flexible tubing or hose to locate the source of the
2. Problem: sounds. Stators can make a squealing sound when
Motor/truck chatters or shutters with wheel off floor and windings are not correct or when windings are open
accelerator pedal slightly pressed; the wheels move in (broken wire) or shorted.
one direction, then the other. Check forward and back. 4. Problem:
Check: Motor has lower power, but reaches full speed.
Forward and reverse. Check:
Check sensor bearing. Check connections at motor terminals both out of motor
Check sensor bearing connector and wiring. and at the inverter connections. Check stator windings.
You will need a meter that checks insulation or can
measure in the million ohm range. From (-) to (-).
Normal readings are shown in the chart below.
Normal Readings
Phase Line Customer Previous

Resistance Remarks Part Number Customer Description
Ω ) Nominal
(mΩ Part Number
3.55 20°C (68°F) 97E20-10080 97E20-00080 9" Traction AC Motor
1.65 20°C (68°F) 97F20-20090 97F20-10090 11" Traction AC Motor
4.46 20°C (68°F) 97E20-10090 97E20-00090 8" Pump AC Motor
3.34 20°C (68°F) 97F20-10080 97F20-00080 9" Pump AC Motor
1.65 20°C (68°F) 97F20-10070 97F20-00070 11" Traction AC Motor
1-66
TROUBLESHOOTING FOR CONTROL CIRCUITS
General Information ................................................................................ 2– 1

E0 Traction Motor, Overheating .......................................................... 2– 3
E2 Pump Motor, Overheating (Transistor Control Type) ................ 2– 6
E2 Pump Motor, Overheating (Contactor Control Type) ................ 2– 9
E5 Traction Inverter, Overheating ....................................................... 2 – 12
E7 Pump Inverter, Overheating ........................................................... 2 – 15
(Transistor Control Type Only)
Brake Oil, Low Level ........................................................................ 2 – 18
2
br Pump Motor, Worn Brushes ........................................................... 2 – 20
(Contactor Control Type Only)
14 Traction Motor Current Sensor Fault ........................................... 2 – 22
15 Traction Motor, Over-current .......................................................... 2 – 24
16 Traction Motor, Stall Timer ............................................................. 2 – 27
34 Pump Motor Current Sensor Fault ............................................... 2 – 29
35 Pump Motor Over-current (Transistor Control Type Only) ....... 2 – 31
40 Line Contactor Fault ........................................................................ 2 – 34
41 Steering Contactor Fault ................................................................ 2 – 37
42 Pump Contactor Fault (Contactor Control Type Only) ............. 2 – 40
45 Traction Motor Open ........................................................................ 2 – 42
47 Pump Motor Open (Transistor Control Type Only) .................... 2 – 45
51 Accelerator Sensor Fault ................................................................ 2 – 48
52 Traction Motor Pulse Input Fault ................................................... 2 – 51
57 Pump Motor Pulse Input Fault ...................................................... 2 – 54
60 Display Communication Fault ........................................................ 2 – 57
61 Logic Card Initialize Failure ............................................................ 2 – 59
62 Logics Fault ....................................................................................... 2 – 60
63 Traction Inverter Fault ...................................................................... 2 – 61
65 Pump Inverter Fault (Transistor Control Type Only) .................. 2 – 64
72 Contactor Coil Fault ......................................................................... 2 – 67
74 Hydraulic Lock Solenoid Fault ...................................................... 2 – 70
75 Electromagnetic Brake Solenoid Fault ........................................ 2 – 72
78 Battery Voltage Too Low ................................................................. 2 – 74
79 Battery Voltage Too High ................................................................ 2 – 76
E Direction Lever or Accelerator, Faulty Setting ........................... 2 – 78
(E) Seat Switch, Faulty Setting For Traction ..................................... 2 – 80
(L) Seat Switch, Faulty Setting For Hydraulic .................................. 2 – 82
H1 Lift Lever, Faulty Setting ................................................................ 2 – 84
H2 Tilt Lever, Faulty Setting ................................................................. 2 – 86
H3 Attachment 1 Lever, Faulty Setting ............................................. 2 – 88
(Lo) Battery Consumption Too Much ................................................... 2 – 90
Battery Consumption ............................................................. 2 – 92
General Information
Before replacing devices

Do not replace devices casually even if replacement is required as a result of troubleshooting. Be sure to check the
following items before replacing devices (logic unit, logic card, power supply card, inverters and inverter DSP cards).
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors or pins pushed back in connector.
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and clean connectors.
See “How to clean harness connectors and system components” on page 2-2.
• Ensure that the main harness is not short-circuited to the truck body by using the following procedures.
Measure voltage between battery cable positive, negative and truck

frame. If voltage is found above 5 volts this should be cleared before
continuing additional trouble-shooting procedures.
Disconnect battery plug and discharge the inverters before

working on electrical system.
Disconnect connector P8 of logic unit. Check continuity between

P8-13(10J) and truck body (logic unit installation bolts, etc.).
No continuity Continuity
Normal Repair or replace harness.
If any of these items (above items) is a source of the trouble, the device will be damaged even if it is replaced with a
new one. Be sure to check the above items and replace carefully.
Connection of the service tool Error code display
1. Turn off the truck power.

3. Find the connector to the service tool near the logic unit.
Logic unit
4. Remove the cover and connect the PC as shown.
5. Turn on the truck power.
6. Start the service tool software.
211358
2-1
How to clean harness connectors and system

components
1. Open-circuits are often caused by dirty harness
connectors and components. Dust, together with greasy
matter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, for worse, electrical separation of surfaces in
contact. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at when servicing the truck. Instead of a
commonly used solvent, use electronic parts cleaner (in
the manner illustrated on the right).
Electronic parts cleaner
211359
Electronic parts cleaner SE000003
NOTE
The cleaner liquid is volatile. All you have to do is just
give a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
2. After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray contact
surface activator onto contact surfaces.
Install and remove the connector several times to wet
the surfaces thoroughly with the activator liquid. Electronic parts
cleaner
After coupling up the connector, check to be sure that it
is in locked state.
Contact surface activator SE000003
NOTE
Do not spray too much liquid into the connector.
Do not completely fill connectors with Nyogel from
kit or you may push pins out of connector.
Cleaner liquid reacts differently with some resins
(plastic materials).
Contact surface
*: Products contained in Terminal Maintenance Kit activator
(SE000003)
205047
2-2
Problem: Traction Motor, Overheating (E0)

(1) Situation
Controller/motor overheat indicator ON. Poor pulling power and acceleration.
Normal pump motor and power steering operations. Service tool "Alarm status" and "E0" displayed.
(2) Possible cause

Overheating of traction motor, faulty traction motor or thermal sensor, faulty or open harness wiring,
faulty traction inverter DSP card, abnormal power supply of logic unit, brake or parking brake drag,
abnormality in front axle, faulty display unit.
(3) How the error code is triggered

Motor temperature is out of range of -25 C to 150 C (-13 F to 302 F).
It becomes normal when motor temperature is in range of -20 C to 70 C (-4 F to 158 F).
(4) Checks
Let truck cool for 15 minutes.
Overheat indicator ON Overheat indicator OFF
(5) Traction motor becomes normal.
If problem reoccurs
(6) Disconnect battery plug. Disengage brake
and parking brake, and check their drag.
No drag Drag
(7) Adjust brake.
(8) Lift front wheels, and disengage parking brake.

Turn key switch to OFF, rotate front wheels.
Confirm there is no difference in rotation load
between right and left wheels.
No difference Difference
(9) Check if truck is operated on steep

upgrade or to pull large cargo load.
Normal
(10) Perform inverter discharging work. See page 1-45.
(11) Replace traction motor. (12) Replace traction

motor or front axle.
See Chassis & Mast. See Chassis & mast.
With service tool
(13) Confirm temperature of traction motor with

Without service tool input/output monitor.
Less than -20 C(-4 F) -20 C to 70 C
or more than 70 C(158 F) (-4 F to 158 F)
(14) Disconnect battery plug. Wait until traction motor (15) Disconnect battery plug.
temperature becomes close to room temperature.
2-3
(16) Perform inverter discharging work. See page 1-45. (17) Troubleshoot display unit by referring Display
Communication Fault (60)-(4).
(18) Disconnect connector P15 of traction motor thermal
sensor. Measure resistance between P15(77) and (83)
at motor side.
581 at 20 C(68 F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 C(68 F), see table
on page 2-5. Out of range
Thermal
(19) Disconnect connector P1 of traction inverter. (20) Replace traction motor. See Chassis & Mast.
Check continuity between P1-1 and P15(83).
Continuity No continuity
Power supply
(21) Check continuity between P8-3 and P1-17(47).
Check continuity between P8-6 and P1-20(44).
CAN
(22) Disconnect connector P3 of logic unit.
Check continuity between P3-5(92A) and P1-3(92).
(23) Connect connector P8, then turn on power again. (24) Repair or replace harness.
(25) Measure voltage between P1-17(47) and

P1-20(44). Confirm value is 14V 2V.
Normal Abnormal
(26) Disconnect battery plug.
(27)Replace power supply card of logic unit. See page 1-56.

With service tool
Without service tool
(28) Ensure all connectors are connected. Check Run
Time Diagnosis data. See page 1-43.
The latest data is "E0". Not "E0"
(29) Disconnect battery (30)Troubleshoot display

plug, then perform unit by referring Display
inverter discharging Communication Fault
work. See page 1-45. (60)-(4).
(31)Replace DSP card of traction inverter. See page 1-52.
2-4
Logic
P3 P1 Traction inverter
G 0 to 5V G
CAN 5 GW 92A 0 to 5V
92
GW
3 Inside Inside Line contactor
6 93A 93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
5V * 1 L 1
Power supply card GND LB V IV
P8 2
12V R Flat
5 cable W IW
0 to 5V W
6
0 to 5V G
7
GND B
19
Traction motor
P14
82 B 4 Speed
G 3 sensor W TW
81
80 W 2 IM V TV
U TU
79
R 1 Thermal
77
LB 2 sensor
391 [-30 C(-22 F)] to
83
L 1 1407 [160 C(320 F)]
P15
*1: With connector disconnected
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 362 391 419
-10 14 428 460 492
0 32 464 498 532
10 50 503 538 574
30 86 587 626 665
50 122 679 722 764
70 158 781 826 872
90 194 891 940 989
110 230 1007 1062 1117
130 266 1128 1194 1259
150 302 1256 1334 1412
211360
2-5
Problem: Pump Motor, Overheating (Transistor Control Type) (E2)

(1) Situation
Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E2" displayed.
(2) Possible cause

Overheating of pump motor, faulty pump motor or thermal sensor, faulty or open harness wiring, faulty pump
motor inverter DSP card, abnormal power supply of logic unit, abnormal oil pressure of gear pump or
hydraulic lines, faulty display unit.

