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CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
CHAPTER 2 TROUBLESHOOTING FOR CONTROL CIRCUITS
3. 3.57
57 PS M
PS Mot otor O
Error code: A5
Error code: A5
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 EPS motor body and terminal for burning and small
(2) Check EPS motor body and terminal for burning and small
(3)
(3) Chec
Check motor terminal (U
motor body and truck frame
motor body and truck frame
N
N
(5) Confirm cable looseness and improper connections
(5) Confirm cable looseness and improper connections
(U W phases) for EPS controller and motor
(U W phases) for EPS controller and motor
(10) Steering and check the jerky at very low speed
(10) Steering and check the jerky at very low speed
(11) Replace EPS
(11) Replace EPS
controller
controller
or Ove
ver- r-cu
curr rren
ent (A
t (A5) 5)
Display: "A5". All truck operations inhibited. Line contactor OP
Display: "A5".
All truck operations inhibited. Line contactor OPEN and ST contactor OPEN.
All operations inhibited except
All operations inhibited except mast
Faulty PS motor. (Contain the bearing sensor)
Faulty PS motor. (Contain the bearing sensor)
Faulty contact or wire breakage of PS motor speed sensor harness.
Faulty contact or wire breakage of PS motor speed sensor harness.
Faulty PS inverter.
Faulty PS inverter.
Faulty contact or wire breakage of DSP flat
Faulty contact or wire breakage of DSP flat cable in PS inverter.
Faulty DSP card of PS inverter.
Faulty DSP card of PS
inverter.
Faulty main harness.
Faulty main harness.
Motor current is more than 116 A (Moment) or 113 A (1 mS) or 112 A (1.6 mS).
Motor current is more than 116 A (Moment) or 113 A (1 mS) or 112 A (1.6 mS).
Normal
Normal
k motor terminal (U
W phases)
W phases)
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
(7) Secure cable if loose or
(7) Secure cable if loose or
connect cable correctly
connect cable correctly
N
N
o
o
r
r
m
m
a
a
l
l
A
A
(12) Replace EPS moter
(12) Replace EPS moter
mast lowering operation.
lowering operation.
cable in PS inverter.
for shorting to
for shorting to t
the
he
(4) Replace EPS motor
(4) Replace EPS motor
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
(6) Remove the all cables of motor and traction inverter
(6) Remove the all cables of motor and traction inverter
terminals (P N U W )
terminals (P N U W )
Check motor terminals for shorting to the motor body
Check motor terminals for shorting to the motor body
b
b
n
n
o
o
r
r
m
m
a
a
l
l
Check the cables for shorting to the frame
Check the cables for shorting to the frame
(8) Replace EPS controller
(8) Replace EPS controller
b
b
n
n
o
o
r
r
m
m
a
a
l
l
1
1
2
2
E-27
E-27
EN and ST contactor OPEN.
Abnormal
Abnormal
N
N
o
o
t
t
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
(9) Replace EPS motor or
(9) Replace EPS motor or
cables
cables
501138
501138
2-127
2-127
s
s
h
h
o
o
r
r
t
t
i
i
n
n
g
g
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