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Mitsubishi FB13PNT Quick Start Manual
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Mitsubishi FB13PNT Quick Start Manual

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Controller 
Controller 
FB13PNT
FB13PNT
FB15PNT
FB15PNT
FB16CPNT
FB16CPNT
FB18CPNT
FB18CPNT
FB16PNT
FB16PNT
FB18PNT
FB18PNT
FB20PNT
FB20PNT
FB16CPN
FB16CPN
FB18CPN
FB18CPN
FB16PN
FB16PN
FB18PN
FB18PN
FB20PN
FB20PN
Service Manual
Service Manual
  EFB21-00011-up
  EFB21-00011-up
  EFB21-50011-up
  EFB21-50011-up
  EFB22-00011-up
  EFB22-00011-up
  EFB22-50011-up
  EFB22-50011-up
  EFB23-00011-up
  EFB23-00011-up
EFB23-50011-up
EFB23-50011-up
  EFB24-00011-up
  EFB24-00011-up
  EFB27-00011-up
  EFB27-00011-up
  EFB27-50011-up
  EFB27-50011-up
 
 
EFB28-00011-up
EFB28-00011-up
 
 
EFB28-50011-up
EFB28-50011-up
 
 
EFB29-00011-up
EFB29-00011-up
FC/MC
FC/MC
99759-5M300
99759-5M300

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Summary of Contents for Mitsubishi FB13PNT

  • Page 1     Service Manual Service Manual Controller  Controller  FC/MC FC/MC FB13PNT FB13PNT   EFB21-00011-up   EFB21-00011-up FB15PNT FB15PNT   EFB21-50011-up   EFB21-50011-up FB16CPNT FB16CPNT   EFB22-00011-up   EFB22-00011-up FB18CPNT FB18CPNT   EFB22-50011-up   EFB22-50011-up FB16PNT FB16PNT   EFB23-00011-up   EFB23-00011-up...
  • Page 3 Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring obligations.
  • Page 4     1 1 . . S S a a f f e e t t y y WARNING WARNING The pro The proper and s per and safe lubr afe lubricati ication and mai on and mainten ntenance fo ance for these f r these forkli orklift truc...
  • Page 5     (19) (19) Tighten connections to th Tighten connections to the correct torque e correct torque. Make sure . Make sure that all heat shields, clamps and guards are installed that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing correctly to avoid excessive heat, vibration or rubbing against other parts during operation.
  • Page 6     3 3 . . U U n n i i t t s s SI SI Un Unit its a s are re us used ed in in th this is ma manu nual al. . The follo following wing table table shows...
  • Page 7     TABLE OF CONTENTS TABLE OF CONTENTS C C h h a a pt pte e r 1 r 1 C C O O NT NTR R O O L L L L E E R R 1. 1. Cont ntro roll ller er Sy Syst stem em .
  • Page 8     TABLE OF CONTENTS TABLE OF CONTENTS Replac lacing ing Log Logic U ic Unit nit ......
  • Page 9     TABLE OF CONTENTS TABLE OF CONTENTS 3.25 3.25 Tract Traction Mo ion Motor L. tor L.H., Pul H., Pulse Inp se Input Faul ut Fault (53) ......2-62 t (53) .
  • Page 10     TABLE OF CONTENTS TABLE OF CONTENTS C C h h a a p p t t e e r r 3 3 M M O O T T O O R R 1. 1. Moto tor I r Ins nsta tall llat atio ion P n Pos osit itio ions ns .
  • Page 11     TABLE OF CONTENTS TABLE OF CONTENTS Chapt apter er 4 4 HO HOW T W TO O RE READ AD CIR CIRCUI CUIT D T DIAG IAGRA RAMS 1. 1. Desc scri ript ption ion of of Ci Circ rcui uit D t Dia iagr gram ams s .
  • Page 13     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER C C h h a a p p t t e e r 1 r 1 C C O O N N TR TRO O L L L L E E R R 1 1 .
  • Page 14     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER System layout for MC type System layout for MC type Contactors Contactors Logic Unit Logic Unit Switches Switches Contactor control signal Contactor control signal Display Display Logic card Logic card  Trave  Traveling control, ling control, Lift lock solenoid/unload solenoid control signal Lift lock solenoid/unload solenoid control signal...
  • Page 15     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1. 1.2 2 Cont ntro roll ller er Ar Area ea Ne Netw twor ork ( k (CA CAN) Each controller is linked with the truck harness to form a Each controller is linked with the truck harness to form a  The input unit and  The input unit and output unit are output unit are used for FC m...
  • Page 16     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1 1 . . 3 3 O O u u t t l l i i n n e e o o f f L L o o g g i i c c U U n n i i t t  This  This controller controller includes...
  • Page 17     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Logic unit Logic unit       500922 500922 1 1 ) ) P P i i n n l l o o c c a a t t i i o o n n o o f f l l o o g g i i c c c c a a r r d d 2 2 ) ) P P i i n n l l o o c c a a t t i i o o n n o o f f p p o o w w e e r r c c a a r r d d Logic card...
  • Page 18     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Power supply card Power supply card                     500924 500924 1 1 ) ) P P o o w w e e r r s s u u p p p p l l y y c c a a r r d d s s i i d d e e 2 2 ) ) H H a a r r n n e e s s s s s s i i d d e e E E - - 0 0 1 1...
  • Page 19     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1 1 . . 4 4 O O u u t t l l i i n n e e o o f f I I n n v v e e r r t t e e r r  The  The inverter is inverter is a a motor drive...
  • Page 20     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1. 1.5 5 O O ut utli line ne of of E E P P S C S Co o nt ntr r ol olle ler r EPS controller is a motor drive controller. It drives the EPS controller is a motor drive controller.
  • Page 21     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1 1 . . 6 6 O O u u t t l l i i n n e e o o f f I I n n p p u u t t u u n n i i t t  This input unit is conne  This input unit is connected to the cted to the FC specification m...
  • Page 22     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 1 1 . . 7 7 O O u u t t l l i i n n e o e of O f Ou u t t p p u u t u t un n i i t t  This output unit is connecte  This output unit is connected to the FC specificatio...
  • Page 23     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 2. 2. Tr Trac acti tion on Co Cont ntro roll ller er Fe Feat atur ure e 2. 2.1 1 Modi difi fica cati tion o on of t f tra ract ctio ion ch n char arac acte teri rist stic ics s Acceleratio Acceleration power, maximum output power and battery consumption can be set.
  • Page 24     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 2 2 . . 3 3 B B o o o o s s t t When truck traveling is blocked by a step, the boost When truck traveling is blocked by a step, the boost Fully depress the accelerator pedal for 2 seconds.
  • Page 25     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 2. 2.5 5 Turn rnin ing g sp spee eed d li limi mit t fu func ncti tion  The  The turning turning radius radius is is calculated calculated from from the the tire tire angle angle and...
  • Page 26     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 2. 2.7 7 P P it itch chin ing C g Con ontr tro o l ( l (O O pt pti i on on) ) Pitching control will reduce the vibration of load when Pitching control will reduce the vibration of load when traveling over bumps or uneven road.
  • Page 27 1 14 1 14     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 3. 3. Li Lift ftin ing g Co Cont ntro roll ller er Fe Feat atur ure e 3. 3.1 1 Sett ttin ing a g and nd li limi mita tati tion on of of li lift ft wo work rk sp...
  • Page 28 1 15 1 15     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 3 3 . . 3 3 L L o o a a d d m m e e t t e e r r ( ( o o p p t t i i o o n n ) ) Function Function  This calculates the...
  • Page 29 1-16 1-16     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 3 3 . . 4 4 T T i i lt lt h h o o r r i i z z o o n ( n (o o p p t t i i o o n n ) ) Function Function  This will stop the...
  • Page 30 1-17 1-17     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER PDS Status transfer chart PDS Status transfer chart  Traction C  Traction Control PDS ontrol PDS Seat SW Seat SW Seat SW off time Seat SW off time Seat Sw ��ag: ON Seat Sw ��ag: ON Delay time Delay time...
  • Page 31 1-18 1-18         CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 4 4 . . 2 2 D D i i s s p p l l a a y y f f u u n n c c t t i i o o n n Main monitor Main monitor ...