Motor temperature is out of range of -25 C to 150 C (-13 F to 302 F).
It becomes normal when motor temperature is in range of -20 C to 70 C (-4 F to 158 F).
(4) Checks
(5) Pump motor becomes normal.

If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(9) Replace pump motor. (10)Repair or replace gear

See Chassis & Mast. pump or piping.
See Chassis & Mast.
With service tool
(11) Confirm temperature of pump motor with

Less than -20 C(-4 F) -20 C to 70 C
or more than 70 C(158 F) (-4 F to 158 F)
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
(16) Disconnect connector P17 of pump motor thermal
sensor. Measure resistance between P17(78) and (89).
581 at 20 C(68 F)
(Min. 555 , Max. 607 )
For resistance at temperature
other than 20 C(68 F), see table
on page 2-8. Out of range
Thermal
(17) Disconnect connector P2 of pump motor inverter. (18) Replace pump motor. See Chassis & Mast.
2-6
Power supply
(19) Check continuity between P8-3(47) and P2-17(47A).
Check continuity between P8-6(44) and P2-20(44B).
CAN
(23) Measure voltage between P2-17(47A) and

P2-20(44B). Confirm value is 14V 2V.
Normal Abnormal
(24)Disconnect battery plug.
(25) Replace power supply card of logic unit. See page 1-56.
With service tool
(26)Ensure all connectors are connected. Check Run
(27) Disconnect battery (28) Troubleshoot display

work. See page 1-45. (60)-(4).
(29) Replace DSP card of pump motor inverter. See page 1-52.
2-7
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
GW GND 44B GW 20 card card
6 44 U IU
5V* 1 LB 1
Power supply card GND LB V IV
2 Flat
P8 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
P16 Pump motor

88 B 4 Speed
G 3 sensor W PW
87
86 W 2 IM V PV
U PU
R
85 1 Thermal
LB sensor
78 2
89
LB 1 391 [-30 C(-22 F)] to
1407 [160 C(320 F)]
*1: With connector disconnected P17
AMBIENT RESISTANCE
TEMPERATURE
( C) ( F) MIN. TYP. MAX.
-30 -22 362 391 419
-10 14 428 460 492
0 32 464 498 532
10 50 503 538 574
30 86 587 626 665
50 122 679 722 764
70 158 781 826 872
90 194 891 940 989
110 230 1007 1062 1117
130 266 1128 1194 1259
150 302 1256 1334 1412
211361
2-8
Problem: Pump Motor, Overheating (Contactor Control Type) (E2)

(1) Situation
Controller/motor overheat indicator ON. Lifting (lift and attachment) operated 1 second only. Normal traction motor
and power steering operations. Service tool "Alarm status" and "E2" displayed.
(2) Possible cause

Overheating of pump motor, faulty pump motor or thermal switch, faulty or open harness wiring, abnormal power
supply of logic unit, abnormal oil pressure of gear pump or hydraulic lines, faulty display unit.

Motor temperature is more than 165 C to 175 C(329 F to 347 F)
(4) Checks
(5) Pump motor becomes normal.
If problem reoccurs
(6) Check if truck is operated to lift large cargo load.
Normal
(8) Check oil pressure of gear pump and hydraulic lines.

Normal Abnormal
(9) Replace pump motor. (10)Repair or replace gear

See Chassis & Mast. pump or piping.
See Chassis & Mast.
With service tool
(11) Confirm thermal switch of pump motor with

Overheated Normal
(12) Disconnect battery plug. Wait until pump motor (13) Disconnect battery plug.
(16) Disconnect terminals T6 and T7 of pump motor.
Measure resistance of pump motor thermal switch.
0 at
165 C(329 F) to 175 C(347 F) Out of range
Thermal
(17) Disconnect connectors P4 and P8 of logic unit. (18) Replace pump motor. See Chassis & Mast.
Check continuity between P4-31 and T7(86).
Check continuity between P8-16 and T6(13C).
2-9
(19) Repair or replace harness.

With service tool
(20)Ensure all connectors and terminals are connected.
Check Run Time Diagnosis data. See page 1-43.
(21) Disconnect battery (22) Troubleshoot display

work. See page 1-45. (60)-(4).
(23) Replace logic card. See page 1-55.
2-10
Power
P8
B
16 13BC
Pump motor
B
Logic 13C T6
P4
W M
31 86 T7
Thermal
switch
T4 T5
211362
2-11
Problem: Traction Inverter, Overheating (E5)
2-12
CAN
(18)Disconnect connector P3 of logic unit.
(19)Connect connector P8, then turn on power again. (20) Repair or replace harness.
(21) Measure voltage between P1-17(47) and P1-20(44).

Confirm value is 14V 2V.
Normal Abnormal
With service tool
(25) Disconnect battery plug, (26) Troubleshoot display

then perform inverter unit by referring Display
discharging work. Communication Fault
See page 1-45. (60)-(4).
(27) Replace DSP card of traction inverter. See page 1-52.
If fault remains
(28) Disconnect battery plug, then perform inverter
discharging work. See page 1-45.
(29) Replace traction inverter. (DSP card is normal.)

See page 1-46.
2-13
Logic
G 0 to 5V G
92 3 Inside Inside Line contactor
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
Power supply card V IV
P8 2
Flat Controller
5 cable thermistor W IW
6
Capacitor
7 thermistor
19
Traction motor
P14
DSP flat Speed
cable 82 4
sensor W TW
81 3
Inverter
2
IM V TV
80
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211363
2-14
Problem: Pump Inverter, Overheating (Transistor Control Type Only) (E7)
2-15
CAN
(21) Measure voltage between P2-17(47A) and P2-20(44B).

Normal Abnormal
With service tool

(25) Disconnect battery plug, (26)Troubleshoot display

then perform inverter unit by referring Display
discharging work. Communication Fault
See page 1-45. (60)-(4).
(27) Replace DSP card of pump inverter. See page 1-52.
If fault remains

(29)Replace pump inverter. (DSP card is normal.)

See page 1-46.
2-16
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U IU
1
2 Flat Controller
P8
5 cable thermistor W IW
6
Capacitor
7 thermistor
19
P16 Pump motor

DSP flat 88 4 Speed
cable sensor W PW
87 3
Inverter IM V PV
case
86 2 U PU
85 1 Thermal
sensor
DSP card 78 2
391 [-30 C(-22 F)] to
89 1 1407 [160 C(320 F)]
P17
211364
2-17
Problem: Brake Oil, Low Level

(1) Situation
Lower brake oil indicator ON. Normal truck operation.
(2) Possible cause

Insufficient brake oil, faulty brake oil level sensor, shorted wiring, faulty logic unit, faulty display unit.

Sensor signal is open or short.
(4) Checks
Check oil level in brake oil reservoir tank.
Normal Abnormal
(5) Add brake oil. See Chassis & Mast.
With service tool
(6) Confirm brake oil level switch with input/output

Without service tool monitor.
ON OFF
(7) Disconnect battery plug, then perform inverter (8) Disconnect battery plug. Replace display unit.
discharging work. See page 1-45. See Chassis & Mast.
(9) Disconnect connectors P4 and P3 of logic unit and

P33 of sensor. Check continuity between P33(84)
and P33(17D) at harness side.
(10) Check continuity of brake oil level sensor connector

coupled to P33. (11) Repair or replace harness.
(12) Replace brake oil level sensor.

With service tool
Without
service tool
(13) Replace display unit. See Chassis & Mast.
If fault remains
(15) Reinstall display unit and replace logic card of logic

unit. See page 1-55.
2-18
Logic Logic
P4 P3
38 23
0V/12V GND
17
WB B
84 17D
P33
Brake fluid
sensor
211365
2-19
Problem: Pump Motor, Worn Brushes (Contactor Control Type Only) (br)
(1) Situation
Display: "br". "br" and truck speed alternately displayed during traveling (when no other fault codes are displayed).
Lifting (lift and attachment) operates for 1 second only. Normal traction motor and power steering operations.
(2) Possible cause

Worn pump motor brushes, wire breakage, faulty logic card.

Pump motor brushes wear.
(4) Checks
Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(5) Disconnect brush wear detector wires T4(87) and T5(88) from pump motor. Reconnect battery plug,
and close key switch. Confirm error code display.
Error code br No error code
(6) Disconnect battery plug, then perform inverter (10) Check brushes and replace, if necessary.
(7) Disconnect connector P4 of logic unit and terminals

T4(87) and T5(88) of pump motor.
(8) Replace logic card of logic unit. See page 1-55. (9) Correct or replace wiring.
2-20
Pump motor
M
Logic
P4 T4 T5
40 87
G
B
41 88
211366
2-21
Problem: Traction Motor Current Sensor Fault (14)
(1) Situation
Display: "14". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN
and steering contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter,
faulty traction inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
(5) Disconnect connector P1 of traction inverter and remove

DSP cover. Check DSP flat cable for looseness or wire
breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between P8-4 and P1-18(46). (7) Secure DSP flat cable if loose.
Check continuity between P8-6 and P1-20(44). Replace inverter if wire breaks. See page 1-46.
Continuity Abnormal and no continuity
CAN
(9) Connect connector P8 to logic unit, then turn on power (10)Repair or replace harness.
again.

Normal Abnormal
(12) Disconnect battery plug, then perform inverter discharging work. See page 1-45.
(13)Replace DSP card of traction inverter. See page 1-52. (14) Replace power supply card of logic unit. See page 1-56.
If fault remains
(15) Perform inverter discharging work, then replace

traction inverter. (DSP card is normal.)
See page 1-46.
2-22
Logic
G 0 to 5V G U current sensor
6 93A 93
GW 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
P8 2
Flat
5 cable W IW
6 V current sensor
7
19
Traction motor
P14
DSP flat Speed
cable 82 4
sensor W TW
81 3
Inverter
2
IM V TV
80
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211367
2-23
Problem: Traction Motor, Over-current (15)

(1) Situation
Display: "15". All truck operations inhibited. Line contactor OPEN and steering contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty
traction inverter, faulty traction motor, faulty contact or wire breakage of traction motor speed sensor harness, faulty
main harness, faulty logic unit.

