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CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
3.12 2 Tra
3.1
Tracti
Error code: 25
Error code: 25
Situation
Situation
Possible
Possible
cause
cause
Trigger of
Trigger of
the error
the error
code
code
Checks
Checks
(1) Disconnect battery plug, then perform inverter discharging work
(1) Disconnect battery plug, then perform inverter discharging work
(2) Check traction motor body and terminal for burning and small
(2) Check traction motor body and terminal for burning and small
(3) Check motor terminal (U V W phases) for shorting to
(3) Check motor terminal (U V W phases) for shorting to
the motor body and truck frame
the motor body and truck frame
N
N
(8) Confirm cable looseness and improper connections
(8) Confirm cable looseness and improper connections
(U V W phases) for traction inverter and motor
(U V W phases) for traction inverter and motor
(9) Disconnect battery plug, then perform inverter discharge
(9) Disconnect battery plug, then perform inverter discharge
work
work
Confirm connection of traction motor speed sensor
Confirm connection of traction motor speed sensor
connector
connector
(12) Disconnect connectors E-06 and E-18
(12) Disconnect connectors E-06 and E-18
Check continuity between E-06-5 and E-18-1 (15)
Check continuity between E-06-5 and E-18-1 (15)
Check continuity between E-06-6 and E-18-4 (18)
Check continuity between E-06-6 and E-18-4 (18)
Check continuity between E-06-7 and E-18-2 (17)
Check continuity between E-06-7 and E-18-2 (17)
Check continuity between E-06-19 and E-18-3 (16)
Check continuity between E-06-19 and E-18-3 (16)
Continuity
Continuity
ction M
on Moto
otor L.
r L.H.,
H., Ove
Over-c
r-curr
Display: "25". All
Display: "25". All truck operations inhibited. Line contactor HOLD and ST contactor HOLD.
truck operations inhibited. Line contactor HOLD and ST contactor HOLD.
Traction moto
Traction motor and pump mo
r and pump motor operation
operations inhibited except mast lowering operation.
operations inhibited except mast lowering operation.
Faulty traction moter. (Contain the bearing sensor)
Faulty traction moter. (Contain the
Faulty contact or wire breakage of traction motor speed sensor harness.
Faulty contact or wire breakage of traction motor speed sensor harness.
Faulty traction inverter.
Faulty traction inverter.
Faulty contact or wire breakage of DSP flat
Faulty contact or wire breakage of DSP flat cable in traction inverter.
Faulty DSP card of traction inverter.
Faulty DSP card of traction inverter.
Faulty main harness.
Faulty main harness.
Motor current is more than 1105 A (Moment) or 893 A (1 mS) or 829 A (1.6 mS).
Motor current is more than 1105 A (Moment) or 893 A (1 mS) or 829 A (1.6 mS).
Normal
Normal
o
o
t
t
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
N
N
o
o
r
r
m
m
a
a
l
l
A
A
Normal
Normal
Abnormal
Abnormal
No
No
urrent (
ent (25)
25)
tor operation inhibited. If this fault o
inhibited. If this fault occurs before S
bearing sensor)
cable in traction inverter.
(4)
(4) Replac
Replace t
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
(5) Remove the all cables of motor and traction inverter
(5) Remove the all cables of motor and traction inverter
terminals (P N U V W )
terminals (P N U V W )
Check motor terminals for shorting to the motor body
Check motor terminals for shorting to the motor body
Check the cables for shorting to the frame
Check the cables for shorting to the frame
N
N
(6) Replace traction
(6) Replace traction
inverter
inverter
b
b
n
n
o
o
r
r
m
m
a
a
l
l
(10) Secure cable if loose or connect cable correctly
(10) Secure cable if loose or connect cable correctly
(11) Connect connector securely
(11) Connect connector securely
continuity
continuity
ccurs before ST contactor CLO
T contactor CLOSE, all
Abnormal
Abnormal
e t
rac
raction
tion
motor
motor
o
o
t
t
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
(7) Replace traction
(7) Replace traction
motor or cables
motor or cables
501136
501136
2-33
2-33
SE, all
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
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