DOWNLOAD PDF Mitsubishi Forklift Truck FB16NT FB18NT FB20NT Service Manual P.NO 99719-78110 by www.heydownloads.com

Service Manual Chassis, Mast & Options FB16NT FB18NT FB20NT

EFB12-00011-up EFB14-00011-up EFB14-50001-up

99719-78110

FOREWORD This service manual is a guide for servicing Mitsubishi forklift trucks. For your convenience the instructions are grouped by systems as a ready reference. The long productive life of your forklift trucks depend on regular and proper servicing. Servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the time of printing. Mitsubishi forklift trucks 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:

! WARNING

! CAUTION

NOTE

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury or damage to the machine. Indicates a condition that can cause damage to, or shorten service life of, the machine

Pub. No. 99719-78110

! WARNING SAFETY

! WARNING

The proper and safe lubrication and maintenance for these forklift trucks, recommended by Mitsubishi forklift truck, are outlined in the OPERATION & MAINTENANCE MANUAL.

Do not operate these trucks unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance on these trucks.

4. Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product. 2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loosefitting or torn clothing. Remove all rings from fingers when working on machinery. 3. Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 9. Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. 12. If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate” tag in the Operator’s Compartment. 14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Place wiring away from oil pipe. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position. 18. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

19. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure, must be installed correctly. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a truck if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

HOW TO USE THIS MANUAL (Removal, Installation, Assembly and Disassembly) Disassembly diagram (example)

1 Procedures are described in the text. Disassembling sequence 209603

Sequence 1 2

Cover , Bolt, Washer (part name) Snap ring ................ (part name)

Suggestion for disassembling 1. Output shaft, Removing Remove output shaft using a special tool.

209604

Service Data

Gear Backlash A: Standard Value B: Repair or Service Limit

0.11 to 0.28 mm (0.0043 to 0.0110 in.)

0.5 mm (0.020 in.)

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 Force

Pressure

Torque

SI unit

Customary unit

0.1020 kgf

(1 lbf)

(0.4536 kgf)

1 kPa

0.0102 kgf/cm2

(1 psi)

(0.0703 kgf/cm2)

1 N·m

0.1020 kgf·m

(1 lbf·ft)

(0.1383 kgf·m)

GROUP INDEX GROUP INDEX

Items

GENERAL INFORMATION

Serial number locations, Dimensions, Technical data

VEHICLE ELECTRICAL COMPONENTS

Console box, Key switch, Lamp specification chart

CONTROLLER

Controller system, Controller features, Setup option, Diagnosis, Removal and installation, Basic check

TROUBLESHOOTING FOR CONTROL CIRCUITS

Faulty central vehicle monitor system, Faulty diagnosis indication, or Other abnormalities

POWER TRAIN

Procedure and suggestions for removal and installation

MOTORS

Motor installation positions, Specifications, Structures, Tightening of highpower cable terminals, Procedures and suggestions for removal and installation, Procedures and suggestions for disassembly and reassembly

TRANSFER UNITS

Procedures and suggestions for disassembly and reassembly

REAR AXLE

Rear axle, Rear wheels

BRAKE SYSTEM

Caliper, Brake pedal, Master cylinder

STEERING SYSTEM

Steering control valve

HYDRAULIC SYSTEM

Tank, Pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve

MASTS AND FORKS

Simplex mast, Duplex mast, Triplex mast

SERVICE DATA

Inspection standards, Periodic replacement of parts, Lubrication standards, Main component weight, Tightening torque for standard bolts and nuts, Special tools

OPTIONS

Working lamp kit, Tire kit, Foot direction control

GENERAL INFORMATION 1 Vehicle Exterior ....................................................................................... Models ....................................................................................................... Serial Number Locations ...................................................................... Chassis and Mast Model Identification ............................................ Dimensions .............................................................................................. Technical Data .........................................................................................

1–1 1–1 1–2 1–3 1–4 1–5

GENERAL INFORMATION

Vehicle Exterior

211334

Models This manual applies to FB16NT, FB18NT and FB20NT.

Truck Model

Serial Number

FB16NT

EFB12-00011-up

FB18NT

EFB14-00011-up

FB20NT

EFB14-50001-up

1-1

GENERAL INFORMATION

Serial Number Locations Mast number

Chassis number

Nameplate

211335

1-2

GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis] FB

T Three wheel models Generation designator

Maximum capacity 16: 1600 kg (3500 lb) 18: 1800 kg (4000 lb) 20: 2000 kg (4400 lb) Battery type

[Mast] 2

Maximum lifting height [“30” stands for 3000 mm (118 in.)] Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 15: 1 ton class 20: 2 ton class Kind of mast G: simplex mast H: duplex mast J: triplex mast Major change (“1” for the original, “2” for the first change, and so on up to “9”)

1-3

GENERAL INFORMATION

Dimensions

B E

D A

211336

1-4

GENERAL INFORMATION

Technical Data Truck Models

FB16NT

FB18NT

FB20NT

Class

1.6 ton

1.8 ton

2.0 ton

N (kgf)/mm [lbf/in.]

15690 (1600)/500 [3000/24]

17650 (1800)/500 [3500/24]

19610 (2000)/500 [4000/24]

Truck size Length to Fork Face A

mm (in.)

1893 (74.5)

1996 (78.6)

2037 (80.2)

mm (in.)

1070 (42.1)

Height of Overhead C Guard

mm (in.)

2040 (80.3)

mm (in.)

1305 (51.4)

1410 (55.5)

Service Weight (including battery)

kg (lb)

3090 (6812)

3290 (7253)

3520 (7760)

E/F

mm (in.)

894/170 (35.2/6.7)

2/2

Front

18 × 7 × 12 1/8

Rear

15 × 5 × 11 1/4

mm (in.)

1517 (59.7)

1620 (63.8)

1645 (64.8)

17/17 (10.6/10.6) 17/15.1 (10.6/9.4)

17/17 (10.6/10.6) 17/14.4 (10.6/8.9)

17/17 (10.6/10.6) 17/13.7 (10.6/8.5)

35/27 30/13

35/25 28/12

35/23 26/11

Load Capacity/Load Center

Width

Wheelbase

Tread Front/Rear Tires Number Front/Rear Tires Size Turning Radius Travel Speeds Unloaded/Loaded

48 V 36 V

km/h (mph)

Maximum gradeability Unloaded/Loaded at 1.6 km/h (1 mph)

48 V 36 V

Lift Speed Unloaded/Loaded

48 V 36 V

m (in.)/sec

0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7) 0.56/0.40 (22.0/15.7) 0.56/0.35 (22.0/13.8) 0.56/0.34 (22.0/13.4)

Lowering Speed Unloaded/Loaded

48 V 36 V

m (in.)/sec

0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5) 0.50/0.52 (19.7/20.5) 0.56/0.40 (22.0/15.7) 0.56/0.35 (22.0/13.8) 0.56/0.34 (22.0/13.4)

Battery Voltage

Battery Rated Capacity (6 hrs.) MAX

675

600

825

720

825

720

Battery Compartment Length × Width × Height

mm (in.)

Tilt Angle (forwards-backwards)

521 × 1006 × 650 624 × 1006 × 650 624 × 1006 × 650 (20.5 × 39.6 × 25.6) (24.6 × 39.6 × 25.6) (24.6 × 39.6 × 25.6) 6°-7°

6°-7°

Traction Motor, 60 min short duty

2 × 5.0

Hydraulic Motor

Traction Motor Control Method

MOSFET

Hydraulic Motor Control Method

MOSFET

1-5

VEHICLE ELECTRICAL COMPONENTS Console Box ............................................................................................ 2 – 1 Functions of Central Vehicle Monitor System ............................................ 2 – 1 Electrical Components in Console Box ..................................................... 2 – 5 Disassembly and Reassembly .................................................................. 2 – 6

Direction Lever ........................................................................................ 2 – 7 Accelerator Control ............................................................................... 2 – 8 Key Switch ............................................................................................... 2 – 9 Lighting Switch ....................................................................................... 2 – 9 Fuses ......................................................................................................... 2 – 10 Lamp Specification Chart .................................................................... 2 – 10 Troubleshooting of Lighting and Horn Systems ............................ 2 – 11

VEHICLE ELECTRICAL COMPONENTS

Console Box 1 2 3 4 5 6

1 6

Central vehicle monitoring system (CVMS) Mode selector button Steering tilt lever Key switch Lighting switch (option) Mode check button

5 3 4

NOTE 103043

For setting the clock and selection of KPH or MPH, refer to “Selection of KPH or MPH” and “Setting the clock”.

Functions of Central Vehicle Monitor System (CVMS)

211131

Operations

No.

Monitor name

When OFF

When ON or flashing

Service indicator

Starts flashing 20 hours before set time. Remains ON when set time is reached.

Seat belt warning light

Seat belt is fastened.

Seat belt is not fastened when operator sits on seat (seat switch is turned on).

2-1

Remarks

VEHICLE ELECTRICAL COMPONENTS

No.

Monitor name

When OFF

When ON or flashing

Controller/motor overheat indicator

Controller, drive motors and Overheating pump motor in normal temperature

Remaining battery charge warning light

Normal battery condition

Remarks Overheating causes a significant output loss. When component temperature returns to normal levels, output power returns.

Flashing indicates battery needs to be recharged soon. ON indicates battery needs to be recharged and lifting function inoperable.

Brake fluid level indicator Normal fluid level

Low fluid level

Parking brake warning light

Parking brake disengaged

Parking brake engaged

Malfunction lamp

Normal

Vehicle malfunction

Speedometer 8 9

KPH, MPH

Error indicator Battery discharge indicator

When no bars show, vehicle is drivable but lifting function is inoperable.

Hour meter

1 2 3 4 5

Indicates remaining battery power.

Advances every 0.1 hour (Number advances every 6 minutes.) Hour indication

2-2

VEHICLE ELECTRICAL COMPONENTS Selection of KPH or MPH

1. Apply the parking brake. 2. Place the direction lever in NEUTRAL. Button 1

3. Turn the key switch to the I (ON) position.

Button 2

4. Push and hold button 1 for one to two seconds. NOTICE: Display will show KPH and a 24-hour clock until it is changed. When MPH is selected, the clock will change to a 12-hour clock.

Setting the clock

103043

1. Apply the parking brake. 2. Place the direction lever in NEUTRAL. 3. Turn the key switch to the I (ON) position. 4. Push and hold button 1 until the minutes’ display flashes. 5. Release button 1. 6. Adjust the minutes with button 2. 7. Push button 1 and release when the hours’ display flashes. 8. Adjust the hour with button 2. 9. Push button 1 to lock in the time.

2-3

VEHICLE ELECTRICAL COMPONENTS Error code display

Indication E

Condition Indicator flickers if seat switch is turned off during driving operation. Then, indicator turns on when seat switch is turned on again. Indicator turns off when direction lever and accelerator pedal are returned.

E 0

Right drive motor overheated

E 1

Left drive motor overheated

E 2

Pump motor overheated

E 5

Right traction inverter overheated

E 6

Left traction inverter overheated

E 7

Pump inverter overheated

H 1

Faulty setting of lift lever

H 2

Faulty setting of tilt lever

H 3

Faulty setting of attachment 1 lever

H 4

Faulty setting of attachment 2 lever

H 5

Faulty setting of attachment 3 lever

(L)

Indicator flickers if seat switch is turned off during lifting operation. Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off when lifting operation is suspended.

2-4

VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Horn cable

Monitor cable

Direction lever switch cable 1

211132

1 2

Key switch Lighting switch (option)

2-5

VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly Disassembly 7

2 6

5 4 211133

Sequence 1 2 3 4

5 6 7

Console box (front panel) Central vehicle monitor panel Direction lever Steering tilt lever

Console box (rear panel) Key switch Light switch

Disassembly procedure (1) Remove the front panel and monitor panel from the console box. (2) Disconnect the harness connectors from the horn and direction lever. (3) Remove the screw from the steering tilt lever, and remove the lever from the rear panel of the console box.

T-nut

Steering tilt lever Screw

(4) Remove the rear panel. 211134

Reassembly Follow the disassembly procedure in reverse.

2-6

VEHICLE ELECTRICAL COMPONENTS

Direction Lever Structure

4 1

211135

1 2

Lever Harness

3 4

2-7

Connector Screw

VEHICLE ELECTRICAL COMPONENTS

Accelerator Control Accelerator pedal

Initial position

Stopper bolt 1.5 to 2.5 Lock nut

Switching position of idle switch Floor plate 30 to 32 mm (1.18 to 1.26 in.)

Accelerator lever Accelerator

Adjusting screw Position meter 211136

Adjustment procedure (1) Disconnect the battery plug. (2) Set the stopper bolt to 30 to 32 mm (1.18 to 1.26 in.) from the floor to the upper face of bolt. (3) Adjust the mounting angle of the position meter using the adjusting screw so the switch inside the position meter turns on when the accelerator lever is moved 1.5° to 2.5° from the initial position. Make sure the inside switch turns ON by checking the continuity between the two terminals (indicated by arrows) by using an ohmmeter.

2-8

206805B

VEHICLE ELECTRICAL COMPONENTS

Key Switch Terminal

Connection destination

Main fuse Battery

Logic card

● (OFF)

●

I (ON)

●

206806

Lighting Switch (option) Terminal

Connection destination

Battery

Head lamps

Working lamp

OFF

●

ON (1)

●

ON (2)

●

5 2

2 5

● Head Lamp

Fuse

Working Lamp 211137

2-9

VEHICLE ELECTRICAL COMPONENTS

Fuses Capacity (A)

Location

Main connecting device

500 500

Drive motor Contactor assembly

15 10

Pump motor Key switch, Lighting switch

Fuse holder

Power relay

NOTE Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart Item Lamp

Quantity Bulb color

Bulb 36 V/48 V

Head lamps (option)

Clear

45 W

Working lamp (option)

Clear

45 W

External diagram

Remarks

205833

2-10

VEHICLE ELECTRICAL COMPONENTS

Troubleshooting of Lighting and Horn Systems

Lamps-general

e) Bulbs burnt out Will light dimly

a) Dead or weak battery b) Burned contact points in switches c) Loose terminals d) Dirty lenses e) Water drops inside lenses f) Bulbs’ service life expired

Check and recharge. Repair or replace. Retighten. Clean. Dry and replace packings. Replace.

Head lamps

a) Dead or weak battery b) Fuses blown c) Open or short in circuit d) Poor grounding

Remedy Recharge or replace. Check and replace. Repair or replace. Clean ground spot and re-make connection. Replace.

Will not light

a) Lighting switch defective b) Bulbs burnt

Replace. Replace.

Working lamp will not light

a) Working lamp switch defective

b) Bulbs burnt out

Correct if improperly installed: replace if internally defective. Replace.

Will not give blast of sound

a) Fuse blown b) Open or short in circuit c) Horn switch defective d) Horn defective e) Horn button defective

Check and replace. Repair or replace. Replace. Replace. Repair or replace.

Will give an offensive blast of sound

a) Horn switch defective b) Horn defective

Replace. Replace.

Horn

Will not light

Possible cause

Other lamps

Complaint

2-11

CONTROLLER Controller System .................................................................................. 3 – 1 System Layout .......................................................................................... 3 – 1 Controller Area Network (CAN) ................................................................. 3 – 2 Outline of Controller .................................................................................. 3 – 3

Controller Features ................................................................................ 3 – 7 Traction Features ...................................................................................... 3 – 7 Lifting Features ......................................................................................... 3 – 9 Outline Features ....................................................................................... 3 – 10

Setup Option ........................................................................................... 3 – 13 Outline ...................................................................................................... 3 – 13 Operation Procedure ................................................................................ 3 – 13 Details of Setup Options ........................................................................... 3 – 15

Diagnostics .............................................................................................. 3 – 32 Outline ...................................................................................................... 3 – 32 Operation Procedure ................................................................................ 3 – 32 Self-Diagnostics ........................................................................................ 3 – 35 Power Steering Diagnostics ....................................................................... 3 – 36 Self-Diagnostics (Power steering system).................................................. 3 – 37 Run Time Diagnostics ............................................................................... 3 – 38

Removal and Installation ...................................................................... 3 – 40 Inverter Discharging Procedure ................................................................ 3 – 40 Replacing Inverter ..................................................................................... 3 – 41 Replacing DSP (Digital Signal Processor) Card ........................................ 3 – 43 Replacing Logic Unit ................................................................................. 3 – 45 Replacing Logic Card ............................................................................... 3 – 46 Replacing Power Supply Card .................................................................. 3 – 47

Basic Check ............................................................................................. 3 – 48 Testing Tools ............................................................................................. 3 – 48 Measurement of Card Voltage .................................................................. 3 – 49 Checking Contactor Coil ........................................................................... 3 – 52 Checking Contactor Tips ........................................................................... 3 – 52 Checking Inverter ...................................................................................... 3 – 53 Regeneration Check ................................................................................. 3 – 54

AC Motor System Basics ..................................................................... 3 – 55

CONTROLLER

Controller System The inverters are connected to each motor.

System Layout

The logic unit is connected to the other devices.

Four independent controllers are linked together by the Controller Area Network (CAN) to communicate with each other to control the truck. The logic unit is the heart of the control system for the forklift trucks.

System layout

Contactors Logic Unit

Switches

Logic card

Display

Power

B2 N

Key switch F

Contactor control signal

Traveling control, Lifting control, Safety function, etc.

Lift lock solenoid control signal FC control lever

Direction lever Motor control command Accelerator

Input unit

FC lever input

Sensing data FC solenoid command

CAN bus

Right traction inverter

Left traction inverter

Pump inverter

DSP card

Sensors

Sensors U

U V

Right traction motor

Sensors

FC solenoid control signal

Output unit

FC hydraulic control valve assembly Lift lock solenoid valve

Left traction motor

Lift cylinder, Tilt cylinder

Pump motor

Hydraulic pump Contactor

Battery

Electric power 213090

3-1

CONTROLLER

Controller Area Network (CAN) Each controller is linked with the truck harness to form a network as follows. The terminal resistors are built into the right traction inverter and the pump inverter. If the terminal resistors are not properly connected, the communication failure may occur between the logic unit and the inverters. For details, see the “Traction Inverter R.H. Fault (63)”, “Traction Inverter L.H. Fault (64)” and “Pump Inverter Fault (65)” in “Troubleshooting for Control Circuits.”

Left traction inverter

Right traction inverter

Pump inverter

Logic unit

CAN H CAN L 211337

The data are expressed as electric potential difference between high- and low-level signals as follows. The signals are transferred to each controller through the serial communication protocol.

Logic

dominant

recessive

potential

Kind of bit

Vdiff

VCAN-L

Vdiff

VCAN-H recessive

dominant

recessive time 211176

Main specifications

Communication protocol

CANbus 2.0B passive

Non-Return to Zero method Broadcast communication protocol

Communication line Communication speed Data length

Dual 2-wire type serial communication 500 kbps 0 to 8 bytes

3-2

CONTROLLER

Outline of Controller 1. Logic unit This controller includes the power card and logic card. It controls all the jobs for the truck based on the operator’s input. The controller sends a motor control command to the right and left traction inverters through the input of the direction lever or the accelerator pedal. It also monitors malfunctions of the traction system. The lever input triggers to send the motor control commands to the pump inverter. It also monitors malfunctions in the hydraulic control system. The truck speed and residual battery power are monitored and shown on the display unit. The logic unit sets its model information and optional default data into internal memory. The information is secured even if the power supply for the logic unit is turned off. This information is set at the factory. The following table shows the model information. The system will not work properly if the actual controller system is different from the model information. Model information

Item Truck type Battery voltage Battery type Hydraulic control selection Mast type Valve section Battery voltage adjust Foot direction

Description Model set 36 V, 48 V Battery type MC type Mast type Number of valves Battery voltage adjustment Optional equipment

The current information is available to confirm and modify. Refer to Setup Option on page 3-13 for details and setting procedure. 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.

3-3

SUO No. #40 #41 #42 #43 #44 #45 #46 #47

CONTROLLER Logic unit

Model Serial No.

XXXXXX

211177

Logic card

CN1

Harness B side CN3

Harness B side CN2

Harness B side CN1

211178

Power supply card

16A70-00500 Ver4.3

CN1

X X X X X X MITSUBISHI HEAVY INDUSTRIES,LTD

2005.Mar.Ver4.3

Harness B side CN4

Power supply card side CN1

The Service Tool connector exists on harness B CN21. 3-4

211179

CONTROLLER

When a malfunction occurs, it stops the motors and informs to the logic unit.

2. Inverter The inverter is a motor drive controller that consists of Digital Signal Processor (DSP) card, Insulated Metal Substrate (IMS) module and their drive boards.

The DSP card has the DSP chips that enables highspeed calculation and controls the AC induction motors.

It drives the AC induction motors according to the motor control command from the logic unit. It also monitors malfunctions of motors and its own condition.

The IMS module has multiple MOS-FET modules which convert battery DC current into AC current for the traction and pump motors. See also the “AC Motor System Basics” section on page 3-55.

Traction inverter (right and left) DSP card

Model Serial No. XXXXXX

211180

Traction inverter DSP card (right and left)

XXXXXX

CN2

Harness B side, Traction Right CN7 Harness B side, Traction Left CN6

Inverter card side CN2

211181

3-5

CONTROLLER Pump inverter DSP card

Model Serial No. XXXXXX

211182

Pump inverter DSP card XXXXXX

CN2

Harness B side, Pump CN5

Inverter card side CN2

211183

3-6

CONTROLLER

Controller Features The following describes the features of controller.

Traction Features 1. Modification of traction characteristics There are two types of auto regeneration and selectable.

Acceleration power, maximum output power and battery consumption can be set. The following two parameters can be set.

Accelerator regeneration type: The regeneration starts when the accelerator pedal is released during traction.

Acceleration rate: Sets acceleration power. Traveling power: Selection of the maximum output power changes the amount of battery consumption. It also influences the acceleration power during loading operation.

Brake regeneration type:

Regeneration power and type of regeneration can be set. There are two types of regeneration and each has availability of setting for regeneration power.

Releasing the accelerator pedal during traction causes dry run. The regeneration starts when the brake pedal is pressed.

The lever regeneration starts when the travel direction and the direction lever are in opposite directions. The amount is determined by the pressure on the accelerator pedal.

Auto regeneration: Normal deceleration that occurs between the traveling and the direction lever when they are in the same direction. Lever regeneration: The deceleration that occurs between the travel and the direction lever when they are in the opposite directions. Setting feature for traction characteristics

Powering

Description Acceleration of traction Max. power, amount of battery consumption Selection of auto regeneration Rate of regeneration at normal slowdown Rate of regeneration when operating to the opposite direction

Acceleration rate Traveling power Regen function Regen adjustment for auto regen

Regeneration Regen adjustment for lever regen

SUO No. #8 #9 #21 #23 #22

Refer to page 3-13 for details and setting procedure of the “Setup Option.”

controlled roll-back function prevents hazardous descending of the truck.

The application preset feature (#1) has the preset setting pattern registered.

The descending speed changes with the steepness of grade, the weight of load and value setting of the SUO #23.

2. Controlled roll-back

NOTICE: When the regeneration is selected by SUO #21, the controlled roll-back does not work.

When the accelerator pedal is released on a grade, the 3-7

CONTROLLER

3. Boost Fully depress the accelerator pedal for 2 seconds. The boost function increases the motor maximum torque for 5 seconds. If the pressure to the accelerator pedal is reduced or the direction lever is moved, the boost function will be cancelled immediately.

When truck traveling is blocked by a step, the boost function prevents stalling of the truck. Usually the motor maximum torque is set by SUO #9, but this function allows the truck to bypass a step regardless of the value setting of the motor maximum torque. Torque [%]

required to * Torque climb over a step #9

* 100

HIGH POWER; Full acceleration

STANDARD; Full acceleration

ECONOMY; Full acceleration

Time [sec] 2

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.

4. Limitation of maximum travel speed Conditional type: The limitation that is triggered from a specific switch input occurrence.

The speed limitation is classified into two major types and available to set each maximum speed. Normal type:

Selectable quadruple input signals. Available to set a speed limit for each signal.

The limitation that functions at all times and is used to keep the speed within the limits.

Feature of maximum speed limit

Normal Conditional

Description Always effective Top travel speed limit Effective when aux. input 1 close/open Auxiliary travel speed limit 1 Effective when aux. input 2 close/open Auxiliary travel speed limit 2 Effective when aux. input 3 close/open Auxiliary travel speed limit 3 Auxiliary maximum travel speed Effective when aux. switch close/open

3-8

SUO No. Harness Pin No. – #7 CN2-30 #11, 12 CN2-40 #14, 15 CN2-41 #17, 18 CN2-31 #30, 31

CONTROLLER

5. Miscellaneous features for traction Miscellaneous features for traction

Item Auxiliary power reduction 1 Auxiliary power reduction 2 Auxiliary power reduction 3 Auxiliary output power limit Speed alarm 1 Speed alarm 2 Tire size adjustment Stall timer

Description Effective when aux. input 1 close/open Effective when aux. input 2 close/open Effective when aux. input 3 close/open Effective when aux. switch close/open Alarm 1 signal output if speed exceeds set value. Alarm 2 signal output if speed exceeds set value. Correction value to compensate for a diameter change resulting from tire wear Stops traction motor to protect if truck does not move within set time.

SUO No. Harness Pin No. CN2-30 #11, 13 CN2-40 #14, 16 CN2-41 #17, 19 CN2-31 #30, 32 CN1-61 #26 CN1-62 #34 – #27 #20

–

Lifting Features 1. Setting and limitation of lift work speed Each lift work speed can be set. The lift work speed can be limited or stopped when specific switch input occurs. Triple input signals are selectable and available to set limit value to each signal.

Feature of lifting work speed setting

Normal

Conditional

Start lift speed Top lift speed Lowering lift speed Tilt speed Auxiliary 1 speed Auxiliary 2 speed Auxiliary 3 speed Auxiliary input for lift 1 Auxiliary input for lift 2 Auxiliary input for lift 3

Description Start lift speed setting Top lift speed setting Lowering lift speed setting Tilt speed setting Attachment 1 Attachment 2 Attachment 3 Stops lift when aux. input 1 close/open Stops lift when aux. input 2 close/open Stops lift when aux. input 3 close/open

Refer to page 3-13 for details and setting procedure of the “Setup Option.” The application preset feature (#1) has the preset setting pattern registered.

3-9

SUO No. Harness Pin No. – #2 – #3 – #35 – #4 – #5 – #6 – #33 CN2-30 #11 CN2-40 #14 CN2-41 #17

CONTROLLER

Outline Features two additional modes: the mode related to truck failure and the mode for setting the truck parameter as shown in the table below.

1. Diagnostics/Run/Setup (DRS) modes In addition to the normal operation mode for controlling the traveling and lifting operations, the controller has DRS modes

Mode Self diagnostics Diagnostics

Description Performs failure diagnostics of each equipment. Displays and deletes fault data that were detected and stored in normal operation mode. Normal operation mode Sets default data of Group 1 & Group 2. Sets basic function (#1 to #10). Sets detailed function (#11 to #35). Sets model information (#40 to #47)

Run time diagnostics –

Run Default data set Group 1 data set Group 2 data set Group 3 data set

Setup

Refer to page 3-13 for details and setting procedure of the “Setup Option.” Also, refer to page 3-32 for details and setting procedure of the “Diagnostics.”

R DRS switch D

DRS switch is installed under floor plate at right side of truck.

211186

2. IPS (Integrated Presence System) features which provides “certain product intelligence” to the operator. The table shows processes for traction and lifting. Refer to the Status Transfer Chart for details.

This controller is part of the “Integrated Presence System” (IPS) of the truck. This system features an enhanced, integral computer based feed back system IPS features

Protect condition Traction control Hydraulic control

Seat

Sit → Leave

Direction lever

F or R

Result Slowdown and Stop

Seat

Sit → Leave

Stop

3-10

Release method Sit Direction lever: N Accelerator pedal: Release Sit Control valve SW: All open

CONTROLLER Status transfer chart Seat SW

Traction Control IPS

Seat Sw flag: ON

Normal operation

Seat SW off time Delay time 2 sec or 3 sec

Seat Sw flag : OFF

Seat SW flag: OFF Seat SW: ON

Direction lever: N (Chosen foot direction: no effect) Seat SW flag: OFF Travel speed 0.5km/h

Motor: Regen brake Display: Blinking "E" Seat SW flag: OFF

Motor: Zero torque Display: Blinking "E" Line Contactor OFF

Seat SW flag: ON

Motor: Regen brake Display: "E"

Seat SW flag: OFF

Direction lever: N Accelerator pedal: OFF

Travel speed

0.5km/h

Seat SW flag: ON

Motor: Zero torque Display: "E" Line Contactor OFF

Direction lever: N Accelerator pedal: OFF

Hydraulic Control IPS

Seat SW Seat Sw flag: ON

Seat SW: ON

Seat SW off time Delay time 2 sec or 3 sec

Seat Sw flag : OFF

Normal operation Seat SW flag: OFF

Lift lock valve: LOCK Unload valve: UNLOAD Display: Blinking "L" Seat SW flag: ON Seat SW flag: OFF

Lift lock valve: LOCK Unload valve: UNLOAD Display: "H1 to H5"

Control valve SW: All off (LIFT lever doesn't have SW to detect DOWN.)

3-11

211338

CONTROLLER

3. BDI display features This feature shows with 11 levels (BDI 0 to BDI 10) of remaining battery capacity of the current battery voltage. Set #41 or #42 depends on installed battery type and voltage. For further details, see OMM.