  • Page 32 1-19 1-19     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 4. 4.3 3 P P ar arki king ng B B r r ak ake e I I nt nte e rl rloc ock  k   The parking  The parking brake (PKB) brake (PKB) interlock will interlock will be activated be activated and “P”...
  • Page 33 1-20 1-20     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 4 4 . . 6 6 H H o o u u r r M M e e t t e e r r  The truck hour  The truck hour meter re meter reading is indicate ading is indicated on the display.
  • Page 34 1-21 1-21     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5 5 . . S S e e t t u u p p O O p p t t i i o o n n 5 5 . . 1 1 O O u u t t l l i i n n e e  The logic unit is  The logic unit is equipped with...
  • Page 35 1-22 1-22     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5. 5.2 2 Deta tail ils of S s of Set etup O up Opt ptio ions ( ns (Gr Grou oup- p-1) 1) #1 Application Pre-Sets (Truck Operation Mode) #1 Application Pre-Sets (Truck Operation Mode)  Truck mode c  Truck mode can be selected...
  • Page 36 1-23 1-23     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #3 Top Lift Speed #3 Top Lift Speed  This setting  This setting affects pum affects pump speed and p speed and FC solenoid FC solenoid current w current when you pull t hen you pull the lift leve he lift lever.
  • Page 37 1-24 1-24     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #5 Auxiliary 1 Speed #5 Auxiliary 1 Speed #6 Auxiliary 2 Speed #6 Auxiliary 2 Speed  This  This setting setting affects affects pump pump speed speed and and FC FC solenoid solenoid current current  This...
  • Page 38 1-25 1-25     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #9 Traveling Power Mode #9 Traveling Power Mode  This setting affec  This setting affects the requir ts the required torque ed torque which is calculated which is calculated from acceler from accelerator pedal posit ator pedal position.
  • Page 39 1-26 1-26     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5. 5.3 3 Deta tail ils of S s of Set etup O up Opt ptio ions ( ns (Gr Grou oup- p-2) 2) #11 Aux Input for Lift/Drive Speed 1 #11 Aux Input for Lift/Drive Speed 1 (Harness pin No.
  • Page 40 1-27 1-27     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #14 Aux Input for Lift/Drive Speed 2 #14 Aux Input for Lift/Drive Speed 2 (Harness pin No. E-03-41) (Harness pin No. E-03-41)  This setting defines the fu  This setting defines the function of “Auxiliary 2” switch. This nction of “Auxiliary 2”...
  • Page 41 1-28 1-28     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #21 Regen Adjustment for Brake Regen #21 Regen Adjustment for Brake Regen  This works when  This works when the brakes are the brakes are applied. applied. When the setting value is When the setting value is higher than “#23”...
  • Page 42 1-29 1-29     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #25 Steering brake force #25 Steering brake force Setting of Setting of maximum steeri maximum steering brake force when the steering angle is not propo ng brake force when the steering angle is not proportional to the steering force dur rtional to the steering force during normal ing normal operation of the steering wheel.
  • Page 43 1-30 1-30     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #35 Lowering Speed ADJ. #35 Lowering Speed ADJ.  This setting is fo  This setting is for adjustment r adjustment of the maximum of the maximum lowering spe lowering speed. In case the lowering speed is higher than the specification as mentioned in the service manual, it can be adjusted. When In case the lowering speed is higher than the specification as mentioned in the service manual, it can be adjusted.
  • Page 44 1-31 1-31     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5. 5.4 4 Deta tail ils o s of Se f Setu tup O p Opt ptio ions ns (G (Gro roup up-3 -3) ) #40 Truck Type #40 Truck Type  This setting def  This setting defines the type of ines the type of truck.
  • Page 45 1-32 1-32     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #43 Hydraulic Control Selection #43 Hydraulic Control Selection  This setting de  This setting defines the type of fines the type of hydraulic contro hydraulic control. l. 0: FC system 1: MC system 0: FC system 1: MC system #44 Mast Type #44 Mast Type...
  • Page 46 1-33 1-33     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER #47 Foot Direction #47 Foot Direction  This setting define  This setting defines the foot dir s the foot direction contr ection control. ol. 1: Standard direction lever 1: Standard direction lever 2: Foot Direction Control (FoDiCo) 2: Foot Direction Control (FoDiCo) 3: Armrest FNR...
  • Page 47 1-34 1-34     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5 5 . . 5 5 S S e e t t u u p O p Op p t t i i o o n n s ( s (G G r r o o u u p 1 p 1) ) Option Option...
  • Page 48 1-35 1-35     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5. 5.6 6 Set t u u p p O O p p ti tion ons s (G (Gro rou u p p 2) 2) Default Default Harness Harness T T i i t t l l e e o o f f O O p p t t i i o o n n D D e e s s c c r r i i p p t t i i o o n n R R a a n n g g e e tion#...
  • Page 49 1-36 1-36     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Default Default Harness Harness T T i i t t l l e e o o f f O O p p t t i i o o n n D D e e s s c c r r i i p p t t i i o o n n R R a a n n g g e e tion#...
  • Page 50 1-37 1-37     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 5. 5.7 7 Set t u u p p O O p p ti tion ons s (G (Gro rou u p p 3) 3) Option Option Default Default T T i i t t l l e e o o f f O O p p t t i i o o n n D D e e s s c c r r i i p p t t i i o o n n R R a a n n g g e e Value...
  • Page 51 1-38 1-38     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 6 6 . . D D i i a a g g n n o o s s t t i i c c s s 6 6 . . 1 1 O O u u t t l l i i n n e e  The controller  The controller monitors status o...
  • Page 52 1-39 1-39     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER (3) When a When all the st ll the steps hav eps have bee e been check n checked thr ed through ough, turn , turn OFF the key switch. Be sure to reinstall the 500 A line OFF the key switch.
  • Page 53 1-40 1-40     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 6 6 . . 3 3 S S e e l l f f - - D D i i a a g g n n o o s s t t i i c c s s S S t t e e p p D D i i a a g g n n o o s s i i s s D D o o t t h h i i s s...
  • Page 54 1-41 1-41     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER S S t t e e p p D D i i a a g g n n o o s s i i s s D D o o t t h h i i s s C C o o n n t t r r o o l l l l e e r r c c h h e e c c k k R R e e s s u u l l t t D D i i s s p p l l a a y y...
  • Page 55 1-42 1-42     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Self-Diagnostics (Power steering system) Self-Diagnostics (Power steering system) S S t t e e p p D D i i a a g g n n o o s s i i s s D D o o t t h h i i s s C C o o n n t t r r o o l l l l e e r r c c h h e e c c k k t t h h i i s s R R e e s s u u l l t t...
  • Page 56 1-43 1-43     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 6 6 . . 5 5 R R u u n n T T i i m m e e D D i i a a g g n n o o s s t t i i c c s s Availability of operation: Availability of operation: : Yes,...
  • Page 57 1-44 1-44     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Display Display     d     d    n    n    r    r    o    o    o    o     i     i     t     t    c    c    g    g    a    a    e    e I CON I CON    n    n    r    r    r...
  • Page 58 inconsistent data. inconsistent data. stop stop 1-45 1-45     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Display Display     d     d    n    n    r    r    o    o    o    o     i     i    c    c     t     t    g    g    e    e    a    a I CON I CON    n...
  • Page 59 1-46 1-46     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Display Display     d     d    n    n    r    r    o    o    o    o     i     i    c    c     t     t    g    g    e    e    a    a I CON I CON    n    n    r    r    r...
  • Page 60 Parking Brake Parking Brake Parking brake short-circuit Parking brake short-circuit     z z z z 75 75 N N o o r r m m a a l l s s t t o o p p T T u u r r n n k k e e y y o o f f f   f   Solenoid Solenoid detected.
  • Page 61 1-48 1-48     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Display Display     d     d    n    n    r    r    o    o    o    o     i     i    c    c     t     t    g    g    e    e    a    a I CON I CON    n    n    r    r    r...
  • Page 62 1-49 1-49     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Display Display     d     d    n    n    r    r    o    o    o    o     i     i     t     t    c    c    g    g    a    a    e    e I CON I CON    n    n    r    r    r...