Motor current is more than 1018 A (Moment). Motor current is more than 990 A (Fixed time 1).
Motor current is more than 985 A (Fixed time 2).
(4) Checks
(5) Check traction motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections

(U, V, W phases) for traction inverter and motor. (7) Replace traction motor.
Normal Abnormal

(9) Secure cable if loose or connect cable correctly.
breakage.
Normal Abnormal
(10) Confirm connection of traction motor speed sensor (11) Secure DSP flat cable if loose.
connector P14. Replace inverter if wire breaks. See page 1-46.
Normal Abnormal
Sensor
(12) Disconnect connectors P1 and P14. (13) Connect connector securely.
8V power
supply
CAN
(16) Connect connector P8 to logic unit, then turn on power (17) Repair or replace harness.
again.
2-24

Normal Abnormal
(19) Disconnect battery plug, then perform inverter discharging work.
(20) Replace DSP card of traction inverter. (21) Replace power supply card of logic unit.
See page 1-52. See page 1-56.
If fault remains
(22) Perform inverter discharging work, then replace traction

inverter. (DSP card is normal.) See page 1-46.
If fault remains
(23) Perform inverter discharging work, then reinstall
traction inverter and replace traction motor.
2-25
Logic
G 0 to 5V G
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
P8 2
12V R Flat
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
Traction motor
P14
DSP flat 82 B 4 Speed
cable G sensor W TW
81 3
Inverter W 2
IM V TV
80 U TU
case R
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211368
2-26
Problem: Traction Motor, Stall Timer (16)

(1) Situation
Display:"16". All truck operations inhibited. Line contactor OPEN and steering contactor HOLD.
(2) Possible cause

Stall current flowed more than set time (#20) in traction motor, faulty traction inverter current sensor, shorted harness
wiring, faulty traction inverter DSP card, faulty logic unit.

Stall timer set time (set by Setup Option #20) is measured while stalling.
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
No error, problem recurs Error code 14
(5) Confirm stall timer set time of Setup Option #20.

(6) See troubleshooting for code "14". See page 2-22.
Maximum value set Larger value can be set
(7) Check to see if truck is operated with heavy cargo load or (8) Change set time. See page 1-27.
on steps when motor stalls.
Normal steeps Heavy load Note: The more stall occurs, the more overheating
occurs. Operate truck under normal condition.

discharging work. See page 1-45. (10) Operate under normal condition.

DSP cover, then check DSP flat cable for looseness or
wire breakage. See page 1-48.
Normal Abnormal
Power supply
(12) Check continuity between P8-5 and P1-16(45). (13) Secure harness if loose. Replace traction inverter if
Check continuity between P8-6 and P1-20(44). wire breaks. See page 1-46.
CAN
(15) Connect connector P8 to logic unit, then turn on power (16)Repair or replace harness.
again.

Normal Abnormal
(19) Replace DSP card of traction inverter. See page 1-52. (20)Replace power supply card of logic unit. See page 1-56.
2-27
Logic
0 to 5V U current sensor
G G
6 93A 93
GW 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
P8 2
Flat
5 cable W IW
6 V current sensor
7
19
Traction motor
P14
82 4 Speed
sensor W TW
81 3
80 2
IM V TV
U TU
79 1 Thermal
sensor
77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211369
2-28
Problem: Pump Motor Current Sensor Fault (Transistor Control Type Only) (34)
(1) Situation
Display: "34". All truck operations inhibited. This fault occurs only when turning on power.
Line contactor OPEN and steering contactor HOLD.
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter,
faulty pump inverter, faulty main harness, faulty logic unit.

When turning on power, current sensor voltage is out of range of -120 A to 120 A.
(4) Checks
(5) Disconnect connector P2 of pump inverter and remove

breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between P8-4(46) and P2-18(46A). (7) Secure DSP flat cable if loose.
Check continuity between P8-6(44) and P2-20(44B). Replace pump inverter if wire breaks. See page 1-46.
CAN
again.

Normal Abnormal
(13) Replace DSP card of pump inverter. See page 1-52. (14) Replace power supply card of logic unit. See page 1-56.
If fault remains
(15) Perform inverter discharging work, then replace pump
2-29
Logic
P3 P2 Pump inverter
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U IU
1
2 Flat
P8
5 cable W IW
6
7 V current sensor
19
P16 Pump motor

DSP flat 88 4 Speed
cable sensor W PW
87 3
Inverter IM V PV
86 2 U PU
case
85 1 Thermal
sensor
DSP card 78 2
391 [-30 C(-22 F)] to
89 1 1407 [160 C(320 F)]
P17
211370
2-30
Problem: Pump Motor Over-current (Transistor Control Type Only) (35)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump
inverter, faulty pump motor, faulty contact or wire breakage of pump motor speed sensor harness, faulty main
harness, faulty logic unit.

Motor current is more than 1018 A (Moment). Motor current is more than 990 A (Fixed time 1).
Motor current is more than 985 A (Fixed time 2).
(4) Checks
(5) Check pump motor and terminal for burning and smell.
Normal Abnormal
(6) Confirm cable looseness and improper connections (U,

V, W phases) for pump inverter and motor. (7) Replace pump motor.
Normal Abnormal

(9) Secure cable if loose or connect cable correctly.
breakage.
Normal Abnormal
(10) Confirm connection of pump motor speed sensor (11) Secure DSP flat cable if loose.
connector P16. Replace pump inverter if wire breaks. See page 1-46.
Normal Abnormal
Sensor
(12) Disconnect connectors P2 and P16.
(13) Connect connector securely.
8V power
supply
CAN
again.
2-31

Normal Abnormal
If fault remains

If fault remains
(23) Perform inverter discharging work, then reinstall pump

inverter and replace pump motor.
2-32
Logic
P3 P2 Pump inverter
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U IU
1
2 Flat
P8 12V R
5 cable W IW
0 to 5V W
6
0 to 5V G
7 V current sensor
GND B
19
P16 Pump motor

DSP flat 88
B 4 Speed
cable G sensor W PW
87 3
Inverter 86
W 2 IM V PV
case U PU
85 R 1
Thermal
sensor
DSP card 78 2
391 [-30 C(-22 F)] to
89 1 1407 [160 C(320 F)]
P17
211371
2-33
Problem: Line Contactor Fault (40)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty main harness, faulty logic unit, faulty traction inverter, faulty pump inverter.

Inverter voltage data is checked when contactor is closed (400 mS).
(4) Checks
Turn off power, then turn on power again. Confirm error code display.
Error code 40 Error code 63 or 65
(5) Block wheels, then confirm line contactor operation in (6) See troubleshooting for code "63" or "65".
self-diagnosis mode [14]. See page 1-41 or 1-42. See page 2-61 or 2-64.
Not operated Operated
With service tool
(7) Check DC voltage of pump and traction inverters (8) Disconnect battery plug, then perform
with monitor. These values should be same as inverter discharging work. See page 1-45.
battery voltage.
Traction inverter value Pump inverter value
abnormal abnormal
(11) Replace traction inverter.
(9) Disconnect battery (10) Disconnect battery See page 1-46.
plug, then perform plug, then perform
inverter discharging inverter discharging If fault remains
work. See page 1-45. work. See page 1-45.
(14) Disconnect battery plug, then perform
(12) Replace traction (13)Replace pump inverter. inverter discharging work. See page 1-45.
inverter. See page 1-46. See page 1-46.

discharging work. See page 1-45. (15)Replace pump inverter. See page 1-46.
(17) Check to see if line contactor tip moves smoothly.

Check line contactor tip for melting.
Normal Abnormal
(18) Measure resistance of contactor coil.

[44 at -30 C(-22 F) to 65 at 80 C(176 F)]
Within range Out of range
(19) Disconnect connectors P5, P8 and P19.

Check continuity between P8-14(10A) and P19-4(10B). (20) Replace line contactor. See Chassis & Mast.
Check continuity between P19-4(10B) and J4-2.
Check continuity between P5-59(30) and P19-5(30).
Check continuity between P19-5(30) and J5.
(21) Perform inverter discharging work, then replace logic (22) Repair or replace harness.
card of logic unit. See page 1-55.
2-34
Logic
P3 P1
G 0 to 5V G Traction inverter
5 92A 92 3
CAN GW 93A 0 to 5V GW
6 93 4 F
Power supply card

P8
Y 10A
14
Logic
P5 P19
Y R R
-
10B 4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
Contactor Control Type
211372
2-35
Logic
P3 P1
5 92A 92 3
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-36
Problem: Steering Contactor Fault (41)

(1) Situation
Display: "41". All truck operations inhibited. Line contactor OPEN and steering contactor OPEN.
(2) Possible cause

Faulty steering contactor, faulty main harness, faulty logic unit.

Inverter voltage data is checked when contactor is opened (1400 mS).
(4) Checks
Block wheels, then confirm steering contactor operation
in self-diagnosis mode [16]. See page 1-41 or 1-42.
(6) Check to see if steering contactor tip moves smoothly. (7) Repair or replace harness.
Check steering contactor tip for melting.
Normal Abnormal

[44 at -30 C(-22 F) to 65 at 80 C(176 F)]
(9) Disconnect connectors P5, P8 and P19.

Check continuity between P8-14(10A) and P19-4(10B). (10)Replace steering contactor. See Chassis & Mast.

logic card of logic unit. See page 1-55.
2-37
Logic
P3 P1
5 92A 92 3
6 93 4 F
Power supply card

P8
Y 10A
14
Logic
P5 P19
Y R R
-
10B 4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-38
Logic
P3 P1
5 92A 92 3
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-39
Problem: Pump Contactor Fault (Contactor Control Type Only) (42)

(1) Situation
Display: "42". All truck operations inhibited. Line contactor OPEN, steering contactor HOLD
and pump contactor OPEN.
(2) Possible cause

Faulty pump contactor, faulty main harness, faulty logic unit.