4. Warning buzzer features • 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.

5. Miscellaneous features The table shows miscellaneous features. Miscellaneous features

Item Service indicator

Display unit

Description Shows or warns maintenance time. Speed, error code, hour-meter, BDI, etc. are shown depending on DRS mode. Diag. mode: Refer to Operation on page 3-32. Run mode: Normal operation mode. Setup mode:Refer to Operation on page 3-13.

3-12

SUO No. #10

–

CONTROLLER

Setup Option

off.

Outline

The model information and various features are set before factory shipment.

The logic unit is equipped with a memory module that retains recorded data even if the main power is turned

The setup options are categorized from Group 1 to Group 3 according to the feature levels.

Setup group

Group Group 1 Group 2 Group 3

Description Basic function (#1 to #10) Detailed function (#11 to #35) Model information (#40 to #47)

The Group 1 and 2 are available to set the default value in a one-step operation and can be customized in accordance with applications. Since the Group 3 is for 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.

each setup mode.

When setting the setup option data for the first time after the assembly is completed or the logic card is replaced, be sure to set Group 3 data first, then the default data of Group 1 and 2, with the “service tool” in

Turning on the key switch allows you to enter one of the modes in each setup group and shows as the figure. You can not transfer to another mode unless the source power is turned off.

Summary list in each group is shown on page 3-28 to 331.

Operation Procedure

Entry to setup mode

Function

Description

Default data set

Sets default data of Group 1 & Group 2. Checks and sets basic function (#1 to #10). Checks and sets detailed function (#11 to #35). Checks and sets model information (#40 to #47).

Group 1 data Group 2 data Group 3 data

DRS switch S S S S

Seat Not seated Not seated Not seated Not seated

Direction lever

Accel. pedal

Lift lever

Tilt lever

Attachment 1 lever

OFF

Pull back

OFF

Pull back

First SUO # of each group “01” for group 1 “11” for group 2 “40” for group 3

Current set value for SUO #11* donE flashes for default data set.

209558

First SUO # of Group 2 setup options (example)

*The current value is displayed. For the meaning of each number or symbol displayed, refer to the “Range” column of the relevant Setup Options table and Notes below the table. 3-13

CONTROLLER Selecting SUO # and changing set value

How to change set value

The set value change procedure consists of selecting the desired SUO # using the DRS switch, changing the set value by moving the direction lever, and registering the new value. • Cycle the DRS switch S → R → S. The set value 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 overwriting the previous value with the value on the screen (registering). When the value is registered, a set of three dotted lines appears on the screen as shown in the illustration on the right. The second half of the operation (R→S) is for advancing the SUO #. • 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. • Use the direction lever to change the set value. The 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.

When changing setting of SUO #20 (stall timer) from default 5 seconds to 3 seconds: Step 1. Since SUO #20 belongs to Group 2 setup options, the first SUO # “11” of the group appears on the screen when using the operation procedure on page 3-13.

Step 2. Move the DRS switch as follows to change the current setting for the SUO #20. S

(1) Move the DRS switch S →R. The display changes as shown below. The set value (0) for the SUO #11 is overwritten simultaneously.

Pull

(2) Move the DRS switch R →S. The display shows the current setting for the next SUO #12.

Pull

(3) Cycle the DRS switch S→R→S 8 times to cause the SUO #20 to appear on the screen.

Default value 5 for SUO #20 Step 3. Change the set value from 5 to 3 by moving the direction lever N→R twice. Direction lever F

Value increases.

N R

Value decreases.

Step 4. Register the new value by cycling the DRS switch S → R → S. The current value is overwritten with the new value. The screen shows the next SUO #21. 213091

3-14

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 (#40 EE type : C only) . •

48V type mode setting

Mode Feature/ Application

b HIGH STANDARD POWER Fast Medium Lift Medium Medium Tilt Fast Medium Vehicle speed Characteristic Fast Medium Acceleration Powerful Standard Power High Medium Regeneration 1 1 Start Lift Speed 10 6 Top Lift Speed 7 5 Tilt Speed 17 15 Max Vehicle Speed Default value 5 3 Acceleration Rate 3 2 Traveling Power Automatic 9 5 Regeneration A

You can modify these 7 settings afterwards individually. When settings are changed, the indication (A to E) flashes to indicate that the settings are modified.

3-15

Slow Medium Slow Medium Economy Low 1 3 5 12 2 1

d LONG DISTANCE Medium Medium Fast Medium Powerful Medium 1 6 7 17 3 3

E SHORT SHUTTLE Medium Medium Medium Fast Standard High 1 6 7 15 5 2

C ECONOMY

SUO# 1

2 3 4 7 8 9 23

CONTROLLER

•

36V type mode setting

Mode Feature/ Application

b HIGH STANDARD POWER Fast Medium Lift Medium Medium Tilt Fast Medium Vehicle speed Characteristic Medium Medium Acceleration Powerful Standard Power High Medium Regeneration 1 1 Start Lift Speed 10 6 Top Lift Speed 7 5 Tilt Speed 17 15 Max Vehicle Speed Default value 3 3 Acceleration Rate 3 2 Traveling Power Automatic 9 5 Regeneration A

#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 in the rise direction will become faster if the setting value is increased. The setting range is 1 to 10 (#40 EE type : 1 to 8).

3-16

Slow Medium Slow Medium Economy Low 1 3 5 12 2 1

d LONG DISTANCE Medium Medium Fast Medium Powerful Medium 1 6 7 17 3 3

E SHORT SHUTTLE Medium Medium Medium Medium Standard High 1 6 7 13 3 2

C ECONOMY

SUO# 1

2 3 4 7 8 9 23

CONTROLLER #3 Top Lift Speed

Pump motor output [%]

This setting affects pump speed and FC solenoid current when you pull the lift lever. If you set a smaller value than #2, then the #2 setting will be ignored.

SUO #3 100

FC spec: speed when the lift lever is pulled

10 9 8

MC spec: speed when lift switch 2 is turned on SUO #2

Lifting speed will become faster if the value setting is increased. The setting range is 1 to 10 (#40 EE type : 1 to 8). 0

SW1

SW2

Lever operation 209553

Pump motor output characteristics (Lift-up operation)

#4 Tilt Speed Pump motor output [%]

This setting affects pump speed and FC solenoid current when you operate the tilt lever or tilt switch. Tilt speed will be faster if the value setting is increased. The setting range is 2 to 10 (#40 EE type : 1 to 7). Tilt speed has priority over lifting speed, when the two levers are operated simultaneously.

SUO #5, #6, #33 10

100

2 1 0

SW Close

Lever operation 209554

Pump motor output characteristics (Tilt and attachment 1, 2 and 3 operations)

3-17

CONTROLLER #5 Auxiliary 1 Speed

This setting affects pump speed and FC solenoid current when you operate the attachment 1 lever or attachment 1 switch. Attachment 1 speed will become faster if the value setting is increased. The setting range is 1 to 10. #6 Auxiliary 2 Speed

This setting affects pump speed and FC solenoid current when you operate the attachment 2 lever or attachment 2 switch. Characteristic is almost the same as auxiliary 1. Attachment 2 speed will become faster if the value setting is increased. The setting range is 1 to 10. #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. The setting range is 5 to 17 [km/h] (#40 EE type : 5 to 13) #8 Acceleration Rate

This setting affects response time to calculate torque order from accelerator pedal position. Acceleration of trucks becomes faster if the value setting is increased. The setting range is 1 to 5 (#40 EE type : 1 to 3)

3-18

CONTROLLER #9 Traveling Power

This setting affects torque order which is calculated from accelerator pedal position.

The figure is a torque characteristic at the time of Powering.

The values are selected from three types : ECONOMY, STANDARD and HIGH POWER (#40 EE type : ECONOMY only).

Torque [%] 100 85 70

HIGH POWER(3) STANDARD(2) ECONOMY(1) Brake limit*1 (48V: 40%, 36V: 52%) Thermal, BDI [0] or Service indicator*2 (48V: 32%, 36V: 42%)

Speed (km/h) 211190

Brake limit : Torque value resulting from reduction in current when the service brake or parking brake is applied.

Thermal, BDI [0] or Service indicator : Curve of limited torque under a condition of overheating or battery voltage low or maintenance time over.

#10 Service Indicator

This setting sets the maintenance time. The time set here is added to the truck’s hour meter and that value is stored in memory as the “maintenance time.”

You can reduce the truck power when the LED flashes by setting the service indicator selection. You can also set the demo-mode, which shows the Service Indicator function in a short period of time.

When the truck’s hour meter reaches maintenance time, the service reminder LED turns on.

The setting value is as follows.

It will flash 20 hours before the time. Maintenance time [hour] Invalid Set data on display Only warning Torque limit

–

6 min (test)

100

150

In increments of 50

950

1000

0.1 =0.1

100 =100

150 =150

····· ·····

950 =950

1000 =1000

The present hour meter time will be registered if the DRS switch is operated after the display of #10.

3-19

CONTROLLER

2. Setup Options (Group-2) #11 Auxiliary Input for Lift and Drive Speed 1 (Harness pin No. CN2-30)

This setting defines the function of “Auxiliary 1” switch. This value has an effect on #12 and #13 when 2, 3, 5 or 6 is selected. The setting value is as follows. Value 0 1 2 3 4 5 6 *1

Travel – – Speed limit (switch closed) Power reduction (switch closed) – Speed limit (switch opened) Power reduction (switch closed)

Lift – Stop lift *1 (switch closed) – – Stop lift (switch opened) – –

Lever is returned to neutral. Lift moves with operating lever again.

#12 Auxiliary Travel Speed Limit 1 (Harness pin No. CN2-30)

#16 Auxiliary Power Reduction 2 (Harness pin No. CN2-40)

This setting defines maximum speed when the “Auxiliary 1” switch is closed or opened.

This setting defines traction power reduction when the “Auxiliary 2” switch is closed or opened.

The setting range is 5 to 17 [km/h]. Effective when the data of #11 is 2 or 5.

The setting range is 0 to 100 [%]. Effective when the data of #14 is 3 or 6.

#13 Auxiliary Power Reduction 1 (Harness pin No. CN2-30)

This setting defines traction power reduction when the “Auxiliary 1” switch is closed or opened. The setting range is 0 to 100 [%]. Effective when the data of #11 is 3 or 6. #14 Auxiliary Input for Lift and Drive Speed 2 (Harness pin No. CN2-40)

This setting defines the function of “Auxiliary 2” switch. This value has an effect on #15 and #16 when 2, 3, 5 or 6 is selected. The setting value is the same as that of #11. #15 Auxiliary Travel Speed Limit 2 (Harness pin No. CN2-40)

This setting defines maximum speed when the “Auxiliary 2” switch is closed or opened. The setting range is 5 to 17 [km/h]. Effective when the data of #14 is 2 or 5. 3-20

CONTROLLER #17 Auxiliary Input for Lift and Drive Speed 3 (Harness pin No. CN2-41)

This setting defines the function of “Auxiliary 3” switch. This value has an effect on #18 and #19 when 2, 3, 5 or 6 is selected. The setting value is the same as that of #11. #18 Auxiliary Travel Speed Limit 3 (Harness pin No. CN2-41)

This setting defines maximum speed when the “Auxiliary 3” switch is closed or opened. The setting range is 5 to 17 [km/h]. Effective when the data of #17 is 2 or 5. #19 Auxiliary Power Reduction 3 (Harness pin No. CN2-41)

This setting defines traction power reduction when the “Auxiliary 3” switch is closed or opened. The setting range is 0 to 100 [%]. Effective when the data of #17 is 3 or 6. #20 Stall Timer

This setting shuts down the truck when the traction motor torque is high and it continues for preset time. This function is used to detect pulse sensor faults and to prevent the controller from overheating. The setting range is 2 to 10 [second]. #21 Regen Function

This setting defines which regeneration function is activated. One is “Brake regen.” “Brake regen” will be applied while “the brake pedal is pressed” and “the accelerator pedal is released.” The other is “Accelerator regen.” “Accelerator regen” will be applied while “the accelerator pedal is released.” In any case, deceleration torque is constant and defined by #23. These two regeneration functions are collectively termed “Auto regen.”

3-21

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.

(%) 100

Amount of lever regeneration

Value of #22 1

100 Level of throttle pedal [%] 213092

Amount of deceleration relative to setting “1” is about 60% of maximum (Setting “10”). “Lever regen” function is available regardless of the #21 setting. Amount of deceleration when the accelerator pedal is released is determined by #23.

3-22

CONTROLLER #23 Regen Adjustment for Auto Regen

Amount of auto regeneration [%] 100 Accelerator regen

This setting defines amount of deceleration when “Auto regen” is activated. Amount of deceleration relative to setting “1” is about 40% of maximum (Setting “10”). The setting range is 1 to 10 (#40 EE type : 1 to 7).

1 2 3 4 5 6 7 8 9 10 Value of #23 211400

Truck speed [m/s]

Brake regen

Accelerator regen

#23 10 9

Truck speed [km/h]

Time [s] 213093

211192

#26 Speed Alarm 1 (Harness Pin No. CN1-61)

This setting defines speed of turning on “Speed alarm 1” light. The setting range is 5 to 17 [km/h]. #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 range setting is 0 to 40. This allows fitting a bigger diameter wheel.

3-23

CONTROLLER #30 Auxiliary Input for Travel Speed (Harness Pin No. CN2-31)

This setting defines the function of “Speed Limit” switch. According to the combination of #30, #31 and #32, you can reduce travel speed or traction power (torque). Value 0 1 2 3 4

Travel speed – Speed limit (switch closed) – Speed limit (switch opened) –

Traction power – – Power reduction (switch closed) – Power reduction (switch opened)

#31 Auxiliary Maximum Travel Speed Setting (Harness Pin No. CN2-31)

This setting defines the maximum travel speed when the speed limit function is activated by #30. The range setting is 5 to 17 [km/h]. #32 Auxiliary Output Power Limit (Harness Pin No. CN2-31)

This setting defines the maximum traction power (torque) when speed limit function is activated by #30. This value means a proportion of output torque to normal condition. The setting range is 0 to 100 [%]. #33 Auxiliary 3 Speed

This setting affects pump speed when you operate the attachment 3 lever. MC spec: Speed when attachment 3 switch is turned on Characteristic is almost the same as tilt. Attachment 3 speed will become faster if the setting value is increased. The range setting is 1 to 10. #34 Speed Alarm 2 (Harness Pin No. CN1-62)

This setting defines speed of turning on “Speed alarm 2” light. The setting range is 5 to 17 [km/h].

3-24

CONTROLLER

3. Setup Options (Group-3) #40 Truck Type

This setting defines the type of truck. The setting value is as follows. Display value II II II II II P16:3 P16:3.E P18:3 P18:3.E P20:3 P20:3.E P16 P18 P20:C

Model No setting FB16NT FB16NTEE FB18NT FB18NTEE FB20NT FB20NTEE FB16N FB18N FB20CN

! 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.”

3-25

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

BDI# 0 1 2 3 4 5 6 7 8 9 10

36V – 34.4 34.5 – 34.8 34.9 – 35.2 35.3 – 35.6 35.7 – 36.0 36.1 – 36.4 36.5 – 36.7 36.8 – 37.0 37.1 – 37.3 37.4 – 37.6 37.7 –

Tubular BDI

48V – 45.9 46.0 – 46.4 46.5 – 46.9 47.0 – 47.4 47.5 – 47.9 48.0 – 48.4 48.5 – 48.9 49.0 – 49.8 49.4 – 49.7 49.8 – 50.1 50.2 –

BDI# 0 1 2 3 4 5 6 7 8 9 10

Reserve BDI

BDI# 0 1 2 3 4 5 6 7 8 9 10

36V – – – – – – – – – – –

48V – – – – – – – – – – –

3-26

36V – 35.2 35.3 – 35.5 35.6 – 35.8 35.9 – 36.1 36.2 – 36.4 36.5 – 36.7 36.8 – 37.0 37.1 – 37.2 37.3 – 37.4 37.5 – 37.6 37.7 –

48V – 46.9 47.0 – 47.3 47.4 – 47.7 47.8 – 48.1 48.2 – 48.5 48.6 – 48.9 49.0 – 49.2 49.3 – 49.5 49.6 – 49.8 49.9 – 50.1 50.2 –

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 which the controller recognizes, and actual battery voltage. The display shows battery voltage which the controller recognizes.

1: MC system #44 Mast Type

This setting defines the type of the mast.

Measure actual battery voltage using a tester (or a multi-meter) and operate the direction lever to adjust the value.

2-FF: 2-stage full-free 3-FF: 3-stage full-free 2-SP: 2-stage panorama

Refer to the “Measurement of battery voltage” below. #45 Valve Section

This setting defines the number of valve sections. 1: 3ways (lift, tilt, attachment 1) 2: 4ways (lift, tilt, attachment 1, 2) 3: 5ways (lift, tilt, attachment 1 to 3) Accelerator pedal – – Release → depress Release → depress

Direction lever N→F N→R F R

Pump contactor

Value change [V] +0.1 –0.1 +10 –10

Line contactor

Contactor

Battery 49.6V V

Set 49.6 on display.

Tester or Multi-meter Right traction inverter

211327

Measurement of battery voltage #47 Foot Direction

This setting defines the foot direction option. 1: Standard direction lever 2: Foot Directional Control (FoDiCo) 3-27

CONTROLLER Setup Options (Group 1)

Option #

#3 #4 #5 #6 #7 #8 #9

#10

NOTICE:

Title of Option

Description

Range

The value setting of the following 7 items are registered beforehand. Top travel speed, Acceleration rate, Application Pre-Sets A, b, C, d, E (Truck Operation Mode) Traveling power, Regen adjustment, Start (1) lift speed, Top lift speed, Tilt speed. Refer to the explanation for details. Beginning lift speed Start lift speed cannot exceed top lift 1 to 10 Start Lift Speed speed. (1: SLOW → 10: FAST) Lift speed when operating the lever at 1 to 10 Top Lift Speed maximum Speed setting for tilt 1 to 10 Tilt Speed Speed setting for attachment 1 1 to 10 Auxiliary 1 Speed Speed setting for attachment 2 1 to 10 Auxiliary 2 Speed 5 to 17 [km/h] Top Travel Speed Limit Maximum travel speed Choice of acceleration rate 1 to 5 Acceleration Rate (1: SLOW → 5: FAST) Choice of power characteristic (1: ECONOMY, 2: STANDARD, 3: HIGH 1, 2, 3 Traveling Power 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 Approached: !LED flashes (20 hour) (In increments of 50 [hour]) Service Indicator Passed :!LED turn on “=”: power reduction and power reduction (selected) 0: no action (2) Refer to the explanation for details.

Default Value

6 5 3 1 15 3 2

(1) Before changing, when parameter data are different from the values of the selected mode, the truck mode indicator (A to E) flashes. 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.

3-28

CONTROLLER Setup Options (Group 2)

Option #

#11

Title of Option

Range

Description

When the auxiliary input 1 signal is on, travel speed or lift speed is limited to set value. Auxiliary Input for The amount of maximum speed is defined at #12. Lift and Drive The amount of power reduction is Speed 1 defined at #13.

Default Harness Value Pin No.

0: Disable 1: Disable lift (switch closed) 2: Speed limit (switch closed) 3: Power reduction (switch closed) 4: Disable lift (switch opened) 5: Speed limit (switch opened) 6: Power reduction (switch opened)

CN2-30

#12

Auxiliary Travel Speed Limit 1

Travel speed limit for #11

5 to 17 [km/h]

CN2-30

#13

Auxiliary Power Reduction 1

Traction power reduction ratio for #11

0 to 100 [%]

CN2-30

#14

When the auxiliary input 2 signal is on, travel speed or lift speed is limited to Auxiliary Input for set value. The amount of maximum speed is Lift and Drive defined at #15. Speed 2 The amount of power reduction is defined at #16.

Same as #11

CN2-40

#15

Auxiliary Travel Speed Limit 2

Travel speed limit for #14

5 to 17 [km/h]

CN2-40

#16

Auxiliary Power Reduction 2

Traction power reduction ratio for #14

0 to 100 [%]

CN2-40

#17

When the auxiliary input 3 signal is on, travel speed or lift speed is limited to Auxiliary Input for set value. The amount of maximum speed is Lift and Drive defined at #18. Speed 3 The amount of power reduction is defined at #19.

Same as #11

CN2-41

#18

Auxiliary Travel Speed Limit 3

Travel speed limit for #17

5 to 17 [km/h]

CN2-41

#19

Auxiliary Power Reduction 3

Power reduction ratio for #17

0 to 100 [%]

CN2-41

Stall Timer

This option allows to shut down truck when the traction motor torque is too high.

2 to 10 [sec]

–

#20

3-29

CONTROLLER

Option # #21

#22 #23

Title of Option

Regen Function Regen Adjustment for Lever Regen Regen Adjustment for Auto Regen

Default Harness Value Pin No.

Description

Range

This option enables one of two Regen Modes.

1: Brake regen (accel must be off) 2: Accelerator regen (also called “auto regen”)

–

10 steps for regen power on lever regen

1 to 10

–

10 steps for regen power on brake/accelerator regen

1 to 10

–

#26

Speed Alarm 1

Sets speed for turning on alarm 1 light.

5 to 17 [km/h]

CN1-61, max.1A

#27

Tire Size Adjustment

Adjusts the amount of tire wear. It changes truck’s speed recognition.

0 to 40

–

#30

Auxiliary Input for Travel Speed

When the auxiliary input signal is on, travel speed or traction power is limited at value of set. The amount of maximum speed is defined at #31. The amount of power reduction is defined at #32.

0: Disabled 1: Travel speed limit (switch closed) 2: Power reduction (switch closed) 3: Travel speed limit (switch opened) 4: Power reduction (switch opened)

CN2-31

#31

Auxiliary Maximum Travel Speed Setting

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

5 to 17 [km/h]

CN2-31

#32

Auxiliary Output Power Limit

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

0 to 100 [%]

CN2-31

#33

Auxiliary 3 Speed

Speed setting for attachment 3

1 to 10

–

#34

Speed Alarm 2

Sets speed for turning on alarm 2 light.

5 to 17 [km/h]

CN1-62, max.1A

3-30

CONTROLLER Setup Options (Group 3)

Option #

Title of Option

#40

Truck Type

#41

Battery Voltage

#42

Battery Type

#43

Hydraulic Control Selection

This option is used to set the size and type of the truck. Refer to the explanation for details. This option is used to set the voltage of the battery. This option is used to set the type of the battery. The electric discharge characteristic of a battery changes with battery type. This option is used to set the type of the hydraulic control.

#44

Mast Type

This option is used to set the type of the mast.

#45

Valve Section

This option is used to set the number of valve sections.

#46

Battery Voltage Adjust

#47

Foot Direction

NOTICE:

Range

Default Value

P16:3 (FB16NT) to P20:C (FB20CN) 9 pattern

–

36, 48 [V]

–

0: Normal BDI 1: Tubular BDI 2: Reserve BDI

–

1: MC specification

–

Description

2FF: 2-stage full-free 3FF: 3-stage full-free 2SP: 2-stage panorama 1: 3ways (lift, tilt, attachment 1) 2: 4ways (lift, tilt, attachment 1,2) 3: 5ways (lift, tilt, attachment 1-3)

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 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 2: Foot Directional Control for foot direction option. (FoDiCo)

–

(1) The data of a 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 a 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.

3-31

CONTROLLER

Diagnostics Outline The controller monitors status of various input/output equipment to allow diagnostics of truck’s malfunction. There are two types of diagnostics: Run Time Diagnostics, diagnostics during normal operation, and Self Diagnostics, performing equipment check during maintenance. Diagnostics

Diagnostics

Mode Self diagnostics Run time diagnostics

Description Checks function of electrical systems. Diagnostics during normal operation.

The logic unit is equipped with a memory module that retains recorded data even if the main power is turned off. The errors occurring during truck use are compared with the Run Time Diagnostics and recorded so as to be able to show. Self diagnostics that exclusively checks the power steering system is also available.

Operation Procedure Turning on the key switch allows to enter each diagnostics mode. You can not transfer to another mode unless the source power is turned off. Entry to diagnostics mode

DRS switch

Seat

Lift lever

Tilt lever

Self diagnostics

–

Run time diagnostics

Not seated

Function

3-32

Note When run time diagnostics can not be performed

CONTROLLER

Perform diagnostics using the following procedure. 1. Preparatory operations

(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 3-40. (5) Place the direction lever in the N position. (6) Set the DRS switch to the D (diagnostics) position. R

(7) Remove the line fuse and pump fuse (500 A).

(8) Connect the battery plug. Pull

2. Diagnostics procedure

Perform the procedure using the Self-Diagnostics table in accordance with the following guide. (1) Start diagnostics with the Step 0 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 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 diagnostics is started without removing the fuse. In this case, diagnostics is prohibited from going even to the first step.

211195

Diagnostics result indication

(2) When the Step 0 has passed the check, diagnostics may advance to the 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 step fails in the check, diagnostics does not advance automatically. In this case, diagnostics can be forcibly advanced to the next step by cycling the DRS switch D→R→D.

209561

3-33

CONTROLLER

(3) When all the steps have been checked through, turn OFF the key switch and place the DRS switch in the R position. Do not forget to reinstall the 500 A line fuse and pump fuse.

R D

Pull

• Turn OFF the key switch to exit from the diagnostics mode. • Repair all faults found immediately after diagnostics. Diagnostics procedure requires moving the DRS switch to the D or R position. Follow the instructions in the diagnostics procedure guide above as well as those in the applicable boxes in the “Do this” column.

211196

3. Fault Data Record of Run Time Diagnostics

When the fault is detected by the Run Time Diagnostics, the fault data will be stored in the memory of the logic card. 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.

Battery discharge indicator at the time of fault

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 data items stored for the fault, “donE” will appear.

Vehicle hourmeter reading 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 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 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 to the S position. When all the stored data have been deleted, “donE” flashes. Never turn off the key switch until “donE” flashes. 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. 3-34

Error code

After all the fault data are reviewed or when there are no data items stored for the fault, "donE" will appear. When all the stored data have been deleted, "donE" flashes. 211413

CONTROLLER

Self-Diagnostics Step

Checking

Power line voltage (Fuse check)

Seat switch

Direction switch

Parking brake

Service brake

Accelerator

Do this Turn on key switch.

Controller check this Close line contactor and check power line voltage.

Lift switch

Pull and release lift lever.

Tilt switch

Pull and release tilt lever.

Auxiliary 1 switch Auxiliary 2 switch Auxiliary 3 switch

Pull and release Aux. 1 lever. Pull and release Aux. 2 lever. Pull and release Aux. 3 lever. Pull any lever and see display. RUN → DIAG → RUN

Hydraulic speed check

Line contactor

Pump contactor Controller software version

Fail -

Present steering wheel SW Steering sensor information is shown.

Fail

Pass

Battery voltage Automatic

Depress accelerator and release.

Pass

Pass Fail Pass Fail Pass Fail Pass Fail

Pass

RUN → DIAG → RUN

Display

Release & press & release Input seat SW. OFF → ON → OFF Cycle direction lever. Input changes as N→R→N→F→N N→R→N→F→N Release & apply & release Input parking brake. OFF → ON → OFF Depress and release Input service brake. OFF → ON → OFF

DIAG → RUN 6

Result

Check battery voltage: (34V-51V) Input OFF → ON → OFF Input OFF → ON → OFF Input OFF → ON → OFF Input OFF → ON → OFF Input OFF → ON → OFF

RUN → DIAG

See line contactor close.

DIAG → RUN

See line contactor open.

RUN → DIAG

See pump contactor close. See pump contactor open.

DIAG → RUN RUN → DIAG → RUN

See software version No. in hourmeter. 3-35

Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail Pass Fail -

Motion Line contactor closes and opens. Line contactor closes and doesn’t open.

02 01 03 02 04 03 05 04 Number 0 to 15 flashes as accelerator is pressed. 06 Number r7-r1, 0, L1-L7 flashes as steering is rotated. 07 08 07 09 08 10 09 11 10 12 11 13 12 Flashing pump speed value Other than above 14 Contactor closes 14 No operation 14 Contactor opens 15 No operation 15 Contactor closes 15 No operation 15 Contactor opens 98 No operation 98 donE

CONTROLLER

Power Steering Diagnostics Perform power steering diagnostics using the following procedure. 1. Preparatory operations

(7) Remove the pump fuse (500 A).

(8) Connect the battery plug.

Pull

2. Diagnostics procedure

Perform the procedure using the Self-Diagnostics (Power steering system) table in accordance with the following guide. 211195

(1) Start diagnostics with the Step 0 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 number “20” 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 diagnostics is started without removing the fuse. In this case, diagnostics is prohibited from going even to the first step.

Diagnostics result indication

(2) When the Step 0 has passed the check, diagnostics may advance to the Step 20 item (steering sensor). Check the steering sensor according to the instruction in the “Do this” box on the Step 20 line.

213094

(3) When all the steps have been checked through, turn OFF the key switch and place the DRS switch in the R position. Do not forget to reinstall the pump fuse.

R S

D Pull

211196

3-36

CONTROLLER

Self-Diagnostics (Power steering system) Step

Checking

Power line voltage (Fuse check)

Do this Turn on key switch.

Controller check this

Result

Close line contactor and

Pass

check power line voltage.

Present steering wheel SW Steering sensor information is shown.