  • Page 63 1-50 1-50     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 6. 6.6 6 Fail il-S -Saf afe e Re Rest stri rict ctio ion n Li List st Availability of operation: Availability of operation: : Yes, : Yes, : No, : No, : Partially operable : Partially operable...
  • Page 64 1-51 1-51     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER *1 *1 The function will not The function will not be recovere be recovered in case of failure d in case of failure and partial failure and partial failure unless the power unless the power is turned off.
  • Page 65 1-52 1-52     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7. 7. Remo mova val a l and I nd Ins nsta tall lla a ti tion 7. 7.1 1 In Inve vert rter er Di Disc scha harg rgin ing P g Pro roce cedu dure re Discharge the inverters by using...
  • Page 66 1-53 1-53     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7 7 . . 2 2 R R e e p p l l a a c c i i n n g g I I n n v v e e r r t t e e r r Removal Removal (1) Perf...
  • Page 67 Forcibly pressing of the connector may cause Forcibly pressing of the connector may cause damage to the DSP card. damage to the DSP card. Hold the connector housing and press Hold the connector housing and press the connector, if  the connector, if  required.
  • Page 68 1-55 1-55     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Installation Installation (1) Align the four Align the four mounting holes mounting holes of the new of the new DSP card with DSP card with the plastic spacer the plastic spacer positions and press positions and press it into place.
  • Page 69 1-56 1-56     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7 7 . . 4 4 R R e e p p l l a a c c i i n n g L g Lo o g g i i c U c Un n i i t t Removal Removal...
  • Page 70 1-57 1-57     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7. 7.5 5 R R ep epl l ac aci i ng ng E E PS PS Co Con n tr trol olle ler r Removal Removal (1) Perf Perform ste orm steps (1) to (6) in Invert ps (1) to (6) in Inverter Disch er Dischargi...
  • Page 71 1-58 1-58     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7 7 . . 6 6 R R e e p p l l a a c c i i n n g L g Lo o g g i i c C c Ca a r r d d Note: When Note: When replacing the logic card, it is...
  • Page 72 1-59 1-59     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7. 7.7 7 Repl plac acin ing g Po Powe wer r Su Supp pply ly Ca Card rd Note: When replacing the power supply card, it is Note: When replacing the power supply card, it is recomme recommended to replace the logic unit as nded to replace the logic unit as an an...
  • Page 73 1-60 1-60     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7. 7.8 8 Repl plac acin ing I g Inp nput ut Un Unit it (F (FC M C MOD ODEL EL ON ONLY LY) ) Removal Removal (1) Tur Turn of n off th f the ke...
  • Page 74 1-61 1-61     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 7. 7.9 9 Repl plac acin ing O g Out utpu put U t Uni nit ( t (FC FC MO MODE DEL O L ONL NLY) Y) Removal Removal (1) Tur Turn of n off th...
  • Page 75 1-62 1-62     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 8 8 . . B B a a s s i i c c C C h h e e c c k k Always follow basic Always follow basic troubleshooting steps. troubleshooting steps.
  • Page 76 1-63 1-63     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Logic card voltage chart Logic card voltage chart N N o o . . N N a a m m e e N N o o t t e e N N o o .
  • Page 77 3 3 5 5 S S E E R R V V I I C C E E B B R R A A K K E E S S W W 3 3 6 6 R R E E V V E E R R S S E E S S W W 1-64 1-64  ...
  • Page 78 1-65 1-65     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER DSP card voltage chart of inverters DSP card voltage chart of inverters N N o o . . N N a a m m e e S S t t a a n n d d - - b b y y v v o o l l t t a a g g e e A A c c t t i i v v e e v v o o l l t t a a g g e e N N o o t t e e M M O O T T O O R R T T H H E E R R M M A A L L + +...
  • Page 79 1-66 1-66     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER EPS controller voltage chart EPS controller voltage chart Stand-by Stand-by Active Active N N O O N N A A M M E E N N O O T T E E T T Y Y P P E E voltage voltage...
  • Page 80 1-67 1-67     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Input unit card voltage chart Input unit card voltage chart N N o o . . N N a a m m e e S S t t a a n n d d - - b b y y v v o o l l t t a a g g e e A A c c t t i i v v e e v v o o l l t t a a g g e e N N o o t t e e G G N N D D...
  • Page 81 1-68 1-68     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER Output unit card voltage chart Output unit card voltage chart N N o o . . N N a a m m e e S S t t a a n n d d - - b b y y v v o o l l t t a a g g e e A A c c t t i i v v e e v v o o l l t t a a g g e e N N o o t t e e G G N N D D...
  • Page 82 3 3 5 5 S S O O L L P P W W M M 9 9 - - / / 1 1 0 0 - - 0 0 V V 0 0 t t o o 0 0 . . 5 5 V V S S P P E E E E D D A A L L A A R R M M - - 36 36 1-69...
  • Page 83 1-70 1-70     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 8 8 . . 5 5 C C h h e e c c k k i i n n g I g In n v v e e r r t t e e r r CAUTION CAUTION Disconnect the battery plug and discharge the inverters before working on electrical system.
  • Page 84 1-71 1-71     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 9. 9. AC M M ot otor or Sy Syst ste e m B m Ba a si sic c s s 9 9 . . 1 1 F F e e a a t t u u r r e e o o f f A A C C m m o o t t o o r r  The AC motor model trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor and  The AC motor model trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor and pump motor.
  • Page 85 1-72 1-72     CHAPTER 1 CONTROLLER CHAPTER 1 CONTROLLER 9 9 . . 3 3 I I n n v v e e r r t t e e r r  The truc  The truck battery k battery delivers DC delivers DC current, current, so the so the current...
  • Page 86 500969 500969 (Fig. 5) (Fig. 5) 1-73 1-73...
  • Page 87     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Chapte pter 2 r 2 TRO TROUBL UBLESH ESHOOT OOTING ING FOR FOR CON CONTRO TROL C L CIRC IRCUIT UITS S 1 1 . . G G e e n n e e r r a a l In l Inf f or orm m a a t t i i o o n n 1.
  • Page 88 502883 502883 1 1 . . E E r r r r o o r r c c o o d d e e d d i i s s p p l l a a y y 2 2 . . C C u u p p h h o o l l d d e e r r  ...
  • Page 89     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 2 2 . . L L i i s s t t of of E E r r ro ror r C C od ode e s s Error Error E E r r r r o o r r n n a a m m e e...
  • Page 90     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3 3 . . T T r r o o u u b b l l e e s s h h o o o o t t i i n n g g 3.
  • Page 91 502803 502803     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS With service tool With service tool (10) C (10) Confirm temperature of right t onfirm temperature of right t raction motor with raction motor with input/output monitor ...
  • Page 92 502804 502804     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07         Logics Logics E-02 E-02  Traction in  Traction inverter (rig verter (right) E-07 E-07 W  W  Inside Inside Inside Inside...
  • Page 93 501135 501135     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.2 2 Tr Trac acti tion on Mo Moto tor r L. L.H. H.,O ,Ove verh rhea eati ting ng (E (E1) 1) Error code: E1 Error code: E1 Controller/m...
  • Page 94 502805 502805     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS (13) Perform inverter discharging work (13) Perform inverter discharging work (14) D (14) Disco isconnect con nnect connector E-15 nector E-15 of left of left traction motor ...
  • Page 95 502806 502806     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside    ...
  • Page 96 501136 501136     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.3 3 Pump mp Mo Moto tor, r,Ov Over erhe heat atin ing( g(E2 E2) ) Error code: E2 Error code: E2 Controller/m Controller/motor overheat indicator ON.
  • Page 97 502807 502807 2-10 2-10     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Thermal Thermal (14) Dis (14) Disconne connect connec connector E-05 of pump of pump motor inverter  motor inverter  Check continuity between E-05-1 and E-16-1(36) Check continuity between E-05-1 and E-16-1(36) Check continuity between E-05-2 and E-16-2(37) Check continuity between E-05-2 and E-16-2(37)
  • Page 98 502808 502808 2-11 2-11     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-05 E-05         Logics Logics E-02 E-02 Pump inverter Pump inverter E-05 E-05 Inside Inside Inside Inside  ...