Inverter voltage data is checked when contactor is opened (1400 mS).
(4) Checks
Block wheels, then confirm pump contactor operation in
self-diagnosis mode[15]. See page 1-42.
(6) Check to see if pump contactor tip moves smoothly. (7) Repair or replace harness.
Check pump contactor tip for melting.
Normal Abnormal

[44 at -30 C(-22 F) to 65 at 80 C(176 F)]
(9) Disconnect connectors P5, P8 and P19. (10)Replace pump contactor. See Chassis & Mast.
Check continuity between P8-14(10A) and P19-4(10B).
(11) Perform inverter discharging work, then replace logic

2-40
Logic
P3 P1
5 92A 92 3
6 93 4 F
Power supply card

P8
Y 10A
14
Logic
P5 P19
Y R R
-
10B 4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-41
Problem: Traction Motor Open (45)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of traction motor cable, faulty traction motor, faulty contact or wire breakage of traction
inverter connector, faulty contact of DSP flat cable in traction inverter, wire breakage of main harness, faulty power
supply card of logic unit, faulty DSP card of traction inverter, faulty traction inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when torque instruction is requested.
(4) Checks
(5) Check traction inverter and motor for cable looseness

and improper contact.
Normal Abnormal
(6) Disconnect traction motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
Less than 1 1 or more
(8) Check connector P1 of traction inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
(10) Disconnect connector P1 of traction (11) Connect connector securely.

inverter and remove DSP cover.
Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal (12) Replace traction motor. (13) Replace motor cables.
Gate power
supply
(14) Check continuity between P8-5 and P1-16(45). (15) Secure DSP flat cable if loose.
Check continuity between P8-6 and P1-20(44). Replace inverter if wire breaks. See page 1-46.
CAN
again.
2-42

Normal Abnormal
(21) Replace DSP card of traction inverter. See page 1-52. (22) Replace power supply card of logic unit.
See page 1-56.
If fault remains
(23)Perform inverter discharging work, then replace traction

2-43
Logic
G 0 to 5V G
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
P8 2
Flat
5 cable W IW
6
7
19
Traction motor
P14
DSP flat 82 4 Speed
cable sensor W TW
81 3
Inverter 80 2
IM V TV
case U TU
79 1 Thermal
sensor
DSP card 77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211374
2-44
Problem: Pump Motor Open (Transistor Control Type Only) (47)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of pump motor cable, faulty pump motor, faulty contact or wire breakage of pump
inverter connector, faulty contact of DSP flat cable in pump inverter, wire breakage of main harness, faulty power
supply card of logic unit, faulty DSP card of pump inverter, faulty pump inverter, when restarting after motor shorted.

Motor voltage is abnormal when power is turned on.
Current does not flow when rotational speed instruction is requested.
(4) Checks
(5) Check pump inverter and motor for cable looseness and
improper contact.
Normal Abnormal
(6) Disconnect pump motor cables from inverter. (7) Secure cable if loose.
Measure resistance of motor cables (U, V and W phases).
(8) Check connector P2 of pump inverter for looseness. (9) Measure resistance between terminals of both cable
Normal Abnormal ends (between U and U, V and V, and W and W).
(10) Disconnect connector P2 of pump (11) Connect connector securely.

inverter and remove DSP cover.
Check DSP flat cable for looseness
or wire breakage.
Normal Abnormal (12) Replace pump motor. (13) Replace motor cables.
Gate power
supply
(14) Check continuity between P8-5(45) and P2-16(45A). (15) Secure DSP flat cable if loose.
Check continuity between P8-6(44) and P2-20(44B). Replace inverter if wire breaks. See page 1-46.
CAN
(17) Connect connector P8 to logic unit, then turn on (18) Repair or replace harness.
power again.
2-45

Normal Abnormal
(21) Replace DSP card of pump inverter. See page 1-52. (22) Replace power supply card of logic unit.
See page 1-56.
If fault remains

pump inverter. (DSP card is normal.) See page 1-46.
2-46
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U IU
1
2 Flat
P8
5 cable W IW
6
7
19
P16 Pump motor

DSP flat 88 4 Speed
cable sensor W PW
87 3
Inverter IM V PV
86 2 U PU
case
85 1 Thermal
sensor
DSP card 78 2
391 [-30 C(-22 F)] to
89 1 1407 [160 C(320 F)]
P17
211375
2-47
Problem: Accelerator Sensor Fault (51)

(1) Situation
(2) Possible cause

Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.

Accelerator sensor voltage is out of range of 0.2 V to 4.8 V.
Sensor voltage is 1.41 V or more when accelerator switch is opened.
Sensor voltage is 0.3 V or less when accelerator switch is closed.
(4) Checks
Raise front wheels until they clear floor.
Without service tool With service tool
(5) Disconnect battery plug. (6) Check accelerator sensor voltage with input/output
monitor and confirm value is in range of 0.2V to 4.8V.
Check relation between sensor voltage and accelerator
switch operation.
(7) Check link length of accelerator pedal. 0.3V or less: OFF
Normal Abnormal 1.41V or more: ON
Abnormal signal Interrupted
(8) Adjust accelerator pedal (9) Disconnect battery plug. (10) Adjust accelerator
linkage. pedal linkage.
(12) Disconnect connectors P4 and P3 of logic unit.

Disconnect connector P9 of accelerator sensor.

(Sensor voltage)

(Switch)


With service tool
Without
service tool
2-48
Without With service tool

service tool
(17) Replace accelerator pedal. (18)Connect connectors P4 and P3. Turn on power and
check voltage between P9-4(56) and P9-1(28).
If fault remains 5V Not 5 V

(20) Turn off power. Short-circuit P9-4(56) and
P9-3(29). Turn on power and check accelerator
voltage with service tool.
(21) Reinstall accelerator pedal, then replace logic card 5V Not 5 V
of logic unit. See page 1-55.
(22) Turn off power. Open P9-4(56) and P9-3(29).
Short-circuit P9-3(29) and P9-1(28). Turn on
power and check accelerator voltage with
service tool.
0V Not 0 V
(23) Replace accelerator (24) Disconnect battery

pedal. plug.
(25) Replace logic card

of logic unit.
2-49
P9
1 2 3 4
Logic 28 15 29 56
P4
YB 12V/0V
SW 42 15
Accelerator
P9
2
B 56
5V
24 4
AN 20 W 29
0.30 to 1.40V
3
CLEAR GND
25 28 1
Logic
P3
211376
2-50
Problem: Traction Motor Pulse Input Fault (52)

(1) Situation
(2) Possible cause

Faulty contact of traction inverter connector, faulty connection of traction motor connector and cable, faulty 12V input
voltage of traction inverter, faulty contact or wire breakage of traction motor speed sensor harness, faulty DSP card of
traction inverter, faulty traction motor speed sensor.

Motor rotation speed is more than 5800 rpm.
(4) Checks
(5) Check to see if traction motor cables (U, V and W-phases)

are connected to traction inverter properly.
Normal Abnormal
(6) Check to see if connector P1 of traction inverter is (7) Connect cables properly.
fastened securely.
Normal Abnormal
(8) Check to see if connector P14 of traction motor speed

(9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
again.
2-51

Normal Abnormal
(18) Replace DSP card of traction inverter. See page 1-52. (19) Replace power supply card of logic unit. See page 1-56.
If fault remains
(20) Perform inverter discharging work, then replace traction

motor. (DSP card is normal.)
2-52
Logic
G 0 to 5V G
6 93A
GW
93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 WL 17
47
8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U IU
1
P8 2
12V R Flat
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
Traction motor
P14
82 B 4 Speed
G sensor W TW
81 3
80 W 2
IM V TV
U TU
79
R 1 Thermal
sensor
77 2 391 [-30 C(-22 F)] to
83 1 1407 [160 C(320 F)]
P15
211377
2-53
Problem: Pump Motor Pulse Input Fault (Transistor Control Type Only) (57)
(1) Situation
(2) Possible cause

Faulty contact of pump inverter connector, faulty connection of pump motor connector and cable, faulty 12V input
voltage of pump inverter, faulty contact or wire breakage of pump motor speed sensor harness, faulty DSP card of
pump inverter, faulty pump motor speed sensor.

Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor.
Motor rotates in reverse.
(4) Checks
(5) Check to see if pump motor cables (U, V and W-phases)

are connected to pump inverter properly.
Normal Abnormal
(6) Check to see if connector P2 of pump inverter is fastened (7) Connect cables properly.
securely.
Normal Abnormal
(8) Check to see if connector P16 of pump motor speed (9) Fasten connector securely.
sensor is fastened securely.
Normal Abnormal
Sensor
Power
supply
CAN
power again.
2-54

Normal Abnormal
If fault remains

motor. (DSP card is normal.)
2-55
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U IU
1
2 Flat
P8 12V R
5 cable W IW
0 to 5V W 6
0 to 5V G
7
GND B 19
P16 Pump motor

88 B 4 Speed
G 3 sensor W PW
87
86 W 2 IM V PV
U PU
R
85 1 Thermal
sensor
78 2
391 [-30 C(-22 F)] to
89 1 1407 [160 C(320 F)]
P17
211378
2-56
Problem: Display Communication Fault (60)

(1) Situation
Display: "60". Normal truck operation.
(2) Possible cause

Faulty main harness, faulty display unit, faulty logic unit.

Communication is impossible.
Hour meter data of display unit is abnormal.
From another troubleshooting flow chart

ex. page 2-4, (17)
(4) Checks
(5) Disconnect connector P3 of controller. Disconnect

connector P6 of display unit.
Check continuity between P8-14(10A) and P6-2(10E).
(6) Check to see if these are shorted to other signal cables. (7) Repair or replace harness.
Not shorted Shorted
(8) Replace display unit. (9) Repair or replace harness.
If fault remains

(11) Replace logic card of logic unit. See page 1-55.
2-57
P46 Key switch

10
Y 1
Power supply card
12
W 2
P8
Y
14 10A Battery +
P19 P20
RW
1 11 4
1
12
W
Fuse holder
P6
Logic P6
P3 Battery voltage Y
10E 2 17 95
G 95
0 to 12V 10E 96
TXD 14 4
Display
W 0 to 12V
RXD 16 96 3
GND 23 B 17
GND
1
211379
2-58
Problem: Logic Card Initialize Failure (61)

(1) Situation
(2) Possible cause

Setup Option Group 3 data not set, Setup Option Group 1 and 2 default data not set, faulty Setup Option data,
faulty logic unit.

Setup Option data is in abnormal setting range.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-19.
(5) Set Setup Option Group 3 data. See page 1-31 to 1-33.
(6) Set Setup Option default data. See page 1-19.
(7) Turn on power in "RUN" mode. See page 1-19.
If fault remains
(8) With service tool, set Setup Option Group 3 data.
(9) With service tool, set Setup Option default data.
If fault remains
(13) With service tool, set Setup Option default data.
2-59
Problem: Logics Fault (62)

(1) Situation
(2) Possible cause

Faulty EEPROM data, faulty logic unit.

ROM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from check
data. RAM of logic card is faulty.
(4) Checks
Turn off power, then turn on power in Setup Option Group 3 setting. See page 1-19.
(5) Set Setup Option Group 3 data.
(6) Set Setup Option default data.
(7) Turn on power in "RUN" mode. See page 1-19.