Fail Pass Fail -

RUN → DIAG → RUN

3-37

Motion Line contactor 20 closes and opens. Line contactor closes dd and doesn’t open. Number r7-rl, 0, L1-L7 flashes as steering is rotated. Display

CONTROLLER

Run Time Diagnostics

How to detect

Traction Motor R.H., Overheating

Thermistor (145°C, -25°C)

Traction Motor L.H., Overheating

Thermistor (145°C, -25°C)

Pump Motor, Overheating

Thermistor (135°C, -25°C) Thermistor (IMS 100°C, -25°C, Capacitor 110°C, -25°C) Thermistor (IMS 100°C, -25°C, Capacitor 110°C, -25°C) Thermistor (IMS 100°C, -25°C, Capacitor 110°C, -25°C)

Traction Inverter R.H., Overheating Traction Inverter L.H., Overheating Pump Inverter, Overheating Brake Oil, Low Level Traction Motor Current Sensor R.H. Fault Traction Motor R.H., Over-current Traction Motor R.H., Stall Timer Traction Motor Current Sensor L.H. Fault Traction Motor L.H., Over-current Traction Motor L.H., Stall Timer Pump Motor Current Sensor Fault Pump Motor Over-current Line Contactor Fault Pump Contactor Fault Traction Motor R.H. Open Traction Motor L.H. Open Pump Motor Open Steering Sensor Fault Accelerator Sensor Fault Traction Motor R.H. Pulse Input Fault Traction Motor L.H. Pulse Input Fault

Power reduction

Cool

Power reduction

Cool

Power reduction

Cool

Power reduction

Cool

Power reduction

Cool

Power reduction

Cool Turn key off Turn key off

Line contactor off Pump contactor hold

Turn key off

* * * * * *

Turn key off

Line contactor off Pump contactor hold Line contactor off Pump contactor hold Line contactor off Pump contactor off

Indicate if it possible

Turn key off Turn key off

Line contactor off Pump contactor off Line contactor off Pump contactor off

* More than 492 Amps (1.6 ms), 557 Amps (1 ms) * Measure time (set by SUO #20) while stalling * Out of normal range * More than 492 Amps (1.6 ms), 557 Amps (1 ms) * Measure time (set by SUO #20) while stalling * Out of normal range * More than 985 Amps (1.6 ms), * 1115 Amps (1.0 ms) Check voltage of power circuit * Check voltage of power circuit * Traction R.H. Motor Open * Traction L.H. Motor Open * Pump Motor Open * Sensor output is 0 or intermittent * (More than 10V) Accel SW ON: Below 0.3V Accel SW OFF: More than 1.41V/Below 0.2V, More than 4.8V Out of normal range (5800 rpm)

Display Communication Fault

When serial communication is not going on SUO Gr. #3 and default setting are not set Parity check of SUO data Sum check of ROM and RAM

To return to normal

Line contactor off(*) Pump contactor hold Line contactor off Pump contactor hold Line contactor off Pump contactor hold Line contactor off(*) Pump contactor hold Line contactor off Pump contactor hold Line contactor off Pump contactor hold Line contactor off(*) Pump contactor off(*) Line contactor off Pump contactor off Line contactor off(*) Pump contactor off(*) Line contactor off(*) Pump contactor off(*) Line contactor off Pump contactor hold Line contactor off Pump contactor hold Line contactor off Pump contactor off Line contactor off(*) Pump contactor hold

Out of normal range

Pump Motor Pulse Input Fault

Logics Fault

Result

Level sensor (Contact)

Out of normal range (5800 rpm) Out of normal range (4000 rpm) With no rotation input during output

Logic Card Initialize Failure

* * * * * *

Code

Fault

Error Brake Oil Parking Brake Battery Low Over Temp. Seat Belt Service Indicator

LED

Steering operation

Display

14 15 16 24 25 26 34 35 40 42 45 46 47

Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off Turn key off

Turn key off Turn key off

Turn key off

Traction Inverter R.H. Fault

When CAN communication is not going on Sum check of ROM & RAM Initial mode SW setting Fault

Line contactor off Pump contactor off

Turn key off

Traction Inverter L.H. Fault

When CAN communication is not going on Sum check of ROM & RAM Initial mode SW setting Fault

Line contactor off Pump contactor off

Turn key off

3-38

CONTROLLER

How to detect

Pump Inverter Fault

When CAN communication is not going on Sum check of ROM & RAM Initial mode SW setting Fault

Contactor Coil Fault

Contactor coil current sensor

Hydraulic Lock Solenoid Fault

Check current of unload valve Check current of lift lock valve Voltage class is not correct

Battery Voltage Too Low Battery Voltage Too High Direction Lever or Accelerator, Faulty Setting Seat Switch, Faulty Setting For Traction

Voltage class is not correct Lever/accel is not neutral at power-on and seat switch closed Seat switch is turned on after lever/accel is operated

Code

Fault

Error Brake Oil Parking Brake Battery Low Over Temp. Seat Belt Service Indicator

LED

Lift Lever, Faulty Setting

Tilt Lever, Faulty Setting

Attachment 1 Lever, Faulty Setting

Attachment 2 Lever, Faulty Setting

Attachment 3 Lever, Faulty Setting

Battery Consumption Too Much Battery Consumption Much

NOTICE:

Result

To return to normal

Line contactor off Pump contactor off

Turn key off

* * * *

Line contactor off Pump contactor off

Turn key off

Disable all lever op.

78 79 E

Switch is off at power-on

(E)

Seat switch is off during operation Seat Switch, Faulty Setting For Hydraulic

Steering operation

Display

Line contactor off Pump contactor off Line contactor off Pump contactor off Line contactor off Disable traction Slow down and Line contactor off Line contactor off Disable traction Slow down and Line contactor off Line contactor off Pump contactor off

Turn key off Turn key off Turn key off FNR Neutral Accel Open Seat SW Close FNR Neutral Accel Open Seat SW Close

Seat switch is off

Disable all lever op.

Lever Off/Neutral Seat SW Close

Lever is not neutral at power-on and seat switch on

Line contactor off Pump contactor off Disable pump and steering op.

Lever Off/Neutral Seat SW Close

Switch is off at power-on

(L)

Seat switch is turned on after lever is pulled

Disable all lever op.

Lever is not neutral at power-on and seat switch on

Line contactor off Pump contactor off Disable pump and steering op.

Seat switch is turned on after lever is pulled

Disable all lever op.

Lever is not neutral at power-on and seat switch on

Line contactor off Pump contactor off Disable pump and steering op.

Seat switch is turned on after lever is pulled

Disable all lever op.

Lever is not neutral at power-on and seat switch on

Line contactor off Pump contactor off Disable pump and steering op.

Seat switch is turned on after lever is pulled

Disable all lever op.

Lever is not neutral at power-on and seat switch on

Line contactor off Pump contactor off Disable pump and steering op.

Seat switch is turned on after lever is pulled Too much consumption with small capacity battery

Much consumption with small capacity battery

(*)

Lever Off/Neutral Seat SW Close

Disable all lever op. (Lo)

Line contactor off(*) Pump contactor off(*) Power reduction

Turn key off Charge battery

(1) E0-E7 don’t appear on the display, but are stored in the history folder. (2) E, (E), (L), H1-H5, and Lo appear on the display, but not stored in the history folder. (E) means flashing. (3) “Line contactor off(*)” means that the contactor will open immediately when a fault is detected. “Line contactor off” means that the contactor will open when a current gets to 0. (4) Contactor “hold” means “no change.” When the error occurs while the contactor is turned on, it keeps on.

3-39

CONTROLLER

Removal and Installation Inverter Discharging Procedure Discharge the inverters by using the following procedure. 1. Turn off the key switch. 2. Disconnect the battery plug. 3. Lift up the seat.

! CAUTION Be careful not to be pinched yourself between the head guard and seat.

211197

4. Place a 150 Ω/25 W resistor between P and N terminals in the right traction inverter to discharge 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 left traction inverter and pump inverter in order to discharge 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. (Discharge all inverters completely before measuring. Longer measurement time reduces resistance value.)

3-40

211198

CONTROLLER

Replacing Inverter Removal 1. Raise the front wheels. 2. Perform step 1 to 5 in Inverter Discharging Procedure.

! CAUTION Be sure to discharge all inverters.

3. Disconnect all five power cables from P, N, U, V and W terminals. For the pump inverter, leave P terminal connected, and disconnect F terminal. 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.

5. Remove M10 bolts (four places) fixing the inverter, then remove the inverter.

Installation 1. Wipe off the dirt and thermal paste from the inverter mounting surface once, and also remove dirt from the mounting surface and the aluminum base plate of the inverter. 2. Apply thermal paste approx. 1 mm (0.04 in.) thick to the area where the aluminum base plate of the inverter comes into contact with the truck body.

! CAUTION Apply thin and even thermal paste since it works to release generated heat from the inverter to the truck body.

3. Fix the inverter with M10 bolts. 4. Connect the power cables to P, N, U, V and W terminals. For the pump inverter, include F terminal.

3-41

211199

CONTROLLER

! 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

U, V and W terminals

16 ± 1.0 N·m [1.63 ± 0.10 kgf·m] [11.80 ± 0.74 lbf·ft]

P, N and F terminals

10 ± 1.0 N·m (1.02 ± 0.10 kgf·m) [7.38 ± 0.74 lbf·ft]

M8 nut

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 press the connector, if required.

3-42

CONTROLLER

Replacing DSP (Digital Signal Processor) Card Removal 1. Perform step 1 to 5 in Inverter Discharging Procedure.

! CAUTION Be sure to discharge inverters before working on the electrical system.

2. Disconnect the connector.

3. Push and lift up at the four corners of the card cover to remove the cover. 211200

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 connector 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.

3-43

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 is secure.

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. Confirm that the cable is inserted squarely into the connector.

4. Install the cover while pushing the flat cable toward the card side slightly.

211202

! CAUTION Do not force the flat cable into 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 press the connector, if required (for the card with vertical type connector).

3-44

211357

CONTROLLER

Replacing Logic Unit Removal 1. Turn off the key switch. 2. Disconnect the battery plug. 3. Remove the right side step.

211203

Logic unit

211204

4. Disconnect the connector (CN1, 2 and 3 complex) from the logic card and the connector (CN4) from the power supply card.

5. Remove M10 bolts (two places) and remove the logic unit.

Installation 211205

Follow the removal sequence in reverse. 3-45

CONTROLLER

Replacing Logic Card Cover

Removal 1. Perform step 1 to 5 in Replacing Logic Unit. 2. Remove M3 flat head screws (two places) from the bottom of the logic unit to remove the cover. 3. Remove M3 screws (four places) fixing the logic card plate to the logic unit case to remove the logic card and logic card plate as an assembly.

Logic unit case 211206 Logic card

Heat sink

Installation Follow the removal sequence in reverse.

Logic card plate

When installing the logic card onto the logic card plate, carefully tighten the logic card and heat sink mounting screws to the specified torque to avoid excessive stresses. Mount the heat sink first.

Logic card

Logic card plate

Tightening torque

M3 screw

211207

CAUTION

0.98 ± 0.20 N·m (0.10 ± 0.02 kgf·m) [0.72 ± 0.15 lbf·ft]

Logic card assembly

3-46

211328

CONTROLLER

Replacing Power Supply Card Removal Cover

1. Perform step 1 to 5 in Replacing Logic Unit. 2. Remove M3 screws (two places) from the bottom of the logic unit to remove the cover. 3. Remove M3 screws (four places) from the logic unit case to remove the logic card and logic card plate as an assembly.

Logic unit case 211208

Power supply card Heat sink

Installation Follow the removal sequence in reverse.

! CAUTION When installing the power supply card onto the logic unit case, carefully tighten the power supply card and heat sink mounting screws to the specified torque to avoid excessive stresses. Mount the heat sink first. Tightening torque

M3 screw

0.98 ± 0.20 N·m (0.10 ± 0.02 kgf·m) [0.72 ± 0.15 lbf·ft] 3-47

Power supply card assembly

211209

CONTROLLER

Basic Check Always follow basic troubleshooting steps. • Talk to the operator. • Confirm the operator’s 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) Multimeter (b) Clamp meter (c) IC clip

(b) (a)

NOTE The illustrations show digital multimeters. In these multimeters, the positive (+) terminal is applied with positive charge, and the negative (–) terminal with negative charge. It should be noted that the terminals must be connected inversely when using an analog meter.

! WARNING Disconnect the battery plug before inspecting or adjusting the controller.

3-48

(c)

208282

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 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 multimeter to the V GND terminal of the card. 6. Set the multimeter to the 100 VDC range. 7. Connect the positive terminal of the multimeter to each pin of connectors detailed on the following pages.

NOTE Be careful not to short-circuit pins. For the normal voltage value, refer to the card voltage chart on the following pages.

3-49

CONTROLLER Logic card voltage chart CN1 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Name GND-L +15V-L GND-L +5V-L CANH CANL BOOT FWE GND DISPLAY1-TxD DISPLAY1-RxD GSE-TxD GSE-RxD POS VOLTAGE ACCEL ANGLE GND +5V GND +5V LIFT LIMIT SW1 SPEED LIMIT SW SEAT BELT SW SEAT SW PARK BRAKE SW SERVICE BRAKE SW REVERSE SW FORWARD SW BRAKE FLUID SW STEERING PRESSURE SW LIFT LIMIT SW2 LIFT LIMIT SW3 ACCEL IDLE SW GND IPS BUZZER DIAG SW SET SW ATTACH3 SW ATTACH2 SW ATTACH1 SW TILT SW LIFT2 SW LIFT1 SW STEERING-1 STEERING-2 STEERING-3 STEERING-4 LIFT LOCK + LIFT LOCK LINE CONTACTOR CON HYDRAULIC CONTACTOR CON ALARM1 ALARM2 CON VE UNLOAD SOL

Stand-by voltage 0V 13.0V to 16.0V 0V 5V 0 to 5V 0 to 5V 11.5V 11.5V 0V

Active voltage 0V 13.0V to 16.0V 0V 5V 0 to 5V 0 to 5V 0V 0V 0V

0 to 12V

0 to 12V Vbatt 0V

0 to 12V Vbatt 0 to 4.7V

0V 5V 0V 5V

11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 0V 0V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 11.5V 0V 0V 0V 0V 0V 0V Vbatt 0V

0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0 to Vbatt 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0 to Vbatt 0V 0 to Vbatt 0 to Vbatt 0 to Vbatt 0 to Vbatt Vbatt 0 to Vbatt

Note

Do not measure the voltage between CAN and Logic GND terminal.

Battery connector attached : Vbatt

Vbatt: Battery voltage

3-50

CONTROLLER Power supply card voltage chart CN1 No.

Name

Voltage

Note

+12V

12V

Fan

GND

Fan

+15V-L

13.0V to 16.0V

DSP

+5V

DSP

+15V-G

12V

DSP

GND

DSP

+VE-L

Vbatt

+VE-L

Vbatt

+15V-L

13.0V to 16.0V

Logic

+5V

Logic

GND

Logic

GND

Logic

V POW

Vbatt

Input

V POW

Vbatt

Input

V GND

Input

V GND

Input

DSP card voltage chart CN2 No.

Name

Active voltage

Stand-by voltage

Note

MOTOR THERMAL +

0 to 5V

MOTOR THERMAL -

0 to 5V

CANH

0 to 5V

Do not measure the voltage between

CANL

0 to 5V

CAN and Logic GND terminal.

ROTARY SENSOR +15V

12V

ROTARY SENSOR A+

0 to 5V

ROTARY SENSOR B+

0 to 5V

MODE1

11.5V

MODE2

11.5V

BOOT

11.5V

GND

TxD(GSE)

RxD(GSE)

CANR+

CANR-

+15V-G

12V

+15V-L

13.0V to 16.0V

+5V

GND

3-51

CONTROLLER

Checking Contactor Coil

! CAUTION Disconnect the battery plug and discharge the inverters before working on electrical system. 1. Disconnect coil lead wire. 2. Set the multimeter to the 200 ohm range. 3. Measure coil resistance. The resistance must be between 44 ohm at -30°C (-22°F) and 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 multimeter to the 200 VDC range. 5. Connect the negative (–) terminal of the multimeter to the negative-side coil terminal (small terminal) and the positive (+) terminal of the multimeter to the positiveside coil terminal (large terminal). 6. Connect the battery, and operate the control device that activates the contactor. 7. The multimeter should indicate about 24V after the contactor operates. When the contactor is found to be normal for the coil resistance test, but measured voltage is not 24V, replace the logic card.

Checking Contactor Tips 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 assembly. Make sure there is no foreign material that could interfere with contactor movement. 4. Measure the gap at the contactor tips using a feeler gauge. [It must be 3 ± 0.5 mm (0.12 ± 0.02 in.)] • If you find any trouble, replace or repair the contactor.

3-52

208284

CONTROLLER

Checking Inverter

! CAUTION Disconnect the battery plug and discharge the inverters before working on electrical system. 1. Disconnect all five power cables from P, N, U, V and W terminals. For the pump inverter, leave P terminal connected, and disconnect F terminal. 2. Check the resistance between the terminal as shown in the following table. Positive probe N U V W

Negative probe U V W

Resistance (ohm)

8k to 11k

Multimeter

211212

NOTICE: Short- or open-circuits of the inverter MOSFET can be confirmed with this check. Other internal faults cannot be determined with this check.

3-53

CONTROLLER

Regeneration Check The AC motor uses a common circuit for current flow in both loading and regeneration. The following procedure will confirm the regeneration operation. 1. Place the clamp ammeter onto the cable connected to the inverter’s P terminal (use DC current range). This is positive direction as current flows from the battery to the inverter.

Clamp ammeter setting direction

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 by an external force. The regeneration power is produced when this energy is larger than the one that is consumed by the controller and motor. This means that the regeneration current is not measured if the speed or load changes gradually.

3-54

211213

CONTROLLER

AC Motor System Basics 1. Feature of AC motor

The frequency and voltage can be controlled in a variety of methods including the “vector control method” employed in the AC motor model trucks. This method provides highly responsive control according to ever changing truck-operating conditions through highspeed calculation on huge amount of data. The vector control calculation is performed by the inverter. (Fig. 2)

The AC motor model trucks covered by this manual use AC motors (three-phase induction motors) as the traction motor and pump motor. AC motors have the following advantages over DC motors: (1) AC motors are simple in construction. Since they do not have friction parts like brushes and commutators, daily maintenance is significantly reduced. (2) AC motors are compatible with high-speed operation.

(3) An AC motor of a certain size produces higher power than a DC motor of the same size.

Inverter

2. Speed control of induction motors

Speed control of DC motors depends on regulation of the field and armature current amounts, while that of AC motors basically depends on adjustment of the frequency of the alternating current power supply. The speed of an AC motor is determined by the frequency of the power supply AC current and the load on the motor. In addition, the voltage and current to the motor must be controlled properly so that the motor operates in its optimum characteristic range. (Fig. 1)

V U

V W t

Low-speed operation (low frequency)

High-speed operation 209542

Fig. 1

Logic unit

Inverter Gate driving pulse

Accelerator

F N R

Torque Calculation for order required output

Vector control calculation

Truck speed

MOS-FET modules

Current

Brake

Speed

211214

Fig. 2

3-55

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 device that converts direct current into alternating current is generally called an “inverter.” The processes involved in creating AC current from DC current are described below.

Load

VL =

T1 × 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 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 T1 and T2 is called “duty ratio.” By changing the duty ratio cyclically, it is possible to obtain cyclically changing DC voltage shown in Fig. 3.

Small duty ratio

Large duty ratio

ON ON ON

OFF OFF

209544

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 arranged as shown in Fig. 4. The outputs thus created forms a three-phase alternating current. Fig. 5 shows on-off condition of each switch (arm) and output voltage variation.

S1 S3 S5 U V W S2 S4 S6

Functioning as switches in the inverter of the AC motor trucks are MOS-FET transistors. The MOS-FET transistors can switch at very high speeds, thus creating smooth waveforms of alternating current.

209545

Fig. 4

S1 ON Switching for U phase S2 ON

S3 ON

Switching for V phase S5 ON

S4 ON

Switching for W phase S6 ON 209546 V lt

b t

Fig. 5

3-56

TROUBLESHOOTING FOR CONTROL CIRCUITS General Information ............................................................................... 4 – 1 E0 Traction Motor R.H., Overheating ............................................. 4 – 3 E1 Traction Motor L.H., Overheating ............................................. 4 – 6 E2 Pump Motor, Overheating ........................................................... 4 – 9 E5 Traction Inverter R.H., Overheating ......................................... 4 – 12 E6 Traction Inverter L.H., Overheating .......................................... 4 – 15 E7 Pump Inverter, Overheating ....................................................... 4 – 18 Brake Oil, Low Level .................................................................... 4 – 21 14 Traction Motor Current Sensor R.H. Fault .............................. 4 – 23 15 Traction Motor R.H., Over-current ............................................ 4 – 25 16 Traction Motor R.H., Stall Timer ................................................ 4 – 28 24 Traction Motor Current Sensor L.H. Fault .............................. 4 – 30 25 Traction Motor L.H., Over-current ............................................ 4 – 32 26 Traction Motor L.H., Stall Timer ................................................ 4 – 35 34 Pump Motor Current Sensor Fault ........................................... 4 – 37 35 Pump Motor Over-current ........................................................... 4 – 39 40 Line Contactor Fault .................................................................... 4 – 42 42 Pump Contactor Fault ................................................................. 4 – 44 45 Traction Motor R.H. Open ........................................................... 4 – 46 46 Traction Motor L.H. Open ........................................................... 4 – 49 47 Pump Motor Open ........................................................................ 4 – 52 50 Steering Sensor Fault .................................................................. 4 – 55 51 Accelerator Sensor Fault ............................................................ 4 – 58 52 Traction Motor R.H. Pulse Input Fault ..................................... 4 – 61 53 Traction Motor L.H. Pulse Input Fault ..................................... 4 – 64 57 Pump Motor Pulse Input Fault .................................................. 4 – 67 60 Display Communication Fault ................................................... 4 – 70 61 Logic Card Initialize Failure ........................................................ 4 – 72 62 Logics Fault .................................................................................... 4 – 73

63 Traction Inverter R.H. Fault ........................................................ 4 – 74 64 Traction Inverter L.H. Fault ......................................................... 4 – 77 65 Pump Inverter Fault ...................................................................... 4 – 79 72 Contactor Coil Fault ..................................................................... 4 – 82 74 Hydraulic Lock Solenoid Fault .................................................. 4 – 84 78 Battery Voltage Too Low ............................................................. 4 – 86 79 Battery Voltage Too High ............................................................ 4 – 88 E Direction Lever or Accelerator, Faulty Setting ...................... 4 – 90 (E) Seat Switch, Faulty Setting For Traction ................................ 4 – 92 (L) Seat Switch, Faulty Setting For Hydraulic ............................. 4 – 94 H1 Lift Lever, Faulty Setting ............................................................. 4 – 96 H2 Tilt Lever, Faulty Setting ............................................................. 4 – 98 H3 Attachment 1 Lever, Faulty Setting .......................................... 4 – 100 H4 Attachment 2 Lever, Faulty Setting .......................................... 4 – 102 H5 Attachment 3 Lever, Faulty Setting .......................................... 4 – 104 ((Lo)) Battery Consumption Too Much ............................................... 4 – 106 (Lo) Battery Consumption Much ....................................................... 4 – 108 Locations of Major Components and Connectors ........................ 4 – 110 Electrical Schematic (AC motor, MC models) ................................ 4 – 113 Electrical Diagram (AC motor, MC models) .................................... 4 – 115

TROUBLESHOOTING FOR CONTROL CIRCUITS

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 • 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 4-2. • Ensure that the main harness is not short-circuited to the truck body by using the following procedures.

Disconnect battery plug and discharge the inverters before working on electrical system. Disconnect connector CN4 of logic unit. Check continuity between CN4-15(21) 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. 2. Remove floor plates. 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.

211331

4-1

TROUBLESHOOTING FOR CONTROL CIRCUITS

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, in the worst case, 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

Electronic parts cleaner

211223

Three Bond 29D or Pow-R-Wash CZ*

NOTE The cleaner liquid is volatile (evaporates by itself). All that is required is to thoroughly wash off the grime with the spray. 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. After coupling up the connector, check to be sure that it is in locked state.

Contact surface activator

Electronic parts cleaner

Three Bond 2501S (aerosol) or Nyogel 760G*

NOTE Do not spray too much liquid into the connector. Cleaner liquid reacts differently with some resins (plastic materials).

*: Products contained in Terminal Maintenance Kit (SE000003)

Contact surface activator 205047

4-2

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor R.H., 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 right traction motor, faulty right traction motor or thermal sensor, faulty or open harness wiring, faulty right 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 145 °C (-13 °F to 293 °F). It becomes normal when motor temperature is less than 70 °C (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. Difference No difference (9) Check if truck is operated on steep upgrade or to pull large cargo load. Normal (10) Perform inverter discharging work. See page 3-40. (11) Replace right traction motor. See page 6-4.

(12) Replace right traction motor or front axle. See page 6-4 or 5-1.

With service tool (13) Confirm temperature of right traction motor with input/output monitor. Less than 70 °C(158 °F) 70 °C(158 °F) or more

Without service tool

(14) Disconnect battery plug. Wait until right traction motor

(15) Disconnect battery plug.

temperature becomes close to room temperature.

4-3

TROUBLESHOOTING FOR CONTROL CIRCUITS

(17) Replace display unit. See page 2-6.

(16) Perform inverter discharging work. See page 3-40.

(18) Disconnect connector CN14 of right traction motor speed and thermal sensor. Measure resistance between CN14(124) and (125) at motor side. 6kΩ at 40°C (104°F) to 19kΩ at 10°C (50°F) Out of range Thermal (20) Replace right traction motor. See page 6-4.

(19) Disconnect connector CN7 of right traction inverter. Check continuity between CN7-1 and CN14(125). Check continuity between CN7-2 and CN14(124). No continuity Continuity Power supply (21) Check continuity between CN4-3 and CN7-17(252). Check continuity between CN4-6 and CN7-20(255). Continuity No continuity CAN (22) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257).

Continuity

No continuity (24) Repair or replace harness.

(23) Connect connector CN4, then turn on power again.

(25) Measure voltage between CN7-17(252) and CN7-20(255). Confirm value is 14V±2V. Abnormal Normal

(26) Disconnect battery plug.

(27)Replace power supply card of logic unit. See page 3-47. With service tool Without service tool

(28) Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E0" The latest data is "E0". (29) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(30)Disconnect battery plug. Replace display unit.

(31)Replace DSP card of right traction inverter. See page 3-43.

4-4

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

Traction inverter (right)

CN7 0 to 5V 0 to 5V

V 3 L 229 4 O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card Y 1 5V * 1 G GND 2 Y 12V 5 0 to 5V Y 6 0 to 5V B 7 GND O 19 224

Inside of cover

Inside of case

IMS card

Flat cable

Fuse

Battery (-)

IUR

IVR

IWR

Traction motor (right)

CN14 O B Y Y G Y

127

Speed sensor

146 145 126

124

Thermal sensor

125

283Ω to 163kΩ

W U

TWR TUR

TVR

1: With connector disconnected

211224

4-5

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor L.H., Overheating (E1) (1) Situation Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering operations. Service tool "Alarm status" and "E1" displayed. (2) Possible cause Overheating of left traction motor, faulty left traction motor or thermal sensor, faulty or open harness wiring, faulty left 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 145 °C (-13 °F to 293 °F). It becomes normal when motor temperature is less than 70 °C (158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

With service tool

(12) Replace left traction motor or front axle. See page 6-4 or 5-1.

(13) Confirm temperature of left traction motor with input/output monitor. Less than 70 °C(158 °F) 70 °C(158 °F) or more

Without service tool

(14) Disconnect battery plug. Wait until left traction motor temperature becomes close to room temperature.

(15) Disconnect battery plug.

4-6

TROUBLESHOOTING FOR CONTROL CIRCUITS

(17) Replace display unit. See page 2-6.

(16) Perform inverter discharging work. See page 3-40.

(18) Disconnect connector CN15 of left traction motor speed and thermal sensor. Measure resistance between CN15(129) and (130) at motor side. 6kΩ at 40°C (104°F) to Out of range 19kΩ at 10°C (50°F) Thermal (19) Disconnect connector CN6 of left traction inverter. Check continuity between CN6-1 and CN15(130). Check continuity between CN6-2 and CN15(129). No continuity Continuity

(20) Replace left traction motor. See page 6-4.

Power supply (21) Check continuity between CN4-3(252) and CN6-17(260). Check continuity between CN4-6(255) and CN6-20(262).

Continuity

No continuity

CAN (22)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229).

Continuity

No continuity (24) Repair or replace harness.

(23) Connect connector CN4, then turn on power again.

(25) Measure voltage between CN6-17(260) and CN6-20(262). Confirm value is 14V±2V. Abnormal Normal

(26) Disconnect battery plug.

(27) Replace power supply card of logic unit. See page 3-47. With service tool Without service tool

(28) Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E1" The latest data is "E1". (29) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(30) Disconnect battery plug. Replace display unit.

(31) Replace DSP card of left traction inverter. See page 3-43.