  • Page 99 501137 501137 2-12 2-12     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.4 4 Tr Trac acti tion on In Inve vert rter er R. R.H. H., O , Ove verh rhea eati ting ng (E (E5) 5) Error code: E5 Error code: E5...
  • Page 100 502809 502809 2-13 2-13     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Thermal Thermal (11) Remove right traction inverter DSP card cover, then (11) Remove right traction inverter DSP card cover, then check flat cable check flat cable looseness or w looseness or...
  • Page 101 502810 502810 2-14 2-14     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07 Logics Logics E-02 E-02  Traction in  Traction inverter (rig verter (right) E-07 E-07 W  W  Inside Inside Inside Inside  ...
  • Page 102 501135 501135 2-15 2-15     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.5 5 Tr Trac acti tion on In Inve vert rter er L. L.H. H., O , Ove verh rhea eati ting ng (E (E6) 6) Error code: E6 Error code: E6...
  • Page 103 502811 502811 2-16 2-16     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Thermal Thermal (11) Remove left traction inverter DSP card cover, then (11) Remove left traction inverter DSP card cover, then check flat cable check flat cable looseness or looseness or...
  • Page 104 502812 502812 2-17 2-17     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside  ...
  • Page 105 501136 501136 2-18 2-18     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.6 6 Pump mp In Inve vert rter er, O , Ove verh rhea eati ting ng (E (E7) 7) Error code: E7 Error code: E7 Controller/mo Controller/motor overheat indicator ON.
  • Page 106 502813 502813 2-19 2-19     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Thermal Thermal (11) Remove pump inverter DSP card cover, then check (11) Remove pump inverter DSP card cover, then check flat cabl flat cable looseness or...
  • Page 107 502814 502814 2-20 2-20     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-05 E-05 Logics Logics E-02 E-02 Pump inverter Pump inverter E-05 E-05 Inside Inside Inside Inside     of  of   ...
  • Page 108 501137 501137 2-21 2-21     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.7 7 PS Co Cont ntro roll ller er,O ,Ove verh rhea eati ting ng (E (E9) 9) Error code: E9 Error code: E9 Controller/m Controller/motor overheat indicator ON.
  • Page 109 502815 502815 2-22 2-22     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Thermal Thermal (11) Check harness looseness or wire breakage (11) Check harness looseness or wire breakage Normal Normal Abnormal Abnormal Power supply Power supply (12) Disc (12)
  • Page 110 502816 502816 2-23 2-23     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-08 E-08 E-02 E-02 Logics Logics E-02 E-02 EPS controller EPS controller E-08 E-08 W  W  Inside Inside Inside Inside     of ...
  • Page 111 501138 501138 2-24 2-24     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.8 8 Tr Trac acti tion M on Mot otor C or Cur urre rent S nt Sen enso sor R. r R.H.
  • Page 112 502817 502817 2-25 2-25     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07 Logics Logics E-02 E-02  Traction in  Traction inverter (rig verter (right) E-07 E-07 W  W  Inside Inside Inside Inside  ...
  • Page 113 501135 501135 2-26 2-26     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.9 9 Tr Trac acti tion on Mo Moto tor R r R.H .H., ., Ov Over er-c -cur urre rent nt (1 (15) 5) Error code: 15 Error code: 15 Display: "15".
  • Page 114 502818 502818 2-27 2-27     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS (12) Disconnect connectors E-07 and CN1 (12) Disconnect connectors E-07 and CN1 Check continuity between E-07-5 and E-17-1 (6) Check continuity between E-07-5 and E-17-1 (6) Check continuity between E-07-6 and E-17-2 (7) Check continuity between E-07-6 and E-17-2 (7) Check continuity between E-07-7 and E-17-4 (8)
  • Page 115 502819 502819 2-28 2-28     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07 Logics Logics E-02 E-02  Traction in  Traction inverter (rig verter (right) E-07 E-07 W  W  Inside Inside Inside Inside  ...
  • Page 116 501135 501135 2-29 2-29     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.10 0 Tra Tracti ction M on Moto otor R. r R.H., H., Sta Stall T ll Time imer (1 r (16) 6) Error code: 16 Error code: 16 Display: “16”.
  • Page 117 502820 502820 2-30 2-30     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07 Logics Logics E-02 E-02  Traction in  Traction inverter (rig verter (right) E-07 E-07 W  W  Inside Inside Inside Inside  ...
  • Page 118 501135 501135 2-31 2-31     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.11 1 Tra Tracti ction Mo on Motor Cu tor Curre rrent Se nt Senso nsor L.H r L.H., Fa ., Fault (2 ult (24) 4) Error code: 24 Error code: 24...
  • Page 119 502821 502821 2-32 2-32     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside  ...
  • Page 120 501136 501136 2-33 2-33     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.12 2 Tra Tracti ction M on Moto otor L. r L.H., H., Ove Over-c r-curr urrent ( ent (25) Error code: 25 Error code: 25 Display: "25".
  • Page 121 (14) Repair or replace harness (14) Repair or replace harness 502822 502822 2-34 2-34     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS (13) C (13) Connec onnect all conne connectors ctors, battery plug a battery plug and turning on nd turning on...
  • Page 122 502823 502823 2-35 2-35     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside  ...
  • Page 123 501136 501136 2-36 2-36     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.13 3 Tra Tracti ction M on Moto otor L. r L.H., H., Sta Stall T ll Time imer (26 r (26) ) Error code: 26 Error code: 26 Display: “26”.
  • Page 124 502824 502824 2-37 2-37     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside  ...
  • Page 125 501136 501136 2-38 2-38     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.14 4 Pu Pump M mp Moto otor Cu r Curre rrent S nt Sens ensor F or Faul ault (34 t (34) ) Error code: 34 Error code: 34 Display: "34".
  • Page 126 502825 502825 2-39 2-39     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-05 E-05 Logics Logics E-02 E-02 Pump inverter Pump inverter E-05 E-05 Inside Inside Inside Inside     of  of   ...
  • Page 127 501137 501137 2-40 2-40     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.15 15 Pu Pump M mp Mot otor O or Ove ver- r-cu curr rren ent (35 t (35) ) Error code: 35 Error code: 35 Display: "35".
  • Page 128 (17) Perform inverter discharging work (17) Perform inverter discharging work (18) Replace the pump inverter ASSY with the original (18) Replace the pump inverter ASSY with the original inverter ASSY again, then replace the pump motor  inverter ASSY again, then replace the pump motor  Please keep the inverter ASSY which is used for ...
  • Page 129 501137 501137 2-42 2-42     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.16 16 Li Line C ne Con onta tact ctor F or Fau ault ( lt (40 40) ) Error code: 40 Error code: 40 Display: "40".
  • Page 130 502827 502827 2-43 2-43     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS (14) Disconnect battery plug, then perform inverter discharging work (14) Disconnect battery plug, then perform inverter discharging work (15) Remove DSP cover of all inverters and check DSP flat cable for looseness or wire breakage (15) Remove DSP cover of all inverters and check DSP flat cable for looseness or wire breakage  ...
  • Page 131 502828 502828 2-44 2-44     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-07 E-07 E-06 E-06 E-02 E-02 E-05 E-05 Logics Logics E-07 E-07 E-02 E-02  Traction  Traction inverter inverter (right) (right) E-06 E-06  Traction in  Traction inverter...
  • Page 132 501142 501142 2-45 2-45     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.17 7 Ste Steeri ering ng Con Contac tactor tor Fau Fault lt (41 (41) ) Error code: 41 Error code: 41 Situat uation Displa...
  • Page 133 (17) Replace EPS controller  (17) Replace EPS controller  502829 502829 2-46 2-46     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Logics Logics E-05 E-05 E-02 E-02 Pump inverter Pump inverter Logics Logics E-04 E-04 FUSE FUSE LINE CON...
  • Page 134 501143 501143 2-47 2-47     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.18 8 Tra Tracti ction on Mot Motor or R.H R.H., ., Op Open en (45 (45) ) Error code: 45 Error code: 45 Display: "45".
  • Page 135 Confirm valu firm value is e is 12 ± 12 ± Normal Normal Abnormal Abnormal (17) Disconnect battery plug, then perform inverter discharging work (17) Disconnect battery plug, then perform inverter discharging work (18) Replace DSP card of right traction inverter  (18) Replace DSP card of right traction inverter ...