Error code "61"
If fault remains "62"
(8) Disconnect battery plug, then perform inverter (9) See troubleshooting for code "61". See page 2-59.

Set Setup Option default data.
2-60
Problem: Traction Inverter Fault (63)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in traction inverter, faulty DSP card of traction inverter, faulty traction
inverter, faulty main harness, faulty logic unit.

Traction inverter is connected as pump inverter (P1-9 is connected to GND).
ROM SUM value of taction inverter is different from check data.
RAM of traction inverter is faulty. Communication with traction inverter is impossible.
(4) Checks

breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between P8-4 and P1-18(46). (7) Refasten flat cable or replace inverter. See page 1-46.
CAN
(9) Measure resistance of CAN with connectors P1 and P3 disconnected.
Resistance between P3-5(92A) and P3-6(93A)

120 5% Other than 120 5%
(10)
Transistor control Contactor control
(11) Perform CAN check of

Pump Inverter Fault (65).

When repairing harness,
repair resistor (120 ) on
harness.
2-61
(13) Measure resistance of CAN for traction inverter DSP card.
Resistance between CN2-3 and CN2-4 of DSP card side connectors

120 5% Other than 120 5%
(14) Replace DSP card of

traction inverter.
(15) Connect connector P1 of traction inverter.

Measure resistance of CAN with connector P3 disconnected.

60 5% Other than 60 5%
Mode
(17) Check P1-8 and P1-9 that pin is not inserted in.
Normal Abnormal
power again.

Normal Abnormal
(22) Replace DSP card of traction inverter. (23) Replace power supply card of logic unit.
2-62
Logic
G 0 to 5V G
92
GW
6 93A 93 4 of of
B cover case F
18 14
B Fuse
15
5 WR 12V WR
45 16 P
WB 14V WB
Power 3 17
47
WL 8V WL N Battery (-)
4 46 18 DSP IMS
GW GND GW card
6 44 20 card U
8
Power supply card V
P8 9
Flat
cable W
DSP flat
cable
Inverter
case
DSP card
211380
2-63
Problem: Pump Inverter Fault (Transistor Control Type Only) (65)

(1) Situation
(2) Possible cause

Faulty contact or wire breakage of DSP flat cable in pump inverter, faulty DSP card of pump inverter, faulty pump
inverter, faulty main harness, faulty logic unit.

Pump inverter is connected as traction inverter (P2-9 is opened).
ROM SUM value of pump inverter is different from check data.
RAM of pump inverter is faulty. Communication with pump inverter is impossible.
(4) Checks

breakage.
Normal Abnormal
8V power
supply
(6) Check continuity between P8-4(46) and P2-18(46A). (7) Refasten flat cable or replace inverter. See page 1-46.
CAN
(9) Measure resistance of CAN with connectors P2 and P3 disconnected.

120 5% Other than 120 5%
(10) Perform CAN check of Traction

Inverter Fault (63).
(11) Measure resistance of CAN for pump inverter DSP card.
Resistance between CN2-3 and CN2-4 of DSP card side connectors

120 5% Other than 120 5%
(12) Replace DSP card of pump

inverter.
2-64
(13) Connect connector P2 of pump inverter.

Measure resistance of CAN with connector P3 disconnected.

60 5% Other than 60 5%
Mode
(16) Check P2-8 that pin is not inserted in.

Normal Abnormal
again.

Normal Abnormal
2-65
Logic
P3 P2 Pump inverter
G 0 to 5V G
CAN 5 GW 92A
0 to 5V
92
GW
6 93A 93 4 of of
B cover case F
73 14
B Fuse
15
5 WR 45 12V 45A WR 16 P
WB 14V 47A WB
Power 3 WL
47
8V 46A WL
17
N Battery (-)
4 46 18 DSP IMS
6 44 U
mode 1 8
Power supply card mode 2 GW V
9 Flat
P8
cable W
44A
DSP flat
cable
Inverter GND
case
DSP card
211381
2-66
Problem: Contactor Coil Fault (72)

(1) Situation
(2) Possible cause

Faulty line contactor, faulty steering contactor, faulty pump contactor, faulty main harness, faulty logic unit.

With short circuit detection signal of logic card.
(4) Checks
Without service tool With service tool
(5) Find faulty contactor (line contactor, steering contactor or

pump contactor) with input/output monitor.
(6) Disconnect battery plug, then perform (faulty unit only)

inverter discharging work. See page 1-45.
(7) Check line contactor, steering contactor or pump contactor.
Line contactor Steering contactor Pump contactor
(8) Remove coil side terminals of (14) Remove coil side terminals of (20) Remove coil side terminals of
line contactor. steering contactor. pump contactor.
(9) Check short circuit between coil (15) Check short circuit between coil (21) Check short circuit between
terminal plus(+)(J4-2) and minus(-) terminal plus(+)(J4-1) and minus(-) coil terminal plus(+)(J4-3) and
(J5) of harness. (J6) of harness. minus(-)(J7) of harness.
Not shorted Shorted Not shorted Shorted Shorted Not shorted
(10) Repair or replace main harness. (16) Repair or replace main harness.
(11) Measure coil resistance. (17) Measure coil resistance. (22) Measure coil resistance.
[44 at -30 C(-22 F) to [44 at -30 C(-22 F) to [44 at -30 C(-22 F) to
66 at 80 C(176 F)] 66 at 80 C(176 F)] 66 at 80 C(176 F)]
Abnormal Normal Abnormal Normal Normal Abnormal
(12) Replace logic card of logic unit. (18) Replace logic card of logic unit.
(13) Replace line contactor. (19) Replace steering contactor. (23) Replace pump contactor.
2-67
Logic
P3 P1
5 92A 92 3
6 93 4 F
Power supply card

P8
Y 10A
14
Logic
P5 P19
Y R R
-
10B 4 J4-2
RW GW Line
59 30 5
contactor
+
J5
Fuse
-
R J4-3
Pump
contactor
60 32 RW GY +
7 J7
LB LR
54 50 12 J12
- Fuse
R J4-1
Steering
contactor
61 31 RW GR +
6 J6
L
55 48 11 LW J11
211372
2-68
Logic
P3 P1
5 92A 92 3
6 93 4 F
P2
Power supply card
P8 G 3
92 Pump inverter
Y 10A GW
14 F
93 4
Logic
P5 P19
10B
Y R R
-
4 J4-2
RW GW Line
59 30 5
contactor
+
J5
- Fuse
R J4-1
Steering
contactor
61 RW GR +
31 6 J6
L
55 48 11 LW J11
211373
2-69
Problem: Hydraulic Lock Solenoid Fault (74)

(1) Situation
Display: "74". Pump motor operation inhibited. Normal traction motor operation and power steering operation.
(2) Possible cause

Faulty lift lock valve, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connector P5 of logic unit. Disconnect connector P11 of lift lock valve.
(6) Check short circuit between P11-1(25) and P11-2(26).

Shorted Not shorted
(8) Check short circuit between lift lock valve side

(7) Repair or replace main harness.
connectors. Measure coil resistance.
[40.5 at -30 C(-22 F) to 52 at 80 C(176 F)]
Normal Abnormal
(9) Replace logic card of logic unit. (10) Replace lift lock valve.
See page 1-51.
2-70
Logic P11
P5
1 Lift
57 BL 25
Y lock
58 26
2 valve
P11
1 2
25 26
211382
2-71
Problem: Electromagnetic Brake Solenoid Fault (75)

(1) Situation
(2) Possible cause

Faulty electromagnetic brake valve, faulty main harness, faulty logic unit.

(4) Checks
(5) Disconnect connector P5 of logic unit. Disconnect connector P24 of electromagnetic brake.
(6) Check short circuit between P24-1(10G) and P24-2(5).
Not shorted Shorted
(7) Check short circuit between electromagnetic brake

side connectors. Measure coil resistance.
[Approximately 22.1 ]
Shorted Not shorted
(9) Replace electromagnetic brake. (10) Replace logic card of logic unit. See page 1-55.
2-72
Power supply card

P8 P24
Y Y Electro-
14 10A 10G 1
magnetic
Logic brake
2
P5
YW
64 5 P24
10G 5
1 2
211383
2-73
Problem: Battery Voltage Too Low (78)

(1) Situation
(2) Possible cause

Faulty or discharged battery, low voltage battery, improper battery voltage setting (Setup Option #41), improper
battery voltage adjustment setting (Setup Option #46), faulty main harness, faulty logic unit.

Corrected battery voltage is too low. Battery voltage is corrected with #46 value.
36 V battery: less than 30 V 48 V battery: less than 42 V
(4) Checks
Disconnect battery plug. Measure battery voltage with tester.
34 V to 55 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

(6) Charge battery or replace with proper battery.
See page 1-19.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-31 to 1-33.
(8) Turn off power and turn on power again.
If fault remains

(10) Check continuity between P3-19(12B) and contactor

POS(J1).
(11) Perform inverter discharging work, then replace logic

2-74
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-75
Problem: Battery Voltage Too High (79)

(1) Situation
(2) Possible cause

Faulty or highly charged battery, high voltage battery, improper battery voltage setting (Setup Option #41),
improper battery voltage adjustment setting (Setup Option #46), faulty logic unit.

Corrected battery voltage is too high. Battery voltage is corrected with #46 value.
36 V battery: more than 42 V 48 V battery: more than 60 V
(4) Checks
Disconnect battery plug. Measure battery voltage with tester.
34V to 55 V Abnormal
(5) Turn on power in Setup Option Group 3 setting.

(6) Replace with proper battery.
See page 1-19.
(7) Set #41 of Setup Option Group 3.

Set #46 of Setup Option Group 3. See page 1-31 to 1-33.
(8) Turn off power and turn on power again.
If fault remains


POS(J1).
(11) Perform inverter discharging work, then replace logic (12) Repair or replace main harness.
2-76
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-77
Problem: Direction Lever or Accelerator, Faulty Setting (E)

(1) Situation
Display: "E". All truck operations inhibited. Line contactor and steering contactor OPEN when turning on power.
Line contactor OPEN (when truck stops) and steering contactor HOLD except when turning on power.
(2) Possible cause

Key switch turned on while direction lever was left either in forward or reverse position, key switch turned on while
accelerator pedal was depressed, seat switch turned off during running, faulty direction lever switch, faulty accelerator
sensor, faulty main harness, faulty logic unit.

Detects following signal when turning on power.
Direction lever: F or R Accelerator sensor voltage: More than 0.3 V
(4) Checks
Move direction lever to neutral, and release accelerator pedal.
If fault remains
(5) Turn off power. Move direction lever to neutral, release

accelerator pedal, then turn on power again.