4-7

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6

Traction inverter (left)

CN6 0 to 5V 0 to 5V

5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 5V * 1 Y 1 GND G 2 12V V 5 0 to 5V L 6 0 to 5V G 7 GND O 19 224

Inside of cover

Inside of case

IMS card

Flat cable

Fuse

Battery (-)

IUL

IVL

IWL

Traction motor (left)

CN15 O G L V G Y

132 148

Speed sensor

147 131

129

Thermal sensor

130

283Ω to 163kΩ

TWL TUL

TVL

*1: With connector disconnected 211225

4-8

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor, Overheating (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. (3) How the error code is triggered Motor temperature is out of range of -25 °C to 135 °C (-13 °F to 275 °F). It becomes normal when motor temperature is less than 70 °C (158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Pump motor becomes normal. If problem reoccurs (6) Check if truck is operated to lift large cargo load. Normal (7) Perform inverter discharging work. See page 3-40. (8) Check oil pressure of gear pump and hydraulic lines. Normal Abnormal (9) Replace pump motor. See page 6-5.

With service tool

(10)Repair or replace gear pump or piping. See page 11-10.

(11) Confirm temperature of pump motor with input/output monitor. 70 °C(158 °F) or more Less than 70 °C(158 °F)

Without service tool

(12) Disconnect battery plug. Wait until pump motor temperature becomes close to room temperature.

(13) Disconnect battery plug.

(14) Perform inverter discharging work. See page 3-40.

(15) Replace display unit. See page 2-6.

(16) Disconnect connector CN20 of pump motor speed and thermal sensor. Measure resistance between CN20(134) and (135). 6kΩ at 40°C (104°F) to 19kΩ at 10°C (50°F) Out of range Thermal (17) Disconnect connector CN5 of pump motor inverter. Check continuity between CN5-1 and CN20(135). Check continuity between CN5-2 and CN20(134). Continuity No continuity

(18) Replace pump motor. See page 6-5.

4-9

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power supply (19) Check continuity between CN4-3(252) and CN5-17(266). Check continuity between CN4-6(255) and CN5-20(268).

Continuity

No continuity

CAN (20) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264).

Continuity

No continuity

(21) Connect connector CN4, then turn on power again.

(22) Repair or replace harness.

(23) Measure voltage between CN5-17(266) and CN5-20(268). Confirm value is 14V±2V. Abnormal Normal (24)Disconnect battery plug.

(25) Replace power supply card of logic unit. See page 3-47. With service tool Without service tool

(26)Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E2" The latest data is "E2". (27) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(28) Disconnect battery plug. Replace display unit.

(29) Replace DSP card of pump motor inverter. See page 3-43.

4-10

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

Pump inverter

CN5 0 to 5V 0 to 5V

V 3 L 239 4 O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card RB 1 5V* 1 W GND 2 L 12V 5 0 to 5V R 6 0 to 5V Y 7 GND V 19 234

Inside of cover

Pump contactor F

Fuse P

IMS card

Flat cable

Battery (-)

Pump motor

CN20 V Y R L W RB

Inside of case

138 137

Speed sensor

136 133

134

Thermal sensor

135

160Ω to 163kΩ

1: With connector disconnected

211226

4-11

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter R.H., Overheating (E5) (1) Situation Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering operations. Service tool "Alarm status" and "E5" displayed. (2) Possible cause Overheating of right traction inverter, faulty right traction inverter thermal sensor, open harness wiring, faulty right traction inverter PC board, abnormal power supply of logic unit, faulty radiation of right traction inverter, faulty display unit. (3) How the error code is triggered Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F). Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F). It becomes normal when temperature is less than 70 °C (158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF

(5) Right traction inverter becomes normal. If problem reoccurs

(6) Check if truck is operated on steep upgrade or to pull large cargo load. Normal

(7) Perform inverter discharging work. See page 3-40. Check thermal paste applied on inverter mounting surface. Thermal paste film should be thin and even. Normal Abnormal (8) Replace right traction inverter. See page 3-41.

With service tool

(9) Clean mounting surface, apply thermal paste, then reinstall inverter. See page 3-41.

(10)Confirm temperature of controller and head capacitor with input/output monitor. 70 °C(158 °F) or more Less than 70 °C(158 °F)

Without service tool

(11) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(12) Disconnect battery plug.

(14) Replace display unit. See page 2-6.

(13) Perform inverter discharging work. See page 3-40. Thermal (15) Remove right traction inverter DSP card cover, then check harness looseness or wire breakage. See page 3-43. Normal Abnormal Power supply (16) Disconnect connector CN7 of right traction inverter. Check continuity between CN4-3 and CN7-17(252). Check continuity between CN4-6 and CN7-20(255). Continuity No continuity

(17) Secure harness if loose. Replace inverter if wire breaks. See page 3-41.

4-12

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (18)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). No continuity Continuity

(20) Repair or replace harness.

(19)Connect connector CN4, then turn on power again.

(21) Measure voltage between CN7-17(252) and CN7-20(255). Confirm value is 14V±2V. Normal Abnormal

(22) Disconnect battery plug.

(23) Replace power supply card of logic unit. See page 3-47. With service tool Without service tool (24) Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E5" The latest data is "E5". (25) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(26) Disconnect battery plug. Replace display unit.

(27) Replace DSP card of right traction inverter. See page 3-43. If fault remains (28) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (29)Replace right traction inverter. (DSP card is normal.) See page 3-41.

4-13

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN7

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Traction inverter (right)

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 5 6 7 19

Flat cable

IMS card Controller thermistor

Fuse

Battery (-)

IUR

IVR

IWR

Capacitor thermistor

Traction motor (right)

CN14 DSP flat cable Inverter case

Inside of case

127

Speed sensor

146 145 126 124

DSP card

W U

TWR TUR

TVR

Thermal sensor

125

211227

4-14

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter L.H., Overheating (E6) (1) Situation Controller/motor overheat indicator ON. Poor pulling power and acceleration. Normal pump motor and power steering operations. Service tool "Alarm status" and "E6" displayed. (2) Possible cause Overheating of left traction inverter, faulty left traction inverter thermal sensor, open harness wiring, faulty left traction inverter PC board, abnormal power supply of logic unit, faulty radiation of left traction inverter, faulty display unit. (3) How the error code is triggered Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F). Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F). It becomes normal when temperature is less than 70 °C (158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Left traction inverter becomes normal. If problem reoccurs (6) Check if truck is operated on steep upgrade or to pull large cargo load. Normal (7) Perform inverter discharging work. See page 3-40. Check thermal paste applied on inverter mounting surface. Thermal paste film should be thin and even. Normal Abnormal (8) Replace left traction inverter. See page 3-41.

With service tool

(9) Clean mounting surface, apply thermal paste, then reinstall inverter. See page 3-41.

(10) Confirm temperature of controller and head capacitor with input/output monitor. Less than 70 °C(158 °F) 70 °C(158 °F) or more

Without service tool

(11) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(12)Disconnect battery plug.

(13) Perform inverter discharging work. See page 3-40.

(14)Replace display unit. See page 2-6.

Thermal (15)Remove left traction inverter DSP card cover, then check harness looseness or wire breakage. See page 3-43. Normal Abnormal Power supply (16)Disconnect connector CN6 of left traction inverter. Check continuity between CN4-3(252) and CN6-17(260). Check continuity between CN4-6(255) and CN6-20(262). Continuity No continuity

4-15

(17) Secure harness if loose. Replace inverter if wire breaks. See page 3-41.

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (18)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). Continuity

No continuity

(20) Repair or replace harness.

(19) Connect connector CN4, then turn on power again.

(21) Measure voltage between CN6-17(260) and CN6-20(262). Confirm value is 14V±2V. Normal Abnormal (22) Disconnect battery plug.

(23) Replace power supply card of logic unit. See page 3-47. With service tool Without service tool (24) Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E6" The latest data is "E6". (25) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(26) Disconnect battery plug. Replace display unit.

(27)Replace DSP card of left traction inverter. See page 3-43. If fault remains (28)Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(29)Replace left traction inverter. (DSP card is normal.) See page 3-41.

4-16

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN6

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Traction inverter (left)

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 5 6 7 19 224

Inside of cover

IMS card

Flat cable

Controller thermistor

Fuse

Battery (-)

IUL

IVL

IWL

Capacitor thermistor

Traction motor (left)

CN15 DSP flat cable Inverter case

Inside of case

132 148

Speed sensor

147 131

DSP card

129

TWL TUL

TVL

Thermal sensor

130

211228

4-17

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter, Overheating (E7) (1) Situation Controller/motor overheat indicator ON. Lifting speed slower than normal. Normal traction motor and power steering operations. Service tool "Alarm status" and "E7" displayed. (2) Possible cause Overheating of pump inverter, faulty pump inverter thermal sensor, open harness wiring, faulty pump inverter PC board, abnormal power supply of logic unit, faulty radiation of pump inverter, faulty display unit. (3) How the error code is triggered Controller temperature is out of range of -25 °C to 100 °C (-13 °F to 212 °F). Capacitor temperature is out of range of -25 °C to 110 °C (-13 °F to 230 °F). It becomes normal when temperature is less than 70 °C (158 °F). (4) Checks Let truck cool for 15 minutes. Overheat indicator ON

Overheat indicator OFF (5) Pump inverter becomes normal. If problem reoccurs (6) Check if truck is operated to lift large cargo load. Normal (7) Perform inverter discharging work. See page 3-40. Check thermal paste applied on inverter mounting surface. Thermal paste film should be thin and even. Normal (8) Replace pump inverter. See page 3-41.

With service tool

Abnormal (9)Clean mounting surface, apply thermal paste, then reinstall inverter. See page 3-41.

(10) Confirm temperature of controller and head capacitor with input/output monitor. 70 °C(158 °F) or more Less than 70 °C(158 °F)

Without service tool

(11) Disconnect battery plug. Wait until inverter temperature becomes close to room temperature.

(12) Disconnect battery plug.

(13) Perform inverter discharging work. See page 3-40.

(14) Replace display unit. See page 2-6.

Thermal (15) Remove pump inverter DSP card cover, then check harness looseness or wire breakage. See page 3-43. Normal

Abnormal

Power supply (16) Disconnect connector CN5 of pump inverter. Check continuity between CN4-3(252) and CN5-17(266). Check continuity between CN4-6(255) and CN5-20(268). Continuity No continuity

4-18

(17) Secure harness if loose. Replace inverter if wire breaks. See page 3-41.

TROUBLESHOOTING FOR CONTROL CIRCUITS

CAN (18)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264). No continuity Continuity (20)Repair or replace harness.

(19) Connect connector CN4, then turn on power again.

(21) Measure voltage between CN5-17(266) and CN5-20(268). Confirm value is 14V±2V. Normal Abnormal (22) Disconnect battery plug.

(23) Replace power supply card of logic unit. See page 3-47. With service tool Without service tool (24) Ensure all connectors are connected. Check Run Time Diagnostics data. See page 3-38. Not "E7" The latest data is "E7". (25) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(26)Disconnect battery plug. Replace display unit.

(27)Replace DSP card of pump inverter. See page 3-43. If fault remains (28) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(29)Replace pump inverter. (DSP card is normal.) See page 3-41.

4-19

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN5

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Pump inverter

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card 234

1 2 5 6 7 19

Flat cable

Pump contactor F

Fuse P

IMS card Controller thermistor

Battery (-)

Pump motor 138 137

Speed sensor

136 133

DSP card

Capacitor thermistor

CN20 DSP flat cable Inverter case

Inside of case

134

Thermal sensor

135

211229

4-20

TROUBLESHOOTING FOR CONTROL CIRCUITS

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.

(3) How the error code is triggered Sensor signal is open or short.

(4) Checks Check oil level in brake oil reservoir tank. Normal

Abnormal

(5) Add brake oil. See page 9-10. With service tool (6) Confirm brake oil level switch with input/output monitor. OFF ON

Without service tool

(8) Disconnect battery plug. Replace display unit. See page 2-6.

(7) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (9) Disconnect connectors CN2 and CN3 of logic unit and CN11 of sensor. Check continuity between CN11(139) and CN11(140) at harness side. No continuity Continuity (10) Check continuity of brake oil level sensor connector coupled to CN11. No continuity Continuity

(11) Repair or replace harness.

(12) Replace brake oil level sensor. Without service tool

With service tool

(13) Replace display unit. See page 2-6. If fault remains (14) Disconnect battery plug.

(15) Reinstall display unit and replace logic card of logic unit. See page 3-46.

4-21

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN2 38

Logic CN3

0V/12V O 139

GND L 140

CN11 O

Brake fluid sensor

211230

4-22

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor Current Sensor R.H. Fault (14) (1) Situation Display: "14". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN and pump contactor HOLD. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction inverter, faulty right traction inverter, faulty main harness, faulty logic unit.

(3) How the error code is triggered When turning on power, current sensor voltage is out of range of -120 A to 120 A. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Disconnect connector CN7 of right traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal 8V power supply (6) Check continuity between CN4-4 and CN7-18(253). Check continuity between CN4-6 and CN7-20(255). Continuity Abnormal and No continuity

(7) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

CAN (8)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). Abnormal and No continuity Continuity (9) Connect connector CN4 to logic unit, then turn on power again.

(10)Repair or replace harness.

(11) Measure voltage between CN7-18(253) and CN7-20(255). Confirm value is 8V±2V. Normal Abnormal (12) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(13)Replace DSP card of right traction inverter. See page 3-43. If fault remains (15) Perform inverter discharging work, then replace right traction inverter. (DSP card is normal.) See page 3-41.

4-23

(14) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN7

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Traction inverter (right)

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 5 6 7 19

Flat cable

U current sensor

IMS card

Fuse

Battery (-)

IUR

IVR

IWR

V current sensor

Traction motor (right)

CN14 DSP flat cable Inverter case

Inside of case

127

Speed sensor

146 145 126

DSP card

124

W U

TWR TUR

TVR

Thermal sensor

125

211231

4-24

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor R.H., Over-current (15) (1) Situation Display: "15". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction inverter, faulty right traction inverter, faulty right traction motor, faulty contact or wire breakage of right traction motor speed sensor harness, faulty main harness, faulty logic unit. (3) How the error code is triggered Motor current is more than 1000 A (Moment). Motor current is more than 788 A (Fixed time 1). Motor current is more than 696 A (Fixed time 2). (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check right traction motor and terminal for burning and smell. Abnormal Normal (6) Confirm cable looseness and improper connections (U, V, W phases) for right traction inverter and motor. Abnormal Normal

(7) Replace right traction motor. See page 6-4.

(8) Disconnect connector CN7 of right traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of right traction motor speed sensor connector CN14. Normal Abnormal Sensor

(11) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

(12) Disconnect connectors CN7 and CN14. Check continuity between CN7-5 and CN14(126). Check continuity between CN7-6 and CN14(145). Check continuity between CN7-7 and CN14(146). Check continuity between CN7-19 and CN14(127). Continuity No continuity 8V power supply (14) Check continuity between CN4-4 and CN7-18(253). Check continuity between CN4-6 and CN7-20(255).

(13) Connect connector securely.

Continuity No continuity CAN (15)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). Continuity No continuity (16) Connect connector CN4 to logic unit, then turn on power again.

(17)Repair or replace harness.

4-25

TROUBLESHOOTING FOR CONTROL CIRCUITS

(18) Measure voltage between CN7-18(253) and CN7-20(255). Confirm value is 8V±2V. Normal Abnormal

(19) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(20)Replace DSP card of right traction inverter. See page 3-43. If fault remains (22)Perform inverter discharging work, then replace right traction inverter. (DSP card is normal.) See page 3-41. If fault remains (23)Perform inverter discharging work, then reinstall right traction inverter and replace right traction motor.

4-26

(21) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

Traction inverter (right)

CN7

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 Y 12V 5 0 to 5V Y 6 0 to 5V B 7 GND O 19

Flat cable

O B Y Y

DSP card

IMS card

Fuse

Battery (-)

IUR

IVR

IWR

Traction motor (right)

CN14 DSP flat cable Inverter case

Inside of case

127

Speed sensor

146 145 126 124

W U

TWR TUR

TVR

Thermal sensor

125

211232

4-27

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor R.H., Stall Timer (16) (1) Situation

Display:"16". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Stall current flowed more than set time (#20) in right traction motor, faulty right traction inverter current sensor, shorted harness wiring, faulty right traction inverter DSP card, faulty logic unit. (3) How the error code is triggered 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 reoccurs (5) Confirm stall timer set time of Setup Option #20. Maximum value set Larger value can be set

Error code 14

(6) See troubleshooting for code "14". See page 4-23.

(7) Check to see if truck is operated with heavy cargo load or on steps when motor stalls. Heavy load Normal steeps

(8) Change set time. See page 3-21. Note: The more stall occurs, the more overheating occurs. Operate truck under normal condition.

(9) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(10) Operate under normal condition.

(11) Disconnect connector CN7 of right traction inverter and remove DSP cover, then check DSP flat cable for looseness or wire breakage. See page 3-43. Normal Abnormal Power supply (12) Check continuity between CN4-5 and CN7-16(254). Check continuity between CN4-6 and CN7-20(255). No continuity Continuity

(13) Secure harness if loose. Replace right traction inverter if wire breaks. See page 3-41.

CAN (14)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). Abnormal and no continuity Continuity (15)Connect connector CN4 to logic unit, then turn on power again.

(16)Repair or replace harness.

(17) Measure voltage between CN7-16(254) and CN7-20(255). Confirm value is 12V±1V. Abnormal Normal (18) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (19) Replace DSP card of right traction inverter. See page 3-43.

4-28

(20)Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

CN7

Traction inverter (right)

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 5 6 7 19

Flat cable

Inside of case U current sensor

IMS card

Fuse

Battery (-)

IUR

IVR

IWR

V current sensor

Traction motor (right)

CN14 127

Speed sensor

146 145 126 124

W U

TWR TUR

TVR

Thermal sensor

125

211233

4-29

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor Current Sensor L.H. Fault (24) (1) Situation Display: "24". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN and pump contactor OPEN.

(2) Possible cause Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter, faulty left traction inverter, faulty main harness, faulty logic unit.

(3) How the error code is triggered When turning on power, current sensor voltage is out of range of -120 A to 120 A.

(4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(5)Disconnect connector CN6 of left traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal 8V power supply (6) Check continuity between CN4-4(253) and CN6-18(261). Check continuity between CN4-6(255) and CN6-20(262). Continuity No continuity

(7) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

CAN (8)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). Continuity

No continuity

(9) Connect connector CN4 to logic unit, then turn on power again.

(10) Repair or replace harness.

(11)Measure voltage between CN6-18(261) and CN6-20(262). Confirm value is 8V±2V. Normal Abnormal

(12)Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(13) Replace DSP card of left traction inverter. See page 3-43. If fault remains (15) Perform inverter discharging work, then replace left traction inverter. (DSP card is normal.) See page 3-41.

4-30

(14) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN6

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Traction inverter (left)

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 5 6 7 19 224

Inside of cover

U current sensor

IMS card

Flat cable

Fuse Battery (-)

IUL

IVL

IWL

Traction motor (left) 132 148

Speed sensor

147 131

DSP card

P N

V current sensor

CN15 DSP flat cable Inverter case

Inside of case

129

TWL TUL

TVL

Thermal sensor

130

211234

4-31

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor L.H., Over-current (25) (1) Situation

Display: "25". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter, faulty left traction inverter, faulty left traction motor, faulty contact or wire breakage of left traction motor speed sensor harness, faulty main harness, faulty logic unit. (3) How the error code is triggered Motor current is more than 1000 A (Moment). Motor current is more than 788 A (Fixed time 1). Motor current is more than 696 A (Fixed time 2). (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check left traction motor and terminal for burning and smell. Abnormal Normal (6) Confirm cable looseness and improper connections (U, V, W phases) for left traction inverter and motor. Normal Abnormal

(7) Replace left traction motor. See page 6-4.

(8) Disconnect connector CN6 of left traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of left traction motor speed sensor connector CN15. Normal Abnormal Sensor (12) Disconnect connectors CN6 and CN15. Check continuity between CN6-5 and CN15(131). Check continuity between CN6-6 and CN15(147). Check continuity between CN6-7 and CN15(148). Check continuity between CN6-19 and CN15(132). Continuity No continuity 8V power supply (14)Check continuity between CN4-4(253) and CN6-18(261). Check continuity between CN4-6(255) and CN6-20(262). Continuity No continuity CAN (15)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). No continuity Continuity

(11) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

(16) Connect connector CN4 to logic unit, then turn on power again.

(17)Repair or replace harness.

4-32

(13) Connect connector securely.

TROUBLESHOOTING FOR CONTROL CIRCUITS

(18)Measure voltage between CN6-18(261) and CN6-20(262). Confirm value is 8V±2V. Normal Abnormal (19) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(20) Replace DSP card of left traction inverter. See page 3-43. If fault remains

(22) Perform inverter discharging work, then replace left traction inverter. (DSP card is normal.) See page 3-41. If fault remains

(23) Perform inverter discharging work, then reinstall left traction inverter and replace left traction motor.

4-33

(21) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

Traction inverter (left)

CN6

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

V 3 L 4 229 14 15 12V 259 RY 16 14V 260RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 12V V 5 0 to 5V L 6 0 to 5V G 7 GND O 19 224

Inside of cover

U current sensor

IMS card

Flat cable

Fuse Battery (-)

IUL

IVL

IWL

Traction motor (left) O G L V

DSP card

P N

V current sensor

CN15 DSP flat cable Inverter case

Inside of case

132 148

Speed sensor

147 131 129

TWL TUL

TVL

Thermal sensor

130

211235

4-34

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor L.H., Stall Timer (26) (1) Situation

Display:"26". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Stall current flowed more than set time (#20) in left traction motor, faulty left traction inverter current sensor, shorted harness wiring, faulty left traction inverter DSP card, faulty logic unit. (3) How the error code is triggered 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 reoccurs (5) Confirm stall timer set time of Setup Option #20. Maximum value set

Error code 24

(6) See troubleshooting for code "24". See page 4-30.

Larger value can be set

(7) Check to see if truck is operated with heavy cargo load or on steps when motor stalls. Heavy load Normal steps

(8) Change set time. See page 3-21.

(9) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(10) Operate under normal condition.

(11) Disconnect connector CN6 of left traction inverter and remove DSP cover, then check DSP flat cable for looseness or wire breakage. See page 3-43. Normal Abnormal Power supply (12) Check continuity between CN4-5(254) and CN6-16(259). Check continuity between CN4-6(255) and CN6-20(262). No continuity Continuity CAN (14)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). Abnormal and no continuity Continuity

(13) Secure harness if loose. Replace left traction inverter if wire breaks. See page 3-41.

(15) Connect connector CN4 to logic unit, then turn on power again.

(16)Repair or replace harness.

Note: The more stall occurs, the more overheating occurs. Operate truck under normal condition.

(17) Measure voltage between CN6-16(259) and CN6-20(262). Confirm value is 12V±1V. Abnormal Normal (18) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (19) Replace DSP card of left traction inverter. See page 3-43.

4-35

(20)Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 WG 254 5 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

CN6 0 to 5V 0 to 5V

Traction inverter (left)

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 5 6 7 19 224

Inside of cover

Inside of case U current sensor

IMS card

Flat cable

Fuse

Battery (-)

IUL

IVL

IWL

V current sensor

Traction motor (left)

CN15 132 148

Speed sensor

147 131 129

TWL TUL

TVL

Thermal sensor

130

211236

4-36

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor Current Sensor Fault (34) (1) Situation Display: "34". All truck operations inhibited. This fault occurs only when turning on power. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered When turning on power, current sensor voltage is out of range of -120 A to 120 A.

(4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Disconnect connector CN5 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal 8V power supply (6) Check continuity between CN4-4(253) and CN5-18(267). Check continuity between CN4-6(255) and CN5-20(268). Continuity No continuity

(7) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See page 3-41.

(10) Repair or replace harness.

(11) Measure voltage between CN5-18(267) and CN5-20(268). Confirm value is 8V±2V. Normal Abnormal (12) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(13) Replace DSP card of pump inverter. See page 3-43.

(14) Replace power supply card of logic unit. See page 3-47.

If fault remains (15) Perform inverter discharging work, then replace pump inverter. (DSP card is normal.) See page 3-41.

4-37

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN5

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Pump inverter

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card 234

1 2 5 6 7 19

Pump contactor F

Fuse P

IMS card

Flat cable

Battery (-)

Pump motor 138 137

Speed sensor

136 133

DSP card

V current sensor

CN20 DSP flat cable Inverter case

U current sensor Inside of case

134

Thermal sensor

135

211237

4-38

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor Over-current (35) (1) Situation Display: "35". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered Motor current is more than 1440 A (Moment). Motor current is more than 1400 A (Fixed time 1). Motor current is more than 1393 A (Fixed time 2). (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check pump motor and terminal for burning and smell. Abnormal Normal (6) Confirm cable looseness and improper connections (U, V, W phases) for pump inverter and motor. Normal Abnormal

(7) Replace pump motor. See page 6-5.

(8) Disconnect connector CN5 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

(9) Secure cable if loose or connect cable correctly.

(10) Confirm connection of pump motor speed sensor connector CN20. Normal Abnormal Sensor (12) Disconnect connectors CN5 and CN20. Check continuity between CN5-5 and CN20(133). Check continuity between CN5-6 and CN20(136). Check continuity between CN5-7 and CN20(137). Check continuity between CN5-19 and CN20(138). No continuity Continuity 8V power supply

(11) Secure DSP flat cable if loose. Replace pump inverter if wire breaks. See page 3-41.

(13) Connect connector securely.

(14)Check continuity between CN4-4(253) and CN5-18(267). Check continuity between CN4-6(255) and CN5-20(268). Continuity No continuity CAN (15)Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264). No continuity Continuity (16) Connect connector CN4 to logic unit, then turn on power again.

(17) Repair or replace harness.

4-39

TROUBLESHOOTING FOR CONTROL CIRCUITS

(18) Measure voltage between CN5-18(267) and CN5-20(268). Confirm value is 8V±2V. Normal Abnormal (19) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(20) Replace DSP card of pump inverter. See page 3-43.

(21)Replace power supply card of logic unit. See page 3-47.

If fault remains

(22) Perform inverter discharging work, then replace pump inverter. (DSP card is normal.) See page 3-41. If fault remains

(23) Perform inverter discharging work, then reinstall pump inverter and replace pump motor.

4-40

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

Pump inverter

CN5

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card 234

1 2 L 12V 5 0 to 5V R 6 0 to 5V Y 7 GND V 19

Fuse P

IMS card

Battery (-)

V current sensor

Pump motor V Y R L

DSP card

Pump contactor F

Flat cable

CN20 DSP flat cable Inverter case

U current sensor Inside of case

138 137

Speed sensor

136 133 134

Thermal sensor

135

211238

4-41

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Line Contactor Fault (40) (1) Situation Display: "40". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (2) Possible cause Faulty line contactor, faulty main harness, faulty logic unit, faulty right traction inverter, faulty left traction inverter. (3) How the error code is triggered 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 (5) Block wheels, then confirm line contactor operation in self-diagnostics mode [14]. See page 3-35. Operated Not operated

(6) See troubleshooting for code "63" or "64". See page 4-74 or 4-77. Without service tool

With service tool

(7) Check DC voltage of right and left traction inverters with monitor. These values should be same as battery voltage. Right inverter value Left inverter value abnormal abnormal (9) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

Error code 63 or 64

(10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(8) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace right traction inverter. See page 3-41. If fault remains (14) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(12)Replace right traction (13) Replace left traction inverter. See page 3-41. inverter. See page 3-41. (15)Replace left traction inverter. See page 3-41. (16) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (17) Check to see if line contactor tip moves smoothly. Check line contactor tip for melting. Abnormal Normal (18) Measure resistance of contactor coil. [44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)] Within range Out of range (19) Disconnect connectors CN1 and CN4 of logic unit. Check continuity between CN4-13(4) and contactor coil plus(+)(249). Check continuity between CN1-59 and contactor coil minus(-)(247). Continuity No continuity

(20) Replace line contactor.

(21) Perform inverter discharging work, then replace logic card of logic unit. See page 3-46.

(22) Repair or replace harness.

4-42

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 5 CAN

CN7

0 to 5V

211

224

0 to 5V

6 WP 212

229

V L

Traction inverter (right)

CN6 224

L 229

Logic CN1

3 4

Traction inverter (left)

voltage

Output 59 G 247

Line contactor

Power card R

249

CN4 13

27V to battery voltage

Fuse

211239

4-43

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Contactor Fault (42) (1) Situation Display: "42". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (2) Possible cause Faulty pump contactor, faulty main harness, faulty logic unit, faulty pump inverter.

(3) How the error code is triggered 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 42 (5) Block wheels, then confirm pump contactor operation in self-diagnostics mode [15]. See page 3-35. Operated Not operated

Error code 65

(6) See troubleshooting for code "65". See page 4-79.

(7) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(8) Check to see if pump contactor tip moves smoothly. Check pump contactor tip for melting. Abnormal Normal

(9) Replace pump inverter. See page 3-41.

(10) Measure resistance of contactor coil. [44Ω at -30 °C(-22 °F) to 65Ω at 80 °C(176 °F)] Within range Out of range (11) Disconnect connectors CN1 and CN4 of logic unit. Check continuity between CN4-13(4) and contactor coil plus(+)(250). Check continuity between CN1-60 and contactor coil minus(-)(248). No continuity Continuity

(12)Replace pump contactor.

(13) Perform inverter discharging work, then replace logic card of logic unit. See page 3-46.

(14) Repair or replace harness.