  • Page 136 501135 501135 2-49 2-49     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.19 9 Tra Tracti ction on Mot Motor or L. L.H., H., Ope Open ( n (46) Error code: 46 Error code: 46 Display: "46".
  • Page 137 (16) Measure (16) Measure voltage between voltage between E 06 16(9) and E 06 16(9) and E 06 20(12) E 06 20(12) Confirm valu firm value is e is 12 ± 12 ± Normal Normal Abnormal Abnormal (17) Disconnect battery plug, then perform inverter discharging work (17) Disconnect battery plug, then perform inverter discharging work (18) Replace DSP card of left traction inverter ...
  • Page 138 E-18 E-18 E-15 E-15 501136 501136 2-51 2-51     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.20 20 Pu Pump mp Mo Moto tor O r Ope pen ( n (47 47) ) Error code: 47 Error code: 47 Situat...
  • Page 139 (17) Disconnect battery plug, then perform inverter discharging work (17) Disconnect battery plug, then perform inverter discharging work (18) Replace DSP card of pump inverter  (18) Replace DSP card of pump inverter  (19) Replace power supply card of logic unit (19) Replace power supply card of logic unit If fault remains If fault remains...
  • Page 140 501137 501137 2-53 2-53     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.21 21 PS PS Mo Moto tor O r Ope pen ( n (49 49) ) Error code: 49 Error code: 49 Situa Situation tion...
  • Page 141 Confirm valu firm value is e is 12 ± 12 ± Normal Normal Abnormal Abnormal (17) Disc (17) Disconnect batt onnect batt ery plug, ery plug, then perform E then perform EPS c controller ontroller discharging work discharging work 502833 502833 2-54 2-54...
  • Page 142 E-27 E-27 H-01(3W) H-01(3W) E-38(4W) E-38(4W) 501145 501145 2-55 2-55     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.22 22 Ti Tire A re Ang ngle S le Sen enso sor Fa r Faul ult (5 t (50) 0) Error code: 50 Error code: 50...
  • Page 143 replaced replaced Replace EPS controller  Replace EPS controller  502834 502834 2-56 2-56     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-04 E-04 E-08 E-08 E-01 E-01 13 1 E-04 E-04 Life Life Signal Signal E- E-08...
  • Page 144 E-27 E-27 H-01(3W) H-01(3W) E-38(4W) E-38(4W) 501145 501145 2-57 2-57     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.23 23 Ac Acce cele lera rato tor Sen r Senso sor Fau r Fault (5 lt (51) 1) Error code: 51 Error code: 51...
  • Page 145 Open E-19-3(55) and E-19-6(52), E-19-2(53) Open E-19-3(55) and E-19-6(52), E-19-2(53) Short-circuit E-19-5(54) and E-19-6(52), E-19-2(53) Short-circuit E-19-5(54) and E-19-6(52), E-19-2(53) Turn on power Turn on power and check and check accelerator voltage with service tool accelerator voltage with service tool (16) Replac (16) Replace accelera...
  • Page 146 501144 501144 2-59 2-59     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.24 4 Tra Tracti ction M on Moto otor R.H r R.H., Pu ., Pulse I lse Inpu nput Fau t Fault (5 lt (52) 2) Error code: 52 Error code: 52...
  • Page 147 (13) Measure voltage between E-07-17(10) and (13) Measure voltage between E-07-17(10) and E-07-20 E-07-20(12) Confirm value is (12) Confirm value is 14 ± 14 ± Normal Normal Abnormal Abnormal (14) Disconnect battery plug, then perform inverter discharging work (14) Disconnect battery plug, then perform inverter discharging work (15) Replace DSP card of right traction inverter ...
  • Page 148 E 14 E 14 E-17 E-17 501135 501135 2-61 2-61     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.25 5 Tra Tracti ction Mo on Motor L tor L.H. .H., Pu , Pulse I lse Inpu nput Fau t Fault (5...
  • Page 149 (13) Measure voltage between E-06-17(10) and (13) Measure voltage between E-06-17(10) and E-06-20 E-06-20(12) Confirm value is (12) Confirm value is 14 ± 14 ± Normal Normal Abnormal Abnormal (14) Disconnect battery plug, then perform inverter discharging work (14) Disconnect battery plug, then perform inverter discharging work (15) Replace DSP card of left traction inverter ...
  • Page 150 E-18 E-18 E-15 E-15 501136 501136 2-63 2-63     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.26 26 FC FC Le Leve ver F r Fau ault lt (5 (54) 4) Error code: 54 Error code: 54 Situa Situation...
  • Page 151 (13) Disconnect battery plug, then perform inverter  (13) Disconnect battery plug, then perform inverter  discharging work discharging work (14) Reinstall input unit and replace harness (14) Reinstall input unit and replace harness (FC-IN harness) (FC-IN harness) 502838 502838 2-64 2-64  ...
  • Page 152 501147 501147 2-65 2-65     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.27 7 Out Output put Uni Unit S t Sole olenoi noid F d Faul ault ( t (55) Error code: 55 Error code: 55 Situa Situation...
  • Page 153 502839 502839 2-66 2-66     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-01 E-01 13 1 Logics Logics Power card Power card E-11 E-11 Output unit Output unit E-11 E-11 Output unit Output unit E-10 E-10...
  • Page 154 501150 501150 2-67 2-67     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.28 8 Out Output put Uni Unit t Sol Soleno enoid id Cur Curren rent L t Leak eak (56 (56) ) Error code: 56 Error code: 56 Situat...
  • Page 155 502840 502840 2-68 2-68     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-01 E-01 13 1 Logics Logics Power card Power card E-11 E-11 Output unit Output unit E-11 E-11 Output unit Output unit E-10 E-10...
  • Page 156 501150 501150 2-69 2-69     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.29 9 FNR L FNR Leve ever or Acc r or Accele elerat rator, F or, Faul aulty Se ty Setti tting (E ng (E) ) Error code: E Error code: E...
  • Page 157 (16) Disconnect battery plug (16) Disconnect battery plug (17) Repair or replace (17) Repair or replace main harness main harness (18) Replace Logic card of logic unit (18) Replace Logic card of logic unit 502841 502841 2-70 2-70     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-04...
  • Page 158 E-12 E-12 501160 501160 2-71 2-71     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.30 0 Sea Seat Swi t Switch tch, Fau , Faulty S lty Sett etting f ing for Tr or Tract action ( ion ((E) (E)) )
  • Page 159 Check Check continuit continuit y between y between C 02 2 C 02 2 and E 04 43(64) and E 04 43(64) Check Check continuit continuit y between y between C-02-3 C-02-3 and E-03-33(58) and E-03-33(58) Continuity Continuity continuity continuity (13) Replace logic card of logic unit (13) Replace logic card of logic unit (14) Repair or replace main harness...
  • Page 160 501161 501161 2-73 2-73     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.31 1 Lif Lift L t Leve ever, r, Fau Faulty lty Set Settin ting ( g (H1) Error code: H1 Error code: H1 Display: "H1"...
  • Page 161 (14) Disconnect battery plug (14) Disconnect battery plug (15) Repair or replace main harness (15) Repair or replace main harness (16) Replace logic card of logic unit (16) Replace logic card of logic unit 502843 502843 2-74 2-74      ...
  • Page 162 501162 501162 2-75 2-75     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.32 2 Til Tilt L t Leve ever, r, Fau Faulty lty Set Settin ting ( g (H2) Error code: H2 Error code: H2 Display: "H2"...
  • Page 163 (14) Disconnect battery plug (14) Disconnect battery plug (15) Repair or replace main harness (15) Repair or replace main harness (16) Replace logic card of logic unit (16) Replace logic card of logic unit   502844   502844 2-76 2-76  ...
  • Page 164 501163 501163 2-77 2-77     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.33 3 Att Attach achmen ment 1 Le t 1 Lever ver, Fa , Fault ulty Se y Setti tting (H ng (H3) 3) Error code: H3 Error code: H3 Display: "H3"...
  • Page 165 (14) Disconnect battery plug (14) Disconnect battery plug (15) Repair or replace main harness (15) Repair or replace main harness (16) Replace logic card of logic unit (16) Replace logic card of logic unit 502845 502845 2-78 2-78     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-12...