With service tool
(6) Check direction lever and accelerator sensor operations (7) Turn on power in diagnosis mode. Inspect direction
with input/output monitor. lever and accelerator sensor. See page 1-38.
(8) Turn off power. (faulty unit only)

Direction lever Accelerator sensor
(9) Disconnect connector P7 of direction lever.

(10) Refer to error code "51". See page 2-48.
Turn on power.
Normal (E)
(11) Replace direction lever. (12) Disconnect connectors P4 and P3 of logic unit.
(13) Check short circuit between P3-23(17) and

P4-36(8), P3-23(17) and P4-37(6).
Not shorted Shorted
(14) Disconnect battery plug. (15) Repair or replace main

harness.
2-78
Logic
P4
P7
G 0/12V
Forward 37 6 F
GW 0/12V Direction
Reverse 36 8 R lever
GND
17H
B
B2
Accel YB
42 15
P7
switch
8 6
17H
Main harness
0/12V
Logic Accelerator
P3 P9
GND 23 B 17 2
+ 5V 24 B 56
5V
4
AN 20 W 29
0 to 5V
3
CLEAR GND
GND 25 28 1
P9
1 2 3 4
28 15 29 56
Main harness
211385
2-79
Problem: Seat Switch, Faulty Setting For Traction ((E))

(1) Situation
Display: "E" flickering. All truck operations inhibited. Line contactor and steering contactor OPEN when turning on
power. Line contactor OPEN (when truck stops) and steering contactor HOLD except when turning on power.
(2) Possible cause

Operator not on seat, seat switch turned off during running, improper seat suspension adjustment, faulty seat switch,
faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during running.
(4) Checks
If this fault occurred If this fault occurred when
during running turning on power
(5) Stop truck, then move direction lever to neutral. Sit

properly in operator's seat and release accelerator pedal.
If fault remains Normal
Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position

(10) Disconnect connector P62, then short-circuit between

terminals (17A) and (7). Turn on power again.
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.
(13) Disconnect connectors P4 and P3 of logic unit.

Check continuity between P62(17A) and P3-23(17).
Check continuity between P62(7) and P4-33.
(14) Replace logic card of logic unit. See page 1-55. (15) Repair or replace main harness.
2-80
Logic
P4
0/12V BR
19 32 Seat belt switch
0/12V R
7 33 Seat switch
Seat belt switch
P62 Logic
1 19
P3
3 7
GND B
2 17A 17 23 GND
Seat switch
P62
7 17A 19
211386
2-81
Problem: Seat Switch, Faulty Setting For Hydraulic ((L))
(1) Situation
Display: "L" flickering. All truck operations inhibited. Line contactor and steering contactor OPEN when turning on
(2) Possible cause

Operator not on seat, seat switch turned off during pump motor operation, improper seat suspension adjustment,
faulty seat switch, faulty main harness, faulty logic unit.

Detects seat switch opening when turning on power or during pump operation.
(4) Checks
If this fault occurred during If this fault occurred when
pump motor operation turning on power
(5) Sit on seat, then stop pump motor operation.

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again.
If fault remains
(7) Turn off power.
(8) Adjust seat suspension.

Faulty seat switch position
(10) Disconnect connector P62, then short-circuit between

terminals (17A) and (7). Turn on power again.
(11) Disconnect battery plug, then perform inverter (12) Replace seat switch.
(13)Disconnect connectors P4 and P3 of logic unit.

Check continuity between P62(17A) and P3-23(17).
Check continuity between P62(7) and P4-33.
2-82
Logic
P4
0/12V BR
19 32 Seat belt switch
0/12V R
7 33 Seat switch
Seat belt switch
P62 Logic
1 19
P3
3 7
GND B
2 17A 17 23 GND
Seat switch
P62
7 17A 19
211386
2-83
Problem: Lift Lever, Faulty Setting (H1)

(1) Situation
Display: "H1" flickering. All truck operations inhibited. Line contactor and steering contactor OPEN when turning on
(2) Possible cause

Key switch turned on while operating lift lever, faulty lift switches 1 and 2, faulty lift down switch, faulty main
harness, faulty logic unit.

Detects lift microswitch 1 or 2, or lift down microswitch when turning on power.
(4) Checks

Fail-safe function
(6) Turn off power. Sit on seat, then turn on power again
without lift operation.
If fault remains
(7) Turn off power.
(8) Disconnect connector P13 of microswitch. Sit on seat,

then turn on power again.
(9) Disconnect battery plug, then perform inverter (10) Replace lift switch 1 or 2.

Check short circuit between P13-5(53) and P13-1(17C).
Check short circuit between P12-1(4) and P12-2(17G).
Continuity, Not shorted No continuity, Shorted
(12) Disconnect battery plug. (13) Repair or replace main harness.
2-84
Logic
P13 P5
0/12V YB
5 53 52 Lift 1
Lift 1
6
0/12V
54 YR 51 Lift 2
Lift 2 1 B 17C
GND
P13 Logic
P3
1 17C 54 6 B 23
17
2 51 53 5
3 52 52A 4
Logic
P12 P5
YB
1 4 48 Lift down
Lift down
2 B 17G
P12
1 2
4 17G
211387
2-85
Problem: Tilt Lever, Faulty Setting (H2)

(1) Situation
(2) Possible cause

Key switch turned on while operating tilt lever, faulty tilt switch, faulty main harness, faulty logic unit.

Detects tilt microswitch when turning on power.
(4) Checks

Fail-safe function
without tilt operation.
If fault remains
(7) Turn off power.

(9) Disconnect battery plug, then perform inverter (10) Replace tilt switch.

2-86
Logic
P13 P5
2
0/12V YG
51 50
Tilt
1 B 17C
GND
P13 Logic
P3
1 17C 54 6 B
17 23
2 51 53 5
3 52 52A 4
211388
2-87
Problem: Attachment 1 Lever, Faulty Setting (H3)

(1) Situation
(2) Possible cause

Key switch turned on while operating attachment 1 or 2 lever, faulty attachment 1 or 2 switch, faulty main harness,
faulty logic unit.

Detects attachment 1 or 2 microswitch when turning on power.
(4) Checks

Fail-safe function
without attachment 1 or 2 operation.
If fault remains
(7) Turn off power.

(9) Disconnect battery plug, then perform inverter (10) Replace attachment 1 or 2 switch.
(11) Check continuity between P5-49, P13-3(52) and

P13-4(52A).
Check short circuit between P13-3(52), P13-4(52A)
and P13-1(17C).
2-88
P13 Logic
YL 52A P5
4
3 YL 0/12V YL
Aux 2 52 52 49
Aux 1
1 B
GND
17C
Logic
P13 P3
B
1 17C 54 6 17 23
2 51 53 5
3 52 52A 4
211389
2-89
Problem: Battery Consumption Too Much ((Lo))

(1) Situation
Display: "Lo" flickering. Battery low indicator ON. All truck operations inhibited.
Line contactor OPEN and steering contactor OPEN.
(2) Possible cause

Extremely consumed battery, faulty main harness, faulty logic unit.

Corrected battery voltage is less than 22 V. Battery voltage is corrected with #46 value.
(4) Checks
Disconnect battery plug.
(5) Check battery voltage.

22V or more Less than 22V
(6) Set #46 of Setup Option Group 3. See page 1-33. (7) Charge battery or replace with new battery.
If fault remains

POS(J1).
2-90
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-91
Problem: Battery Consumption

(1) Situation
Battery low indicator flickers. Traction motor operation restricted to "ECONOMY" mode. Normal pump motor
and power steering operations.
(2) Possible cause

Consumed battery, improper battery voltage adjustment setting (Setup Option #46), faulty main harness,
faulty logic unit.

Corrected battery voltage is less than 25 V. Battery voltage is corrected with #46 value.
(4) Checks
Disconnect battery plug.
(5) Check battery voltage.

25V or more Less than 25V
(6) Set #46 of Setup Option Group 3. See page 1-33. (7) Charge battery or replace with new battery.
If fault remains

POS(J1).
2-92
Line contactor
P20 P19
4 RW
11 1 NEG
Fuse W RW J1
1 12 2
POS
+
Logic
P3 Battery
W
19 12B
211384
2-93
MOTORS
Motor Installation Positions ................................................................. 3–1
Specifications ........................................................................................... 3–1

AC Drive Motor ......................................................................................... 3–2
AC Drive Motor with Brake ....................................................................... 3–3
AC Pump Motor ........................................................................................ 3–4
DC Pump Motor ........................................................................................ 3–5
DC Steer Motor ........................................................................................ 3–6
Tightening of High-Power Motor Cable Terminals ........................... 3–7

Traction Motor & Power Steering Cable Routing ...................................... 3–7
AC Hydraulic Motor Cable Routing ........................................................... 3–8
DC Hydraulic Motor Cable Routing .......................................................... 3–8
Procedures and Suggestions for Removal and Installation of Drive Motors ........ 3–9
3
Removal ................................................................................................... 3–9
Installation ................................................................................................ 3–9
Hydraulic Pump Motor Removal .......................................................... 3–9
Steer Pump Motor Removal ................................................................. 3 – 10

AC Motors ................................................................................................. 3 – 10
External Inspection ................................................................................... 3 – 10
Procedures and Suggestions for Disassembly and Reassembly .............. 3 – 10
AC Drive Motor ......................................................................................... 3 – 11
AC Drive Motor with Brake ....................................................................... 3 – 12
AC Pump Motor ....................................................................................... 3 – 13

Suggestions for Disassembly and Reassembly ........................................ 3 – 13
Trouble Shooting (AC Motors) .............................................................. 3 – 14

Trouble Shooting (DC Motors) .............................................................. 3 – 15
Service Data (AC Motors) ...................................................................... 3 – 23
MOTORS
Motor Installation Positions
Specifications
Item 9” AC Drive Motor 11” AC Drive Motor w/o Brake 11” AC Drive Motor w/ Brake
Type Induction three phase Induction three phase Induction three phase
Voltage (V) 36 48 36 48 36 48
Output (kW) 6.16 kW 6.84 kW 10.2 kW 12.81 kW 10.2 kW 12.81 kW
(S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min)
Weight kg (lb) 80 (176) 136 (299) 136 (299)
Item 8” AC Pump Motor 9” AC Pump Motor