4-44

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 5 CAN

CN5

0 to 5V

211

234

0 to 5V

212

239

V L

Pump inverter

Fuse F

Logic CN1 27V to battery voltage

Pump contactor

Power card 27V to battery voltage R R 250 4 CN4 13

Output 60

B 248 B

211332

4-45

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor R.H. Open (45) (1) Situation

Display: "45". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Faulty contact or wire breakage of right traction motor cable, faulty right traction motor, faulty contact or wire breakage of right traction inverter connector, faulty contact of DSP flat cable in right traction inverter, wire breakage of main harness, faulty power supply card of logic unit, faulty DSP card of right traction inverter, faulty right traction inverter, when restarting after motor shorted. (3) How the error code is triggered Motor voltage is abnormal when power is turned on. Current does not flow when torque instruction is requested. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check right traction inverter and motor for cable looseness and improper contact. Normal Abnormal (6) Disconnect right traction motor cables from inverter. Measure resistance of motor cables (U, V and W phases). Less than 1Ω 1Ω or more

(7) Secure cable if loose.

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W).

(8) Check connector CN7 of right traction inverter for looseness. Normal Abnormal (10) Disconnect connector CN7 of right traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

Less than 1Ω

1Ω or more

(11) Connect connector securely.

(12) Replace right traction motor.

(13) Replace motor cables.

Gate power supply (15) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

(14) Check continuity between CN4-5 and CN7-16(254). Check continuity between CN4-6 and CN7-20(255). Continuity No continuity CAN (16) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). No continuity Continuity (17) Connect connector CN4 to logic unit, then turn on power again.

(18) Repair or replace harness.

4-46

TROUBLESHOOTING FOR CONTROL CIRCUITS

(19) Measure voltage between CN7-16(254) and CN7-20(255). Confirm value is 12V±1V. Normal Abnormal (20) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(21)Replace DSP card of right traction inverter. See page 3-43. If fault remains

(23)Perform inverter discharging work, then replace right traction inverter. (DSP card is normal.) See page 3-41.

4-47

(22) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN7

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Traction inverter (right)

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 5 6 7 19

Flat cable

IMS card

Fuse

Battery (-)

IUR

IVR

IWR

Traction motor (right)

CN14 DSP flat cable Inverter case

Inside of case

127

Speed sensor

146 145 126

DSP card

124

W U

TWR TUR

TVR

Thermal sensor

125

211241

4-48

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor L.H. Open (46) (1) Situation

Display: "46". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Faulty contact or wire breakage of left traction motor cable, faulty left traction motor, faulty contact or wire breakage of left traction inverter connector, faulty contact of DSP flat cable in left traction inverter, wire breakage of main harness, faulty power supply card of logic unit, faulty DSP card of left traction inverter, faulty left traction inverter, when restarting after motor shorted. (3) How the error code is triggered Motor voltage is abnormal when power is turned on. Current does not flow when torque instruction is requested. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check left traction inverter and motor for cable looseness and improper contact. Normal Abnormal (6) Disconnect left traction motor cables from inverter. Measure resistance of motor cables (U, V and W phases). Less than 1Ω 1Ω or more

(7) Secure cable if loose.

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W).

(8) Check connector CN6 of left traction inverter for looseness. Normal Abnormal (10) Disconnect connector CN6 of left traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

Less than 1Ω

1Ω or more

(11) Connect connector securely.

(12) Replace left traction motor.

(13) Replace motor cables.

Gate power supply (14) Check continuity between CN4-5(254) and CN6-16(259). Check continuity between CN4-6(255) and CN6-20(262). Continuity No continuity CAN (16) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). Continuity

(15) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

No continuity

(17) Connect connector CN4 to logic unit, then turn on power again.

(18) Repair or replace harness.

4-49

TROUBLESHOOTING FOR CONTROL CIRCUITS

(19) Measure voltage between CN6-16(259) and CN6-20(262). Confirm value is 12V±1V. Normal Abnormal (20) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(21) Replace DSP card of left traction inverter. See page 3-43. If fault remains (23) Perform inverter discharging work, then replace left traction inverter. (DSP card is normal.) See page 3-41.

4-50

(22) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN6

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

DSP flat cable Inverter case

0 to 5V 0 to 5V

Traction inverter (left)

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 5 6 7 19 224

Inside of cover

Inside of case

IMS card

Flat cable

Fuse Battery (-)

IUL

IVL

IWL

Traction motor (left)

CN15 132 148

Speed sensor

147 131

DSP card

P N

129

TWL TUL

TVL

Thermal sensor

130

211242

4-51

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor Open (47) (1) Situation Display: "47". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered Motor voltage is abnormal when power is turned on. Current does not flow when rotational speed instruction is requested. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check pump inverter and motor for cable looseness and improper contact. Abnormal Normal (6) Disconnect pump motor cables from inverter. Measure resistance of motor cables (U, V and W phases). Less than 1Ω 1Ω or more

(7) Secure cable if loose.

(9) Measure resistance between terminals of both cable ends (between U and U, V and V, and W and W).

(8) Check connector CN5 of pump inverter for looseness. Normal Abnormal (10) Disconnect connector CN5 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal

Less than 1Ω

1Ω or more

(11) Connect connector securely.

(12) Replace pump motor.

(13) Replace motor cables.

Gate power supply (14) Check continuity between CN4-5(254) and CN5-16(265). Check continuity between CN4-6(255) and CN5-20(268). Continuity No continuity

(15) Secure DSP flat cable if loose. Replace inverter if wire breaks. See page 3-41.

CAN (16) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264). No continuity Continuity (17) Connect connector CN4 to logic unit, then turn on power again.

(18) Repair or replace harness.

4-52

TROUBLESHOOTING FOR CONTROL CIRCUITS

(19) Measure voltage between CN5-16(265) and CN5-20(268). Confirm value is 12V±1V. Normal Abnormal (20) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(21) Replace DSP card of pump inverter. See page 3-43.

(22) Replace power supply card of logic unit. See page 3-47.

If fault remains

(23) Perform inverter discharging work, then replace pump inverter. (DSP card is normal.) See page 3-41.

4-53

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN5

BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

0 to 5V 0 to 5V

Pump inverter

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card 234

1 2 5 6 7 19

Pump contactor F

Fuse P

IMS card

Flat cable

138 137

Battery (-)

Speed sensor

136 133

DSP card

Pump motor

CN20 DSP flat cable Inverter case

Inside of case

134

Thermal sensor

135

211243

4-54

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Steering Sensor Fault (50) (1) Situation

Display: "50". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Faulty steering sensor, faulty main harness, faulty logic unit. (3) How the error code is triggered All signal is zero. (longer 200 mS) (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. Power supply (5) Disconnect connectors CN4 of logic unit and CN28 of steering sensor. Check continuity between CN4-13(4) and CN28(112). Check continuity between CN4-15(21) and CN28(113). No continuity Continuity Signal cable (6) Disconnect connector CN1 of logic unit. Check continuity between CN1-56 and CN28(117). Check continuity between CN1-55 and CN28(116). Check continuity between CN1-54 and CN28(115). Check continuity between CN1-53 and CN28(114). No continuity Continuity

Without service tool

(7) Repair or replace harness. With service tool (9) Connect connectors CN1 and CN4. Short-circuit CN28(114) and CN28(113). Turn on power and check "Steer angle sw." of service tool input/output monitor. 0001 [bin] Abnormal

(8) Replace steering sensor. If fault remains (10)Disconnect battery plug. Reinstall steering sensor and replace logic card of logic unit. See page 3-46.

(11) Turn off power. Open CN28(114) and CN28(113). Short-circuit CN28(115) and CN28(113). Turn on power and check "Steer angle sw." of service tool input/ output monitor. 0010 [bin] Abnormal (12) Turn off power. Open CN28(115) and CN28(113). Short-circuit CN28(116) and CN28(113). Turn on power and check "Steer angle sw." of service tool input/output monitor. 0100 [bin] Abnormal (13) Turn off power. Open CN28(116) and CN28(113). Short-circuit CN28(117) and CN28(113). Turn on power and check "Steer angle sw." of service tool input/output monitor. 1000 [bin] Abnormal

4-55

TROUBLESHOOTING FOR CONTROL CIRCUITS

(14) Disconnect battery plug. Replace steering sensor.

4-56

(15) Disconnect battery plug. Replace logic card of logic unit. See page 3-46.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power card CN28 CN4 Battery voltage 112 113 R 4 13 114 117 BW 21 15 Logic CN1

115 116

GND

CN28 R G 114 W 115 116 Y L 117 B 113 112

sig 1 53 G sig 2 54 W Y sig 3 55 L sig 4 56

Angle Left

Center

Right

sig 4 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

sig 3 1 1 1 1 0 0 0 0 0 0 0 1 1 1 1

Steering sensor

sig 2 0 0 1 1 1 1 0 0 0 1 1 1 1 0 0

sig 1 0 1 1 0 0 1 1 0 1 1 0 0 1 1 0

"0": 12 V "1": 0 V Sensor type is open collector.

211244

4-57

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Accelerator Sensor Fault (51) (1) Situation

Display: "51". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

(2) Possible cause Improper accelerator pedal linkage, faulty accelerator sensor, faulty main harness, faulty logic unit.

(3) How the error code is triggered 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 (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. 0.3V or less: OFF 1.41V or more: ON Interrupted Abnormal signal

(5) Disconnect battery plug.

(7) Check link length of accelerator pedal. Abnormal

Normal

(8) Adjust accelerator pedal linkage.

(9) Disconnect battery plug.

(11) Perform inverter discharging work. See page 3-40. (12) Disconnect connectors CN2 and CN3 of logic unit. Disconnect connector CN16 of accelerator sensor. (13) Check continuity between CN3-20 and CN16(142). (Sensor voltage) Continuity No continuity (14) Check continuity between CN2-42 and CN16(144). (Switch) No continuity Continuity (15) Check continuity between CN3-24 and CN16(141). Check continuity between CN3-23(140) and CN16(143). No continuity Continuity

(16) Repair or replace harness. With service tool Without service tool

4-58

(10) Adjust accelerator pedal linkage.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Without service tool

With service tool (18)Connect connector CN2 and CN3. Turn on power and check voltage between CN16(141) and CN16(140). Not 5 V 5V

(17) Replace accelerator pedal. If fault remains (19) Disconnect battery plug.

(20) Turn off power. Short-circuit CN16(141) and CN16(142). Turn on power and check accelerator voltage with service tool. Not 5 V 5V

(21) Reinstall accelerator pedal, then replace logic card of logic unit. See page 3-46.

(22) Turn off power. Open CN16(141) and CN16(142). Short-circuit CN16(142) and CN16(143). Turn on power and check accelerator voltage with service tool. 0V Not 0 V (23) Replace accelerator pedal.

(24) Disconnect battery plug. (25) Replace logic card of logic unit. See page 3-46.

4-59

TROUBLESHOOTING FOR CONTROL CIRCUITS

CN16 Logic CN2 SW 42

143 144 142 141

12V/0V

144

5V RW 141 24 0.30 to 1.40V G 142 ACCEL ANGLE 20 L 140 GND 143 23

CN16 L RW G B

Accelerator

Logic CN3

211245

4-60

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor R.H. Pulse Input Fault (52) (1) Situation

Display: "52". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

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

(3) How the error code is triggered Motor rotation speed is more than 5800 rpm. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check to see if right traction motor cables (U, V and Wphases) are connected to right traction inverter properly. Normal Abnormal (6) Check to see if connector CN7 of right traction inverter is fastened securely. Normal

(7) Connect cables properly.

Abnormal

(8) Check to see if connector CN14 of right traction motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

Sensor (10) Disconnect connectors CN7 and CN14. Check continuity between CN7-5 and CN14(126). Check continuity between CN7-6 and CN14(145). Check continuity between CN7-7 and CN14(146). Check continuity between CN7-19 and CN14(127). Continuity No continuity Power supply

(11) Fasten connector securely.

(12) Check continuity between CN4-3 and CN7-17(252). Check continuity between CN4-6 and CN7-20(255). Continuity

No continuity

CAN (13) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). No continuity Continuity (14) Connect connector CN4 to logic unit, then turn on power again.

(15) Repair or replace harness.

4-61

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between CN7-17(252) and CN7-20(255). Confirm value is 14V±2V. Normal Abnormal (17) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(18) Replace DSP card of right traction inverter. See page 3-43. If fault remains (20) Perform inverter discharging work, then replace right traction motor. (DSP card is normal.) See page 6-4.

4-62

(19) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

Traction inverter (right)

CN7 0 to 5V 0 to 5V

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card 224

1 2 Y 12V 5 0 to 5V Y 6 0 to 5V B 7 GND O 19

Flat cable

Inside of case

IMS card

Fuse

Battery (-)

IUR

IVR

IWR

Traction motor (right)

CN14 O B Y Y

127

Speed sensor

146 145 126 124

W U

TWR TUR

TVR

Thermal sensor

125

211246

4-63

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Motor L.H. Pulse Input Fault (53) (1) Situation

Display: "53". Traction motor operation inhibited. Pump motor and power steering operations inhibited if this fault occurs before pump contactor CLOSE, and both operable if it occurs after pump contactor CLOSE. Line contactor OPEN and pump contactor CLOSE or OPEN.

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

(3) How the error code is triggered Motor rotation speed is more than 5800 rpm. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Check to see if left traction motor cables (U, V and Wphases) are connected to left traction inverter properly. Normal Abnormal (6) Check to see if connector CN6 of left traction inverter is fastened securely. Normal

(7) Connect cables properly.

Abnormal

(8) Check to see if connector CN15 of left traction motor speed sensor is fastened securely. Normal Abnormal

(9) Fasten connector securely.

Sensor (10) Disconnect connectors CN6 and CN15. Check continuity between CN6-5 and CN15(131). Check continuity between CN6-6 and CN15(147). Check continuity between CN6-7 and CN15(148). Check continuity between CN6-19 and CN15(132). Continuity No continuity Power supply (12) Check continuity between CN4-3(252) and CN6-17(260). Check continuity between CN4-6(255) and CN6-20(262). Continuity

(11) Fasten connector securely.

No continuity

CAN (13) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). Continuity

No continuity

(14) Connect connector CN4 to logic unit, then turn on power again.

(15) Repair or replace harness.

4-64

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between CN6-17(260) and CN6-20(262). Confirm value is 14V±2V. Normal Abnormal (17) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(18) Replace DSP card of left traction inverter. See page 3-43. If fault remains (20) Perform inverter discharging work, then replace left traction motor. (DSP card is normal.) See page 6-4.

4-65

(19) Replace power supply card of logic unit. See page 3-47.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

Traction inverter (left)

CN6 0 to 5V 0 to 5V

V 3 L 4 229 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card 1 2 12V V 5 0 to 5V L 6 0 to 5V G 7 GND O 19 224

Inside of cover

Inside of case

IMS card

Flat cable

Fuse

Battery (-)

IUL

IVL

IWL

Traction motor (left)

CN15 O G L V

132 148

Speed sensor

147 131 129

TWL TUL

TVL

Thermal sensor

130

211247

4-66

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Motor Pulse Input Fault (57) (1) Situation Display: "57". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered Motor rotation speed is more than 4000 rpm. Motor rotation speed is zero while current flows to motor. Motor rotates in reverse. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (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 CN5 of pump inverter is fastened securely. Normal

(7) Connect cables properly.

Abnormal

(8) Check to see if connector CN20 of pump motor speed sensor is fastened securely. Normal Abnormal Sensor (10) Disconnect connectors CN5 and CN20. Check continuity between CN5-5 and CN20(133). Check continuity between CN5-6 and CN20(136). Check continuity between CN5-7 and CN20(137). Check continuity between CN5-19 and CN20(138). Continuity No continuity Power supply (12) Check continuity between CN4-3(252) and CN5-17(266). Check continuity between CN4-6(255) and CN5-20(268).

(9) Fasten connector securely.

(11) Fasten connector securely.

Continuity No continuity CAN (13) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264). No continuity Continuity (14) Connect connector CN4 to logic unit, then turn on power again.

(15) Repair or replace harness.

4-67

TROUBLESHOOTING FOR CONTROL CIRCUITS

(16) Measure voltage between CN5-17(266) and CN5-20(268). Confirm value is 14V±2V. Normal Abnormal (17) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(18) Replace DSP card of pump inverter. See page 3-43.

(19) Replace power supply card of logic unit. See page 3-47.

If fault remains (20) Perform inverter discharging work, then replace pump motor. (DSP card is normal.) See page 6-5.

4-68

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3 BG CAN 5 WP 211 212 6 5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

Pump inverter

CN5 0 to 5V 0 to 5V

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card 234

1 2 L 12V 5 0 to 5V R 6 0 to 5V Y 7 GND V 19

Inside of case

Pump contactor F

Fuse P

IMS card

Flat cable

Battery (-)

Pump motor

CN20 V Y R L

138 137

Speed sensor

136 133 134

Thermal sensor

135

211250

4-69

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Display Communication Fault (60) (1) Situation Display: "60". Normal truck operation

All truck operations inhibited (2) Possible cause

(2) Possible cause

Faulty logic unit

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

(3) How the error code is triggered Communication is impossible. Hour meter data of display unit is abnormal.

(3) How the error code is triggered Communication is impossible.

(4) Checks

Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(5) Disconnect connector CN3 of controller. Disconnect connector CN8 of display unit. Check continuity between CN3-14 and CN8(149). Check continuity between CN3-16 and CN8(150). Check continuity between CN3-23(140) and CN8(152). Check continuity between CN4-13(4) and CN8(151). No continuity Continuity

(5) Replace logic card of logic unit. See page 3-46.

(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 (10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace logic card of logic unit. See page 3-46.

4-70

TROUBLESHOOTING FOR CONTROL CIRCUITS

Key switch

CN9 R G

Power card CN4

13 Battery +

CN18 G G

10 A Fuse holder

CN8

Logic CN3 TXD 14 RXD 16

CN8 Battery voltage

151

WB 149

0 to 12V

GND 23 L

150 140

GND

152

152 149 151150

R Display

211251

4-71

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Logic Card Initialize Failure (61) (1) Situation Display: "61". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered Setup Option data is in abnormal setting range. Other model is set at #40 while steering sensor is installed. (4) Checks Turn off power, then turn on power in Setup Option Group 3 setting. See page 3-13.

(5) Set Setup Option Group 3 data. See page 3-25 to 3-27.

(6) Set Setup Option default data. See page 3-13.

(7) Turn on power in "RUN" mode. See page 3-13. 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 (10) Disconnect battery plug.

(11) Replace logic card of logic unit. See page 3-46.

(12) With service tool, set Setup Option Group 3 data.

(13) With service tool, set Setup Option default data.

4-72

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Logics Fault (62) (1) Situation Display: "62". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.

(2) Possible cause Faulty EEPROM data, faulty logic unit.

(3) How the error code is triggered ROM/RAM SUM value of logic card is different from check data. EEPROM SUM value of logic card is different from check data.

(4) Checks Turn off power, then turn on power in Setup Option Group 3 setting. See page 3-13.

(5) Set Setup Option Group 3 data.

(6) Set Setup Option default data.

(7) Turn on power in "RUN" mode. See page 3-13. Error code "61" If fault remains "62" (8) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(9) See troubleshooting for code "61". See page 4-72.

(10) Replace logic card of logic unit. See page 3-46.

(11) With service tool, set Setup Option Group 3 data. Set Setup Option default data.

4-73

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter R.H. Fault (63) (1) Situation Display: "63". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in right traction inverter, faulty DSP card of right traction inverter, faulty right traction inverter, faulty main harness, faulty logic unit. (3) How the error code is triggered Right traction inverter is connected as pump inverter (CN7-9 is connected to GND). ROM/RAM SUM value of right traction inverter is different from check data. Communication with right traction inverter is impossible. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Disconnect connector CN7 of right traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Normal Abnormal 8V power supply (6) Check continuity between CN4-4 and CN7-18(253). Check continuity between CN4-6 and CN7-20(255). Continuity

(7) Refasten flat cable or replace inverter. See page 3-41.

No continuity

CAN (8) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN7-3(224). Check continuity between CN3-6(212) and CN7-4(229). Check continuity between CN7-14 and CN7-15(257). No continuity Continuity (9) Measure resistance of CAN with connectors CN3 and CN7 disconnected. Resistance between CN3-5 (211) and CN3-6 (212) 120Ω±5% Other than 120Ω±5%

(10) Perform CAN check of Pump Inverter Fault (65).

4-74

TROUBLESHOOTING FOR CONTROL CIRCUITS

(11) Measure resistance of CAN for right traction inverter DSP card. Resistance between CN2-3 and CN2-4 of DSP card side connectors Other than 120Ω±5% 120Ω±5%

(12) Replace DSP card of right traction inverter.

(13) Connect connector CN7 of right traction inverter. Measure resistance of CAN with connector CN3 disconnected. Resistance between CN3-5(211) and CN3-6(212) Other than 60Ω±5% 60Ω±5%

(14) Repair or replace harness.

Mode (15) Check CN7-8 and CN7-9 that pin is not inserted in. Normal Abnormal

(16) Connect connector CN4 to logic unit, then turn on power again.

(17) Repair or replace harness.

(18) Measure voltage between CN7-18(253) and CN7-20(255). Confirm value is 8V±2V. Normal Abnormal

(19) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(21) Replace power supply card of logic unit. See page 3-47.

(20) Replace DSP card of right traction inverter. See page 3-43.

4-75

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN7 0 to 5V 0 to 5V

BG CAN 5 WP 211 212 6

Traction inverter (right)

V 3 Inside L of 229 4 cover O 14 O 15 12V WG 16 14V RP 17 8V RL 18 DSP GND B 20 card

5 WG 254 RP Power 3 RL 252 253 4 B 255 6

224

mode 1 8 mode 2 9

Power card CN4

Inside of case

IMS card

Fuse

Battery (-)

U V

Flat cable

DSP flat cable Inverter case DSP card

211252

4-76

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Traction Inverter L.H. Fault (64) (1) Situation Display: "64". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (2) Possible cause Faulty contact or wire breakage of DSP flat cable in left traction inverter, faulty DSP card of left traction inverter, faulty left traction inverter, faulty main harness, faulty logic unit. (3) How the error code is triggered Left traction inverter is connected as pump inverter (CN6-9 is connected to GND). ROM/RAM SUM value of left traction inverter is different from check data. Communication with left traction inverter is impossible. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Disconnect connector CN6 of left traction inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

8V power supply (6) Check continuity between CN4-4(253) and CN6-18(261). Check continuity between CN4-6(255) and CN6-20(262). Continuity

(7) Refasten flat cable or replace inverter. See page 3-41.

No continuity

CAN (8) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN6-3(224). Check continuity between CN3-6(212) and CN6-4(229). No continuity Continuity Mode (9) Check continuity between CN4-6(255) and CN6-8(262). Continuity No continuity (10) Check CN6-9 that pin is not inserted in. Normal Abnormal (11) Connect connector CN4 to logic unit, then turn on power again.

(12) Repair or replace harness.

(13) Measure voltage between CN6-18(261) and CN6-20(262). Confirm value is 8V±2V. Normal Abnormal (14) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (15) Replace DSP card of left traction inverter. See page 3-43.

(16) Replace power supply card of logic unit. See page 3-47.

4-77

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN6 0 to 5V 0 to 5V

BG CAN 5 WP 211 212 6

Traction inverter (left)

V 3 Inside L 4 of 229 cover 14 15 12V 259 RY 16 14V 260 RGr 17 8V 261 R 18 DSP GND 262 B 20 card B mode 1 8 262 mode 2 9

5 WG 254 RP Power 3 RL 252 253 4 B 255 6 Power card CN4

224

Flat cable

Inside of case

IMS card

Fuse

Battery (-)

U V W

GND

DSP flat cable Inverter case DSP card

211253

4-78

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Pump Inverter Fault (65) (1) Situation Display: "65". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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. (3) How the error code is triggered Pump inverter is connected as traction inverter (CN5-9 is opened). ROM/RAM SUM value of pump inverter is different from check data. Communication with pump inverter is impossible. (4) Checks Disconnect battery plug, then perform inverter discharging work. See page 3-40. (5) Disconnect connector CN5 of pump inverter and remove DSP cover. Check DSP flat cable for looseness or wire breakage. Abnormal Normal

8V power supply (6) Check continuity between CN4-4(253) and CN5-18(267). Check continuity between CN4-6(255) and CN5-20(268). Continuity

(7) Refasten flat cable or replace inverter. See page 3-41.

No continuity

CAN (8) Disconnect connector CN3 of logic unit. Check continuity between CN3-5(211) and CN5-3(234). Check continuity between CN3-6(212) and CN5-4(239). Check continuity between CN5-14 and CN5-15(264). No continuity Continuity (9) Measure resistance of CAN with connectors CN5 and CN3 disconnected. Resistance between CN3-5(211) and CN3-6(212) 120Ω±5% Other than 120Ω±5% (10) Perform CAN check of Traction Inverter R.H. Fault (63). (11) Measure resistance of CAN for pump inverter DSP card. Resistance between CN2-3 and CN2-4 of DSP card side connectors 120Ω±5% Other than 120Ω±5% (12) Replace DSP card of pump inverter.

4-79

TROUBLESHOOTING FOR CONTROL CIRCUITS

(13) Connect connector CN5 of pump inverter. Measure resistance of CAN with connector CN3 disconnected. Resistance between CN3-5(211) and CN3-6(212) 60Ω±5% Other than 60Ω±5%

(14) Repair or replace harness. Mode (15) Check continuity between CN4-6(255) and CN5-9(263). Continuity No continuity (16) Check CN5-8 that pin is not inserted in. Normal Abnormal (17) Connect connector CN4 to logic unit, then turn on power again.

(18) Repair or replace harness.

(19) Measure voltage between CN5-18(267) and CN5-20(268). Confirm value is 8V±2V. Normal Abnormal (20) Disconnect battery plug, then perform inverter discharging work. See page 3-40. (21) Replace DSP card of pump inverter. See page 3-43.

(22) Replace power supply card of logic unit. See page 3-47.

4-80

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN3

CN5 0 to 5V 0 to 5V

BG CAN 5 WP 211 212 6

Pump inverter

V 3 Inside L of 239 4 cover O 14 O 15 12V 265 RG 16 14V 266 RY 17 8V 267 RW 18 DSP GND 268 B 20 card

5 WG 254 RP Power 3 RL 252 253 4 B 255 6

234

mode 1 mode 2 B

Power card CN4

263

8 9

Inside of case

Pump contactor F

Fuse P

IMS card

Battery (-)

U V

Flat cable

GND

DSP flat cable Inverter case DSP card

211254

4-81

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Contactor Coil Fault (72) (1) Situation Display: "72". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.

(2) Possible cause Faulty line contactor, faulty pump contactor, faulty main harness, faulty logic unit.

(3) How the error code is triggered With short circuit detection signal of logic card.

(4) Checks Without service tool

With service tool (5) Find faulty contactor (line contactor or pump contactor) with input/output monitor.

(6) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(7) Check line contactor or pump contactor.

(Check faulty contactor if found with service tool.) Pump contactor

Line contactor (8) Remove coil side terminals of line contactor. Disconnect connector CN1 of logic unit.

(14) Remove coil side terminals of pump contactor. Disconnect connector CN1 of logic unit.

(9) Check short circuit between coil terminal plus(+)(249) and minus(-) (247) of harness. Not shorted Shorted

(15) Check short circuit between coil terminal plus(+)(250) and minus(-)(248) of harness. Shorted Not shorted

(10) Measure coil resistance. [44Ω at -30 °C (-22 °F) to 66Ω at 80 °C (176 °F)] Normal Abnormal

(12) Replace line contactor.

(11) Repair or replace main harness.

(13) Replace logic card of logic unit. See page 3-46.

4-82

(16) Measure coil resistance. [44Ω at -30 °C (-22 °F) to 66Ω at 80 °C (176 °F)] Normal Abnormal

(17) Replace pump contactor.

TROUBLESHOOTING FOR CONTROL CIRCUITS

CN4 13

27V to battery voltage

249

Power card

27V to battery voltage

Line contactor 250

27V to battery voltage

248

G 59 B 60

247

Logic CN1

Pump contactor

211257

4-83

TROUBLESHOOTING FOR CONTROL CIRCUITS

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

(3) How the error code is triggered With short circuit detection signal of logic card.

(4) Checks Without service tool

With service tool (5) Find faulty valve (unload valve or lift lock valve) with input/output monitor.

(6) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(7) Disconnect connector CN4 of logic unit.

(Check faulty valve if found with service tool.)

Unload valve

Lift lock valve

(8) Disconnect connector CN1 of logic unit. Disconnect connector CN27 of unload valve.

(14) Disconnect connector CN1 of logic unit. Disconnect connector CN24 of lift lock valve.

(9) Check short circuit between CN27 (317) and CN27(318).

(15) Check short circuit between CN24(308) and CN24(309).

Not shorted

Shorted

(10) Check short circuit between unload valve side connectors. Measure coil resistance. [7.5Ω at -30 °C (-22 °F) to 12.8Ω at 80 °C (176 °F)] Shorted Not shorted

(11) Repair or replace main harness.

(12) Replace unload valve.

(13)Replace logic card of logic unit. See page 3-46.

4-84

Not shorted

(16) Check short circuit between lift lock valve side connectors. Measure coil resistance. [7.5Ω at -30 °C (-22 °F) to 12.8Ω at 80 °C (176 °F)] Normal Abnormal

(17) Replace lift lock valve.