  • Page 166 501164 501164 2-79 2-79     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.34 4 Att Attach achmen ment 2 Le t 2 Lever ver, Fa , Fault ulty Se y Setti tting (H ng (H4) 4) Error code: H4 Error code: H4 Display: "H4"...
  • Page 167 (14) Disconnect battery plug (14) Disconnect battery plug 502846 502846 2-80 2-80         CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-12 E-12 H-07 H-07 FC speci��cation FC speci��cation FC-IN harness FC-IN harness H-07 H-07 E-12...
  • Page 168 501165 501165 2-81 2-81     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.35 5 Sea Seat Swit t Switch, F ch, Faul aulty Set ty Settin ting for Hy g for Hydra drauli ulic ((L) c ((L)) ) Error code: (L) Error code: (L)
  • Page 169 Check Check continuit continuit y between y between C-02-2 C-02-2 and E-04-43(64) and E-04-43(64) Check Check continuit continuit y between y between -02-3 -02-3 and E-03-33(58) and E-03-33(58) Continuity Continuity continuity continuity 502847 502847 2-82 2-82     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-03 E-03...
  • Page 170 501161 501161 2-83 2-83     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.36 36 FN FNR L R Lev ever F er Fau ault ( lt (EE EE) ) Error code: EE Error code: EE Situat uation Gear ar of of lev...
  • Page 171 With FNR lever in position other than neutral With FNR lever in position other than neutral check continuity between E-12-19 and 14 check continuity between E-12-19 and 14 Open Open short short     (12) With FNR lever in neutral (12) With FNR lever in neutral (13) Replace FNR lever ...
  • Page 172 502260 502260 2-85 2-85     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.37 7 Dis Displa play C y Comm ommuni unicat cation ion Fau Fault lt (60 (60) ) Error code: 60 Error code: 60 Display: "60".
  • Page 173 (13) Disconnect battery plug, then perform inverter  (13) Disconnect battery plug, then perform inverter  (14) Repair or replace harness (14) Repair or replace harness discharging work discharging work (15) Replace logic card of logic unit (15) Replace logic card of logic unit 502849 502849 2-86...
  • Page 174 501151 501151 2-87 2-87     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.38 8 Log Logic C ic Card ard Ini Initia tializ lize F e Fail ailure ure (61 (61) ) Error code: 61 Error code: 61 Situat uation...
  • Page 175 502850 502850 2-88 2-88     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.39 39 Lo Logi gics cs Fa Faul ult ( t (62 62) ) Error code: 62 Error code: 62 Situat uation Displa play: "6...
  • Page 176 502851 502851 2-89 2-89     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.40 0 Tra Tracti ction I on Inve nverte rter R. r R.H., H., Fau Fault ( lt (63) Error code: 63 Error code: 63 Display: "63".
  • Page 177 (8) (Already disconnected. E-01, E-02 and E-07) (8) (Already disconnected. E-01, E-02 and E-07) (9) Repair or replace main harness (9) Repair or replace main harness Resistance between Resistance between E-02-5(3) and E-02-6(4)of harness side connectors E-02-5(3) and E-02-6(4)of harness side connectors ...
  • Page 178 (29) Replace Logics Unit (29) Replace Logics Unit (30) Replace DSP EPS (30) Replace DSP EPS controller  controller  502853 502853 2-91 2-91     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-07 E-07 Logics Logics E-02...
  • Page 179 E-14 E-14 E-17 E-17 501135 501135 2-92 2-92     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.41 1 Tra Tracti ction I on Inve nverte rter L r L.H. .H., F , Faul ault (6 t (64) 4) Error code: 64 Error code: 64...
  • Page 180 (10) Perform CAN check of (10) Perform CAN check of Pump inverter Fault (65) Pump inverter Fault (65) (11) Connect connector E-06of traction inverter  (11) Connect connector E-06of traction inverter  (Already disconnected. E-02 and E01) (Already disconnected. E-02 and E01) Measure resistance of CAN with connector E-02 Measure resistance of CAN with connector E-02 disconnected...
  • Page 181 502855 502855 2-94 2-94     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-06 E-06 Logics Logics E-02 E-02  Traction in  Traction inverter (left) verter (left) E-06 E-06 W  W  Inside Inside Inside Inside  ...
  • Page 182 E-18 E-18 E-15 E-15 501136 501136 2-95 2-95     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.42 42 Pu Pump mp In Inve vert rter er Fa Faul ult( t(65 65) ) Error code: 65 Error code: 65 Display: "65".
  • Page 183 Continuity Continuity continuity continuity (7) Repair of replace main harness (7) Repair of replace main harness (8) Resistance between E-02-5 and E-02-6 of harness side connectors (8) Resistance between E-02-5 and E-02-6 of harness side connectors   ± ± Other Other than...
  • Page 184 controller  controller  502857 502857 2-97 2-97     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-05 E-05 Logics Logics E-02 E-02 Pump inverter Pump inverter E-05 E-05 Inside Inside Inside Inside     of ...
  • Page 185 E-16 E-16 501137 501137 2-98 2-98     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.43 43 In Inpu put Un t Unit it Fa Faul ult (6 t (67) 7) Error code: 67 Error code: 67 Situat uation...
  • Page 186 502858 502858 2-99 2-99     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-12 E-12 E-01 E-01 H-02 H-02 13 1 (female) (female) (male) (male) Power card Power card FC-IN FC-IN harness harness E-12 E-12 H-02 H-02 E-01...
  • Page 187 501152 501152 2-100 2-100     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.44 44 Ou Outp tput ut Un Unit it Fa Faul ult ( t (68 68) ) Error code: 68 Error code: 68 Situat uation Displa...
  • Page 188 502859 502859 2-101 2-101         CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-01 E-01 13 1 Power card Power card E-02 E-02 E-10 E-10 E-01 E-01 Output Output unit unit E-21 E-21 Logics Logics E-02...
  • Page 189 Emetrgency SW Emetrgency SW (female) (female) (male) (male) 501153 501153 2-102 2-102     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.45 45 EP EPS Co S Cont ntro roll ller F er Fau ault lt (7 (71) 1) Error code: 71 Error code: 71...
  • Page 190 (8) Repair or replace harness (8) Repair or replace harness (7) Resistance between E-02-5(3) and E-02-6(4) of harness (7) Resistance between E-02-5(3) and E-02-6(4) of harness side connectors side connectors     ± ± Other than 60 Other than 60 ±...
  • Page 191 502861 502861 2-104 2-104     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-04 E-04 E-08 E-08 E-01 E-01 13 1 E-04 E-04 Life Life Signal Signal E- E-08 EPS Co Cont ntr ol olle ler E-02 E-02...
  • Page 192  Tire  Tire angle angle sensor sensor  TWR  TWR  TVR  TVR E-27 E-27 E-27 E-27 H-01(3W) H-01(3W) E-38(4W) E-38(4W) 501145 501145 2-105 2-105     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.46 46 Co Cont ntac acto tor C r Coi oil F l Fau ault lt (7 (72) 2)
  • Page 193 502862 502862 2-106 2-106     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Fuse Fuse       +       +    -    - Line contactor Line contactor       +       + Br/R Br/R Logics Logics    -    - E-04 E-04 Steering contactor Steering contactor E-04 E-04...
  • Page 194 501154 501154 2-107 2-107     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.47 7 Hyd Hydrau raulic lic Loc Lock So k Solen lenoid oid Fau Fault lt (74 (74) ) Error code: 74 Error code: 74 Display: "74".
  • Page 195 502863 502863 2-108 2-108     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Key Switch Key Switch Harness B Harness B Logics Logics E-13 E-13 E-04 E-04 Lift Lift lock  lock  valve valve E-04 E-04 E-13 E-13...
  • Page 196 501155 501155 2-109 2-109     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.48 48 Pa Park rkin ing g Br Brak ake e Fa Faul ult t (7 (75) 5) Error code: 75 Error code: 75 Display: "75".
  • Page 197 502864 502864 2-110 2-110     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-23 E-23 (female) (female) (male) (male) Key Switch Key Switch Logics Logics E-23 E-23 E-04 E-04 PKB1 PKB1 PKB2 PKB2 PDS buzzer PDS buzzer Key Switch Key Switch...