Type Induction three phase Induction three phase
Voltage (V) 36 48 36 48
Output (kW) 7.41 kW 6.84 kW 10.2 kW 12.81 kW
(S3-15%) (S3-15%) (S3-15%) (S3-15%)
Weight kg (lb) 55 (121) 75 (165)
Item 8” DC Pump Motor 9” DC Pump Motor DC Steering Pump Motor

Type Series Series Permanent Magnet
Voltage (V) 36 48 36 48 36 48
Output (kW) 10 kW 14 kW 15.1 kW 22.1 kW 0.69 kW 0.93 kW
(S3-20%) (S3-20%) (S3-20%) (S3-20%) (S2-60 min) (S2-60 min)
Weight kg (lb) 52 (114) 78 (172) 14 (30)
3-1
MOTORS
Structures
AC Drive Motor
U, V, W Terminals
3-2
MOTORS
Structures
AC Drive Motor with Brake
U, V, W Terminals
3-3
MOTORS
Structures
AC Pump Motor
U, V, W Terminals
3-4
MOTORS
Structures
DC Pump Motor
3-5
MOTORS
Structures
DC Steer Motor
3-6
MOTORS
Tightening of High-Power Motor Cable Terminals
! CAUTION
Truck Size Number of Terminals Tightening Torque
If the high-power cable terminals of the battery 1 Ton 11.3 ± 1.1 N•m
operated vehicle are not tightened properly, the Drive 3 (1.2 ± 0.1 kgf•m)
increased contact resistance causes excessive & Pump [8.33 lbf•ft]
heat generation, and could cause a fire in the 2 / 3 Ton 14.7 ± 1.1 N•m
worst case. To prevent accidents and equipment Drive 3 (1.5 ± 0.1 kgf•m)
problems, be sure to regularly check the & Pump [11 lbf•ft]
tightening torque of the high power cable
terminals. Do not pull the cables to check
connections or during adjustment. If the cable
terminal sections are moved, re-tighten the
connections.
Traction Motor & Power Steer Motor Cable Routing
3-7
MOTORS
Tightening of High-Power Motor Cable Terminals
AC Hydraulic Motor Cable Routing
DC Hydraulic Motor Cable Routing
3-8
MOTORS
Procedures and Suggestions for Hydraulic Pump Motor Removal

Removal and Installation of Drive
Motors Removal
(1) Disconnect the battery from the truck.
Removal
(2) Disconnect the hoses attached to the pump fittings.
(1) Disconnect the battery plug.
(3) Disconnect the power cables and wire leads from
(2) Using a crane, remove the batteries. the pump motor.
(3) Remove the floor plate and battery cover. (4) Raise the truck enough to allow the pump and
(4) Disconnect the power cables connected to the motor assembly to be removed from below the
motor. truck. Make sure that the truck is stable and
(5) Remove the drain plug on the front axle housing secure in the raised position.
to let the oil drain out. (5) Secure the motor from above with a crane, hoist,
(6) Disconnect the connectors of the traction motor or other adequate device, or support it at its
harness and pulse generator harness. center with a garage jack.
(7) Remove the traction motor, Reduction and (6) Remove the motor and pump assembly from the
Deferential Assembly and transfer assembly as truck.
one unit, from the front axle housing.
(7) Remove the hydraulic fittings and pump assembly
(8) Separate the three assemblies removed in step (7)
from the motor.
from each other.
(9) Using a crane, lift the drive motor to suspend it.
NOTE
Position the hook above the gravitational center

of the drive motor.
Each motor is equipped with the provision of an
installing and lifting hook for motor removal and
installation.
Installation
Installation
3-9
MOTORS
Steer Pump Motor Removal AC Motors
(1) Remove the battery. External Inspection

(2) Remove the acid tray. External Inspection should include:
(3) Disconnect the cables and wires from the steer
(1) Check terminal studs and mounting bolts to
pump motor. Mark the wire leads and cables so
ensure they are clean and tight.
they can be correctly reconnected.
(2) Check all cooling openings to ensure they are free
(4) Disconnect the hydraulic lines from the pump.
of any debris or restrictions that could prevent
(5) Remove the pump motor. proper airflow and hinder cooling.
(3) Lubricate internal and external spline couplings.
(4) Check for any oil leaks and make any corrections
or repairs immediately.
Disassembly and Reassembly

(1) Remove the bolts holding the drive end bell and
rear end bell in place and remove the rear end
bell with wavy spring from the stator assembly.
The drive end bell and rotor assembly with the
rear bearing will remain inside the stator
assembly.
(2) Remove the drive end bell and rotor assembly
from the stator assembly.
(3) Remove drive end bell from the rotor assembly.
(4) Use a bearing puller to remove rear bearing from
the rotor assembly. Discard the bearing.
Installation (5) Remove the bolts holding the bearing pressure
plate in place and remove the bearing press plate.
Follow the removal sequence in reverse. Use a sleeve to press the bearing out of the drive
end bell-bearing bore and discard the bearing.
(6) Carefully blow out any accumulated dust and dirt
from the end bells and stator assembly using
clean, oil free, compressed air.
(7) If the stator assembly requires maintenance, see
Trouble Shooting Section.
(8) Press a new bearing into the rotor assembly rear
end, pressing on the inner-race only.
(9) Replace the sensor bearing on the drive end bell,
pressing on the outer race only. Then screw the
bearing press plate in place.
(10) Press the drive end bell into the rotor assembly
and tighten the screws with the stator assembly.
(11) Place the wavy washer into the bearing bore of
the rear end bell and tighten the screws with the
stator assembly.
3-10
MOTORS
AC Motors
Disassembly and Reassembly AC Drive Motor
(12) Connect the motor to an AC supply and run the ITEM DESCRIPTION
motor at 25 volts, 50 Hz for 30 minutes.
1 Seal
(13) Repair or replace headband (if necessary) and 2 Bolt
install the headband on the motor (if applicable).
3 Lock Washer
(14) If applicable, place a small drop on the lip of the
seal for optimum seal life before replacing the oil 4 Drive End Bell
seal. If the shaft has a keyway, protect the lip of 5 EE Motor Kit (headband)
the seal from being cut on the keyway edge. 6 Sensor Bearing Kit
7 Thermal Sensor Repair Kit
Suggestion for Disassembly and 8 Stator
Reassembly 9 Terminal Block Assembly
10 Rotor
Ball bearings at both ends are maintenance free. If it is 11 Rear End Bearing
necessary to remove the bearing when repairing the
12 Rear End Bell
motor, the bearings and seals must be replaced.
13 Bolt
If a bearing which is said to be replaced has only one
sealing lip, it should be greased with quality bearing
grease when installing it.
Replace the bearings and the seals after approximately
10,000 operating hours.
AC DRIVE MOTOR
3-11
MOTORS
AC Motors
AC Drive Motor with Brakes ITEM DESCRIPTION

1 Seal
2 Bolt
3 Lock Washer
4 Drive End Bell
5 Sensor Bearing Kit
6 EE Motor Kit (headband)
8 Stator
9 Terminal Block Assembly
10 Rotor
11 Key C8X20
12 Brake End Bearing
13 Brake End Bell
14 Bolt
15 Brake Pad
AC DRIVE MOTOR with BRAKES
3-12
MOTORS
AC Pump Motor
ITEM DESCRIPTION
1 Bolt
2 Lock Washer
3 Drive End Bell
4 EE Motor Kit (headband)
5 Sensor Bearing Kit
7 Thermal Block Assembly
8 Stator
9 Rotor
10 Rear End Bearing
11 Rear End Bell
AC PUMP MOTOR
3-13
MOTORS
Trouble Shooting
AC Motor
Faulty thermal sensor or Repair or replace

thermal sensor connection
Faulty sensor bearing or Repair or replace

bearing sensor connection
Low supply voltage Charge battery and improve power

supply condition
Motor does not start.
Blown fuse Replace
Excess load Reduce load
Faulty wire connection Repair, or re-tighten wire connections

Broken wire in control device Repair or replace
Broken wire in stator coil Repair or replace
Low supply voltage Charge battery and improve power

Motor starts but does supply condition
not run at rated
speed. Excessive resistance to Remove resistance
rotation
Defective bearings Replace bearings

Motor produces
abnormal vibrations Loose mounting bolts Retighten bolts and nuts
and noise.
Contact between rotor and stator Repair or replace
Incorrect installation Correct installation condition
Severe external vibration Remove the cause of vibration, or

take appropriate vibration-insulating
Bearing overheats. measures
Defective bearings Replace
Oil degradation or shortage in Replace

bearings
3-14
MOTORS
Trouble Shooting
DC Motor
SUCCESSFUL INSULATION SYSTEM

COMMUTATION REQUIREMENTS
• Insulation resistance - 0.10 Mega-ohm (or greater)
• Good contact between commutator and brush
• Less than 0.10 Mega-ohm, investigate:
• Mechanically true commutator – Excessive dirt
– Moisture
• Brushes free to move in holders – Insulation breaK down
• Copper-Oxide-Carbon film (as opposed to pure
copper surface) noted by color variations For moisture, bake in an oven at 90 degrees C (190F)
• Commutator surface should be clean and smooth • 600V - 60HZ - 1 minute
• Clean commutator • Test old motors at 75% of above values
NOTE: Refer to the next following pages for charts

on “Unsatisfactory Brush Performance” and ARMATURE WINDING PROBLEMS
illustrations of “Commutator Surfaces” which show
the main patterns of film build-up on commutators, • Open Circuit
and indicate the type of brush/commutator – Thin red sparks encircling commutator
interaction which give rise to each pattern. – Blackens or flattens commutator bars,
especially at edges
SPARKING AT BRUSHES • Short Circuit

– Blue spark in vicinity of brush holder
• Commutator in poor condition
– Commutator bars oxidize or burn
• Eccentric or rough commutator
• Grounded
• Excessive vibration – High current draw
– Rapid brush wear
• Broken or sluggish spring
• Brushes to short
• Machine overloaded
• Short circuit in armature
3-15
MOTORS
Trouble Shooting
Unsatisfactory Brush Performance

TABLE ONE – PRIMARY SOURCES OF UNSATISFACTORY BRUSH PERFORMANCE
• Poor operation of commutator surface

• High mica
Preparation and Care of Motor • Side mica
• Need for periodic cleaning
• Clogged ventilating ducts
• Brushes tight in holders

• Brushes too loose in holders
• Brush holders loose at mounting
Mechanical Fault in Motor • Loose pole pieces
• Loose or worn bearings
• Dynamic imbalance
• Variable angular velocity
• Open or high resistance connection at commutator