TROUBLESHOOTING FOR CONTROL CIRCUITS

Power card CN4 13

CN27 4

318

Logic CN1 B 64

CN27

Logic CN1

Harness B CN24

57 Y 58 B

317

Unload valve

317 318

309 308

Y B

Lift lock valve

CN24 308 309

Harness B 211258

4-85

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage Too Low (78) (1) Situation Display: "78". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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.

(3) How the error code is triggered 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 multimeter. 36 V battery: 34 V to 42 V, 48 V battery: 45 V to 60 V

Abnormal

(5) Turn on power in Setup Option Group 3 setting. See page 3-13.

(6) Charge battery or replace with proper battery.

(7) Set #41 of Setup Option Group 3. Set #46 of Setup Option Group 3. See page 3-25 to 3-27.

(8) Turn off power and turn on power again. If fault remains (9) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(10) Check continuity between CN3-19(269) and contactor POS(3). No continuity Continuity

(11) Perform inverter discharging work, then replace logic card of logic unit. See page 3-46.

(12) Repair or replace main harness.

4-86

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor Logic CN3 Battery voltage R 269 19 3

NEG

Fuse

Battery

211259

4-87

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Voltage Too High (79) (1) Situation Display: "79". All truck operations inhibited. Line contactor OPEN and pump contactor OPEN. (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.

(3) How the error code is triggered Corrected battery voltage is too high. Battery voltage is corrected with #46 value. 48 V battery: more than 60 V 36 V battery: more than 42 V (4) Checks Disconnect battery plug. Measure battery voltage with multimeter 36 V battery: 34 V to 42 V, 48 V battery: 45 V to 60 V

Abnormal

(5) Turn on power in Setup Option Group 3 setting. See page 3-13.

(6) Replace with proper battery.

(7) Set #41 of Setup Option Group 3. Set #46 of Setup Option Group 3. See page 3-25 to 3-27.

(8) Turn off power and turn on power again. If fault remains (9) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(10) Check continuity between CN3-19(269) and contactor POS(3). No continuity Continuity

(11) Perform inverter discharging work, then replace logic card of logic unit. See page 3-46.

(12) Repair or replace main harness.

4-88

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor Logic CN3 Battery voltage R 269 19 3

NEG

Fuse

Battery

211259

4-89

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Direction Lever or Accelerator, Faulty Setting (E) (1) Situation Display: "E". Traction motor operation inhibited. Normal pump motor and power steering operations. Line contactor OPEN.

(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.

(3) How the error code is triggered 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. Without service tool With service tool (6) Check direction lever and accelerator sensor operations with input/output monitor.

(8) Turn off power.

(7) Turn on power in diagnostics mode. Inspect direction lever and accelerator sensor. See page 3-32.

(Check faulty unit if found with service tool.) Accelerator sensor

Direction lever (9) Disconnect connector CN10 of direction lever. Turn on power. Normal (E)

(10) Refer to error code "51". See page 4-58.

(11) Replace direction lever.

(12) Disconnect connectors CN2 and CN3 of logic unit.

(13) Check short circuit between CN4-15(21) and CN2-36(104), CN4-15(21) and CN2-37(103). Shorted Not shorted

(14) Disconnect battery plug.

(15) Repair or replace main harness.

(16) Replace logic card of logic unit. See page 3-46.

4-90

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN2 Forward 37 OL 103 Reverse 36 Br 104

F R B2

144

Direction lever

CN10 1

Accel idle 42 L switch

CN10 OL Br 0/12V G GND 102 0/12V

103

104

Power card CN4 GND 15 BW 21

102

Main harness 0/12V

Accelerator Logic CN3 + 5V 24 RW 141 G 142 ACCEL ANGLE 20 L 140 GND 23

CN16 L RW G 0 to 5V GND B 143 5V

CN16 143 144 142 141

Main harness

213095

4-91

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Seat Switch, Faulty Setting For Traction ((E)) (1) Situation Display: "E" flashes. Traction motor operation inhibited. Normal pump and power steering operations. Line contactor OPEN. (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. (3) How the error code is triggered Detects seat switch opening when turning on power or during running. (4) Checks If this fault occurred during running

If this fault occurred when 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. If fault remains

Normal Faulty seat switch position

(9) Disconnect battery plug. (10) Disconnect connector CN25, then short-circuit between terminals (110) and (111). Turn on power again. If fault remains Normal (11) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(12) Replace seat switch.

(13) Disconnect connectors CN2 and CN3 of logic unit. Check continuity between CN25(110) and CN3-25(108). Check continuity between CN25(111) and CN2-33. No continuity Continuity (14) Replace logic card of logic unit. See page 3-46.

(15) Repair or replace main harness.

4-92

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN2 0/12V 0/12V

CN25

Seat belt switch

G 310 YW 111 G 110 Seat switch

G 32 YW 33

GND

Logic CN3 W 108 25 GND

CN25 111 110 310

Main harness

211261

4-93

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Seat Switch, Faulty Setting For Hydraulic ((L)) (1) Situation Display: "L" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (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. (3) How the error code is triggered Detects seat switch opening when turning on power or during pump operation. (4) Checks If this fault occurred when turning on power

If this fault occurred during pump motor operation (5) Sit on seat, then stop pump motor operation. 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. If fault remains

Normal Faulty seat switch position

(9) Disconnect battery plug. (10) Disconnect connector CN25, then short-circuit between terminals (110) and (111). Turn on power again. Normal If fault remains (11) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(12) Replace seat switch.

(13) Disconnect connectors CN2 and CN3 of logic unit. Check continuity between CN25(110) and CN3-25(108). Check continuity between CN25(111) and CN2-33. No continuity Continuity

(14) Replace logic card of logic unit. See page 3-46.

(15) Repair or replace main harness.

4-94

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN2 0/12V 0/12V

CN25

Seat belt switch

G 310 YW 111 G 110 Seat switch

G 32 YW 33

GND

Logic CN3 W 108 25 GND

CN25 111 110 310

Main harness

211261

4-95

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Lift Lever, Faulty Setting (H1) (1) Situation Display: "H1" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (2) Possible cause Key switch turned on while operating lift lever, faulty lift switches 1 and 2, faulty main harness, faulty logic unit.

(3) How the error code is triggered. Detects lift microswitch 1 or 2 when turning on power.

(4) Checks If this fault occurred when turning on power

If this fault occurred during pump motor operation (5) Sit on seat, then stop pump motor operation. Normal If fault remains Fail-safe function (6) Turn off power. Sit on seat, then turn on power again without lift operation. Error code "L" flashes If fault remains (7) Turn off power.

(8) Refer to error code "(L)".

(9) Disconnect connector CN22 of microswitch. Sit on seat, then turn on power again. If fault remains Normal (10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace lift switch 1 or 2.

(12) Check continuity between CN1-52 and CN22(303). Check continuity between CN1-51 and CN22(304). Check short circuit between CN22(303) and CN22(302). Check short circuit between CN22(304) and CN22(302). No continuity, Shorted Continuity, Not shorted (14) Repair or replace main harness.

(13) Disconnect battery plug.

(15) Replace logic card of logic unit. See page 3-46.

4-96

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN1

CN22 0/12V GND 302

Lift 1

304

W 51

Logic CN3 W 108 25

Lift 2

302 304 CN22 305 303 306 307

Main harness

0/12V

303

Logic CN1 Y 52

213147

4-97

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Tilt Lever, Faulty Setting (H2) (1) Situation Display: "H2" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (2) Possible cause Key switch turned on while operating tilt lever, faulty tilt switch, faulty main harness, faulty logic unit.

(3) How the error code is triggered Detects tilt microswitch when turning on power.

(4) Checks If this fault occurred when turning on power

If this fault occurred during pump motor operation (5) Sit on seat, then stop pump motor operation. Normal If fault remains Fail-safe function (6) Turn off power. Sit on seat, then turn on power again without tilt operation. Error code "L" flashes If fault remains (7) Turn off power.

(8) Refer to error code "(L)".

(9) Disconnect connector CN22 of microswitch. Sit on seat, then turn on power again. If fault remains Normal (10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace tilt switch.

(12) Check continuity between CN1-50 and CN22(305). Check short circuit between CN22(305) and CN22(302). Continuity, Not shorted

No continuity, Shorted (14) Repair or replace main harness.

(13) Disconnect battery plug.

(15) Replace logic card of logic unit. See page 3-46.

4-98

TROUBLESHOOTING FOR CONTROL CIRCUITS

CN22 0/12V

Tilt 302

Logic CN1 L 305 50

GND

108

Logic CN3 W

302 304 CN22 305 303 306 307

Main harness

213148

4-99

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attachment 1 Lever, Faulty Setting (H3) (1) Situation Display: "H3" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (2) Possible cause Key switch turned on while operating attachment 1 lever, faulty attachment 1 switch, faulty main harness, faulty logic unit. (3) How the error code is triggered Detects attachment 1 microswitch when turning on power.

(4) Checks

If this fault occurred when turning on power

If this fault occurred during pump motor operation

(5) Sit on seat, then stop pump motor operation. Normal If fault remains Fail-safe function (6) Turn off power. Sit on seat, then turn on power again without attachment 1 operation. Error code "L" flashes If fault remains (7) Turn off power.

(8) Refer to error code "(L)".

(9) Disconnect connector CN22 of microswitch. Sit on seat, then turn on power again. If fault remains Normal (10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace attachment 1 switch.

(12) Check continuity between CN1-49 and CN22(306). Check short circuit between CN22(306) and CN22(302). Continuity, Not shorted

No continuity, Shorted

(13) Disconnect battery plug.

(14) Repair or replace main harness.

(15) Replace logic card of logic unit. See page 3-46.

4-100

TROUBLESHOOTING FOR CONTROL CIRCUITS

CN22

Logic CN3 302

GND

Aux 1 0/12V

108

Logic CN1 G 306 49

302 304 CN22 305 303 306 307

Main harness

213149

4-101

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attachment 2 Lever, Faulty Setting (H4) (1) Situation Display: "H4" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (2) Possible cause Key switch turned on while operating attachment 2 lever, faulty attachment 2 switch, faulty main harness, faulty logic unit. (3) How the error code is triggered Detects attachment 2 microswitch when turning on power.

(4) Checks

If this fault occurred when turning on power

If this fault occurred during pump motor operation

(5) Sit on seat, then stop pump motor operation. If fault remains

Normal Fail-safe function

(6) Turn off power. Sit on seat, then turn on power again without attachment 2 operation. Error code "L" flashes If fault remains (7) Turn off power.

(8) Refer to error code "(L)".

(9) Disconnect connector CN22 of microswitch. Sit on seat, then turn on power again. If fault remains Normal (10) Disconnect battery plug, then perform inverter discharging work. See page 3-40.

(11) Replace attachment 2 switch.

(12) Check continuity between CN1-48 and CN22(307). Check short circuit between CN22(307) and CN22(302). Continuity, Not shorted

No continuity, Shorted

(14) Repair or replace main harness.

(13) Disconnect battery plug.

(15) Replace logic card of logic unit. See page 3-46.

4-102

TROUBLESHOOTING FOR CONTROL CIRCUITS

CN22

Logic CN3 302

GND

108

Aux 2

0/12V

Logic CN1 R 307 48

302 304 CN22 305 303 306 307

Main harness

213150

4-103

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Attachment 3 Lever, Faulty Setting (H5) (1) Situation Display: "H5" flashes. Pump motor and power steering operations inhibited. Pump contactor OPEN if this fault occurs when turning on power. Pump contactor CLOSE if this fault occurs during pump operation and then OPEN if truck stops. (2) Possible cause Faulty logic unit.

(3) How the error code is triggered Detects attachment 3 signal when turning on power.

(4) Checks If this fault occurred when turning on power

If this fault occurred during pump motor operation

(5) Sit on seat, then stop pump motor operation. If fault remains

Normal Fail-safe function

(6) Turn off power. Sit on seat, then turn on power again. If fault remains

(7) Check to see if dust is accumulated on terminal CN1-47. Normal

Abnormal

(8) Clean terminal. If fault remains (9) Disconnect battery plug.

(10) Replace logic card of logic unit. See page 3-46.

4-104

TROUBLESHOOTING FOR CONTROL CIRCUITS

Logic CN1 47 Attachment 3 switch

Logic CN3 25

GND

211266

4-105

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Consumption Too Much ((Lo)) (1) Situation Display: "Lo" flashes. Battery low indicator ON. All truck operations inhibited. Line contactor OPEN and pump contactor OPEN.

(2) Possible cause Extremely consumed battery, faulty main harness, faulty logic unit.

(3) How the error code is triggered 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

(7) Charge battery or replace with new battery.

(6) Set #46 of Setup Option Group 3. See page 3-27. If fault remains (8) Perform inverter discharging work. See page 3-40.

(9) Check continuity between CN3-19(269) and contactor POS(3). No continuity Continuity

(10) Replace logic card of logic unit. See page 3-46.

(11) Repair or replace main harness.

4-106

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor Logic CN3 Battery voltage R 269 19 3

NEG

Fuse

Battery

211259

4-107

TROUBLESHOOTING FOR CONTROL CIRCUITS

Problem: Battery Consumption Much (Lo) (1) Situation Battery low indicator flashes. 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.

(3) How the error code is triggered 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

(7) Charge battery or replace with new battery.

(6) Set #46 of Setup Option Group 3. See page 3-27. If fault remains

(8) Perform inverter discharging work. See page 3-40.

(9) Check continuity between CN3-19(269) and contactor POS(3). No continuity Continuity

(10) Replace logic card of logic unit. See page 3-46.

(11) Repair or replace main harness.

4-108

TROUBLESHOOTING FOR CONTROL CIRCUITS

Line contactor Logic CN3 Battery voltage R 269 19 3

NEG

Fuse

Battery

211259

4-109

TROUBLESHOOTING FOR CONTROL CIRCUITS

Locations of Major Components and Connectors NOTE 1. The figures described below contain the major components and connectors based on the actual model. 2. The component names are basically quoted from the Electrical Schematic and some of the names may be different from the text and the Electrical Diagram.

Logics, micro switches and connectors

Seat assy

Micro switch CN22

Logics GSE CN21

Logics power CN4

Seat harness

Control valve Logics DRS switch CN17

211343

4-110

TROUBLESHOOTING FOR CONTROL CIRCUITS

Head lamp (R)

Head lamp (L)

Display FNR lever assy

CN10 CN8 Horn

IPS relay IPS buzzer

CN15 CN14 211290

Accelerator, foot brake switch, park brake switch, brake fluid sensor and connectors Horn SW

Park brake SW

CN11

Accelerator CN16

Brake fluid sensor

Foot brake SW 211291

4-111

TROUBLESHOOTING FOR CONTROL CIRCUITS

Motors, inverters, contactor panel assembly and battery cable Traction motor R

Traction inverter (L) Traction inverter (R) Battery cable

Pump inverter

Contactor panel assy

Traction motor L Pump motor

211288

Wheel angle sensor, backup buzzer, working lamp and connectors

Working lamp

Backup buzzer

Inverter pump CN5 Inverter trac (L) CN6 Inverter trac (R) CN7

Wheel angle sensor

CN28 CN20

211292

4-112

POWER TRAIN Procedures and Suggestions for Removal and Installation .......

5–1

Removal ....................................................................................................

5–1

Installation .................................................................................................

5–7

Service Data ............................................................................................

5–9

POWER TRAIN

Procedures and Suggestions for Removal and Installation Removal 1. Remove the masts. (Refer to MASTS AND FORKS section.) 2. Removing batteries (1) Disconnect the battery plug. (2) Open the battery cover, and lock it in the open position. (3) Remove the side covers (L.H., R.H.) and front covers (L.H., R.H.).

213016

(4) Attach suspending ropes or adequate lifting device to the batteries. Unit: kg (lb) Truck Model Item Battery weight (maximum)

FB16NT

FB18NT, FB20NT

1090 (2403)

1225 (2700)

(5) Remove the battery retaining plate and pin, and then remove the batteries.

5-1

206918

POWER TRAIN

3. Removing front wheels (1) Pull the parking brake lever and block the rear wheels. (2) Loosen the wheel nuts by two turns. Then, raise the front end of the truck using a hoist or the hydraulic system. (a) Hoisting Using a sling and eye-bolts at both ends of the cross member at the top of the outer mast, lift the front end of the truck with a hoist. (b) Using hydraulic system Tilt the mast fully backward and place wood blocks under the mast. Tilt the mast forward to raise the front end.

! CAUTION After raising the front end, place wood blocks under the frame to prevent the truck from falling. 210757

(3) Remove the wheel nuts. (4) Remove the wheel. Truck Model Item Tire size of front wheels

Cushion tire

1 ton class

2 ton class

18 × 7 × 12 1/8

211344

4. Removing steps and floor plates (1) Steps (L.H., R.H.) (2) Step plates (L.H., R.H.) (3) Floor plate

(3) Floor plate B (1)

(1) (2)

Remove floor plate B.

Floor plate A

Disconnect the accelerator connector mounted on the back side of the floor plate, then remove floor plate A.

(2) 211153

5-2

POWER TRAIN

5. Removing steering hoses Disconnect the steering hoses and pipes at the connectors.

206922

6. Removing delivery pipe and drive motor harness (1) Remove the drive motor harness at the connector. Disconnect the harnesses of the thermal and speed sensors located on the right and left sides. (2) The harnesses are secured to the delivery pipe with clamps. Loosen the clamps, and remove the delivery pipe.

Delivery pipe

5-3

211345

POWER TRAIN

7. Removing brake components

(i)

(ii)

(iii) (v)

(iv) (vi)

206824

(1) Loosen the parking brake lever, and remove parking brake cable assemblies (i) (L.H.) and (ii) (R.H.). Disconnect the parking brake cables at the calipers, and keep the cables together on the frame near the center brake. (2) Position a drip pan, and disconnect brake fluid tube (iii) at the master cylinder. (3) Disconnect brake pipes (iv, v) (L.H., R.H.) at the master cylinder. Disconnect the branch brake hoses (L.H., R.H.) from the brake pipes. (4) Remove brake pedal assembly (vi).

5-4

POWER TRAIN

8. Removing return hoses Remove return hose (1) from the control valve, and return hose (2) from the lift cylinder.

(1)

(2) 206925

9. Remove drive motors cables (L.H., R.H.). 10. Removing tension rods and brackets

(3)

Loosen right and left nuts (1) by approximately 6 mm (0.24 in.). Remove bolts (2), and take out bracket (3) and tension bolt (4) together from each side of the vehicle.

Left transfer

(3)

(2)

(2) (4)

Right transfer

(1) 206926

5-5

POWER TRAIN

11. Removing transfer assemblies, drive motors and calipers

Left transfer

Right transfer (iii) Gravity center (ii)

(ii)

(i) (i) Frame Frame (iv)

Gravity center

(iii)

(iv) 206927

Remove the transfer assemblies with the drive motors and calipers mounted. First, dismount the left transfer, lower it, then pull it out from the front of the vehicle. Then, dismount the right transfer, lower it, then pull it out from the front.

Cow hitch

(1) When suspending the assembly, position the wire rope at the gravity center. The suspending wire rope must be cow hitched. When using a textile sling, make two loops to prevent slipping. (2) Remove bolt (i) from the lower part of the step and remove bolt (ii) from the frame, then remove the assembly. (3) Remove bolt (iii), and dismount the caliper assembly. (4) Remove bolt (iv) and dismount the drive motor. (See illustration No. 206927.)

5-6

206928

Total weight of transfer, drive motor and caliper

115 kg (253.5 lb)

POWER TRAIN

Installation Follow the removal sequence in reverse. For installation, follow the instructions below.

! CAUTION When mounting the transfer assembly on the frame, do not insert a finger into the bolt hole to check hole alignment.

1. Be sure to tighten bolts to the specified torque.

Front of vehicle 3

5 2 2

206785

A: Standard value Drive motor mounting bolt 1

108 ± 10 (11 ± 1) [79.56 ± 7.23]

508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]

Transfer assembly mounting bolt 2 Tightening torque Bracket mounting bolt 3 N·m (kgf·m) [lbf·ft] Bolt nut 4

176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]

231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]

Hub nut 5

157 (16) [115.8]

2. Bleed the brake oil line. (Refer to BRAKE SYSTEM section.) 5-7

POWER TRAIN

3. After installing the parking brake cable, be sure to adjust. (Refer to BRAKE SYSTEM section.) 4. Pour oil into the transfer cases: Left transfer

Remove oil level plug (1). Remove oil inlet plug (2). Pour appropriate oil in the oil inlet. Make sure the oil level reaches the level plug location.

(2)

Unit: liter (U.S. gal) (1)

Left transfer

Right transfer

1.09 (0.29)

1.86 (0.49)

Oil quantity

Front of vehicle

Right transfer

(2)

(1)

206786

5. Bleeding hydraulic oil line and inspecting oil level Operate the tilt cylinders in the forward and backward directions to bleed the tilt cylinders. Operate the lift cylinders in the vertical directions to fill the cylinders with oil. Lower the lift cylinders to the lowest position, and check the oil level gauge. If the oil level is low, add oil to the specified level. 6. Checking steering oil line Operate the steering wheel to make sure that it operates smoothly.

5-8

POWER TRAIN

Service Data A : Standard value Truck Models

Item Tightening torque

1 ton class

2 ton class

Drive motor mounting bolt 1

108 ± 10 (11 ± 1) [79.56 ± 7.23]

Transfer assembly mounting bolt 2

508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]

176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]

231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]

157 (16) [115.8]

N·m Bracket mounting bolt 3 (kgf·m) [lbf·ft] Bolt nut 4 Hub nut 5

Power Train

5 2 2

206785

5-9

MOTORS Motor Installation Positions ................................................................ 6 – Specifications .......................................................................................... 6 – Structures ................................................................................................. 6 – Tightening of High-power Cable Terminals ..................................... 6 – Procedures and Suggestions for Removal and Installation ....... 6 – Procedures and Suggestions for Disassembly and Reassembly .......................................................................................... 6 – Troubleshooting ...................................................................................... 6 – Service Data ............................................................................................ 6 –

1 1 2 3 4 6 8 9

MOTORS

Motor Installation Positions

Brake discs

Pump motor

Traction motor Output shaft

211164

Specifications Item Type

Traction Motor

Pump Motor

Induction, three-phase AC

Voltage

(V)

Output

(kW)

6.3 kW [6.3 kW (S2 60 min.) (S2 60 min.)]

Weight

kg (lb)

50 (110)

14 kW (S3 15%)

[14 kW (S3 15%)]

46 (101)

6-1

MOTORS

Structures Traction Motor

Thermal and speed sensor connector U, V, W terminals

211165

Pump Motor

U, V, W terminals Thermal and speed sensor connector

211166

For the feature and speed control of AC motors, see “AC Motor System Basics” in CONTROLLER section.

The AC motor model forklift trucks covered by this manual use three-phase induction AC motors as the traction motors and pump motor. 6-2

MOTORS

Tightening of High-power Cable Terminals

! CAUTION If the high-power cable terminals of the batteryoperated vehicle are not tightened properly, the increased contact resistance causes excessive heat generation, and could cause a fire in the worst case. To prevent accidents and equipment problems, be sure to regularly check the 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.

Number of Terminals

Tightening Torque

Traction motor

15 N·m (1.5 kgf·m) [11 lbf·ft]

Pump motor

15 N·m (1.5 kgf·m) [11 lbf·ft]

Name of Motor

Right traction motor (3 terminals)

Left traction motor (3 terminals)

Pump motor (3 terminals)

211167

6-3

MOTORS

Procedures and Suggestions for Removal and Installation Traction Motors Removal

(1) Disconnect the battery plug. (2) Using a crane, remove the head guard and batteries. (3) Remove the floor plate and battery cover. (4) Disconnect the harness and cables connected to the motor. (5) Remove the brake caliper. (6) Remove the bolts that secure the front axle on the vehicle frame. With the traction motor still mounted on the vehicle, remove the front axle from the vehicle frame. (7) Using a crane, lift the traction motor to suspend it.

NOTE Position the hook above the gravitational center of the traction motor.

Installation

Follow the removal sequence in reverse.

206902

6-4

MOTORS

Pump Motor Removal

(1)

Disconnect the battery plug.

(2)

Remove the controller cover and the battery partition plate.

(3)

Disconnect the harness, cables and pipes connected to the motor.

(4)

Remove the pump motor.

Installation

Follow the removal sequence in reverse.

6-5

MOTORS

Procedures and Suggestions for Disassembly and Reassembly Disassembly Traction motor

12 11

1 5

8 7

4 211168

Sequence 1 2 3 4 5

Drive end cover Commutator end plate Rotor Stator Ball bearing

6 7 8 9 10

Seal Sensor bearing Wavy washer O-ring Sensor connector

6-6

11 12

Terminal Terminal base

MOTORS Pump motor

1 8 7

5 6

211169

Sequence 1 2 3 4

Commutator end plate Drive end cover Rotor Stator

5 6 7 8

Ball bearing Seal Sensor bearing Wavy washer

Suggestion for Disassembly and Reassembly Ball bearings at both ends are of maintenance free. If it is necessary to remove the bearings when repairing the motor, the bearings and seals must be replaced. If a bearing which is to be replaced has only one sealing lip, it should be greased with quality bearing grease when installing it. Replace the bearings and seals after approximately 10,000 operating hours.

6-7

9 10 11

O-ring Sensor connector Terminal

MOTORS

Troubleshooting Low supply voltage

Motor does not start.

Blown fuse Excess load Faulty wire connection Broken wire in control device Broken wire in field coil Broken wire in armature coil Low supply voltage

Charge battery and improve power supply condition. Replace. Reduce load. Repair, or re-tighten wire connections. Repair or replace. Repair or replace. Repair or replace.

Motor starts but does not run at rated speed.

Faulty connection of armature circuit

Charge battery and improve power supply condition. Repair connections.

Motor produces abnormal vibrations and noise.

Defective bearings Loose mounting bolts Contact between armature and field coil

Replace bearings. Retighten bolts and nuts. Repair or replace.

Incorrect installation Severe external vibration

Correct installation condition. Remove the cause of vibration, or take appropriate vibration-insulating measures. Replace. Replace.

Bearing overheats. Defective bearings Oil degradation or shortage in bearings

6-8

MOTORS

Service Data A: Standard value Unit: mm (in.) Truck Models 1 ton class

2 ton class

Traction motor and pump motor

Item Stator coil insulation resistance Traction motor Terminal conductivity (V) Pump motor

1 MV min.

U–V

V–W

W–U

N·m (kgf·m) [lbf·ft]

Cable terminal tightening torque

6-9

15 N·m (1.5 kgf·m) [11 lbf·ft]

TRANSFER UNITS Specifications .......................................................................................... 7 – 1 Structure and Functions ....................................................................... 7 – 2 Procedures and Suggestions for Disassembly and Reassembly ............................................................................................. 7 – 4 Disassembly ............................................................................................. 7 – 4 Inspection after Disassembly .................................................................... 7 – 5 Reassembly .............................................................................................. 7 – 6

Service Data ............................................................................................ 7 – 8

TRANSFER UNITS

Specifications Truck Model Item

1 ton class

Gear type

2 ton class

Constant-mesh type, 3 stages (helical gears)

Transfer 58 x 83 x 45 =20.151 24 16 28

Reducing gear ratio

7-1

TRANSFER UNITS

Structure and Functions (Part 1)

Front of vehicle

8 9

5 4

5 2

206785

1 2 3 4 5

Transfer (left) Drive motor (left) Transfer (right) Drive motor (right) Frame

6 Wheel hub 7 Front tire 8 Bracket 9 Tension rod Section A: Mast support mounting section

Sections A support masts.

Since two drive motors are installed in a limited space, the drive motors are offset in position. Tension rod 9 connects brackets 8, and includes a turnbuckle to serve as a thrust rod for the left and right transfer units.

7-2

TRANSFER UNITS

Structure and Functions (Part 2) 17 7 9 10

Left side

8 16 17

11 Front of vehicle 6 12

Right side 4 16 15

15 (View from left side)

Bolts marked with × : Bolts for mounting transfer units to frame 1 2 3 4 5 6 7

Drive motor Input gear Second gear Third gear Output shaft Wheel hub Cover

8 9 10 11 12 13 14

Main case Nut Plate Spacer Retainer Taper roller bearing Oil seal

211346

15 16 17

Ball bearing Oil level plug Air breather

Helical gears are used for reduced operating noise.

The left and right transfer units are identical, and are mounted on the frame with bolts marked with an × in the diagram.

The output shaft is provided with two taper roller bearings to withstand heavy loads.

The left and right transfer units are installed to the drive motors. The motor shafts are jointed to the involute splines of the input gears.

Transfer reducing gear ratio

Driving force is transmitted via the input gear, second gear, third gear, then to the output shaft that rotates the wheel hub. 7-3

20.151

TRANSFER UNITS

Procedures and Suggestions for Disassembly and Reassembly Preparation 2. Drain oil from the transfer.

1. Remove the power train consisting of the transfer, drive motor and caliper. (Refer to Removal and Installation of Power Train.)