  • Page 198 501569 501569 2-111 2-111     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.49 49 PD PDS S Bu Buzz zzer er Fa Faul ult t (7 (76) 6) Error code: 76 Error code: 76 Si Situ tuat atio ion n Di Disp spla lay: "7 y: "76"...
  • Page 199 502865 502865 2-112 2-112     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-03 E-03 35 3 Logics Logics E-03 E-03 Key Switch Key Switch PDS buzzer PDS buzzer Logics Logics E-04 E-04 E-04 E-04...
  • Page 200 502542 502542 2-113 2-113     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.50 50 Ba Batt tter ery V y Vol olta tage T ge Too L oo Low ( ow (78 78) ) Error code: 78 Error code: 78 Situat...
  • Page 201 502866 502866 2-114 2-114     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Fuse Fuse Logics Logics E-02 E-02 E-02 E-02...
  • Page 202 501154 501154 2-115 2-115     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.51 51 Ba Batt tter ery Vo y Volt ltag age To e Too Hi o High ( gh (79 79) ) Error code: 79 Error code: 79 Situat...
  • Page 203 502867 502867 2-116 2-116     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Fuse Fuse Logics Logics E-02 E-02 E-02 E-02...
  • Page 204 501154 501154 2-117 2-117     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.52 2 Bat Batter tery C y Cons onsump umptio tion To n Too Mu o Much ( ch (Lo) Error code: (Lo) Error code: (Lo) Display: "Lo"...
  • Page 205 502871 502871 2-118 2-118     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Fuse Fuse Logics Logics E-02 E-02 E-02 E-02...
  • Page 206 501154 501154 2-119 2-119     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.53 53 Ti Tilt A lt Ang ngle S le Sen enso sor Fa r Faul ult (8 t (80) 0) Error code: 80 Error code: 80  Tilt mechanism fo...
  • Page 207 502868 502868 2-120 2-120     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-01 E-01 13 1 E-02 E-02 E-03 E-03 Logics Logics E-02 and E-03 E-02 and E-03  Tilt Angle Senso  Tilt Angle Sensor E-01 E-01 E-02...
  • Page 208 Power card Power card 501157 501157 2-121 2-121     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.54 54 Lo Load ad Se Sens nsor or Fa Faul ult t (8 (81) 1) Error code: 81 Error code: 81 Pitch control and tilt mechanism to secure horizontal operation are disabled.
  • Page 209 502869 502869 2-122 2-122     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-20 E-20 Logics Logics E-02 E-02 E-20 E-20 Logics Logics E-03 E-03 E-03 E-03 35 3...
  • Page 210 501158 501158 2-123 2-123     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.55 55 Ha Hand ndle le Se Sens nsor or Fa Faul ult ( t (82 82) ) Error code: 82 Error code: 82 Display: "82".
  • Page 211 502870 502870 2-124 2-124     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-04 E-04 E-08 E-08 E-01 E-01 13 1 E-04 E-04 Life Life Signal Signal E- E-08 EPS Co Cont ntr ol olle ler E-02 E-02...
  • Page 212 H-01(3W) H-01(3W) E-38(4W) E-38(4W)  Tire  Tire angle angle sensor sensor  TWR  TWR  TVR  TVR E-27 E-27 E-27 E-27 H-01(3W) H-01(3W) E-38(4W) E-38(4W) 501145 501145 2-125 2-125     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.56 6 PS M PS Moto otor Cu...
  • Page 213 502872 502872 2-126 2-126     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-08 E-08 E-02 E-02 Logics Logics E-02 E-02 EPS controller EPS controller E-08 E-08 W  W  Inside Inside Inside Inside     of ...
  • Page 214 E-27 E-27 501138 501138 2-127 2-127     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.57 57 PS M PS Mot otor O or Ove ver- r-cu curr rren ent (A t (A5) 5) Error code: A5 Error code: A5 Display: "A5".
  • Page 215 502873 502873 2-128 2-128     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-08 E-08 E-02 E-02 Logics Logics E-02 E-02 EPS controller EPS controller E-08 E-08 W  W  Inside Inside Inside Inside     of ...
  • Page 216 E-27 E-27 501138 501138 2-129 2-129     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.58 58 PS PS Ha Hand ndle B le Bra rake F ke Fau ault lt (A (A7) 7) Error code: A7 Error code: A7 Situat...
  • Page 217 502874 502874 2-130 2-130     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-02 E-02 E-04 E-04 E-08 E-08 E-01 E-01 13 1 E-04 E-04 Life Life Signal Signal E- E-08 EPS Co Cont ntr ol olle ler E-02 E-02...
  • Page 218 F-01 F-01 H-01(3W) H-01(3W) E-38(4W) E-38(4W)  Tire  Tire angle angle sensor sensor  TWR  TWR  TVR  TVR E-27 E-27 E-27 E-27 H-01(3W) H-01(3W) E-38(4W) E-38(4W) 501145 501145 2-131 2-131     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3.59 9 Bat Batter tery Sid...
  • Page 219 502875 502875 2-132 2-132     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-04 E-04 Logics Logics     E-04 E-04 Br/B Br/B Interlock SW Interlock SW Logics Logics E-04 E-04   ...
  • Page 220 501159 501159 2-133 2-133     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.60 60 Ba Batt tter ery Co y Cons nsum umpt ptio ion Mu n Much Error code: None Error code: None Battery low indicator flashes.
  • Page 221 502876 502876 2-134 2-134     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS Fuse Fuse Logics Logics E-02 E-02 E-02 E-02...
  • Page 222 501154 501154 2-135 2-135     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.61 61 Br Brak ake O e Oil il, L , Low L ow Lev evel el Error code: None Error code: None Si Situ tuat atio ion n Br Brak ake f e flu luid i id ico...
  • Page 223 502877 502877 2-136 2-136     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS E-03 E-03     E-04 E-04 35 3 Logics Logics Logics Logics E-04 E-04 E-03 E-03     Br/B Br/B C-01 C-01 C-01 C-01 C-01...
  • Page 224 501139 501139 2-137 2-137     CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS 3. 3.62 62 R R TC TC B B a a tt tte e ry ry L L ow Error code: None Error code: None S S i i t t u u a a t t i i o o n n F F l l a a s s h h i i n n g o...
  • Page 225 502878 502878 2-138 2-138     CHAPTER 3 MOTOR CHAPTER 3 MOTOR C C h h a a p p t t e e r r 3 3 M M O O T T O O R R 1. 1. Moto tor I r Ins nsta tall llat atio ion P n Pos...
  • Page 226 502714 502714 1. 1. Tr Trac act t io ion m n mot otor ors s 3 3 . . P P u u m m p m p mo o t t o o r r 2. 2. El Elec ectr tro- o-ma magn gnet etic ic br brak ake e 4 4 .
  • Page 227 1 1 . . T T r r a a c c ti tio o n m n mo o to tor r s s 3 3 . . P P u u m m p p m m o o t t o o r r 2.
  • Page 228     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 3 3 . . S S t t r r u u c c t t u u r r e e s s  The AC motor model forklift trucks covered by  The AC motor model forklift trucks covered by this manual use three-phase induction AC this manual use three-phase induction AC motors as the Traction motors and motors as the Traction motors and...
  • Page 229     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 3 3 . . 2 2 P P u u m m p p m m o o t t o o r r 502717 502717 1 1 . . W te e r r m m i i n n a a l l 4.
  • Page 230     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 3 3 . . 3 3 E E P P S S m m o o t t o o r r 502718 502718 1. 1. T T o R o Re e ar ar ax axle le (3 (3 W) 2.
  • Page 231     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 4. 4. Removi oving ng Tra Transf nsfer er Ass Assem embli blies, es, Tra Tracti ction on mot motors 501116 501116 1 1 . . F F r r a a m m e e 1 1 ) ) M M o o t t o o r r m m o o u u n n t t i i n n g g b b o o l l t t s s , , 3 3 p p l l a a c c e e s s 2) 2)
  • Page 232 and slightly pull the transfer with the jack away from and slightly pull the transfer with the jack away from the frame. the frame. 501117 501117 After making sure that the transfer can be pulled out After making sure that the transfer can be pulled out horizontally, remove the bolts that secure the transfer horizontally, remove the bolts that secure the transfer to the frame, and remove the transfer with the jack ...