• Connection at series terminal
Electric Fault in Motor • Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole
• Overload
• Dynamic braking
• Low average current density in brushes
• Contaminated atmosphere
Load or Service Condition • “Contact positions”
• Oil on commutator or oil mist in air
• Abrasive dust in air
• Humidity too high
• Humidity too low
• Silicone contamination
• Loose or damaged motor mounting

• External source of vibration
• External short circuit
• Contact drop of brushes too high
Disturbing External Condition • Contact drop of brushes too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush
• Brushes too abrasive
• Lack of carrying capacity
3-16
MOTORS
Trouble Shooting

TABLE TWO – INDICATIONS APPEARING AT BRUSHES
INDICATION
Indication IMMEDIATE CAUSES
Immediate Causes PRIMARY FAULTS
Primary Faults
Sparking Commutator surface condition • Poor operation of commutator surface

• High mica
• Side mica
• Low average current density in brushes
• Contaminated atmosphere
• Contact positions
• Oil on commutator or oil mist in air
• Lack of polishing action in brush
Mechanical fault in motor • Clogged ventilating ducts

• Brushes too loose at mounting
• Loose pole pieces
• Loose or worn bearings
• Dynamic unbalance
• Incorrect spring tension
Electrical fault in motor • Open or high resistance connection

at commutator
• Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole
Bad load condition • Overload

• Rapid change of load
Vibration • Loose or damaged motor mountings

Chattering of brushes • See Chattering or Noisy Brushes
Wrong brush grade for • Lack of film-forming properties in brush

application
Other • Silicone contamination
Etched or Burned Embedded copper • See Copper in Brush Face

Bands on Brush Face
Rapid Brush Wear Commutator surface condition • See specific surface fault in evidence
• Silicone contamination
Severe sparking • See Sparking
3-17
MOTORS
Trouble Shooting

TABLE TWO – INDICATIONS APPEARING AT BRUSHES (CONT’D)
INDICATION IMMEDIATE CAUSES PRIMARY FAULTS
Rapid Brush Wear Imperfect contact w/commutator • Incorrect spring tension

(cont’d) • Brushes tight in holders
• Brushes too loose in holders
• Brushes holders loose at mounting
• Loose or damaged motor mountings
Wrong brush grade f/application • Lack of film-forming properties in brush
Copper in Brush Face Commutator surface condition • High mica

• Side mica
Bad service condition • Oil on commutator or oil mist in air

• Humidity too high

Chattering or Commutator surface condition • Raised Commutator Bars

Noisy Brushes
Looseness in motor • Brushes too loose in holders

• Brushes holders loose at mounting
• Incorrect spring tension
High friction • Clogged ventilating ducts

• Contact poisons
3-18
MOTORS
Trouble Shooting

TABLE THREE – INDICATIONS APPEARING AS HEATING
Heating in Windings Severe load condition • Overload

(Field or Armature) • External short circuit
• Stalled motor
Unbalanced magnetic field • Loose or worn bearings

• Short circuit in field or armature winding
Lack of ventilation
Heating at Commutator Severe load condition • Overload
Severe sparking • Contact positions

• See Sparking
High friction • Incorrect spring tension

• Contact poisons
Poor commutator surface • See specific surface fault in evidence
Depreciation • Clogged ventilating ducts
High contact resistance • Contact drop of brushes too high
Heating at Brushes Severe load condition • Overload
Faulty motor adjustment • Incorrect spring tension
Raw streaks on commutator • See Streaking or Threading of Surface
Embedded copper • See Copper in Brush Face
Wrong brush grade f/application • Contract drop of brushes too low

• Lack of carrying capacity
3-19
MOTORS
Trouble Shooting

TABLE FOUR – INDICATIONS APPEARING AT COMMUTATOR SURFACE
Bar Marking at Sparking • Lack of polishing action in brush

Slot Pitch Spacing • Lack of film-forming properties in brush
Flat Spot Sparking • Open or high resistance connection at

commutator
• Stalled motor
Discoloration of High temperature • See Heating at Commutator

Surface
Atmospheric condition • Contaminated atmosphere
• Oil in commutator or oil mist in air
Wrong brush grade f/application • Lack of polishing action in brush

Raw Copper Surface Embedded copper • See Copper in Brush Face
Bad service condition • Contact positions


Rapid Commutator Burning • High mica

Wear with • Side mica
Blackened Surface • Incorrect spring tension
Rapid Commutator Foreign material in brush face • Contact positions

Wear with • Abrasive dust in air
Bright Surface • Humidity too low
Wrong brush grade f/application • Brushes too abrasive

• Lack of film-forming properties
Copper Dragging Brush Vibration • External source of vibration

3-20
MOTORS
Trouble Shooting

COMMUTATOR SURFACES
GOOD CONDITION UNSATISFACTORY CONDITION

LIGHT FILM UNEVEN FILM
Uniform coloring indicates Patchy colors of varying densities
satisfactory operation of and shape. Due to unclean
machine and brushes. Film color operating conditions or incorrect
is largely an effect of thickness, physical condition of commutator.
therefore provided the film is
uniform it is perfectly
acceptable.
SATISFACTORY CONDITION UNSATISFACTORY CONDITION

LIGHT AND DARK PATTERN FILM WITH DARK AREAS
This is not a good condition but These areas can be isolated or
in our experience it is known regular. Commutator out of
that machines having this round. This can be caused by
commutator pattern have vibration or mechanical
operated with satisfactory deficiencies in equipment
results for long periods of time. operation, bearings, couplings,
This condition can appear in etc.
alternating bars as shown or
every 3rd or 4th bar, etc. This is
related to the winding design of
the armature. Difficulty caused
from split windings crossing in
the same slot.
UNSATISFACTORY CONDITION UNSATISFACTORY CONDITION

STREAKY FILM WITH NO EXAMPLE OF POOR
COMMUTATOR WEAR COMMUTATOR
Frequently due to under-loaded MACHINING
operation, machine grossly over- Bars are low on entry and
brushed or brush grade leaving edges giving rise to the
incorrect for particular machine brushes riding on the middle of
application. Atmosphere and the bars.
environmental conditions can
contribute.
3-21
MOTORS
Trouble Shooting

COMMUTATOR SURFACES

EXAMPLE OF POOR BRUSH CONTACT MARK
COMMUTATOR Storage of machines, for lengthy
MACHINING periods, with brushes in position.
Bars are low in the middle giving This can also result from
rise to the brushes riding on operation of machine in
entry and leaving bar edges. prolonged stall conditions.
This and the previous illustration
indicate the need for better
maintenance.

STREAKY FILM WITH BAR EDGE BURNING
COMMUTATOR WEAR CAUSE HIGH MICA
This is a further development of Illustration shows high mica in
the third example, previous every slot. Same effect can
page. Brush grade, machine occur on one bar only. Similar
applications and working conditions can be caused by a
environment all suspect. Earlier high or low bar.
corrective action should have
been taken.

DOUBLE POLE PITCH SMALL BRIGHT SPOTS
Darkening of commutator in Related to over-loaded machines
sequences two pole pitches and low brush pressure. Due to
apart is due to armature fault, sparking under brush which
defective coil, riser bars or gives rise to spots being of a
equalizer connections. random distribution. If not
corrected, will result in scored
commutator.
3-22
MOTORS
Service Data
AC Motor
Truck Models
1 Ton Class 2 / 3 Ton Class
Item
Stator Coil Insulation Resistance 1MΩ min. 1MΩ min.
AC Drive Motor and Pump Motor
U-V 0 0
Drive Motor
Terminal Conductivity V-W 0 0
(Ω) Pump Motor
W-U 0 0
N•m 11.3 ± 1.1 N•m 14.7 ± 1.1 N•m

Cable Terminal Tightening Torque (kgf•m) (1.2 ± 0.1 kgf•m) (1.5 ± 0.1 kgf•m)
[lbf•ft] [8.33 lbf•ft] [11 lbf•ft]
DC Motor
Truck Models
1 Ton Class 2 / 3 Ton Class
Item
0Ω 0Ω
Pump Motor
Resistance between PA1 & PS2

6.8 N•m 13.5 N•m
DC Pump Motor
Cable Terminal tightening torque 0.69kgf•m 1.4 kgf•m

5 lbf•ft 10 lbf•ft
Resistance between Neg. & Pos. 0Ω 0Ω
Steer Pump
Motor
6.8 N•m 6.8 N•m

Cable Terminal tightening torque 0.69 kgf•m 0.69 kgf•m
5 lbf•ft 5 lbf•ft
3-23

Service Manual: Controller

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

Service Manual: Controller

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual: Controller

Uploaded by

Copyright:

Available Formats

Service Manual

Safety Related Signs

The following safety related signs are used in this service

Indicates a specific potential hazard

Indicates a specific potential hazard

Indicates a condition that can cause

Pub. No. 99759-7C110

Disassembly diagram (example)

Procedures are described in the text.

Suggestion for disassembling

Item SI unit Customary unit

GROUP INDEX Items

Controller system, Controller features, Setup option, Diagnosis, Removal and

Motor installation positions, Specifications, Structures, Tightening of high-power

Controller System .................................................................................... 1 – 1

System Configuration for Contactor Control Type

Input switch signals RS232C

Sensing data Motor control command

System Configuration for Transistor Control Type

Input switch signals

Sensing data Motor control command Sensing data

Traction Inverter Pump Inverter

Controller Area Network (CAN)

Network for Contactor Control Type

*1: Connected to inside of

Network for Transistor Control Type

Traction Logic Pump

Built-in CAN H Built-in

The data are expressed with electric potential difference

recessive 1 recessive dominant recessive

Communication protocol CANbus 2.0B passive Non-Return to Zero method

Item Description SUO No.

The current information is available to confirm and

Logic card side CN1

Power supply card

Power supply card side CN1 Main harness side P8

The Service Tool connector exists on main harness P18.

Traction and pump inverters

Traction and pump inverter

Traction inverter card side CN2 Main harness side, Traction P1

Traction Control Features

85 STANDARD; Full acceleration

(3) Limitation of maximum travel speed

(1) Accelerator regeneration (Auto regen)

(2) Lever regeneration

Lifting Control Features

1. Contactor Control Type 2

2. Transistor Control Type Pump motor

Pump motor output characteristics

Steering Control Features

Diagnosis/Run/Setup (DRS) Modes

1. Mode setting with DRS switch

NOTICE: If the DRS switch is set with the key switch

To enter the Diagnosis and Setup modes, it is required to

2. Mode setting on display unit (for setting SUO #1

2.1 Turning on key switch in RUN mode

2.2 Setting SUO #1 (checking and changing data)

“APP-A” lights. When “A” is set