3. Remove the drive motor and caliper.

Disassembly 8 12 19

9 7

4 10

3 11

16 14

17 18 2

15 16

13 14

1 211047

Sequence 1 2 3 4 5 6 7 8 9

Bolt Remove parts 2 to 12 as sub-assembly. Cover Cap Nut Plate Spacer, O-ring Wheel hub, Hub bolt Taper roller bearing Retainer

10 Output shaft, O-ring 11 Taper roller bearing 12 Oil seal 13 Input gear 14 Ball bearing 15 Second gear 16 Ball bearing 17 Third gear 18 Ball bearing 19 Main case, Dowel pin

7-4

TRANSFER UNITS

Suggestions for Disassembly 1. Removing nut 4

Nut 4 is secured to output shaft 10 by punching. Use a chisel to scrape punched section carefully. Do not scratch output shaft 10. Nut 4 is not reusable.

206789

2. Cover 2

Outer laces of taper bearings 8 and 11 that are press-fit into cover 2 do not have to be disassembled if inspection finds no abnormality. Remove oil seal 12, and use a new seal.

Inspection after Disassembly 1. Inspect the gear teeth and splines for wear and damage. 2. Inspect the bearings for wear, damage, rotating resistance and noise. 3. Inspect main case 19 and cover 2 for cracking and damage. 4. Inspect the oil seal contact surface of retainer 9 for scratches and damage.

7-5

TRANSFER UNITS

Reassembly 1 6

8 11

10 14

2 14 13 15 16 16 18 17 18 19 211048

Sequence Assemble parts 1 to 4 prior to final assembly. 1 Cover 2 Taper roller bearing (outer) 3 Taper roller bearing (outer) 4 Oil seal 5 Output shaft, Inner lace of taper roller bearing 2, O-rings Assemble parts 6 and 7, and inner lace of taper roller bearing 3 prior to final assembly. 6 Wheel hub, Hub bolt 7 Retainer Install sub-assemblies 5 and 6 in cover 1.

8 9 10 11 12 13 14 15 16 17 18 19

7-6

Spacer, O-ring Plate Nut Cap Main case Third gear Ball bearing Second gear Ball bearing Input gear Ball bearing Bolt

TRANSFER UNITS

Suggestions for Reassembly 1. Inspect the mounting surfaces of cover 1 and main case 12 for dents and burrs, and clean the surfaces.

Unit: mm 3- φ16.5

2. To install oil seal 4, use a jig. Tap the jig to fit the oil seal evenly.

80 68 .2 54

3. Tighten nut 10, and check the preload of taper roller bearings 2 and 3.

109

Apply a thin coat of liquid gasket (Three Bond #1104) on the oil seal mounting surface of cover 1.

2- φ18

When tightening the nut, insert vinyl tubes on three symmetrical locations relative to the hub bolt and use a hub holding tool.

207207

Hub holding tool: To be fabricated at service location

NOTE Cut a vinyl tube with an inside diameter of 14 mm (0.55 in.) into pieces of 25 mm (1 in.) in length, and use these vinyl tube pieces to protect the screw sections when using the spring scale for measurement.

Preload

Tangential force on hub bolt

59 to 88 N (6 to 9 kgf) [13.3 to 19.8 lbf]

206791

4. After checking preload, stake one side of nut 10 with a dull punch to secure the nut in place. Make sure the groove is flattened completely and the flattened area measures more than 4 mm (0.16 in.) in diameter. 5. When installing cover 1 sub-assembly on main case 12, apply a thin coat of liquid gasket (Three Bond #1104) on the mounting surfaces. Tighten bolt 19 to the specified torque.

Bolt tightening torque

108 ± 10 N·m (11.0 ± 1.0 kgf·m) [79.7 ± 7.4 lbf·ft]

Unit: mm (in.)

φ4 (0.16)

206792

7-7

TRANSFER UNITS

Service Data

A: Standard value Unit: mm (in.) Truck Model 1 ton class

2 ton class

Item Input gear and second gear 1 A

0.11 to 0.24 (0.0043 to 0.0094)

Second gear and third gear 2 A

0.11 to 0.24 (0.0043 to 0.0094)

Third gear and output shaft 3 A

0.12 to 0.30 (0.0047 to 0.0118)

Preload of output shaft and taper roller bearing 4 Tangential force on hub bolt A N (kgf) [lbf]

59 to 88 (6 to 9) [13.3 to 19.8]

Tightening torque of cover mounting bolt 5 N·m (kgf·m) [lbf·ft] A

108 ± 10 (11.0 ± 1.0) [79.7 ± 7.4]

Gear backlash

5 4

Transfer

3 2

211049

7-8

REAR AXLE Structure and Functions ....................................................................... 8 – 1 Rear Wheels ............................................................................................. 8 – 2

Procedures and Suggestions for Removal and Installation ........ 8 – 3 Rear Wheels ............................................................................................. 8 – 3 Rear Axle .................................................................................................. 8 – 4

Procedures and Suggestions for Disassembly and Reassembly ............................................................................................. 8 – 7 Steering Axle ............................................................................................ 8 – 7 Rear Axle Assembly .................................................................................. 8 – 10

Inspection and Adjustment ................................................................. 8 – 14 Making sure of Minimum Turning Radius .................................................. 8 – 14

Service Data ............................................................................................ 8 – 15

REAR AXLE

Structure and Functions 1 2 3 4 19 18

8 9 12

13 14 15 16 17 16

1 2 3 4 5 6 7

Housing Pinion gear Rack gear Piston Cap Taper roller bearing Taper roller bearing

8 9 10 11 12 13 14

Oil seal Steering axle Wheel hub Hub bolt Hub nut Oil seal Taper roller bearing

15 16 17 18 19

206811

Taper roller bearing Nut Lock washer Hydraulic oil inlet (left wheel) Hydraulic oil inlet (right wheel)

The steering axle connected to the pinion gear is linked to two symmetrically arranged rear wheels. The steering axle and the taper roller bearing of the pinion gear support the rear wheel load.

The rear axle is coupled with the pinion gear and rack gear. The rack gear is mounted with pistons on both ends, and converts the reciprocal motion generated by oil pressure to the rotational movement of the pinion gear. The pinion gear serves as a steering device. 8-1

REAR AXLE

Rear Wheels

φ381 mm (15 in.)

φ292.1 mm (11.5 in.)

Cushion Tire

127 mm (5 in.)

1 3 2 211347

1 2

Steering axle Rear wheel

Tire size

3 4

15 × 5 × 11 1/4

8-2

Wheel nut Rim

REAR AXLE

Procedures and Suggestions for Removal and Installation Rear Wheels Removal 1 2

Wheel nut Rear wheel

Sequence

1. Pull the hand brake lever, and place wheel stoppers at the front wheels. 2. Turn the key switch ON, and turn the steering wheel all the way to either the right or the left. 3. Locate the hub nut on the one side of the vehicle where it is visible from the rear. Loosen the hub nut by turning it two or three rotations.

206813

4. Turn the steering wheel to the opposite direction, and loosen the hub nut on the opposite side by turning it two or three rotations. 5. Turn the key switch OFF, and lift the back of the vehicle until the rear tires are off the ground. a.

Place a jack at the rear center (under the draw bar pin) of the counterweight, and lift.

b. Attach a wire rope to the draw bar pin and lift with a crane. 6. After the back of the vehicle is lifted, place jack stands under the frame on both sides at the rear as a safety measure. 7. Turn the key switch ON, turn the steering wheel, and remove the right and left tires. 8. Turn the key switch OFF. 211050

Installation Follow the removal sequence in reverse.

NOTE Tighten the wheel nuts evenly to the specified torque.

Wheel nut tightening torque

157 N·m (16 kgf·m) [116 lbf·ft]

101212

8-3

REAR AXLE

Rear Axle Removal (Part 1)

11 2 12

10 4 1

6 9

213037

Sequence 1 2 3 4 5 6

Battery cover, Gas spring, Seat Controller cover Battery Battery shield Controller Suction pipe

7 8 9 10 11 12

Preparation 1. Remove the rear wheels. (Refer to Rear Wheel Removal procedure.) 2. Disconnect the battery plug located on the right side of the foot area of the operator’s seat to cut off power.

8-4

Hose (hydraulic suction) Pipe (hydraulic delivery) Motor, Hydraulic pump Hose (hydraulic return) Hose (rear axle return) Hydraulic tank

REAR AXLE

Suggestions for Removal The rear axle is mounted to the counterweight. To remove the rear axle, it is necessary to remove all the surrounding components such as the motor, hydraulic pump, hydraulic tank and controller.

Removing battery cover Before removal, open the battery cover and disconnect the seat switch terminal. Remove the gas spring from the frame, and remove the hinge bolts located on the counterweight. The seat does not have to be removed.

Removing controller Remove all cables connected to the controller. During removal, record cable connecting locations so that they can be reconnected to the original positions. Disconnect all harness connectors, and bind them to keep them out of the way during rear axle removal.

Removing motor and hydraulic pump Disconnect the cables and harness connectors of the motor. Arrange an oil pan to receive drained oil, and remove hoses 6, 7 and pipe 8. Do not remove the pipe on the suction side.

Removing hydraulic tank Disconnect hoses 10, 11, then remove the hydraulic tank. Since the tank contains oil, keep the tank balanced during removal.

8-5

REAR AXLE

Removal (Part 2)

15 13 16

206816

Sequence 13 14

Connector Overflow hose

15 16

Suggestions for Removal A steering sensor is mounted on the top of the rear axle. Be careful not to damage the sensor when lifting the assembly.

Installation Follow the removal sequence in reverse.

Suggestions for Installation Tighten the rear axle assembly mounting bolts to the specified torque.

Bolt tightening torque 436 N·m (44.5 kgf·m) [322 lbf·ft]

8-6

Steering hose Rear axle assembly and Steering axle assembly

REAR AXLE

Procedures and Suggestions for Disassembly and Reassembly Steering Axle Disassembly

7 8

6 5 4 3 2 1

Sequence 1 2 3 4 5

Cap Nut Lock washer Nut Taper roller bearing

6 7 8 9

Suggestions for Disassembly 1. Removing wheel hubs

Use a puller to remove the wheel hubs from the steering axle.

8-7

Wheel hub, Hub bolt Oil seal Taper roller bearing Steering axle

206817

REAR AXLE

Reassembly

7 211051

Sequence 1 2 3 4 5

Steering axle Taper roller bearing Oil seal Wheel hub Taper roller bearing

6 7 8 9

Nut Lock washer Nut Cap

Suggestions for Reassembly 1. Assembling wheel hubs

(1) Insert the inner races of the taper roller bearings using the bearing installer A (special tool).

Special tool needed Bearing installer A

91268 - 01500

206820

8-8

REAR AXLE

(2) Filling insides of rear axle hubs with grease Insert grease into the rear axle hubs. See the diagram for proper grease filling condition. Add grease to the roller holding devices. Fill grease to approximately 80% of the cavity. Do not add grease to the full level. Adding grease to the maximum level causes excessive heat generation and quickly deteriorates the grease. When coating oil seal lips with grease, be careful not to apply too much grease, as an excessive amount of grease can cause leaks.

Refilling with grease

206821

2. Preload adjustment and lock nut

First, adjust the inside nut, next tighten the outside nut (lock nut) to the specified torque, and then, check the preload. To measure the preload, attach a spring balance to one of the hub bolts, then read the force to start the rotation of hub. Use the following allowable ranges when readjusting used bearings.

Preload of hub bearing

Inside nut

0.5 to 5 N·m (0.051 to 0.51 kgf·m) [0.37 to 3.7 lbf·ft]

Tangential force on hub bolt

6.5 to 65 N (0.66 to 6.6 kgf) [1.46 to 14.6 lbf]

Lock nut tightening torque

157 N·m (16 kgf·m) [116 lbf·ft]

8-9

Outside nut 206821

REAR AXLE

Rear Axle Assembly Disassembly

Section A 10

4 11

9 7

8 A

3 5 15

6 13

4 207204

Sequence 1 2 3 4 5 6 7 8 9

Bolt Plate Shim Pinion gear Taper roller bearing (inner) Taper roller bearing (inner) Bolt, washer Cap Seal, O-ring

10 11 12 13 14 15 16 17

8-10

Bolt, washer Piston assembly Rack gear Oil seal Oil seal Taper roller bearing (outer) Taper roller bearing (outer) Housing

REAR AXLE

Suggestions for Disassembly

Press

1. Removal of the pinion gear 17

Remove bolt 1, plate 2 and shim 3. Position housing 17 on a base, and use a press to remove pinion gear 4.

2. Inspect taper roller bearing (inner) 6 which is press-fit in pinion gear 4 and taper roller bearings 15, 16 which are press-fit in housing 17. If the roller bearings are in good condition, they do not have to be removed.

Inspection after Disassembly 1. Housing Inspect the sliding surface of piston assembly 11 for damage. If there are small scratches on the surface, use sandpaper to remove the scratches.

2. Pinion gear and rack gear Inspect the tooth surfaces for damage. Inspect the steering axle mounting screw at the lower pinion gear section for damage. Inspect the contact section of the oil seal at the lower pinion gear section for damage.

3. Taper roller bearing Inspect the rolling contact surface of the bearing. 4. Inspect the contact section of the oil seal of plate 2 for damage.

5. Oil seal, O-ring and other parts Replace oil seals 4, 5, other seals, O-ring 9, and piston seal of piston assembly 11 with new parts.

8-11

207205

REAR AXLE

Reassembly 16

Section A 12 8

9 11

10 A

B 14 3

13 5

Sequence 1 2 3 4 5 6 7 8 9

Housing Taper roller bearing (outer) Taper roller bearing (outer) Oil seal Oil seal Rack gear Piston assembly Bolt, washer Seal, O-ring

10 Cap 11 Bolt, washer 12 Pinion gear 13 Taper roller bearing (inner) 14 Taper roller bearing (inner) 15 Shim 16 Plate 17 Bolt B: Overflow port

For reassembly, follow the disassembly sequence in reverse.

Suggestions for Reassembly 1. When inserting oil seals 4, 5 into housing 1, use a backing plate and strike the oil seals uniformly to set the seals evenly into position. 8-12

207204

REAR AXLE

2. Before installing piston assembly 7, apply sealant 1E2200J on the periphery of the piston and the sliding surface of housing 1. 3. When installing taper roller bearings (inner) 13, 14, coat them with hydraulic oil. 4. Coat the lips of oil seals 4, 5 with hydraulic oil and install the seals.

To adjust the bearing end play after the installation of taper roller bearings 13, 14, measure clearance between pinion gear 12 and taper roller bearing 14. Subtract a value of 0.01 to 0.035 mm (0.0004 to 0.0014 in.) from the measured value, and insert a shim having the thickness of the calculated value, then tighten plate 16.

Clearance

Clearance – 0.01 to 0.035 mm = Shim thickness (0.0004 to 0.0014 in.)

207206

6. Tighten bolt 17 to the specified torque.

Bolt tightening torque

45 ± 7 N·m (4.6 ± 0.7 kgf·m) [33.2 ± 5.2 lbf·ft]

7. After reassembly, pour hydraulic oil into overflow port B until the oil surface reaches the overflow port. Cover the overflow port with tape.

8-13

REAR AXLE

Inspection and Adjustment Making sure of Minimum Turning Radius (1) While operating the vehicle at low speed, turn the steering wheel all the way to the right, then to the left, and check the diameter of the tire tracks in both turning operations. (2) Calculate minimum turning radius R by dividing the turning diameter by two then adding the distance between the center of the outside rear wheel and the outside edge of the counterweight.

Unit : mm (in.) 206822

Item Truck Model

Minimum turning radius

FB16NT

1517 (59.7)

FB18NT

1620 (63.8)

FB20NT

1645 (64.8)

8-14

REAR AXLE

Service Data

A: Standard value Truck Model 1 ton class

2 ton class

Item Preload of hub bearing 1

N·m (kgf·m) [lbf·ft] A

Tangential force on hub bolt Rear axle

N (kgf) [lbf] A

Lock nut 2

Tightening torque N·m (kgf·m) [lbf·ft]

0.5 to 5.0 (0.051 to 0.51) [0.37 to 3.7] 6.5 to 65 (0.66 to 6.6) [1.46 to 14.6]

157 (16) [116]

Rear axle tightening bolt 3 A

436 (44.5) [322]

Steering axle tightening bolt 4 A

224 (22.9) [166]

Wheel nut 5

157 (16) [116]

Plat bolt 6

45 ± 7 (4.6 ± 0.7) [33.2 ± 5.2] 6

4 5 1

2 211052

8-15

BRAKE SYSTEM Specifications .......................................................................................... 9 – 1 Structure and Functions ....................................................................... 9 – 2 Caliper Assembly ...................................................................................... 9 – 3 Brake Pedal Assembly .............................................................................. 9 – 4 Master Cylinder ........................................................................................ 9 – 5 Parking Brake Lever .................................................................................. 9 – 6

Procedures and Suggestions for Disassembly and Reassembly ............................................................................................. 9 – 7 Master Cylinder ........................................................................................ 9 – 7

Inspection and Adjustment ................................................................. 9 – 9 Pad Clearance Adjustment ....................................................................... 9 – 9 Brake Pedal Adjustment ............................................................................ 9 – 9 Brake Switch Installation ........................................................................... 9 – 10 Brake Fluid Line Bleeding ......................................................................... 9 – 10 Parking Brake Adjustment ......................................................................... 9 – 10

Troubleshooting ....................................................................................... 9 – 11 Service Data ............................................................................................ 9 – 12

BRAKE SYSTEM

Specifications Truck Model 1 ton class

2 ton class

Item Type

Hydraulic (mechanical) motor disc brake system

Brake disc effective diameter mm (in.)

162 (6.378)

Disc outside diameter mm (in.)

200 (7.874)

Disc thickness mm (in.) Disc effective thickness mm (in.) Brake system

Main brake and parking brake

Pad area cm2 (in2.) Pad thickness mm (in.)

10 (0.39) 9 (0.35) 28.8 × 2 (4.46 × 2) 5 (0.2)

Pad effective thickness mm (in.)

4 (0.16)

The minimum clearance of disc and pads mm (in.)

0.4 (0.016)

Pad material

NS 179

Wheel cylinder inside diameter mm (in.) Wheel cylinder area cm2 (in2.)

9-1

19.05 (0.75) 2.85 (0.44)

BRAKE SYSTEM

Structure and Functions 8

5 7

4 206824

1 2 3 4

Caliper assembly Brake disc Traction motor Brake pedal assembly

5 6 7 8

Reservoir tank Parking lever assembly Equalizer bracket Lever D

The brake pads clamp the brake disc, mounted on the traction motor, to provide stopping force.

The brake pedal assembly is mounted on the left side of the frame.

The caliper assemblies are installed on the rib section of the drive motor.

The cable linked to the parking lever pulls lever D of the caliper to provide stopping force.

9-2

BRAKE SYSTEM

Caliper Assembly 8

1 3

9 10 4 8

5 14

13 1

8 10

6 11 5

12 4

206825

1 2 3 4 5 6 7

Body assembly Lever A Lever B Pin, Split pin Lever C Lever D Pin, Split pin

8 9 10 11 12 13 14

Pin Spring Pad assembly Bolt, Washer Adjustment bolt Adjustment bolt Lock nut, Washer

15 Spring 16 Bleeder screw 17 Brake disc A: Brake fluid inlet B: Parking brake cable mounting hole

link sides, causing the pad assembly to clamp the brake disc. When the parking brake cable connected to section B pulls the lever in the direction of the arrow, the pad assembly operates mechanically. Adjustment bolts 12, 13 and spring 15 maintain proper clearances between the brake disc and pads. The caliper assembly installed on the opposite side of the vehicle is symmetrically constructed.

The brake pads clamp the brake disc, mounted on the traction motor, to provide stopping force. The caliper assemblies are installed on the traction motor. Pressurized brake fluid entering from section A pushes the piston into the cylinder of the body assembly. The piston then presses pin 7, which then pushes levers C and D to an open position. Levers A and B move with pin 4 as the fulcrum and open their 9-3

BRAKE SYSTEM

Brake Pedal Assembly

Brake fluid

5 7

1 4 211053

1 2 3 4

Pedal bracket Brake pedal Brake link Return spring

5 6 7

Master cylinder Adjustment bolt Brake switch

Brake fluid is supplied to the master cylinder from the reservoir tank located under the left side of the dashboard.

The brake pedal assembly is mounted on the left side of the frame. The adjustment bolt is used to set the brake pedal height. The installation length of the brake switch is preadjusted. When the pedal is pressed, the switch activates and controls the operating speed of the traction motor.

9-4

BRAKE SYSTEM

Master Cylinder

12 13 1 8 10

14 15 16 5

17 18

211054

1 2 3 4 5 6 7 8 9

Cylinder body Safety ring Piston Secondary cup Primary cup Spring pad Spring Dust cover Push rod

10 11 12 13 14 15 16 17 18

The inside diameter of the cylinder is 19.05 mm (3/4 in.), and the maximum stroke is 30 mm (1.2 in.).

9-5

Clevis Nut Filler Gasket Clevis pin Snap pin Valve Valve body Valve seal

BRAKE SYSTEM

Parking Brake Lever

5 6 4 7 Maximum stroke: 50°

2 8

211055

1 2 3 4

Lever body Gear Notch Grip

5 6 7 8

Stopper Spring Hook Pin

The maximum lever stroke is 50 degrees. There are a total of 14 gear teeth. Adjust the parking brake so that the brake activates and applies force when the third or fourth tooth of gear 2 engages with the notch.

The parking brake lever is mounted on the left side of the dashboard. When the grip is pulled, the parking brake cable moves the pad assembly of the caliper to clamp the brake disc and apply stopping force. Notch 3 engages with gear 2 to retain the lever in position. To release the parking brake, pull the grip and press stopper 5. This disengages the gear from the notch, and the lever returns to the original position.

Grip operating effort

9-6

343 N (35 kgf) [77 lbf]

BRAKE SYSTEM

Procedures and Suggestions for Disassembly and Reassembly Master Cylinder Disassembly

8 6 5

4 2

213017

Sequence 1 2 3 4

Clevis, Nut, Push rod Boot Stopper ring Secondary cup, Piston

5 6 7 8

NOTE Parts marked with (❋) are included in the repair kit.

9-7

Cup spacer, Primary cup, Spring seat Return spring Cylinder body Filler, Clamp

BRAKE SYSTEM

Inspection after Disassembly 1. Cylinder body

(1) Check the inner surface of the cylinder for rust, corrosion and scuffing. (2) Check the inlet port and relief port for clogging. And check the joint bolts and boot for damage. A : Standard value B : Service or repair limit

2. Piston

Check the piston for damage, and replace if damaged. If the clearance between the piston and cylinder exceeds the limit, replace both cylinder and piston.

Clearance between cylinder and piston

3. Return spring

Replace the return spring once a year. 4. Primary cup, Secondary cup and Spring seat

Inspect rubber parts for damage and swelling. Replace the primary cup, secondary cup and spring seat once a year.

Reassembly Follow the disassembly sequence in reverse. Also follow the instructions below. (1) Clean metal parts with a volatile cleaning solution, and thoroughly dry using compressed air. (2) Apply a thin coat of brake rubber grease (Metal Rubber #20) or brake fluid on the inner surface of the cylinder and the piston cup.

9-8

0.020 to 0.105 mm (0.0008 to 0.0041 in.)

0.2 mm (0.0078 in.)

BRAKE SYSTEM

Inspection and Adjustment Pad Clearance Adjustment Pad B

Loosen the lock nut and turn adjustment bolt A to adjust pad A clearance. Pad B moves as adjustment bolt A is turned. Therefore, use adjustment bolt B to adjust pad B clearance. One rotation of adjustment bolt A moves pads A and B approximately 1 mm (0.04 in.) to the right or left according to the direction of the bolt rotation. One rotation of adjustment bolt B moves pad B approximately 1 mm (0.04 in.) to the right or left according to the direction of the bolt rotation. Adjust the clearance to a range of 0.4 to 1.1 mm (0.0157 to 0.0433 in.) at the tip on each side.

Clearance Pad A

Lock nut Adjustment bolt

206825A

Adjustment bolt A

After adjustment, tighten the lock nut. 2.94 to 5.88 N·m (30 to 60 kgf·cm) [2.17 to 4.34 lbf·ft]

Lock nut tightening torque

Adjustment bolt B 206825B

Brake Pedal Adjustment (1) Use the stopper bolt to adjust pedal height A (distance between frame and the top of pedal pad). (2) Set push rod length B to the specified dimension, and install the push rod into the master cylinder. The clearance between the push rod and piston should be 0.5 to 1.5 mm (0.02 to 0.06 in.). The pedal play C should be 3 to 9 mm (0.12 to 0.35 in.).

C D

A’ A Stopper bolt

(3) After adjustment, check to make sure that pedal stroke D (brake activating point) is as specified. Unit : mm (in.) Truck Model Item

1 ton class

2 ton class

Pedal height A from floor plate

192.6 (7.58)

Pedal height A’ from frame

198.6 (7.82)

Push rod length B

118.6 (4.67)

Free play C Pedal stroke D (brake activating point)

3 to 9 (0.12 to 0.35) 21 to 32 (0.8 to 1.3) 9-9

206830

BRAKE SYSTEM

Brake Switch Installation (ON/OFF point)

(1) Use the adjustment bolt to adjust the brake pedal height, then tighten the lock nut.

0.7 to 1.3 mm (0.027 to 0.05 in.)

Brake switch

(2) By rotating the push rod of the brake master cylinder, adjust the clearance between the push rod and piston to a range of 0.5 to 1.5 mm (0.019 to 0.059 in.). When properly adjusted, the pedal should travel a distance of 3 to 9 mm (0.12 to 0.35 in.) when pressed. (3) Install the brake switch, and adjust so that the switch activates when the brake pedal is pressed 7 to 13 mm (0.27 to 0.51 in.). Then, tighten the lock nut.

Lock nut 205753

The brake switch should turn ON and OFF with pedal movement of 0.7 to 1.3 mm (0.027 to 0.051 in.).

Brake Fluid Line Bleeding When any part of the brake fluid system is disassembled for repair or when brake pedal movement is spongy, bleed the brake fluid line as follows: (1) Attach a clear vinyl tube to the bleeder screw of the right caliper assembly, which is located furthest from the master cylinder. (2) Check the brake fluid level in the reserve tank. Add if the level is low. (3) Pump the brake pedal several times, and then keep the pedal pressed. While holding the pedal pressed, loosen the bleeder screw. While brake fluid is flowing into the vinyl tube, tighten the bleeder screw. (4) Repeat the above procedure until no air bubbles are in the brake fluid. Repeat the same procedure to bleed the left caliper assembly. After air bleeding is completed, add brake fluid in the tank to the specified level.

Parking Brake Adjustment When the pad clearances are adjusted to approximately 1.1 mm (0.043 in.), the notch should engage with the third or fourth tooth of the gear when the parking brake lever is pulled. If the pads are worn, tighten the adjustment bolts of the calipers to adjust the clearances. To adjust the cable length, use the cable adjustment bolt.

206833

9-10

BRAKE SYSTEM

Troubleshooting

Inspect cylinder. If no abnormality is found, replace piston cup. If piston cup is deformed, replace cup and brake fluid (use genuine brake fluid).

Oil leak from oil pipe joint

Re-tighten, or replace pipe and joint.

Inadequate braking force

Excessive pedal stroke Foot brake

Imbalance in braking power

Brake squealing

Parking brake stroke too short

Parking brake

Abnormal noise from hand brake during driving

Parking brake not producing stopping force

Oil leak from master cylinder primary cup Oil leak from caliper cylinder cup

Worn lining

Replace.

Oil adhesion on lining

Clean with brake component cleaner and repair or replace.

Air in hydraulic system

Bleed master cylinder and caliper cylinder.

Faulty master cylinder or piston cup

Replace piston cup.

Low oil level in master cylinder

Add brake fluid.

Excessive clearance of master cylinder push rod

Adjust.

Brake fluid leak

Refer to above section marked with *.

Oil or grease adhesion on lining or disc

Clean with brake component cleaner and repair. If oil and grease cannot be removed from lining, replace lining.

Brake disc wobbling or loose mounting

Replace disc. If problem is caused by loose mounting, re-adjust and re-tighten.

Lining surface too smooth

Replace brake pad.

Worn lining Loose caliper tightening bolt

Re-tighten.

Dirty disc

Clean with brake component cleaner.

Inadequate clearance between disc and lining

Adjust to standard clearance value.

Parking brake cable too short

Adjust cable length using adjustment bolt.

Inadequate clearance between brake pad and disc

Adjust to standard clearance value.

Warped brake disc

Repair brake disc according to repair standard, or replace.

Parking brake cable too long

Adjust cable length using adjustment bolt.

Brake lining worn beyond limit

Replace brake pad.

Excessive clearance between brake pad and disc

Adjust clearance between brake pad and disc.

9-11

BRAKE SYSTEM

Service Data

A: Standard value Unit: mm (in.) Truck Model 1 ton class

2 ton class

Item

Brake pedal

Pedal height 1 (between upper pedal edge and floor)

192.6 (7.58)

Pedal stroke 2 (brake activating point)

21 to 32 (0.8 to 1.3)

Free play 3

3 to 9 (0.12 to 0.35)

Push rod length 4 (standard assembly dimension)

118.6 (4.67)

Clearance between piston and push rod 5

0.5 to 1.5 (0.019 to 0.059)

Brake switch activating pedal stroke 6

7 to 13 (0.27 to 0.51)

Brake switch activating dimension 7

0.7 to 1.3 (0.027 to 0.05)

6 3 7 1

9-12

206831

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model 1 ton class

2 ton class

Item Cylinder body inside diameter 1

+0.052

Piston outside diameter 2

19.05 0

Clearance between cylinder and piston Primary cup lip-side outside diameter 3 Secondary cup lip-side outside diameter 4 Master cylinder Return spring free-movement length 5

19.05

-0.020 -0.053

+0.00205

(0.7500 0 (0.7500

-0.00079 -0.00209

) )

0.020 to 0.105 (0.00079 to 0.00413 )

0.2 (0.08)

20 -0.3 (0.79 -0.012)

(Replace once a year.)