  • Page 233 502719 502719 1 1 . . B B o o l l t t W W a a s s h h e e r r 7 7 . . E E n n d c d co o v v e e r r 2 2 .
  • Page 234 If the motor is tested by itse If the motor is tested by itself, fix the motor on a work bench se lf, fix the motor on a work bench securely. curely. The motor may mo The motor may move suddenly when starting. ve suddenly when starting.
  • Page 235 3-10 3-10     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 7. 7. Resa sass ssem embl blin ing T g Tra ract ctio ion mo n moto tor r Follow the disassembling in Follow the disassembling in reverse. reverse. 7 7 . . 1 1 R R e e s s a a s s s s e e m m b b l l y S y Se e q q u u e e n n c c e e 502722...
  • Page 236 the clearance between the terminal and the clearance between the terminal and stator core. stator core.  THREEBOND [#1104]  THREEBOND [#1104] around the seal. around the seal. 2) 2) 11± 1 N 11± 1 N·m ( 1 ·m ( 1.12 ± 0 .12 ±...
  • Page 237 Tightening torque for flange bolt Tightening torque for flange bolt 38.6 to 47.2 N·m (4.0 38.6 to 47.2 N·m (4.0 to 4.8 kgf ·m) [28.5 to 34.8 lbf·ft] to 4.8 kgf ·m) [28.5 to 34.8 lbf·ft] 3-12 3-12     CHAPTER 3 MOTOR CHAPTER 3 MOTOR (5) Remov...
  • Page 238 3-13 3-13     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 9. 9. Di Disa sass ssem embi bing ng Pu Pum m p M p Mot otor or     CAUTION CAUTION Ball bea Ball bearing rings at both en s at both ends are of ma ds are of mainten intenance fr...
  • Page 239 502727 502727 1 1 . . B B o o l l t t W W a a s s h h e e r r 7 7 . . E E n n d c d co o v v e e r r 2 2 .
  • Page 240     CAUTION CAUTION If the motor is tested by itse If the motor is tested by itself, fix the motor on a work bench se lf, fix the motor on a work bench securely. curely. The motor may mo The motor may move suddenly when starting.
  • Page 241 3-16 3-16     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 11. Res Resass assemb emblin ling Pu g Pump m mp moto otor r Follow the disassembling in Follow the disassembling in reverse. reverse. 11.1 .1 Re Resa sass ssem embl bly y Se Sequ quen...
  • Page 242 the clearance between the terminal and the clearance between the terminal and stator core. stator core. in M8 thread holes.] in M8 thread holes.] 2) 2) 11± 1 N 11± 1 N·m ( 1 ·m ( 1.12 ± 0 .12 ± 0.1 kg .1 kgf·m f·m) [ 8.
  • Page 243 3-18 3-18     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 13. . Re Remo movi ving E ng EPS PS Mo Moto tor r 13.1 .1 Su Sugg gges esti tion ons f s for R or Rem emov oval al  ...
  • Page 244 502732 502732 1 1 . . B B o o l l t t 5 5 . . C C o o v v e e r ( r (D D ) ) 2 2 . . E E n n d d c c o o v v e e r r ( ( C C ) ) 6 6 .
  • Page 245 3-20 3-20     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 15. . In Insp spec ecti ting EP ng EPS Mo S Motor 15.1 .1 In Insp spec ecti ting ng Ar Arma matu ture re Inspection for damage Inspection for damage Check the armature for damage, especially for burning.
  • Page 246 502735 502735 φ φ D D 1. 1. I I t t e e m m S S t t a a n n d d a a r r d d L L i i m m i i t t 30 mm 30 mm 29 mm...
  • Page 247 502737 502737 1 1 . . P P o o s s i i t t i i v v e e 2 2 . . N N e e g g a a t t i i v v e e T T o o o o l l S S p p e e c c i i f f i i c c R R e e s s i i s s t t a a n n c c e e  Tester...
  • Page 248 Conne Connect ct (WHIT (WHITE) w E) wire ire to to the the (pos (positive itive [+]) [+])term terminal inal of of the the batte battery. ry. Connec nect (BL t (BLACK ACK) wir ) wire to th e to the (ne e (negat gative [ ive [-]) t...
  • Page 249 3-24 3-24     CHAPTER 3 MOTOR CHAPTER 3 MOTOR 16. . In Insp spec ecti ting EP ng EPS Mo S Motor 1 1 6 6 . . 1 1 B B r r u u s s h h (1) Me Measu asure the t...
  • Page 250 502741 502741 1. 1. Br Brus ush h 1) 1) Go Good 2. 2. Com Commut mutato ator r 2) 2) Not Not goo good d (3) If the c If the condit ondition is no ion is not good t good, inser , insert a sand pa t a sand paper [...
  • Page 251 3-26 3-26     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS Chap apte ter 4 r 4 HO HOW TO W TO RE READ AD CI CIRC RCUI UIT DI T DIAG AGRA RAMS 1.
  • Page 252     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS 2. 2. How t w to R o Rea ead C d Cir ircu cuit it Di Diag agra rams  The circuit of each system from fuse to GND (earth) is indicated. The circuits indicate the  The circuit of each system from fuse to GND (earth) is indicated.
  • Page 253 501952 501952     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS 1. 1. Depa part rtur ure e e equ quip ipme ment nt na name 11. Used pl Used place of r ace of relay co elay coil (Des il (Descrip...
  • Page 254 CONNECTOR CONNECTOR  TWIST WIRE  TWIST WIRE (SOCKET/PLUG) (SOCKET/PLUG)  TERMINAL  TERMINAL SHIELD WIRE SHIELD WIRE (SOCKET) (SOCKET)  TERMINAL  TERMINAL BRANCHING BRANCHING (PLUG) (PLUG)  TERMINAL  TERMINAL     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS (3) Sta Standa ndard rd pas...
  • Page 255  THREE-PHASE  THREE-PHASE BATTERY BATTERY INDUCTION MOTOR INDUCTION MOTOR DC MOTOR DC MOTOR     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS (6) Swit Swithes, c hes, contr ontrol an ol and pro d protect tective d ive devic evices es...
  • Page 256 S S Y Y M M B B O O L L N N A A M M E E S S Y Y M M B B O O L L N N A A M M E E HORN HORN LAMP...
  • Page 257     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS 2 2 . . 3 3 C C o o n n n n e e c c t t i i n n g g L L i i n n e e s s (1) Ther There are t e are two thic...
  • Page 258 W W h h i i t t e e B B l l u u e e S S b b S S k k y y b b l l u u e e R R e e d d L L g g L L i i g g h h t t g g r r e e e e n n P P u u r r p p l l e e...
  • Page 259 F F L L W W F F u u s s i i b b l l e e l l i i n n k k C C a a p p a a c c i i t t o o r r R R Y Y R R e e l l a a y y D D i i o o d d e e...
  • Page 260 (3) The connector The connector terminal num terminal number is indicat ber is indicated next to ed next to the connector the connector symbol. However symbol. However, for the , for the terminals such terminals such as round as round shape terminal, plug terminal and flat shape shape terminal, plug terminal and flat shape terminal, etc., the terminal number is indicated.
  • Page 261 501962 501962 1. 1. Te Term rmin inal al co conn nnec ecto tor r nu numb mber er 2. 2. Gr Grap aphi hic c sy symb mbol ol 4-10 4-10     CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS CHAPTER 4 HOW TO READ CIRCUIT DIAGRAMS (2) When co When connect...
  • Page 262 501964 501964 1. 1. The c The circ ircuit po uit porti rtion wh on which di ich diffe ffers de rs depen pendin ding on the g on the 2. 2. The cir circu cuit o it of an f anoth other er spe specif cifica...
  • Page 263 502710 502710 1. 1. L L o o ck ( ck (Bl Blac ack k en ened ed) ) (1) The co The connect nnector diag or diagram is a vi ram is a view fro ew from its ma m its mating fa ting face.
  • Page 264 4-13 4-13...
  • Page 265     CHAPTER 5 CIRCUIT DIAGRAM CHAPTER 5 CIRCUIT DIAGRAM Chap apte ter 5 r 5 C C IR IRCU CUI I T DI T DIA A GR GRAM...
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