20.2 ± 0.2 (0.795 ± 0.008 )

(Replace once a year.)

46.8 (1.843 )

(Replace once a year.)

5 208380A

9-13

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model 1 ton class

2 ton class

Item Tightening torque N·m (kgf·cm) [lbf·ft]

Pad assembly tightening bolt 1

17.65 to 26.48 (180 to 270) [13.02 to 19.53]

Adjustment bolt lock nut 2 A

2.94 to 5.88 (30 to 60) [2.17 to 4.34]

Bleeder screw 3

6.86 to 11.77 (70 to 120) [5.06 to 8.68]

5 (0.2)

1 (0.039)

Lever D pin hole stroke with 1.1 mm (0.043 in.) of clearance between brake disc and pad 5

5 (0.197)

Lever D pin hole stroke with 4 mm (0.157 in.) of pad thickness wear 6

20 (0.787)

Brake disc thickness 7

10 (0.394)

Pad lining thickness 4

Caliper 4 2

206832

9-14

STEERING SYSTEM Specifications ..........................................................................................10 – 1 Structure and Functions .......................................................................10 – 2 General .....................................................................................................10 – 2 Steering Control Valve ..............................................................................10 – 3

Procedures and Suggestions for Removal and Installation .......10 – 4 Steering Column Assembly .......................................................................10 – 4

Steering Control Valve ..........................................................................10 – 6 Disassembly .............................................................................................10 – 6 Inspection .................................................................................................10 – 8 Reassembly ..............................................................................................10 – 9

Hydraulic Circuit Diagram .................................................................... 10 – 14 Troubleshooting ...................................................................................... 10 – 15 Service Data ............................................................................................ 10 – 16

STEERING SYSTEM

Specifications Truck Models Items Type

1 ton class

2 ton class

All hydraulic power steering

Diameter of steering wheel

mm (in.)

Manufacturer

328 (12.9) Ognibene

Steering control valve Flow rate

liter (cu. in.) /min

10-1

7.6 (464)

STEERING SYSTEM

Structure and Functions General 3

P R

Priority valve

LS 1

Oil flow Tank 1

Pump 2

Right turn: R

Left turn:

T L

Tank 1 211349

1 2 3 4

Hydraulic tank Hydraulic pump Steering wheel Steering gear

5 6 7 8

Steering cylinder Hydraulic control valve Pressure switch Return line

the steering wheel and forces the oil into the steering cylinder through port R or L. This pushes the piston in steering cylinder 5 and forces the oil on the other side, towards port L or R of the steering gear. The oil then goes out of the steering gear through port T and enters port T2 of hydraulic control valve 6. From port T1 of the hydraulic control valve, the oil flows into hydraulic tank 1.

The steering system of this vehicle is hydraulically operated and controlled. The oil drawn by hydraulic pump 2 from hydraulic tank 1 is forced to steering gear 4 through port CF in the priority valve. When steering wheel 3 is not turned, the oil from port CF is blocked by the directional control valve in steering gear 4. When the operator turns the steering wheel, the oil flows through the control valve (that is now opened) to a small hydraulic pump in the steering gear. The pump rotor in the small hydraulic pump rotates together with

When the operator stops rotating the steering wheel, the flow of oil through the steering gear is interrupted.

10-2

STEERING SYSTEM

Steering Control Valve

T L

R P

9 10

12 4

208230

1 2 3 4 5 6 7

Long housing Spacer plate “Gerotor” set End cap Thrust needle Centering spring Pin

8 9 10 11 12 13

Drive shaft Control sleeve Control spool Spacer Spacer Check valve

10-3

P: Pump port T: Tank port L: Cylinder port (left) R: Cylinder port (right)

STEERING SYSTEM

Procedures and Suggestions for Removal and Installation Steering Column Assembly Removal

8 5

B 2 9 B 10

A 9

7 7

211085

Sequence 1 2 3 4 5 6

Steering wheel, Cap, Nut, Washer Console box (front panel) Central vehicle monitor panel Direction lever Console box (rear panel) Floor plate

7 8 9 10

10-4

Hose, Pipe, Hose clamp, Connector, O-ring Tilt steering lock lever, Spacer, Shaft, Bolt, Split pin Pin, Washer, Split pin Steering column assembly

STEERING SYSTEM

Suggestion for Removal Steering wheel removal

Use the Wheel puller (special tool). Special tool needed Wheel puller

91268 - 10600

205770

Inspection

(1) Steering wheel free play Check the free play with the key switch in the ON position. (2) Steering effort (a) Apply the parking brake with the key switch in the ON position, operate the lift lever to raise and lower the lift bracket until the hydraulic oil temperature increases to 30 to 60°C (86 to 140°F). (b) Attach a spring scale to the rim (or a spoke) of the steering wheel. Pull the scale in a tangential direction and read the scale just as the wheel begins to turn.

Steering effort

1.6 N·m (0.16 kgf·m) [1.18 lbf·ft]

Spring balance reading

16 N (1.6 kgf) [3.6 lbf]

10-5

206836A

STEERING SYSTEM

Steering Control Valve Disassembly

4 11 6 5

7 9 8 10

208232

Sequence 1 2 3 4 5 6

End cap, Bolts, O-ring and Spacers “Gerotor” set, O-ring Drive shaft, Spacer plate and O-ring Retaining ring Seal gland bushing, O-ring, Oil seal and Dust seal Thrust needle, Race bearing

7 8 9 10 11 12

10-6

Control sleeve Control spool Pin Centering springs Check valve, Check ball retainer, Ball, O-ring, Check seat and Screw Long housing

STEERING SYSTEM

Suggestions for Disassembly (1) Retaining ring removal Remove the ring from the housing by prying the end of the ring out of the groove. Do not damage the machined surface.

208233

(2) Seal gland bushing removal Position the control spool and control sleeve assembly so that the pin is even with the center of the assembly. Remove the bushing.

208234

(3) Control spool and sleeve removal Remove the control spool and sleeve assembly from the housing by pulling it toward the end of the housing opposite to the flange. Remove the pin from the assembly.

NOTE To prevent damage to the housing, slowly pull out the assembly while twisting. 208235

(4) Control spool and sleeve disassembly

NOTE Before removing the spool from the sleeve, put a mark across the spool and sleeve so that the spool can be installed in the same position.

Pull the control spool from the sleeve enough to permit removal of the centering springs. Remove the centering springs. Remove the spool from the sleeve by pulling it toward the rear end of the sleeve while turning slowly. 10-7

200668

STEERING SYSTEM

Inspection Spool movement in housing and sleeve (a) Check for sliding movement in the sub-assembly condition. (b) If any defective movement is found, check sliding surfaces. If any defect such as abnormal wear, scratch, burr or rust is found, replace the entire unit with a new one.

10-8

STEERING SYSTEM

Reassembly

2 9 7

208236

Sequence 1 2 3 4 5 6

Long housing Check valve, Check ball retainer, Ball, O-ring, Check seat and Set screw Control sleeve Control spool Centering springs Pin

7 8 9 10 11 12

Start by :

(a) Replace worn or defective parts. (b) Wash all metal parts and blow dry. (c) Replace O-rings and seals. (d) Apply grease to O-rings and other sealing parts.

10-9

Thrust needle, Race bearings Seal gland bushing, Oil seal, Dust seal and O-ring Retaining ring Drive shaft, Spacer plate and O-ring “Gerotor” set, O-ring End cap, O-ring, Spacer and Bolts

STEERING SYSTEM

Suggestions for Reassembly (1) Check valve assembling Put the retainer in position on the housing. Put the seat in position in the housing with the hole at the bottom. Apply Loctite 271 to the threads of the set screw and tighten the screw to the specified torque. 11.3 N·m (1.2 kgf·m) [8.3 lbf·ft]

Tightening torque for set screw

208237

(2) Control spool and sleeve assembling Check the direction in which the spring groove of the sleeve is aligned with that of the spool and then, slide the spool into the sleeve while twisting the spool. If there are any alignment marks made at the time of disassembly or alignment marks installed by the manufacturer, use the marks to align the assemblies.

NOTE 200670

Check that the control spool rotates smoothly in the control sleeve.

(3) Centering spring installation Align the spring grooves of the spool-and-sleeve and stand the spool-and-sleeve on a flat bench. Use the spring inserting tool to install springs. Place each set of three springs back to back and pinch six springs in the tool with notches on both sides facing downward. See the illustration on the right. As shown in the illustration, push one end of the springs with fingers and push the springs into the spool-and-sleeve groove. In case there is no inserting tool, assemble the springs by inserting them one by one and right and left alternately. Spring inserting tool

97157 - 00100

10-10

200671

STEERING SYSTEM

(4) Control spool and sleeve assembly installation to housing Insert the pin into the hole of the control spool-andsleeve assembly and align both ends of the pin with the outside diameter of the sleeve. Insert the spool-andsleeve assembly into the housing from the rear (in the direction as shown in the illustration). Insert the spool-and-sleeve assembly while slowly twisting it with the pin kept at a horizontal position. Insert the spool-and-sleeve assembly until its rear edge face becomes flush with the edge face of the housing. Do not insert any further.

208238

(5) Seal installation • Install the dust seal on the seal gland bushing to place the flat side facing the bushing. • Install the quad ring seal in the bushing by smoothing it into place with your finger.

207184

(6) Reassembling the seal gland bushing • Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a soft head mallet. Make sure the bushing is flush against the bearing race.

208239

• Install the retaining ring in the housing and pry it with a screwdriver around the entire circumference to ensure a good sitting.

207195

10-11

STEERING SYSTEM

(7) Reassembling the wear plate • Clamp the housing in a vise, equipped with soft jaws or softened with rag. Clamp lightly over the flats of the flange. Do not overtighten the vise jaws.

NOTE Check that the spool and sleeve are flush with or slightly below the surface of the housing. 208240

• Install the O-ring in the housing. Place the spacer plate on the housing and align the bolt holes with the tapped holes in the housing.

208241

(8) Reassembling the drive shaft Turn the control spool-and-sleeve assembly to make the port surface of the housing parallel with the pin. Insert the drive shaft to engage the pin in the yoke of the drive shaft. To ensure positioning in the following work process, draw a line such as line B in the illustration right below on the end face of the drive shaft spline with a felt-tip pen.

Port surface Drive

Pin parallel with port surface Pin 208242

10-12

STEERING SYSTEM

(9) Reassembling the Gerotor set • Install O-ring in the Gerotor set.

Gerotor set star valley

• Face the O-ring side of the Gerotor set toward the spacer plate side. Fit the Gerotor set into the drive shaft by aligning the root (line A) of the Gerotor set with line B of the drive shaft.

A B

Drive(marked)

Check that lines A, B, C, and D are in parallel with each other.

Align bolt holes of the Gerotor set with the drive shaft and star kept engaged. This procedure is important in determining the valve timing of this unit.

Port surface

208243

(10) Reassembling the end cap • Install the drive spacer in the Gerotor set. Install the O-ring in the end cap. Install the end cap in the Gerotor set and align the holes.

End cap Cap screw

O-ring Drive spacer 208244

• Apply oil to bolt threads and tighten bolts evenly in the sequence as shown in the illustration on the right. The tightening torque is shown in the table below. Initial torque for screws

12 N·m (1.2 kgf·m) [8.9 lbf·ft]

Finishing torque for screws

22 N·m (2.2 kgf·m) [16.2 lbf·ft]

200677

After installing the end cap, install the steering shaft to the spool and make sure the spool rotates smoothly.

10-13

Hydraulic control valve (AC motor, MC models )

P 18.1 MPa

10-14 T2

Return filter 15 mm

M Pump motor 36/48V Dual voltage 11.56 kW Operation at 48V

Priority valve

Pressure switch

Suction strainer 100 mesh

Gear pump Displacement: 24.5 cm3 (1.49 cu. in.)/rev

Displacement: L 63 cm3 (3.8 cu. in.)/rev

Steering cylinder

213018

STEERING SYSTEM

Hydraulic Circuit Diagram

STEERING SYSTEM

Troubleshooting

Clogged metering section

Disassemble and clean.

Faulty spool operation

Disassemble and clean.

Faulty bearing

Disassemble and replace.

Faulty piston seal

Replace.

Others

Flattened pipe, mixing of foreign particles

Clean or replace oil line.

Control valve malfunction

Sticking of spool or sleeve

Replace.

Damaged centering spring

Replace.

Flattened pipe, mixing of foreign particles

Clean or replace oil line.

Faulty piston seal in rear axle cylinder

Replace.

Control valve malfunction Heavy steering wheel operation

Rear axle cylinder malfunction

Instability in steering wheel operation Others

10-15

STEERING SYSTEM

Service Data A: Standard value Unit: mm (in.) Truck Models 1 ton class

2 ton class

Items Steering effort (at steering wheel rim) N·m (kgf·m) [lbf·ft] (Standard value measured with key switch ON, A steering wheel turning speed of 1 revolution/sec, and stationary swing operation) Steering wheel Turning angle

Inside wheel

83°

Outside wheel

56°

Steering wheel nut

A 53.9 to 58.8 (5.5 to 6.0) [39.8 to 43.4]

Steering bracket bolts

deg

Tightening torque N·m (kgf·m) [lbf·ft]

29.4 (3) [21.7]

Displacement

cc (cu. in.)/rev. A

63 (3.84)

Rated flow rate

liter (cu. in.)/min. A

7.6 (464)

Maximum operating pressure

6.5 (66.3) [943]

End cap bolts 1

22 (2.2) [16.2]

Check valve set screw 2

11.3 (1.2) [8.3]

MPa (kgf/cm2) [psi] Tightening torque N·m (kgf·m) [lbf·ft] Steering control valve

1.6 (0.16) [1.18]

208246

10-16

MCFA Document # 000012-09M Issue Date 3/16/2009

TITLE: Voltage Check & Code Verification

MODEL AND SERIAL NUMBER:

FB16NT, FB18NT, FB20NT EFB12-00011+, EFB14-00011+, EFB14-50001+

SUBJECT: A voltage check and code verification worksheet will make troubleshooting error codes quicker and easier.

CAUSE: Unpublished information, that will provide a relation from the code to the wire number.

The information provided on this web site is considered to be confidential information and is intended to assist you in resolving product issues. In addition, the information on this web site is not to be considered as an authorization for any financial claim against MCFA. Always follow all Safety, Warning, Caution and Precaution information that is provided in the appropriate Service Manual and Operation and Maintenance Manual(s).

RESOLUTION: Through practical testing, we have established which wires are associated with each code based on disconnection.

Conn

Wire

Exp. Gen. Code Code

CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN3 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN2 CN1 CN1 CN1 CN1 CN1 CN1

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

241 242 243 244 211 212 205 204 201 N/A N/A N/A N/A 149 N/A 150 202 203 269 142 N/A N/A 140 141 108 N/A N/A N/A N/A N/A N/A 310 111 109 109 107 104 103 139 153 153 153 153 N/A N/A 144 N/A 311 245 246 N/A 307

None 78 None 78 62 62

None N/A N/A N/A N/A 60 N/A 60 60 60 51 N/A N/A None 78 None N/A N/A N/A N/A N/A N/A None None None None None

Oil 50 50 50 50 N/A N/A 51 N/A None None None N/A

None Multi None 60 63, 64, 65 63, 64, 65 None None None N/A N/A N/A N/A 60 N/A 60 None None 78 51 N/A N/A None 51 E, L N/A N/A N/A N/A N/A N/A None None None None None None None None None None None None N/A N/A 51 N/A None None None N/A None

Term Point

CN4-11 CN4-9 CN4-12 CN4-10 CN21-1 CN21-2 CN21-6 CN21-5 GND N/A N/A N/A N/A CN8-149 N/A CN8-150 CN21-9 CN21-7 BATT (+) CN16-142 N/A N/A GND CN16-141 GND N/A N/A N/A N/A N/A N/A CN25-310 CN25-111 PDS RELAY 2 PARK BRK SW FOOT BRK CN10-104 CN10-103 BRK FLD SNSR PDS RELAY 5 CN13-153 HEAD LAMP 6 HEAD LAMP 8 N/A N/A CN16-144 N/A PDS RELAY 3 CN17-245 CN17-246 N/A CN22-307

Volt Volt Key Key On Off 0 0.03 0.01 14.84 0 0.03 0 5.04 0 2.95 0 2.37 0 4.81 0 4.81 0 0.03 N/A N/A N/A N/A N/A N/A N/A N/A 0 9 N/A N/A 0 2.9 0 9.63 (-) 0 0.03 37.24 0 0 0.4 N/A N/A N/A N/A 0 0.06 0 5.04 0 0.03 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 0 0.03 0 11.75 36.82 11.76 36.82 11.76 0 11.75 0 36.5 0 11.76 0 11.75 0 0.15 0 0.15 0 0.15 0 0.15 N/A N/A N/A N/A 0 11.74 N/A N/A 0 36.75 0 11.76 0 11.75 N/A N/A 0 11.75

Symptoms

Normal Operation Lo, H1, H2, H3, H4, H5, 51, 63, 64, 65, 78 @ Startup Normal Operation No Operation @ Startup No Operation @ Startup No Operation @ Startup Normal Operation Normal Operation Normal Operation N/A N/A N/A N/A No Operation @ Startup N/A No Operation @ Startup Normal Operation Normal Operation No Operation @ Startup No Operation @ Startup N/A N/A Flickering Screen @ Startup No Operation @ Startup No Operation @ Startup N/A N/A N/A N/A N/A N/A No Operation ; Seat Belt Buzzer Normal Operation Normal Operation ; Parking Brake Light Constant Normal Operation ; Parking Brake Light Constant Normal Operation No Reverse (Normal Op Otherwise) No Forward (Normal Op Otherwise) Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation N/A N/A On Acceleration (Forward or Reverse) N/A Normal Operation Normal Operation Normal Operation N/A Normal Operation

Conn

Wire

CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN4 CN5

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 63 64 1 2 3 3 4 4 5 5 6 6 7 8 9 10 11 12 13 13 13 13 13 13 13 13 14 14 14 14 14 14 14 14 15 16 1

306 305 304 303 114 115 116 117 309 308 247 248 N/A N/A 325 325 317 N/A N/A 252 252 253 253 254 254 255 255 N/A N/A 242 244 241 243 4 4 4 4 4 4 4 4 25 25 25 25 25 25 25 25 21 22 135

Exp. Gen. Code Code H2 H1 H1 50 50 50 50 H1 H1 40 74 N/A N/A

N/A N/A

None None None None None None None None 74 74 74 72 N/A N/A 40 40 N/A N/A 63, 64, 65 63, 64, 65 63, 64, 65 63, 64, 65 45, 46, 47 45, 46, 47 63, 64, 65 63, 64, 65 N/A N/A Multi 60 None None None None None None None None None None None None None None None None None None None APP-A 01 None

Term Point

CN22-306 CN22-305 CN22-304 CN22-303 CN28-114 CN28-115 CN28-116 CN28-117 UNL VALVE 309 UNL VALVE 308 CON (TRCT) 247 CON (PUMP) 248 N/A N/A CON (TRCT) 249 CN28-112 LIFT LOCK 317 N/A N/A CN6-17 CN7-17 CN7-18 CN6-18 CN7-16 CN6-16 CN6-20 CN7-20 N/A N/A CN3-2 CN3-4 CN3-1 CN3-3 CN4-14 LIFT LOCK 318 CN19-18 CN19-16 CN8-151 PDS RELAY 3 CN9-4 PDS RELAY 1 CN4-13 LIFT LOCK 318 CN19-18 CN19-16 CN8-151 PDS RELAY 3 CN9-4 PDS RELAY 1 BATT (-) BATT (-) CN20-135

Volt Volt Key Key On Off 0 11.76 0 11.75 0 11.76 0 11.76 0 11.76 0 11.76 0 11.76 0 0.1 0 0.03 0 0.09 0 36.99 0 36.99 N/A N/A N/A N/A 0 36.99 0 36.99 0 36.99 N/A N/A N/A N/A 0.39 14.86 0.39 14.86 0 7.97 0 7.97 0 11.99 0 11.99 0 0.03 0 0.03 N/A N/A N/A N/A 0.36 14.86 0 5.04 0 0.02 0 0.02 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 36.99 0 0.02 0 0.02 0 3.33

Symptoms

Normal Operation No Tilt Extend ; Normal Op Otherwise Half Speed Max ; Normal Op Otherwise Half Speed Max ; Normal Op Otherwise Half Speed Max ; Code 50 @ Full Speed + Turn Half Speed Max ; Code 50 @ Full Speed + Turn Half Speed Max ; Code 50 @ Full Speed + Turn Half Speed Max ; Code 50 @ Full Speed + Turn No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup N/A N/A No Operation @ Startup No Operation @ Startup N/A N/A No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup N/A N/A Lo, H1, H2, H3, H4, H5, 51, 63, 64, 65, 78 @ Startup No Operation @ Startup Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation Normal Operation No Operation ; APP-A on Left, 01 on Right Normal Operation

Conn

Wire

CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN5 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN7 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6 CN6

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13

134 234 239 133 136 137 N/A 263 N/A N/A N/A N/A 264 264 265 266 267 138 268 125 124 224 229 126 145 146 N/A N/A N/A N/A N/A N/A 257 257 254 252 253 127 255 130 129 224 229 131 147 148 258 N/A N/A N/A N/A N/A

Exp. Gen. Code Code 65 65 57 57 57 N/A N/A N/A N/A N/A

47 65 65 57 None None None 63 63 52 52 52 N/A N/A N/A N/A N/A N/A None None 45 63 63 None None None None 64 64 53 53 53 64 N/A N/A N/A N/A N/A

None 65 65 57 57 57 N/A 63, 65 N/A N/A N/A N/A None None 47 65 65 57 None None None 63 63 53 53 53 N/A N/A N/A N/A N/A N/A None None 45 63 63 53 63 None None 64 64 52 52 52 64 N/A N/A N/A N/A N/A

Term Point

CN20-134 CN21-1 CN21-2 CN20-133 CN20-136 CN20-137 N/A GND N/A N/A N/A N/A CN5-15 CN5-14 CN4-5 CN4-3 CN4-4 CN20-138 GND CN14-125 CN14-124 CN21-1 CN21-2 CN14-126 CN14-145 CN14-146 N/A N/A N/A N/A N/A N/A CN7-15 CN7-14 CN4-5 CN4-3 CN4-4 CN14-127 GND CN15-130 CN15-129 CN21-1 CN21-2 CN15-131 CN15-147 CN15-148 GND N/A N/A N/A N/A N/A

Volt Volt Key Key On Off 0

3.01

10.25

0 N/A 0 N/A N/A N/A N/A

5.01 N/A 0.08 N/A N/A N/A N/A

2.82

0.43

14.82

0.09

0 0 0 0 0 0 0 N/A N/A N/A N/A N/A N/A 0 0 0 0.53 0 0 0 0 0 0 0 0 0 0 0 N/A N/A N/A N/A N/A

3.45 0.1 2.71 2.36 10.39 5.04 0.2 N/A N/A N/A N/A N/A N/A 2.36 2.38 12 14.8 7.92 0.11 0.9 3.42 0.1 2.7 2.36 10.31 0.18 5.08 0.09 N/A N/A N/A N/A N/A

Symptoms

Normal Operation No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup N/A No Operation @ Startup N/A N/A N/A N/A Normal Operation Normal Operation No Operation @ Startup No Operation @ Startup No Operation @ Startup No Operation @ Startup Normal Operation 3-4 MPH @ Full Speed (Forward or Reverse) 3-4 MPH @ Full Speed (Forward or Reverse) No Operation @ Startup No Operation @ Startup Only @ Max Speed (Forward or Reverse) Only @ Max Speed (Forward or Reverse) Only @ Max Speed (Forward or Reverse) N/A N/A N/A N/A N/A N/A Normal Operation Normal Operation No Operation @ Startup No Operation @ Startup No Operation @ Startup Only @ Max Speed (Forward or Reverse) No Operation @ Startup 3-4 MPH @ Full Speed (Forward or Reverse) 3-4 MPH @ Full Speed (Forward or Reverse) No Operation @ Startup No Operation @ Startup Only @ Max Speed (Forward or Reverse) Only @ Max Speed (Forward or Reverse) Only @ Max Speed (Forward or Reverse) No Operation @ Startup N/A N/A N/A N/A N/A

Conn

Wire

Exp. Gen. Code Code

CN6 CN6 CN6 CN6 CN6 CN6 CN6

14 15 16 17 18 19 20

N/A N/A N/A N/A 259 46 260 64 261 64 132 None 262 None

N/A N/A 46 64 64 54 64

Term Point

N/A N/A CN4-5 CN4-3 CN4-4 CN15-132 GND

Volt Volt Key Key On Off N/A N/A N/A N/A 0 12 0.45 14.8 0 7.92 0 0.09 0 0.09

Symptoms

N/A N/A No Operation @ Startup No Operation @ Startup No Operation @ Startup Only @ Max Speed (Forward or Reverse) No Operation @ Startup

MCFA Document # 000013-09M Issue Date 3/16/2009

TITLE: Connector Pin Removal Photos & Instructions

MODEL AND SERIAL NUMBER:

FB16NT, FB18NT, FB20NT, FBC15N, FBC18N, FBC20N, FBC25N, FBC30N EFB12-00011+, EFB14-00011+, EFB14-50001+, A4BC1-10200+, A4BC1-40200+, A4BC1-20200+, A4BC1-50200+, A4BC2-10200+, A4BC2-30200+, A4BC2-20200+, A4BC2-40200+, A4BC3-40200+, A4EC3-60200+ SUBJECT: How to properly disconnect & re-attach the harness from the wire.

CAUSE: This can be used for testing, inspection, & repair of wire harnesses pins.

RESOLUTION: Demonstrate proper pin removal. In the following pages, you will see how to open the latch to remove the pins. You will also see how to unlatch the pin with a pick for easy removal.

MCFA Document # 000013-09M

TITLE:

Connector Pin Removal Photos & Instructions

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000013-09M

12 Page ______ of ______

MCFA Document # 000017-08M Issue Date February 23, 2008

TITLE: Troubleshooting AC Motor and Controller Failures Using Amp Readings from the U, V and W Cables on FBC15N - FBC30LN, FBC15NS - FBC20NS and FB16NT FB20NT Trucks

MODEL AND SERIAL NUMBER:

FBC15N, FBC18N, FBC18LN, FBC20N, FBC25N, FBC25EN, FBC25LN, FBC30N, FBC30LN Serial Number Prefixes - A4BC1, A4BC2, A4BC3, A4BC4 FBC15NS, FBC18NS, FBC20NS Serial Number Prefixes - A2BS1, A2BS2 FB16NT, FB118NT, FB20NT Serial Number Prefixes - EFB12, EFB14 SUBJECT: Information on troubleshooting AC motors when other related components have failed and all other trouble shooting and testing procedures have not provided a clear cause. This would also be a good choice when the truck has failed more than one inverter and all other testing has been completed and reveled no root cause for the inverter failure.

CAUSE: This information is not in the service manual. The information provided on page 2 of this article

has been created as a result of testing and feedback from the field. Servicce Engineering is contuing tto gather information for other truck models.

RESOLUTION: When there is a question on the condition of the AC motor, you can check the amps on each leg (U,V and W). This reading may prove helpful in diagnosing a possible motor problem where all other testing has not shown a problem. This testing must be done with and external AC amp meter on each leg.

What you should see is that all the U, V and W leg readings are very close to each other for any given RPM range. As with many troubleshooting procedures, this method is not fool proof. You could have all the same reading and all be a little low or just a little high. We are still compiling the readings for the different trucks so if you do the testing please forward the results to Service Engineering by e-mail.

2 2 Page ______ of ______

MCFA Document # 000017-08M

TITLE:

Troubleshooting AC Motor and Controller Failures Using Amp Readings from the U, V and W Cables on FBC15N - FBC30LN, FBC15NS - FBC20NS and FB16NT FB20NT Trucks Traction Readings COMMANDED SPEED (RPM) 400 1000 2000 2250 STALL FEEDBACK <20 TO 50 RPM Phase Amperage U 140 100 65 100 400 V 140 100 65 100 400 W 150 100 65 100 400 NOTE: All rpm readings were taken at no load except stall Amp clamp set to AC scale, connected to Fluke 87 set on AC voltage Pump Readings SPEED SETTING PUMP COMMANDED SPEED

1 900

5 1785

10 2250

249 130 409

186 107 473

280 125 480

Phase Amperage (average) Tilt forward Tilt backward Stall

The tilt function is signaling the logics through the auxiliary wire, so the speed settings could be changed for the measurements. This modification was done for testing but can also be used for slowing down the tilt speeds. Note: If these test still do not provide an answer it may be advisable to remove the motor for Hi-pot or Megger and Milli-ohm testing of the stator legs. This type of testing usually can be performed at the local motor shop. Our industry has evolved to AC motors it may be time for new tooling to allow your dealership to preform this testing. Please contact Service Engineering using the HEAT system before removing the motor for this type testing.